S5114-Mm09-Aux. Boiler

Customer : SPP Shipbuilding CO.
, LTD SPECIFICATION
Hull No. : S-5112/3/4/5/6/7 Boiler type – PB0301AS12 x 1 set/ship
Boiler capacity – 18 ton/hr
Classification : DNV
Boiler working pressure – 7 kg/cm2
Work order No. : PBW11DY5112/3/4/5/6/7
Burner type – SFDTU-405
Auxiliary Boiler
40,WOUNGNAM-DONG,CHANGWON CITY,KOREA
TEL : 055) 269 ~ 7700(REP) / 7892(DIR)
FAX : 055) 269 ~ 7795~9
E-MAIL: [email protected]
Boiler type : PB0301AS12
CONTENTS
1. BOILER DESIGN DATA

2. DRAWINGS OF BOILER
3. BOILER ACCESSORIES
4. BURNER SPECIFICATION
5. F.O SYSTEM WITH EQUIPMENTS
6. CONTROL PANEL
7. SPARE PARTS AND TOOLS
PLAN HISTORY
0 2011.11.16 FOR APPROVAL H.W.NOH K.J.AHN B.J.KIM

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
KANGRIM HEAVY INDUSTRIES CO., LTD.

1. BOILER DESIGN DATA

LIST OF BOILER DESIGN DATA
NO DRAWING NO. TITLE REV. REMARK

1 - Boiler design data 0
2 MB-TE-01 Design data
- Information table of instruments 0
- Proposal water level 0
- Proposal drum pressure setting point 0
- Thermal expansion of boiler 0
3 MB-INT-001 Installation of boiler 0
4 MB-MN-01 Preservation of boiler 0
5 MB-MN-05 Soda boiling procedure 0

Boiler design data

General description
The PB type boiler is a cylinderical two drum boiler with membrane water wall panel. The steam
generating section consists of straight tubes with bent pin that provide a high heat transfer.
Circulation is ensured by placing downcomers outside the membrane walls. The boiler is insulated
and preassembled with boiler mountings for easy installation and operation. The boiler is top -
fired and equipped with a steam atomizing burner. As the burner, the control panel and all
mountings are mounted on top of the boiler, this can easily be operated. (Refer to Fig.1)
A. Technical data
Number of boiler /ship : 1 Set
Steam production : 18000 Kg/hr
Working pressure : 7 Kg/cm2G
Design pressure : 9 Kg/cm2G
Feed water temperature : 80 ℃
Ambient temperature : 45 ℃
Fuel oil consumption (at H.F.O) : 1315 Kg/hr
Air consumption at 45℃ : 20773 Kg/hr
Flue gas flow : 23049 Kg/hr
Flue gas temperature : Max. 450 ℃
Recommend ship yard E/G duct draft loss : Max.15 mmAq
Total heating surface : 233 M2
B. Dimension
Diameter excl. of insulation : 3050 mm
Height excl. of nozzle : 6300 mmr
Water volume at normal water level : 10.2 m3
Steam volume at normal water level : 4 m3
Weight of boiler (dry) approx : 23 Ton
Weight of boiler including of burner and fittings(dry) : 26.5 Ton
C. Classification
Hull No. S-5112/3/4/5/6/7 : DNV
D. Paint color
Boiler body : Maker standard
Control panel : Munsell No. 7.5 BG 7/2

FIG 1] PB type boiler lay out.

Information table of instruments

Meas. Item Set Burner Alarm limit
No. Item Unit Location
range No. point trip High Low
Diff. pressure transmitter
1 mmH2O 0~690 A29 Boiler
For water level
High water level - - - +165 ●
Control
Low water level - - - -85 ●
panel
Too low water level - - - -145 ● ●
Level switch
2 mmH2O - A31 -145 ● ● Boiler
For too low water level
Pressure transmitter BE-03- Gauge
3 Kg/cm2 0~25 -
For steam drum 11 board
E01 Control
4 For Burner start/stop Kg/cm2 2~25 6.7/7.5
(SDC40) panel
Pressure switch Gauge
6 Kg/cm2 2~25 A32-13 8.5 ●
For high steam pressure trip board
E01 Control
7 High steam pressure alarm Kg/cm2 2~25 8.5 ●
(SDC40) panel
8 Kg/cm2 2~25 A32-16 5 ●
For low steam pressure board
E01 Control
9 Low steam pressure Kg/cm2 - 5 ●
(SDC40) panel
Pressure switch F.O PS- Fuel oil
10 Kg/cm2 2~25 (12) ●
For F.O pump stand-by start 03 line
Temperature transmitter F.O TX-
11 ℃ 0~200 - - - - Burner
For F.O temperature display 13
Temperature switch Fuel oil
12 ℃ 20~200 F.O-10 140 ●
For F.O high temperature line
Temperature switch Fuel oil
13 ℃ 20~200 F.O-11 85 ● ●
For F.O low temperature line
14 Kg/cm2 2~25 A32-03 9 ● ●
For F.O low pressure board
15 Kg/cm2 1~10 A32-10 3.5 ● ●
For atomizing steam low pressure board
Diff. pressure transmitter Gauge
16 mbar - A32-07 - - - -
For combustion air pressure board
Diff. pressure switch Gauge
17 inH2O 4~20 A32-06 (6) ● ●
For combustion air low pressure board

Information table of instruments

Meas. Item Set Burner Alarm limit
No. Item Unit Location
range No. point trip High Low
Temperature switch Gauge
18 ℃ 40~300 A32-15 200 ● ●
For wind box high temperature board
19 Kg/cm2 1~10 A32-14 3 ● ●
For instrument air low pressure board
Pressure transmitter Gauge
20 Kg/cm2 0~25 A32-01 -
For F.O pressure display board
Temperature switch FG TS- Fuel oil
21 ℃ 0~200 55 ●
For MGO high temperature 12 line
Temperature transmitter E/G
22 ℃ 0~600 G01 450 ●
For exh. Gas high temperature DUCT
25 Salinity indicator ppm 0~200 W03 80 ● F/W line
Cascade
26 High oil content - - W04 ●
tank
Control
28 F.D Fan overload - - - - ● ●
panel
Control
29 Emergency stop - - - - ● ●
panel
Control
30 Power fail - - - - ●
panel
Control
31 Flame fail - - - - ●
panel

Proposal water level
(20 mA)
+380 mmH2O
B
O High Water Level (15 mA)
+165 mmH2O
I
L
E
R
L
E
V
Normal Water Level (11.2 mA)
E
L
G
A
U 0 mmH2O
G
E
Low Water Level (9.2 mA)

C
T
-85 mmH2O
O
C
:
6
9
Too Low Water Levle (7.8 mmA)
0
-145 mmH2O
(4 mA)
-310 mmH2O

Proposal drum pressure setting point
 9.0 Safety valve open / Design pressure
 8.5 High steam pressure trip / alarm
 8.0 Dump valve open
 7.5 Burner stop
 7.0 Boiler working pressure
 6.5 Burner start
 5.0 Boiler low pressure
PRESSURE UNIT : kg/cm2G

Thermal expansion of boiler
Design Specification
Boiler max. evaporable capacity : 18000 kg/hr
Boiler working(W.P)/design(D.P) pressure : 7 kg/cm2
Steam temperature at W.P / D.P : 169.7/203.5 ℃
Ambient temperature Min / Max. : 0/45 ℃
UNIT: mm
Point Design length Expansion at W.P Expansion at D.P
H1 5280 5.5 5.8
H2 5920 6.2 6.5
H3 6300 6.6 7.0
L1 1741 3.6 3.9
L2 2500 5.2 5.5

OPERATION AND MAINTENANCE
BOILER TYPE : PB
KOREA (CHANGWON FACTORY) KOREA (POHANG FACTORY)

Kangrim Heavy Industries Co.,Ltd. Kangrim Heavy Industries Co.,Ltd.
40, WOONGNAM-DONG. NATIONAL INDUSTRIAL COMPLEX YONGHAN-RI
CHANGWON, KYUNGNAM, KOREA. HEUNGHAE-EUP POHANG, KYUNGBUK, KOREA
TEL : 82-(0)55-269-7700(Rep) TEL : 82-(0)54-230-7000(Rep)
FAX : 82-(0)55-269-7795(Rep) FAX : 82-(0)54-230-7221(Rep)
E-mail : [email protected] E-mail : [email protected]
KOREA (SNINPYUNG FACTORY) KOREA (DADAE FACTORY)

KangRim Insulation Co.,Ltd. KangRim Insulation Co.,Ltd.
505, SNINPYUNG-DONG. 1505, DADAE-DONG.
SAHA-GU, PUSAN, KOREA. SAHA-GU, PUSAN, KOREA.
TEL : 82-(0)51-220-6000(Rep) TEL : 82-(0)51-264-2345(Rep)
FAX : 82-(0)51-220-6006(Rep) FAX : 82-(0)51-265-2434(Rep)
CHINA (CHANGZHOU FATORY) CHINA (SHANGHAI OFFICE)

KangRim Heavy Industries Co., Ltd KangRim Heavy Industries Co., Ltd
Kohler-road 8#, Xinbei-area, Changzhou city Jiangsu, No.58 New Jinqiao Road, Pungdong
CHINA Shanghai, YinDong 28 Foor D
TEL : +86 519 822 3601 TEL : +86 21 503 0923517
FAX : +86 519 822 3630 FAX : +86 21 503 0236
Operation and maintenance for PB boiler 1

CONTENTS
1. General description
2. Operating procedure
2.1 General notes on boiler operation
2.1.1 Introduction
2.1.2 Performance
2.1.3 Operation
2.1.4 Water level
2.1.5 Others
2.2 Preparations
2.2.1Boiler
2.2.2Fuel burning equipment
2.3 Pressure raising
2.4 Cold start-up
2.5 Shut down
2.6 Emergency operation
3. Treatment of feed and boiler water

3.1 Control of feed water and boiler – water
impurities
3.2 Limits of chemical concentration
3.3 Boiler blow-down
3.4 Maker up – water and boiler water treatment
3.5 Restriction of individual impurities
3.6 Boiling out
4. Maintenance
4.1 Cleaning
4.2 Water washing and soot blowing
4.3 Preservation of boiler
5. Plugging and replacement of tubes in PB boiler
6. Boiler check list

1. General description
The auxiliary boiler generates steam required for tanker service,

the auxiliary boilers, in some occasion, operated together with the
exhaust gas economizer.
When the main engine is out of service, the exhaust gas

economizer cannotnaturally be used and the steam necessary for
tanker service is supplied by the auxiliary boiler only.
After starting the main engine, the exhaust gas economizer shall
be used.While the load of the main engine is low, the exhaust gas
economizer and theauxiliary boiler shall be used together.
Astheengine load increases, the exhaust gas economizer

evaporated more steam and the auxiliary boiler is placed out of
service. The exhaust gas economizer thus remains in service
alone.
Such an independent operation of the exhaust gas economizer is

generally the casewhile at sea. However, in case more steam than
generated by the exhaust gaseconomizer is required, the auxiliary
boiler must be placed in service to supplement the exhaust gas
economizer.
When in port, if the engine load is very low or the engine is at rest,
the exhaust gas economizer is put out of service and the auxiliary
boiler is used alone. Therefore, there are three kinds of boiler
operation modes as shown below.
(1) Auxiliary boiler alone to be operated.Tanker Service Mode
(2) Auxiliary boiler and exhaust gas economizer Eco. Back-up

Mode to be operated together.
(3) Exhaust gas economizer alone to be operated. Economizer

Mode

2. Operation procedure
2.1 General notes on boiler operation
2.1.1 Introduction
The following notes on boiler operation are of general nature to be

observed by the boiler operators. Although some basic rules must
be strictly followed in operation and maintenanceof the boiler and
ancillary equipment, it is up to the operators familiarize themselves
with characteristics of individual equipment.
This can only be accomplished by diligently observing, recording,
checking and comparing data and details. Such attentions and
proper measures promptly taken by the operators often prevent
boiler outages and repairs.
2.1.2 Performance
a) The boiler is designed to deliver steam at required pressure and

temperature when supplied with feed water at the specified
temperature. Operating conditionsexceeding the design limitations
will shorten the life of the boiler and component parts.
b) The concentration of solids entrained in the steam leaving the

steam drum dependsto a great extend upon the quality of the feed
water.Suitable feed water treatment and adequate blow-down
should be used to maintainthe boiler water alkalinity and
concentration of total solids below a predetermined point.
c) If each heating surface of the unit is kept clean, the temperature

of the gas leaving the boiler and the draft loss through the boiler will
normally be constant for a given load and excess air ratio.This
illustrates the desirability of keeping records of boiler performance
from thestart of operation. If a standard is set up when the boiler is
new, the deviation from it will serve as an indicator that shows the
operating condition of the boiler as well as its own condition.Then,
steps may be taken to determine and correct the cause for the
discrepancy and often avoid the development of difficulties.It is
desirable to keep records of operating data in a form that
facilitatescomparison of similar operating conditions.

d)The amount of fuel oil consumed should be measured.Fuel oil
should also be periodically sampled and analyzed to check calorific
value, chemical composition, etc.
e) The temperature and analysis of gases leaving the boiler are

invaluable as an index of complete and economical combustion.The
best percentage of excess air to use depends upon the nature of
the fuel, thedesign of the fuel burning equipment and other factors.
The most desirable conditions for different rates of evaporation
should be established through the diligent study of the performance
of the boiler.
2.1.3 Operation
a)When hot water is used to fill the boiler, care should be exercised
to feed slowly to avoid severe temperature strains on drums,
headers, etc. Always see that each part of the unit is properly
vented, and fill it till water level appears in the levelgauge.The vent
valve of the steam drum should be kept open during the
fillingoperation and should not be closed till all the air is vented from
the unit.The unit will have been completely vented by the time when
the drum pressure reaches approximately 2 kg/cm2g.
b)The time required to bring the boiler up to pressure and

temperature depends upon the pressure and temperature at which
it is to operate. During initial start up of a new boiler, the longer time
than the standard must be used for heating up and pressure raising
so as to allow careful inspection of expansion movements and
clearances of various parts. Increase of firing rate should not
exceed a saturation temperature rise of 67℃( 120℉ ) per hour for a
natural circulation boiler.Ordinary start-up can be done at faster rate
than the above. But, the operating procedure for starting up the
boiler safety should be established through measurements of
metaltemperatures of important parts of the boiler, and the boiler
should be started accordingly.
2.1.4 Water level
a) When the boiler is to be filled for operation, slowly feed water till

the water appears 25 to 50mm high in the level gauge. This is a
precaution against the swell that occurs when the boiler water is
heated and begins evaporating and also against the sudden fall of
the boiler pressure when feeding comparatively cold water.A liberal
blow-down will serve to clear the drain valve seat of any foreign
matterthat may be present.When the new boiler is in operation,
routine check of the water level gauge should be made at least
once a day. If the action of the water in the gauge is sluggish when
the drain valve is opened or closed, investigation should be made of
the cause and the condition should be corrected immediately.
c) Even through the boiler is equipped with the reliable automatic

feed water regulator and the remote water level indicator, the water
level in the level gauge should be observed periodically during
normal operation.Never shut off the feed water supply completely to
the steaming boiler even foronly a short period.
d) Unless otherwise instructed, the water level should be carried

near the center of the gauge glass. Any adjustment of the water
level should be gradual. If the water level is too high, priming may
occur, especially when the steam demand is large or rapidly
fluctuating.If priming occurs, blow down the boiler water and
changing over the feed control to manual operation, reduce the
water level.But, the water level should be maintained as such that is
just sufficient to takecare of a drop in level that may occur in the
subsequent change in steam demand. Reduce the steaming rate if
necessary. Investigate the condition of the boiler water with regard
to concentration of alkalinity and total solids, and examine the
condition of the drum internals when the opportunity is afforded.
e) While the boiler is being brought up to pressure, gradually heat

and properly drain all cold steam piping.
f) During the pressure raising operation, the drum water level often
rises higher thanthe normal level due to the expansion of water.If it
is desired to keep the water level visible in the level gauge at this
time, boiler water should be blow down.
g) Observe the drum water level at times to confirm the proper

functioning of the automatic feed water regulator.

2.1.5 Others
a) When re-igniting the burner to bring the boiler back into service
from the standby state, the furnace still remains hot, filled with un-
burnt fuel particles and un-burnt gas, and thus requires internal
purging by means of forced draft fan (this is anexceptional
instance in which the furnace, still hot, may be air-purged).
b) In case of re-lighting the burner, an igniter must be used. Never

attempt to lightthe burner with hot refractory in the furnace.
c) Check chemical contents of the boiler water at least once a

day.Add chemicals or blow down the boiler water as required to
maintain properconcentration of chemicals in the boiler water.
d) Check frequently the smoke indicator to maintaining efficient

combustion.
e) Keep burner tips clean as they are adopt to be fouled with dirt
and soot.
CAUTION!
Be absolutely sure to use the steam drum surface blowoff
valve when blowing boiler water during boiler operation
and to blow boiler water using the water drum bottom
blowoff valve only during boiler outage.
2.2 Preparations
Prior to starting the boiler, attention should be paid to the following

items andthrough should be made on them.
2.2.1 Boiler
a) All foreign materials have been removed from pressure parts.
b) All gas side heating surface are clean and all refractories are in
good condition.
c) The furnace bottom and the burner wind box have been cleaned
of oil and others.

d) All personnel are clear.
e) All manhole covers are securely tightened.
f) Inspect safety valve and see that gags have been removed and
easing levers are in good condition.
g) Open root valves for all instruments and controls connected to

the boiler.
h) Open the vent valve of the steam drum.
i) Open all pressure gauge valves and check and see all valves on
the pressure gauge piping are open.
j) Check and close all blow-off valves and drain valves.
k) Fill the boiler till water level appears 25 to 50 mm high in the

gauge glass.
The boiler shall be filled in the following procedure and the feed
water line shall be inspected simultaneously.
(1) When the boiler was laid up wet (Refer to “Protection of the
boiler during shutdown”.), drain the boiler till the water level falls
down to the bottom of thegauge glass, and bring the water level
up again to about 25mm high in the gauge glass feeding
through the auxiliary feed water line.
(2) When the boiler was laid up dry, first fill the boiler feeding
through the auxiliary feed water line till the water level just
appears at the bottom of the gauge glass. Then, raise the
water level feeding through the main feed water line up to about
25 to 50mm higher than the normal water level. This practice
serves to check that both the auxiliary and the main feed water
lines are ready for service. Use distilled water for feed water
whenever possible. Boiler compound shall be added as
instructed by the expert of boiler water treatment.

2.2.2 Fuel burning equipment
a)Make sure that all fuel oil lines including oil filters, etc. are in good
condition.
b)Make sure that no oil residue is in the burner wind box.
c)Make sure that F.D Fan inlet vane is clean and moves smoothly.
2.3 Pressure raising
a) Make sure of the drum water level by the water level gauge.
That is, the water level should fall when the drain valve of the water
level gauge is opened, and it should return to the previous level
when the valve is closed.Attention must be paid not to take the
empty level gauge for full of water or stains on the gauge glass for
water level.
b) Start the forced draft fan at low speed

Prior to lighting off, place the forced draft fan with inlet damper fully
opened and purge the furnace for at least one minute.
c) Start the fuel oil burning pump and begin the use of the fuel oil
heater, using heavy fuel oil with normal tip which condition is
operated by H.F.O. mode. Start the fuel oil firing pump and open
the oil re-circulation valve to re-circulate oil through the oil heater
and burner manifold discharging cold heavy oil in the line.
d) Reduce air pressure at wind box to 10 to 20 mmAq. And securely

close the oil re-circulation valve. Check the fuel oil control valve
opening by the output signal to ensure it is ready for service.
e) Light off the burner and immediately make a necessary

adjustment of oil pressure and air pressure to ensure a stabilized
combustion of the fuel. At this time, care should be taken to obtain
such a burning condition that the fuel oil burns completely without
scattering unburned particles or producing heavy smoke.
Frequently check the smoke and the flame through the observation
holes, especially after making any change in firing rate or burner
inlet air pressure.

f) When raising the pressure, keep the burner firing 5 minutes and
out of service 15 minutes repeatedly at the lowest oil pressure (2.5
kg/cm2g) for one hour and then again repeatedly light off and shut
down the burner to raise the steam pressure at the rate indicated in
Fig.1 or less.
Fig.1] Recommend pressure rise
g) When the drum pressure has risen to about 2 kg/cm2g, close the
drum vent valve.
h) Close the valve of the pressure gauge and remove the gauge.
Then, open the valve a crack and release steam to make sure the
tubing for the gauge is clear. Reinstall the pressure gauge and see
that it works as soon as the valve is opened. In this case, care
should be taken to allow several minutes to cool the line before
opening the valve.
i) Check the water level gauge to see nothing is the matter with it by
opening and closing its drain valve, and make sure of the drum
water level again.
j) Drain and warm all steam supply lines to the ancillary equipment
and devices. It is very important to discharge drain water from these
lines and warm them up to near the operating temperature before
loading the boiler.

k) When the drum pressure is raised to about 3 to 4 kg/cm2g below
the normal operating pressure, check the safety valves with the
easing gear. Care must betaken to open and close the valve quickly
so as to prevent damaging the discand the seat of the valve.
2.4Cold Start-up
a) When the boiler is to be started from the cold state in which no

steam is available from the land or the exhaust gas economizer,
use the starting diesel oil for fuel till the steam necessary for the oil
heater becomes available.
b) Fill the boiler with the best water available. For this purpose,
prepare distilled water in the feed tank as much as necessary to
start the boiler before shutting down the boiler.
It is advisable to fill the boiler up to 50 to 80 mm above the normal
water level so that no additional feed water is required till the feed
water pump is placed in service.
c) Start the diesel generator and light off the burner using diesel oil
with the nor tipwhich condition is operated by air atomizing
F.O.temperature. By pass mode and burner manual mode.
Before lighting off, never fail to purge the furnace adequately.
d) Takenecessary measures as described in “PREPARATION”.
e) Close valves of the heavy oil lines from the fuel oil tank to the
burner manifold and open valves of the diesel oil line from the
diesel oil tank.
f) Start the fuel oil pump and open the oil re-circulation valve to
discharge heavy oil remaining in the line, burner manifold and oil
inlet pipes to burners thoroughly.
g) Set the atomizing air pressure at 6K and fuel oil pressure at 3K.
h) Run the forced draft fan at low revolutions and ignite the burner
using the pilot burner.
i) When the steam pressure has risen to about 2 kg/cm2g, start

warming the steam pipe lines and the feed water pump pipe lines,

and turn on steam to the setting tank.
j) When the heavy oil in the setting tank has been heated enough to
be pumped by the F.O. pump, turn on steam supply to the oil heater
in preparation for changeover from diesel oil firing to heavy oil firing.
k) Circulate oil through the oil heater and the oil re-circulation line till
the oil of the proper temperature is available in the burner manifold.
Then, switch diesel oil firing to heavy oil C firing and continue
pressure raising.
l) Start the feed water pump as early as possible so that it can feed
water to the boiler immediately when the drum water level should
fall.
2.5 Shut down
a) Shut down the burner.
b)Continue operation of the forced draft fan for a while after shutting
down, keeping air pressure of about 150 mmAq at burner inlet and
purge the furnace of combustible gases adequately.
c) Maintain the drum water level visible about 50 m in the gauge

glass.
d) When keeping the boiler temporarily out of service or in what is

called the “Standby state”, be sure to light off the burner from time
to time in order to maintain the steam pressure at the normal
working pressure and below.
e) In order to maintain drum water level visible about 50 mm in the

gauge glass even the boiler in cold, raise the water level 70 to 120
mm above the normal water level before closing the feed water.
f) When the boiler is to be shut down completely, close the steam

stop valve immediately after the boiler stops steaming.
g) When the boiler pressure has fallen to the atmospheric pressure,

open the drum vent valve.

h) It is 4 hours after shut down, the boiler may be cooled with the
forced draft fan operation as the case may require.But, if possible,
such a forced air cooling should be avoided not damage refractory
in the furnace. Do not attempt to cool the boiler by blowing down
the hot boiler water or by refilling the boiler with cold water after
blowing down.
2.6 Emergency operation
a) Water level low
If the water level falls down to 200 mm or more below the normal
water level due to failure of the feed water supply or neglect of the
operator, the alarm lamp on the boiler control panel goes on and
simultaneously the alarm buzzer sounds. If the level falls further
down to 240 mm or more below the normal water level, the fuel oil
emergency trip valve fully closes cutting of the fuel supply to the
boiler automatically. Then, fully close the feed water valve and the
steam stop valve and shut down a burner completely and stop the
forced draft fan.
In this case, never attempt to feed water to the boiler till the boiler
has cooled sufficiently, since, otherwise, there may be a danger of
quenching the hot pressure parts with comparatively cold feed
water.
b) Flame out
In the event of a flame out, immediately close the oil inlet valves
and reduce air pressure at burner inlet so as to present overcooling
the furnace.Prior to re-lighting burner, purge the furnace adequately
following the procedure mentioned in “Lighting off and pressure
raising”. A pilot burner must be used for re-lighting a burner. Never
attempt to light a burner by the heat from the hot refractory in the
furnace.
c) Failure of evaporating tube
(1) In case of a tube failure which results in a loss of water so

great that the water level cannot be maintained, use the method
outlined below :

(Ⅰ) Shut off oil supply to burner to extinguish the fire. When
thetube failure is resulted from low water, shut off feed water to
the boiler closing the feed water valve and the steam stop valve.
This is to avoid the damage that may be caused by quenching

hot pressure partsother than the failed tube with comparatively
cold feed water. Refer to “Water level low”.
(Ⅱ) When the failure of the evaporating tube is resulted from

the cause other than low water, maintain the water level, if
possible, at the normal level till theboiler has cooled enough and
then close the steam stop valve and open the drum vent valve.
(Ⅲ) In either case of the above, keep the forced draft fan in
operation to maintain sufficient air flow to carry the escaping
steam out through the stack, adjusting the F.D Fan inlet valve to
such an opening so as to avoid damaging refractory by quick
cooling.
(Ⅳ) Don’t blow down the boiler to lower the pressure rapidly
unless the failure is so severe as to endanger the personnel
near the boiler.
(Ⅴ) Dump the boiler water overboard through the bottom blow
valve after cooled enough.
(Ⅵ) When the furnace has cooled enough to permit a man to

enter it, make a thorough inspection of all pressure parts for any
indication of damage. After necessary repairs have made, apply
a hydrostatic test to see whether the unit may be put back in
service or not.
(2) In case of a leak which does not involve a serious difficulty,

the water level should be maintained and the boiler taken out of
service in the normal manner.

(Ⅰ) Switch the combustion control equipment to manual control
and reduce combustion rate following the normal procedure.
(Ⅱ) Continue air flow through the unit at reduced rate till all
combustible gases, vapors, etc. Have been removed.
(Ⅲ) Manually adjust the feed water flow rate to maintain the
water at a high level. Once the boiler evaporation has come to a
halt, let the pressure to down by natural cooling. When the drum
pressure has come down to 2 kg/cm2g, open the drum air
ventvalve to discharge boiler water.
d) Fire inside the casing

Shut off oil supply to the burners immediately and close the forced
draft fan inlet vane.
e) Failure of forced draft fan

In case of a failure of the forced draft fan, oil supply to the burners
is stopped automatically with the fuel oil emergency trip valve Close
oil inlet valves to the burner.

3. Treatment of feed and boiler water
The below values are, unless special conditions are to be taken into
consideration,to be kept for KangRim Boilers.
3.1 Control of feed water and boiler - water impurities

With boiler in service, it is recommended that at least once everyday
feed water and boiler water be sampled for analysis and appropriate
measures taken for qualitative control.When sampling boiler water,
care is to be exercised so as to take the sample that truly represents
boiler water, by for example cleaning the sampling vessel twice to
three times with boiler water beforehand.
Feedwater and boiler water sampled are to be thoroughly and
carefully analyzed using an appropriate analysis equipment, in
accordance with instruction given on the use of the equipment.
Every effort is to be made to control oxygen, pH, salt, dissolved solids,
phosphoric acid, etc. in feed water and boiler water to within the
specified limits. Requirements specified for the ship’s boiler as
regards the control of feed water and boiler water impurities follow.
a) Feed water
(1) Oxygen :
The oxygen content of feed water is to be controlled to below
0.5ppm
(2) pH :
The recommended pH value is 7.0 to 9.0. For the pH control
purpose,however, it is recommend that the target be set at 8.5 to
9.0
b) Boiler water
(1) pH :
pH of boiler water requires to be controller to 10.8 to 11.3.
(2) Salt :
The salt content of boiler water (as Cl-) requires to be controlled
to 300ppm and as far below as possible, preferably below
150ppm .

(3) Dissolved solids :
Dissolved solids in boiler water require to be controlled to
2000ppm and as far below as possible.
(4)Phosphoric acid :
Phosphoric acid of boiler water (as PO43-) requires tobe
controlled 20 to 40ppm
3.2 Limits of chemical concentration
Boiler water Feed water to boiler

PH(at 25°C) 10.8~11.3 7.0-8.0
Phenolphthalein Alkalinity(CaCO3) / ppm Max.500 -
Total Alkalinity(CaCO3) / ppm Max.600 -
Chloride (Cl-) /ppm Max.300 -
Total solid / ppm Max.2000 -
Excess Phosphate (PO43-) / ppm 20~40 -
Hardness(CaCO3) / ppm - Max.1.0
Oxygen / mg/l - Max.500
Hydrazine / mg/l -
Table.1 ]Recommend limits of chemical contcentration.
NOTICE!
Estimate the pH value from alkalinity tends to give pH
readings varying with silica, Ca, Mg, and other salt
contents of boiler water and hence is not necessarily
deemed appropriate : resort to this method only as a
means to obtain a rough guide (alkalinity serves merely
as an auxiliary means in determining the pH level). Also,
be sure to control pH to the target value while, on the
other hand, Keeping alkalinity at the minimum necessary
level. Limiting the P alkalinity to within a certain range
would make it possible to inhibit the alkali corrosion even
if boiler water concentration should take place on the
heating surface, etc.

3.3 Boiler blow-down
Blowing down boiler water by operating the blow-down valve and

replenishing theamount of water blown down with fresh water is of
vital importance to reducing the concentration of boiler water to
satisfactory level for operation. Also, the boiler blow-down is just as
important to discharging sludge, oily substance, and other impurities
accumulated in the boiler.
The amount of boiler water to blow down and how often to blow down
are to be decided based on factual data, such as the results of
boilerwater analysis, turbidity of sampled boiler water, etc., so that the
aforementioned requirements on boiler water chemistry can be
satisfied.
3.4 Makeup-water and boiler water treatment
The boiler disorders caused by inadequate control of boiler water and

feed water may be broadly defined as follows.
a) Overheating of heat-transfer surfaces due to accumulation of

scale and oil/ grease deposits.
b) Corrosion (and caustic embrittlement)
c)Turbine and other associated equipment disorders due to

carryover some restrictions, therefore, require to be imposed as
follows in order to prevent the above disorders.
NOTICE!
To cope with (1) above, the hardness and oil/grease
content of feed water require to be controlled to within
allowable limits, as does silicic acid contained in boiler
water.
NOTICE!
To deal with (2) above, feed water pH and boiler water
pH require to be controlled to allowable levels.

NOTICE!
Salts defy the generalization, some serving to inhibit the
corrosion and some promoting the corrosion.
Chlorine(chloride), however, generally promotes the
corrosion when present in a large amount and hence
requires to be controlled to as low a level as is
practicable.
NOTICE!
To prevent the problem (3), dissolved solids and
oil/grease contained in boiler water require to be
controlled to within allowable limits.
3.5 Restriction of individual impurities
a)Hardness
The formation of scale deposits in the boiler drum and evaporating
tube internal surfaces and accumulation of sludge within the boiler
are attributable, principally, to hardness-constituting elements
carried into the boiler by feed water.
Leaving the feed water supply as it is while obviously high in
hardness and treating it in the boiler has potential of having the
impurities adhere to fiat-absorbing surfaces and also can cause the
rise in anti-scale consumption and quantity dissolved solids.
The best practice dictates, therefore, that the hardness of feed
water be restricted to within an allowable limit and what is left of the
hardness removed boiler water treatment in the boiler.
Specifically, the hardness of feed water for a 16kg/cm2g boiler is to
be controlled to 1ppm. With makeup water produced by distilling
seawater in a desalinationplant, assuming impurities carried over
through evaporation to be same as those in raw seawater (of total
salts, Cl-55%, Ca - 1.2%, and Mg - 3.7%), the hardness brought in
per 1 ppm of chlorine ( C ) is 0.34 ppm. Then, even with the
allowable limit of chlorine at 5ppm, the hardness upon evaporation
is 1.7 ppm, which suggests that judging from the rate of makeup
feed, restricting the feed water hardness to within the above
mentioned limit is not difficult.
In cases where the distilled water tank is coated with water de-mint
(definitely not encouraged) or where there is leakage in eventually
enterthe boiler, warranting due precaution.
In some instances the required hardness is specified for boiler

water, The hardness values suggested for boiler water are prone to
error and often turn out to be unrealistic. For this reason and also
since the boiler water hardness should remain about 1ppm as long
as excess phospheric acid and pH of boiler water are controlled to
the values given in Table.1.
b) pH value (Alkalinity)
The boilers are made almost entirely of steel, and iron, beside
beingsusceptible to heavy corrosion in acidic environments,
dissolves in neutral pure water to produce iron hydroxide as follows.
Fe + 2 H2O = Fe(OH)2 + H2
Iron water iron hydroxide hydrogen
When iron has dissolved in pure water, pH with Fe(OH)2 at the

saturation point is 0.9. The larger the pH value, i.e., the higher the
alkalinity, the more sharply the amount of iron dissolution goes
down. It therefore is necessary for the pH value to be maintained
constantly at a high level in order for iron being prevented from
becoming corroded. A word of caution is deemed in order because
pH at too high a level can beck-fire in the form of caustic corrosion
or caustic embrittlement or carryover .
Also, it is known that boiler water is not uniform in concentration
throughout its body. So, everything considered, the reasonable
proposition is that pH of boiler water be maintained at 10.8 to 11.3.
Alkalinity may be divided into total alkalinity and active alkalinity.
Included in the total alkalinity reading are caustic soda, potassium
carbonate, and potassium bicarbonate, all these being put
together. The active alkalinity, on the other had, called
phenolphthalein alkalinity(or P alkali, in short) represents theamount
of alkali high enough in strength to turn phenolphthalein indicator in
color.
It is the active alkalinity that serves as a rough guide to the pH
level.With all the foregoing in consideration, therefore, the
phenolphthalein alkalinity as CaCO3 is to be controlled to about 50
to 300 ppm when boiler water is in excess of 1000 ppm in
concentration and to about 30 to 400 ppm when boiler water
concentration is below 1000 ppm.

c) Dissolved oxygen
The dissolved oxygen constitutes a single greatest factor in causing
corrosion, being responsible for boiler steel corrosion in well more
than 50% of time.
In reaction between water and iron, which is defined as Fe + 2H2O
= Fe(OH)2 + H2, hydrogen thereby produced is absorbed in metal
surface to serve as a negative factor in the reaction, When oxygenis
present, however, it causes hydrogen to disappear by oxidation, so
the reaction progresses toward the right term of the formula with the
dissolution of iron taking place continuously.
In addition, iron hydroxide turns into ferric hydroxide by being
oxidized by oxygen, ferric hydroxide setting down to produce rust,
thereby causing the corrosion of iron to progress intermittently.
2Fe(OH)2 + 1/2O2 + H2O = 2Fe(OH)2

iron ferric
hydroxidehydroxide
The pitting corrosion, found concentrated under the drum waterline,

is attributable to the dissolved oxygen. Iron transported from the
feed water piping into the drum, plus iron oxide produced within the
drum, accumulates as deposits or settles down to cause the pitting.
The presence of carbon dioxide gas together with dissolved oxygen
in saturatedsteam piping can cause a total corrosion. Carbon
dioxidegas is produced by dissolution of bicarbonate in makeup
feed as well as by dissolution of sodium carbonate within the boiler.
2NaHCO2 → Na2CO3+ H2O+ CO2

Sodium Sodium Carbon
bicarbonate carbonate dioxide gas
Na2CO3 + H2O → 2NaOH + CO2

Sodium Caustic Carbon
carbonate soda dioxide gas
The use of sodium carbonate as boiler anti-scale, therefore, is not

recommendable.Carbon dioxide gas dissolves in water and acts as
carbonic acid but does notcause by itself so heavy corrosion. If
there is oxygen together, however, the effect ofthe Dissolved carbon
dioxide gas becomes pronounced, as if to play a role of some
oxidizing medium as indicated by the following reaction formulas.

Fe + 2H2CO3 = Fe(HCO3) + H2 •••••••••••••(1)
Carbonic Ferrous
acid bicarbonate
2Fe(HCO3)2 + 1/2O2 + 5H2O = 2Fe(OH)3 + 4H2CO3 ••••(2)

Ferric
Hydroxide
The dissolved oxygen in feed water, therefore, requires to be strictly

controlled,preferably to below 0.05 ppm for a 16 kg/cm2g boiler
even though it is specified to be 0.5 ppm.
For removal of dissolved oxygen, it is recommended that volatile
hydrazine be continuously added to feed water. Hydrazine reacts as
follows.
N2H4 + O2 → N2 + 2H2O
d) Chlorine (Chloride)
Salts, when present in large quantity, raise the electric conductivity
of liquid to promote the corrosion and hence require to be controlled
to as low a level in quantity as is practicable.
Feed water containing too large an amount of magnesium salt
canproduce the sediment of magnesium hydroxide upon entering
the boiler, and this is said to raise he corrosiveness of boiler water
by bringing down the boiler water pH value.
All the same pH and oxygen remain the greatest factors in causing
the corrosion, and the measurement of chloride is performed more
or less to obtain a rough idea as to the amount of dissolved solids
contained.
The relation between the dissolved solids and chlorine ion, though
subject to some variations depending on the water quality or
performanceof the watermaking device, can be established by
measuring these elements in boiler water of each individual boiler
beforehand. Then, it is possible, as well as does no harm for
practical purposes, to estimate the amount of dissolved solids.
It is assumed that the concentration of boiler water, as long as it is
controlledof boiler water, as long as yardstick, cannot rise to such a
level as to greatly promote the corrosion except in special instances.
The feed water committee, therefore, sets forth no requirements in
particular as to the allowable limit of chlorine.

e) Oil / Grease
Oil / grease coming out of auxiliary machinery, especially those
started in reciprocating motions, enters feed water and then
adheres to the boiler heat absorbing surfaces to cause
theoverheating trouble there upon oxidation.Also, since boiler water
is alkaline, both animal and vegetable oils are liable to be emulsified
in it. The results are foaming of boiler water and degradation in
steam purity.
Although the allowable limit is specified for the amount of oil /
grease in boiler water in some instances, it seems highly likely that
such as oil/grease will be several hundreds fold greater in
concentration at the boiler water surface than the mean oil / grease
content. As specifying such a limit is deemed to make not so much
of sense, it is only requested that feed water and boiler water be
controlled so that the amount of oil / grease can be kept to zero as
far as is practicable.
f) Silica (Silicic Acid)

The scale that contains silica is the poorest in heat transfer and
thus the most harmful to boiler operation.Also, what is called the
silica carryover takes place, in which silica carried in steam enters
the turbine and deposits itself on the turbine blades as hard scale
encrustation. This is the single most nettlesome phenomenon,
which warrants a serious consideration in connection the care of
high pressure boilers.
For a 16 kg/cm2g boiler, it is recommended that the silica content of
boiler water be controlled to below 50ppm to cope with both the
scale formation and silica carryover.
Silicic acid should be no cause of concern so long as distilled water
produced from seawater is used as makeup feed in nearly all the
instances. When water is obtained from land, however, necessary
precautions are to be taken in this respect.
g) Dissolved solids
The larger the amount of dissolved solids in boiler water, the bore
dampened the steam becomes, to the point where a large amount
of solids are carried in steam as carryover to the turbine. The
tendency of such a carryover varies with the steam evaporation rate,
boiler type, and performance of the steam separator in the steam
drum, as well as with constituents of solids even if the solids are

same in quantity. Although the relation between these factors still
defiesquantitativedefinition,atleast a rough standard can be given
for safe and practical operational purposesfrom the past experience.
In normal operation, the amount of dissolved solids is to be kept to
below 2000ppm.
3.6 Boiling out
If the presence of oil is found on the waterside of the boiler, it must be

removed by boiling out. This is necessary after assembly of a new
tubes, or if oil has entered the feed water from some other source.
Boiling out is also a quick and efficient method of removing various
types of scale. The chemicals to be used and the strength of solution
required, depends on the character of the scale. Consult the boiler
water chemist.
Boiling out to remove oil requires the use of a fairly strong caustic
solution. One such solution is 2kg of caustic soda and 4kg of tri-
sodium phosphate, for each 1000kg of cold water required to fill the
boiler. This chemical solution is sufficient to remove ordinary
compounded lubricating oils or the usual protective oil coating applied
to tubes before shipment.
Straight mineral lubricatingoils used for high temperature
enginesrequires stronger solutions. If such oil is present in the boiler
used 4kg tri-sodium phosphate and 4 to 5kg caustic soda per 1000kg
of water. In addition it is advisable to add detergent (wetting agent)
amounting to about 0.5 percent of the boiler water. There are other
chemical solutions that can be used.
There are many satisfactory compounds for boiling out. They are sold
under various trade names by reputable firms. When such
compounds are used, follow the manufacture instructions.
a) Steaming method
This is a method in which steam is injected by way of a temporary
piping externally connected to the air vent valve, for soda boiling.
Water is to be discharged by way of the bottom blow down valve
and through a temporary discharge piping. The discharge piping is
to be connected to the boiler water sampling tank, which is required
for inspection or analysis of boiler water.
(1) Inject chemicals into the water wall tubing as required,

usingthe chemical injection device. Dissolve the chemicals in

clean water, in proportion to the weight of water required to
completelyfill respective boiler parts, for injection. See the
“planning particulars” included in this manual for the weight of
water required to fill each of the boiler parts.
Upon finishing the injection of chemical solution, gradually blow
in steam in such a manner as to permit condensed water to
collect until the boiler is completely filled with water to the point
where water begins to overflow by way of the air vent valve.
(2) Maintain the boiler pressure at about 3.5 kg/cm2g and adjust
each airvent so that the quantity of overflowing water from each
individual air vent valve and bottom blow down valve will
beapproximately in proportion to the quantity of water in each
corresponding boiler part.
(3) Determine the progress in removal of oil through test of

sample water taken from the discharge piping. Analyze the
sample water for alkalinity and then add chemicals required to
maintain the chemical concentration at the specified level : by so
doing, continue the soda boiling until no trace of oil can be seen
in the sampled water.
The oil content can be detected by examining the surface of
cooled sample water for sign of oil. If possible however, analysis
by ether method, etc. should be in order.
b) Firing method
If steam and electric power are available and the auxiliaries are
ready for service a boiler can be boiled out using a light fire. When
the firing method can be used, it is much simpler and does not
require temporary piping.
The quantity of solution to use should be figures for the weight of
cold water required to fill the boiler to normal steaming level.
(See “Design Data”.)
(1) Dissolve the chemicals in water and inject into the boiler with
the compound ejector.
(2) Close the boiler and fill to the normal starting level.
(3) In cases where the boiler is of new construction with new

refractory in it, avoid the sharp thermal expansion of the
refractory by preheating the furnace internals by burning
firewood inside the furnace for 3 to 4 hours or by firing the
burner intermittently.
(4) Ignite and shut down one burner using the smallest capacity
burner tip, repeatedly.
(5) Until the pressure is gradually raised to the level

corresponding to 85 to 88% of normal operating pressure.
Maintain the pressure at that level, for soda boiling. If necessary
to maintain the pressure, intermittently fire the burner.
(6) If the refractory is new, alternate the burner at fifteen minute

intervals.
(7) When the boiler is thoroughly heated, raise the water level
slowly to about 75 to 100mm above normal, operating level, then
give a surface blow followed by several short bottom blows to
bring the water level 30 to 50mm below normal.
Refill the boiler slowly, until the water level is reached to about
75 to 100mm above normal, and additional chemical based on
the approximate amount of water blown down.
(8) Perform the soda boiling continuously for 6 to 8hours,

blowing down boiler water through the blow down valve by 100
to 150 mm on the level gauge each time.
c) Wash and inspect
(1) After boiling out is completed by the firing method, blow down
the boiler through the water drum bottom blow off valve while the
boiler is fairly warm. Discharge the water overboard, to avoid
damaging paint in the bilge by the strong caustic solution.
(2) Open up the boiler and wash it down with a high pressure
water playing the hose into all tubes.
(3) Carefully inspect the boiler, and if any trace or oil remains,
repeat the boiling out process.

4. Maintenance
4.1 Cleaning
a) If the feed water is properly treated the possibility of impurities at

the water and steam side of the boiler should be minimal.
b) Deposits in the tubes are notoriously extremely small owing to

the heavy water circulation. If impurities, which cannot be boiled out,
should come inside the tubesthe tubes can be cleaned from the
upper drum by scraper. If the oil burner is functioning correctly and
the combustion is complete the soot deposit on the tubes will be
minimal, but in practice it can hardly be avoided that soot deposits
will occur in the course of time, e.g. due to the starting periods of
the oil burner.
c) If the combustion has been had during a long period and the soot
deposit has been so heavy that an ordinary soot blowing is
insufficient the tubes can be brushed outside though the door in the
uptake and through the tree doors in the plate covering round the
tube section.
4.2 Water washing and soot blowing
a) Water washing
Water washing is easily carried out from the smoke box outlet with
washing hose. And when washing is carried out the boiler must
beout of operation and its temperature below 110℃.
After washing is completed the furnace bottom refractory must be
cleaned with alkaline water due to the washing water is very
corrosive. The boiler must be boiled out immediately after the water
washing has been completed in order to avoid damage on
refractory and heating surface.
The boiler must be lighted-up and pressured as the above
described.
b) Soot blowing
Generally, deposits on the heating surfaces cause to reduce

combustion quality. These deposits will accumulate on the
generating tubes if not removed. This boiler is equipped with soot
blowers for cleaning. These are manually operated and arranged
for direct connection to the steam system of the ship. In order
toobtain an efficient soot cleaning, the steam pressure must be at
normal working pressure and boiler load should not be lower than
50%.
Soot cleaning procedure is as follows.
(1)Check the steam pressure.
(2)Check that main valve and two manual valves of soot blower
are closed.
(3)Open the drain valve to drain water from main tube for a few
seconds and close it again.
(4)Open the main valve.
(5)Open the lower manual valve for approx. 5 sec. and close it
again.
(6)Open the upper manual valve for approx. 5 sec. and close it
again.
(7)Repeat above 4) to 6) 3~4 times.
(8)Close the main valve.
(9)Check that both ball valves are closed.

Fig.2] Boiler soot blower arrangement
4.3 Preservation of boiler
a) General
Boiler to be held out of service must be carefully handled and

closely watched in order to minimize any tendency of corrosion of
parts.
The casing and other exterior parts of the boilers should be kept
free from dirt and soot. They should be kept as clean and dry as
possible.
Outer steel casing should not be cleaned with abrasives or acids.
The tops of the casings should be properly protected against
corrosion caused by drippings from air vents, stop valves or other
sources. The spaces at the back and sides of the boilers should be
kept clear to allow access to all parts and nothing wet or
combustible stowed over or around them.

The air spaces in air-encased boilers, uptake enclosures, and the
air ducts and casings of forced-draft systems should be examined
frequently and any accumulation of dirt or rust therein prevented.
(1) Fire side
A boiler which is to be held out of service for any period should

have the fireside thoroughly cleaned and dried. Soot on the
boiler surfaces will absorb moisture from the air and cause
external corrosion. The furnace and burner air registers of all idle
boilers should be kept closed except for occasional. Every effort
should be made to maintain the firesides and the interior
surfaces of the casings of idle boilers in as dry a condition as
possible.
(2) Water side
If a boiler is to be held out of service more than four days

duration; usually for a period of several weeks or months. it is
recommended that it be laid up in accordance with the water fill
method.
If no water is available, a dry layup method should be used as

outlined below. Laying up of the watersides can be
accomplished by the following wet or dry methods.
- Wet method : Water Fill Method

- Dry method : Absorption Agent
b) Method.
(1) Lay-up by Water Fill Method -Long Term
A long term lay-up is considered a time period longer than four

days duration; usually for a period of several weeks or months.
But, the temperature of fire side shall be kept over freezing
always.
(Ⅰ)Inject appropriate quantities of chemicals for boiler water

treatment and sodium sulfite into the boiler’s water side using
Chemical dosing unit so that the boiler water will be PH110~12
(Alkalinity : 300~400ppm), about 50ppm in phosphoric-
acid(PO4) content and 80~100ppm in sodium sulfite(Na2SO3).
The water concentration should be remained at extremely high

level during wet storage period compared with what it is when
in service.
(Ⅱ) When the pressure of the boiler has gone down to nearly
zero(0) bar., open the air vent valve and fill the boiler with
distilled water until it effuse from air vent pipe, then close the
air vent valve
(Ⅲ)Put the hydrostatic pressure of 3.5~5bar g. on the boiler.

Hold this pressure until the boiler has cooled to surrounding
temperature then bleed the boiler using air vent valve and to
be sure all air is out. Hold the hydrostatic pressure of 2~3.5bar
g. on the boiler.
(Ⅳ)Maintaining the alkalinity at uniform level throughout

respective boiler parts is an important consideration, so
periodically sample the boiler water for analysis during lay up
and replenish what have been spent of alkalinity and sodium
sulfite.
CAUTION!
Machinery space to be installed the boiler shall not be
lower than 5 deg.C so as to prevent from boiler water
freezing
(2)Lay up by Use Of absorption agent.
In case water is not available, this(Dry lay up) method can be

used.
(Ⅰ) Drain out the boiler water while boiler is fairly warm and
make sure no water is left in thewater side of boiler. All parts

where water is liable to accumulate in pockets should be blown
out with an air hose.
(Ⅱ)If necessary, burn the coke or charcoal in the furnace of

boiler to promote the internal surface drying.
(Ⅲ)When completely dried, open the manhole and put the

absorption agent (VCI or Silica gel) in the boiler and close
quickly.Use 2~5kg VCI(Volatile Corrosion Inhibitor) for 1,000kg
of boiler water or 1.8kg of silica gel for 1,000kg of boiler water.
(Ⅳ)Be sure to close securely all mounting valves, manhole and

access door.
(Ⅴ) Check the absorption agent every 1~2 weeks at the

beginning and every 1~2 months thereafter at the
circumstances call for and renew deteriorated absorption agent.
The length of time the silica gel remains effective will depend
upon atmospheric conditions and how tightly the boiler is
closed up. It is recommended that a couple of bags be
examined after two weeks. When the silica gel becomes
saturated it can be dried by baking at a temperature of about
150 deg.C. The relative humidity within the boiler must be held
below 30 percent to insure adequate protection.
CAUTION!
All connections on the boiler shall be kept close tightly so
as to avoid entering of air to boiler.

5. Plugging and replacement of tubes in PB boiler
a)Plugging and replacement of wall tubes.
(1) Remove the manhole in the steam/water drum.
(2) The damaged tube ends should be cleaned before plugging.
(3)The plugged tubes should be cut vertically along the connections

with fins between the tubes in panel wall, Fig. 3.
(4) Weld a number of anchors on the fin and inside the rest of tube.
(5) Refractory against it must be carried out in the full height inside
the furnace.
(6) The insulation around the damaged panel wall tubes should be
removed.
(7) The damaged tubes must be cut below and above the tube
sheets.
(8) The tubes are removed by cutting out in the fin.
(9) Scraps of metal or welding in the tube holes and the tube plates
must be grind off.
(10) The new furnace panel wall tubes must be welded on as

shown in Fig.4

Fig.3] Repair works of wall tubes
Fig.4] Repair works of wall tubes

b)Plugging and replacement of generating tubes.
(1) Plugging of the generating tubes are shown in Fig. 5.
CAUTION!
Up to 10% of all generation tubes can be plugged with a
conical plug but if more tubes are damaged, an exchange
of tubes are necessary.
(2) For replacement, an opening in the surrounding panel wall must

be cut according to the above procedure.
(3) New pin tubes are build-up one by welding on to the tube plates.
CAUTION!
The tubes are inserted 5-10 mm in the tube
plates before welding inside the tube hole.
(4) During assembling the supports are arranged and adjusted.
(5) Finally the opening in the panel wall must be rebuild.
Fig.5] Repair works of generating tubes

6. Boiler check list
No. Item Checking method Frequency
1 Water level Open and close the drain valve and see the Once a
gauge response of the water level in the gauge. day
2 Boiler water Measure concentration of chemicals in boiler Once a

water and check water quality. day
3 Remote water Lower the drum water level down to 100mm by Once per
level indicator
operating the feed water regulator by hand and six months
compare the indication of the remote
waterlevel indicator with that of the
transparentwater level gauge.
4 Burner flame When the burner only is in service, shut it Once per 6
eye down and see that the indicator lamp for loss months
of fire goes on.
5 Water level When the boiler is running under low load, Once per 2
alarm change the drum water level. weeks
6 F.O cut off When the boiler is stopping, change the drum Once per 3
condition level (low-low), stop the F.D Fan, and stop the months
F.O Pump.
7 Steam leakage Check the boiler press. Parts, flanges, and Once a
water leakage valves. day

2. DRAWINGS OF BOILER

LIST OF DRAWING

1 PB08-PL-01 Part list of steam/water piping system 0
2 PB0801DS38-01 Piping system diagram 0
3 PB0801DS38-02A No.1 Arrangement of boiler 0
4 PB0801DS38-02B No.2 Arrangement of boiler 0
5 PB0801DS38-05A No.1 boiler grating & handrail detail 0
6 PB0801DS38-05B No.2 boiler grating & handrail detail 0
7 PB0801DS38-07 Outside insulation 0
8 STD-002-06 Lifting lug “C” type 0 30~35 TON
9 STD-001 Lifting lug “D” type 0 30~35 TON

DOC. No. : PB-PL-01
PART LIST OF STEAM/WATER PIPING SYSTEM ( 1 OF 3)

** Define the part number **
A : Mounted boiler valve and accessory.
W : Loosing equipment for installed on the ship yard feed water and circulation line.
G : Loosing equipment for installed on the ship yard E/G duct.
T : Tools
E : Equipment for electric part.
PART NO DESCRIPTION TYPE/SPEC. QT’Y REV. REMARK

A01 Safety valve with drip pan 20K-80A/125A 2 0 2093963
A01.01 Remote device for safety valve PULLY 3 0 5005451
A01.02 Manual operation easing gear - 1 0 3001223
A01.04 Wire Unit : m 30 0 4000438
A01.05 Clip 15 0 4000433
A02 Main steam valve JIS F7314, 20K-250A 1 0 2N06638
A03 Main steam swing check valve 16K-250A 1 0 2008476
A04 Feed water valve JIS F7314, 20K-65A 2 0 2N00264
A05 Feed water check valve(SDNR) JIS F7473, 20K-65A 2 0 2N03490
A06 Scum check valve(SDNR) JIS F7474, 20K-40A 1 0 2N90290
A09 Blow down check valve(SDNR) JIS F7473, 20K-40A 1 0 2N15252

A10 Water level gauge valve JIS F7421, 20K-25A 4 0 2N01734
A10.02 Manual operation handle - 8 0 5000641
A10.03 Wire - 45 0 4000438
A10.04 Clip - 15 0 4000433
A11 Water level regulation valve JIS F7421, 20K-25A 2 0 2N01734
A12 Low water level switch valve JIS F7421, 20K-25A 2 0 2N01734
A13 Sampling valve JIS F7336, 30K-15A 1 0 2N01719
A14 Air vent valve JIS F7388, 20K-6A 1 0 2N01730
A15 Pressure gauge valve JIS F7388, 20K-6A 1 0 2N01730
A16 Max. pressure switch valve JIS F7388, 20K-6A 1 0 2N01730
A17 Furnace side drain valve JIS F7363, 5K-50A 1 0 2N05941
A19 Smoke box drain valve JIS F7363, 5K-50A 1 0 2N05941

PART LIST OF STEAM/WATER PIPING SYSTEM ( 2 OF 3)

A20 Circulation inlet valve JIS F7313, 20K-100A 1 0 2N01710
A21 Circulation outlet valve JIS F7313, 20K-50A 1 0 2N01707
A22 Circulation outlet valve(SDNR) JIS F7473, 20K-50A 1 0 2N04070
A23 By-pass steam valve JIS F7421, 20K-25A 1 0 2N01734
A25 Soot blow manual valve JIS F7313, 20K-50A 2 0 2N01707
A26 Soot blow stop valve JIS F7313, 20K-65A 1 0 2N01708
A27 Condensate reservoir - 1 0
A28 Connection bend - 1 0
A29 Differential pressure transmitter GTX31D 1 0 3003331
with 3-way valve manifold
A30 Water level gauge(Illumination) C to C 690 1 0 -
A31 Water level switch C to C 525 1 0 3003732
A32 Gauge board PB-TYPE 1 0 3007758
S06 Sampling cooler 100A 1 0 3000837
W01 Feed water control valve 16K-50A 1 0 2008290

W02 Chemical dosing unit - 1 0 3005807
W03 Salinity indicator SI-30 1 0 3010964
W04 Oil detector CLS-112 1 0 3008503
G01 Temperature transmitter for PT100 1 0 3003683

Fuel gas high
E01 Boiler control panel - 1 0

E06 Remote water level indicator 144 SPDA 1 0 6000739
E07 Remote steam pressure 0~25 kg/cm2 1 0 3003587
indicator

3. BOILER ACCESSORIES

PART LIST OF BOILER ACCESSORY ( 1 OF 3 )
DRAWING NO. DESCRIPTION PART NO. REV. REMARK

MB-DP-01 Safety valve with drip pan A01 0
JKS-1321-001 Calculation sheet for safety - 0
MB-EG-01 Remote device for safety valve A01.01
MB-EG-02 Manual operation easing gear A01.02 0
MB-JF-7314 Main steam valve A02 0 20K-250A
Feed water valve A04 0 20K-65A
MB-JPC-DW13 Main steam check valve A03 0 16K-250A

MB-JF-7473 Feed water check valve (SDNR) A05 0 20K-65A
Scum check valve (SDNR) A06 0 20K-40A
Blow down check valve (SDNR) A09 0 20K-40A
Circulation outlet valve(SDNR) A22 0 20K-50A
MB-JF-7313 Circulation inlet valve A20 0 20K-100A
Circulation outlet valve A21 0 20K-50A
Soot blower inlet valve A25 0 20K-50A
Soot blower stop valve A26 0 20K-65A
MB-JF-7421 Water level gauge valve A10 0 20K-25A
Water level regulation valve A11 0 20K-25A
Low water level switch valve A12 0 20K-25A
By-pass steam valve A23 0 20K-25A
MB-JF-7336 Sampling valve A13 0 30K-15A

MB-JF-7388 Air vent valve A14 0 20K-6A
Pressure gauge valve A15 0 20K-6A
Max. pressure switch valve A16 0 20K-6A
MB-JF-7363 Furnace side drain valve A17 0 5K-50A

Smoke box drain valve A18 0 5K-50A
MB-CR-01 Condensate reservoir A27 0

Connection bend A28 0


DPT-01 Differential pressure transmitter with 3- A29 0 GXT31D
way valve manifold
MB-RLG-02 Water level gauge(Illumination) A30 0 C to c 690
MB-LS-01 Water level switch A31 0 C to C 525
MB-GB-01 Gauge board A32 0
Pressure transmitter for F.O. line A32-01 0 8244.xx
F.O pressure gauge A32-02 0 SS-3020
Pressure switch for F.O low press A32-03 0 9bO.xx
F.O pressure gauge A32-04 0 SS-3020
Pressure gauge for F.D fan A32-05 0 SS-3020
D.P.S for low comb. Air A32-06 0 1950
D.P.T for comb. Air A32-07 0 SET47B
D.O inlet pressure gauge A32-08 0 SS-3020
Atomizing steam pressure gauge A32-09 0 SS-3020
Press. Switch for atomizing steam low A32-10 0 9bO.xx
Pressure transmitter for boiler press. A32-11 0 8244.xx
Pressure gauge for boiler press. A32-12 0 SS-3020
Press. Switch for boiler high press. A32-13 0 9bO.xx
Press. Switch for instrument air low A32-14 0 9bO.xx
Temp. switch for windbox high temp. A32-15 0 471
Press. Switch for boliler low press. A32-16 0 9bO.xx
Pressure switch for MGO low press A32-17 0 9bO.xx
MGO pressure gauge A32-18 0 SS-3020
MB-SC-01 Sampling cooler S06 0
MB-PC-03 Feed water control valve W01 0 16K-50A

MB-DU-02 Chemical dosing unit W02 0
MB-SI-01 Salinity indicator W03 0 SI-30
MB-OD-01 Oil detector W04 0 CLS-112


MB-TT-03 Temperature transmitter for Fuel gas G01 0
high
MB-RL-01 Remote water level indicator E06 0
MB-PI-01 Remote steam pressure indicator E07 0

DOC. NO. JK-WIP-E-04
INSTRUCTION MANUAL REV. NO. 1
FOR
DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 1 of 14
CONTENTS
No. Title Page
1 Design/Construction 2
2 Operating Cycle 5
3 Installation 7
4 Caution on Hydraulic Test 9
5 Adjustment 10
6 Troubles and Shooting 12
7 Repair and Lapping 13
8 Reassembly 14
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SAFETY RELIEF VALVE
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1. DESIGN / CONSTRUCTION
Full Bore Type is provided that Seat Opening Diameter (SOD) is not less than 1.15 times the throat
Opening Diameter(TOD), and that the steam passage area of the seat when opened is not less than
1.05 times of the throat opening area, and that the area of the valve inlet and the connection nozzle
are not less than 1.7 times of the throat opening area.
Those valves have a unique Nozzle Seat which provides maximum capacity obtainable. The
discharge through this nozzle enters a body chamber which is carefully proportioned in the internal
contours and in the ratio of inlet to outlet area to minimize flow restriction and body pressure.
Especially for the positive proper adjustment of operating characteristic on fluid, One Ring is
adopted to obtain substantial adjustment to its pop action.
For easy access to resume normal seating face. if need due to failure of its trueness, the most
important characteristic of Flat Seat Nozzle Valve is the ease with which seating surface can be
reconditioned the slight deviation from the specific angles can lead leakage and faulty operation.
All important part are thermally balanced and precisely machined, thus assuring accurate alignment
regardless of temperature variation.
1.1 Valve trim
Trim parts in a safety relief valve include disc and nozzle seat only.
(1) Disc
A disc acts as the top guide and is guided by a cylindrical valve guide, standard
construction of safety relief valves includes metal-to-metal seats in a view of tightness
which provide commercial tightness acceptable for most applications or special bubble
tightness under certain conditions.
For reinforcement of seating faces both on disc and nozzle seat to insure their trueness from
violent and rapid shout down force during operating,
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SAFETY RELIEF VALVE
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Surfaces are carefully stilted and precisely lapped.

Maintaining the necessary operating clearance between disc and its guide assures free
movement under a certain temperature ranges given.
Please refer to limiting service conditions for keeping them from exposing thermal
expansion trouble as specified in catalog.
(2) Nozzle seat

As the nozzle seat is fully and tightly screwed up into the main body keeping seating face
same contour parallel, it will not come out of the position and any deviation from disc
contacting center.
Also, with a view to avoid any malfunction, leaks, or other problems which may be caused
by stress from the outlet piping or by thermal strains, the seat surface is designed to occupy
a position at the center of the body cylinder and separated as far as possible from the
contact position with body.
Since the fluid channel from the throat to the valve seat is the most important part
determining the performance of the valve, a logical Shape is provided so that there will be
no interruption in the fluid expansion.
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SAFETY RELIEF VALVE
PAGE 4 of 14
1.2 Adjust Ring
The ring screwed onto the circumference of nozzle seat,
The area expansion due to a small amount of fluid leakage just before the blow-off produces
pressure enough to lift the disc. this force causes a quick popping action of the valve. The
ring adjusts the simmer of the fluid.
The other name is (popping) Control Ring or Nozzle Ring.
1.3 Body
The body maintains tightness with its precise finishing and its stout construction ensures
safety against thermal stress due to the rapid variation in the temperature of the fluid to be
blown off as well as securing it against the reaction strength resulting from a large amount
of fluid blown off.
1.4 Bonnet
Standard construction of bonnet includes closed one to protect the internal spring and support
the adjusting screw.
On model SSRF open and yoke bonnet can be provided to ensure safety against thermal
stress due to rapid variation in the temperature of the discharging flow during blowing off
1.5 Cap construction and Lever
Standard caps for pressure relief valve are screwed or Bolted Top and Open Lever Top to
provide periodical test, for usage of which hermetic sealing is not required (with most uses
for steam and air) Adopted Test Gag on two kinds o top cap, when required, is handy for use
in hydraulic test.
On standard open lever, Fork lever are adopted to larger size valve.
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DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 5 of 14
1.6 Adjust cock (or needle)
When the safety valve is blowing off fluid, back pressure is applied to the back of disc and
the guide. The back pressure interferes with the valve when it is being lifted but assists it
when the valve is being closed.
To apply the back pressure most effectively, on additional cock which can be handled from
the outside, can be provided. Safety valve can be suitable provided with the adjust needle on
construction of open bonnet to prevent any trouble in the operation of it even if the throttle is
closed too much.
2. OPERATING CYCLE
All of safety-relief valves are of the direct spring loaded construction. The operating mechanism
of each type is as follows:
Should the pressure upstream of the valve rise abnormally and reach near to the set pressure, it
cause the balanced spring to push upward and the valve disc be slightly lifted up to make an
initial opening. Steam or gas gushing out of this initial opening will be guided by the properly
adjusted lower ring to exert dynamic pressures on the valve disc and the valve disc will be lifted
quickly, the valve will start to discharge.
In case of the Full Bore Type Valve. operating characteristic of which is controlled by the ring,
fluid discharged by the initial blowing-out will be deflected in a downward direction through
upper ring and this deflection as well as pressure generated between two ring are exerted on the
face of the valve disc to lift it to a higher position.
As the Low-Lift Type Valve is not provided with an upper ring, the fluid is deflected through a
chamber formed by the lower face of the valve disc and the lower ring. The valve disc is lifted by
static and dynamic pressure.
2.1 Close
when inner pressure is lower than set pressure, the valve disc keeps the condition of full close
due to differential power between the fluid pressure and the condition of full close due to
differential power between the fluid pressure and the counter-pressure by the adjusted spring
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SAFETY RELIEF VALVE
PAGE 6 of 14
2.2 Initial open
(Commence-to-blowout)
In case that the inner fluid pressure reaches near the set pressure, the power retaining valve
closed by the spring will be gradually overcome by the inner pressure allowing a little fluid
leakage into accumulating chamber which is formed between the lower and upper rings.
2.3 Full open
The pressure condensed in the accumulating chamber makers greater force to lift the disc
upward against spring force. This pressure leads popping action to lift up the disc quickly in
this case, the full open can be easily attained at the given overpressure above the set pressure.
2.4 Re-seating
Re-seating will be duly obtained at the adjusted ring mechanism after enhancement of
blow-off.
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SAFETY RELIEF VALVE
PAGE 7 of 14
3. INSTALLATION
3.1 Storage and Conveyance
Safety-relief valve are often off hand at the job site several months before they are actually
installed. Unless they are properly stored and protected their performance may be affected
deadly. Roughness in handling may damage valve appearance sharp, worst to crack, or cause
misalignment of the valve part. Furthermore carrying by pulling up the lever may cause
change of the spring set pressure and alignment of the stem.
3,2 Inlet side piping
It is the best practice to directly mount the safety and safety-relief valve in vertical position
on a nozzle of pressure vessel or a short connection which smooth flow of fluid.
Where rounded or beveled approaches can not be provided ahead of the safety-relief valve, it
is recommended that one size larger riser or fitting be used. The pressure drop in the valve
inlet piping should not exceed 3% of the set pressure.
Valves are sometimes badly damaged just as they go into service because of failure to clean
the connections.
It is essential that the boiler, pressure vessel, valve inlet, and all connections should be
cleaned thoroughly before the valve is mounted.
(1) Caution at inlet piping

Most of leak on valve performance are caused from failure to clean. Many valve are
damaged when first placed in service or even hydraulic pressure test under undue preparation
due to failure to properly clean the connections and piping when installed.
3.3 Outlet side piping
When arranging the discharge piping, pay due attention to the following points talking into
consideration that discharge piping should be simple and direct :
(1) Minimize the length and the number of bends of discharge piping so as to reduce the back
pressure of the valve to a minimum. Especially, when a silencer is used, note that the
discharge pipe tends to be long and
FOR
DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 8 of 14
Gives a large pressure drop due to discharge exceed 10% of the set pressure.
(2) Discharge piping should be so designed that the weight of the piping will at no time be taken
up by the valve body.
A sufficient flexibility to the discharge piping is also essential to avoid strain on the valve
caused by thermal pipe expansion.
(3) Care on multi installation

When two more valves are installed to discharge into a common header the discharge
pressure due to the opening pressure of the remaining valves in the system.
(가) Valve with bonnet not vented
The discharge line pressure of these valves will increase the opening
pressure by the amount (kg/cm2) of the discharge pressure.
(나) Valve with bonnet vented
The set pressure of the remaining valves in the system will be reduced by the
amount (kg/cm2) of the discharge pressure.
FOR
DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 9 of 14
※ Where either of the above conditions are unacceptable, the use of balanced bellows valves is
recommended.
Conventional valve with vented bonnet is not suitable for continuous back pressure.
Therefore never try to arrange discharge pipe from two or more valves into a common
header.
4. CAUTION on HYDRAULIC TEST
When hydraulic pressure test on the pressure vessel is conducted without removing the safety
valve installed on it. increase inner pressure of the vessel to 80 to 90% of the set pressure of the
valve, then mount the test gag to hold the end of the stem lightly in order to protect the valve
from damage caused by undue load.
Removal of the gag shall also be conducted at 80 to 90% of the set pressure.
When several valves are installed on a vessel or pipe line and one of the valves is being on
adjustment. The same caution should be taken at the mounting of the test gag or gags on the other
valve or valves to prevent it or them from blowing off.
4.1 Cautions
The test gag can not be mounted on the ordinary type caps. Therefore, the caps should be
replaced with those made for the purpose.
In case of pressure test for pressure vessels without using test gag, test them without the
safety valves for safety of it.
Removed valve should be covered at the flange parts against intrusion of dusts, etc.
Replace with a plug and gasket in case of closed top (or take off when open top) after the test,
otherwise the valve will not operate thereby creating a dangerous situation.
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SAFETY RELIEF VALVE
PAGE 10 of 14
4.2 Test gag

- Test gag should be used only when hydrostatic testing is performed at field
- Safety valve & safety relief valve are usually shipped with this gag
- The test gag should be furnished in accordance with following
5. ADJUSTMENT
consideration of service pressure characteristic
(differential between operating and set pressure)
In order to avoid unsatisfactory operation of safety relief valves in normal processing service. the
operating pressure of the system should not exceed 90% of the set pressure. in the pump and
compressor delivery line, however, the difference between the set pressure and the operating
pressure should be made large on account of the pulsation attributable to the pump delivery
pressure is a better method.
Before re-adjustment, remove a Pb seal to cap and set screws which is sealed to prevent arbitrary
adjustment by an incompetent and visual check of any external changes of set pressure or
blowdown pressure.
5.1 Adjustment of set pressure

The set pressure of each safety valve has precisely been adjusted and sealed
At our factory before the shipment, however in case that it is necessary to readjust at the
job-site to the state of the exhaust pipe, the amount of blowing capacity, and other factors,
readjustment can be done in the following procedure :
FOR
DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 11 of 14
Take off cap, loosen lock nut and turn down the adjusting screw to the right(clockwise
viewing from above) to raise set pressure and turn up the left (anti-clockwise viewing from
above) to lower the set pressure.
At the readjustment, be sure to lower the pressure of the system at below 90% of the set
pressure.
After completion of re-adjustment, screw up the adjusting screw with lock nut.
Tolerance of set pressure

unit : kg/cm2
SET PRESSURE TOLERANCE
5 excl. and under ± 0.14

over 5 and 23 excl. ± 3% (of set pressure)
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SAFETY RELIEF VALVE
PAGE 12 of 14
6. TROUBLES and SHOOTINGS
6.1 Leakage
The most frequent causes of leakage are from damages on the valve seat and adhering of
foreign materials on it. In these cases, pull the lever to blow off the dirt sticking from the
seat. If the leakage does not stop, the seat must have been damaged.
To avoid seating surfaces damaged by foreign materials. care should be taken thoroughly
from storage to installation which is the best practice after completely flushing out.
Refer to, when it is need, the repair and lapping procedures in para 7 for reconditioning
6.2 Incorrect popping pressure
If the safety valve does not operate at specified pressure, a major cause is accumulation of
dirt or scale between the disc and the guide or the change of the spring load due to bent of
stem. in the case, cleaning or
Dismounting for servicing is required.
6.3 Unstable operation
Unstable operation often results from wrong adjustment. the followings are the state of
unstable operation and its remedy.
(1) Simmer
When a simmer is present raise the lower ring(push the notches to the right while viewing
in front of notch) by one noter at a time. ( Never set the lower ring in contact with the
valve disc)
this is the case of the slightly weakening dynamic power to lower accumulation not
enough to lift up the disc.
(2) Chattering
This is a rapid reciprocating variations in valve lift during which the disc repeatedly
contacts the seat. It is because popping power is weak. In this case, bring up the lower ring
(closer to the bottom face of the disc but never contact each other)
(3) Hunting
This is the states where the disc repeats violent vertical motion during operation as if it
beat the seat violently. This is often caused when there is much flow restriction in the
piping connected with inlet and discharge side of the safety valve or when blowdown is
excessively too short, in this case, open the gland cock or needle valve or bring down the
upper ring to increase blowdown.
If hunting is not ceased despite the above adjustment, rechecking of the piping is
necessary.
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DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 13 of 14
7. REPAIR and LAPPING
In practice, the main necessary repair work will be lapping on the sealing surfaces of disc and
nozzle seat. Its procedure is as follows:
7.1 Kind of lapping compound

No. 1 Lapping compound:
Pasty mixture of compound No. 200 kneaded with rape oil into a cream form.
Pasty mixture of compound No. 800 kneaded with rape oil into a form between cream and
liquid,
Pasty mixture of compound No. 4000 kneaded with rape oil into a form between cream and
liquid.
7.2 Lapping procedure

(1) Coat a surface of lapping block thinly with No.1 lapping compound.
Elliptically move the lapping block to remove large scratches.
(2) Use No.2 lapping compound and make lapping in the same manner as procedure 1 to reduce
scratches in size.
(3) Finish with No.3 lapping compound. The lapping manner is the same as procedure 1.
(4) Finally, use No.3 lapping compounds and make mutual lapping of the valve disc and the
valve seat to finish them.
Mutual lapping is effected by lightly turning and reversing the valve disc on the valve seat.
The width of turning and reversing motion is 5 to 10mm, and mutual lapping should not be
continued too long. If it is continued too long, the outer side of the seating surface will
become dull. When the lapping is felt heavy by hand, stop doing it.
7.3 Washing
Carefully wash the valve seat and valve disc with cleaning oil or liquid after lapping to make
them completely free from lapping compound.
7.4 Inspection of lapped surfaces

Inspection of lapped surface is extremely difficult. Try the following method:
Lighten the lapped surface. If the brightness is even all over the surface, the lapping is
complete. If any shady portion is present, the lapping is incomplete.
Especially the following attention should be paid:

(1) Pay extra care not to damage or soil the lapped surfaces of valve disc and valve seat.
(2) Properly center the tip end of the valve spindle on the valve disc.
(3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
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DATE 2005. 11. 16
SAFETY RELIEF VALVE
PAGE 14 of 14
8. REASSEMBLY
Reassembly will be made following the reverse order of disassembly.
Especially the following attention should be paid:
(1) Care should be taken not to damage or soil the lapped surfaces of valve disc and valve seat.
(2) Properly center the tip end of the valve spindle on the valve disc.
(3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
Manual for Operation Instruction
Company JOKWANG I.L.I CO., LTD
Department Technical Department No. ER-2011-0608

Subject Manual for Operation Instruction for JSV-FF21, Steam Safety Valves
JSV-FF21 series were designed and developed primarily for steam

service safety valves. They satisfy use in the harsh environments of
high temperature and pressure.
Safety valves need proper mechanisms that provide good reliability.
A good example is the back pressure adjustment mechanism of our
safety valves.
In additional to clear-popping and valve lifting force adjustment
mechanisms, our valves have a unique back pressure adjustment
mechanism that allowing them control blow down and good
performance without malfunction.
This guideline is operation instruction for exact performance and for
being preventive the effect of back pressure when valve opening.
Therefore please keep our recommendation instruction.
Operating Adjustment Mechanism

1) Running Clearance for exact performance during the valve
operation
For the exact performance during disc open and close at set pressure
and overpressure, running clearance between outside of stem and
inside of yoke body is absolutely and properly needed. This design
construction provide exact operating characteristics and the moving of
stem (up and down). Please refer to “A: running clearance” in
attachment.
1/2
Operation Instruction
2) Adjustment Valve Installation for the prevention of back pressure

during the valve operation
This adjustment valve can eliminate (vent) the effect of back pressure
which is generated and is accumulated gradually due to valve disc is
moved up in the space area during the valve operating.
This adjustment valve has important function for disc full lift and the
required flow capacity at the time of performance. And wrong handing
of this adjustment valve cause malfunction such as hunting during
the operating as well.
Therefore ANY connection and ANY adjustment elements to the
adjustment valve are not permitted. This is our “ Back pressure
adjustment mechanism”
Please refer to “B: adjustment valve” in attachment.
If In case of necessary installation for the copper connection (or other

connection elements) into the adjustment valve, we strongly
recommend that the inside diameter of copper pipe should be larger
than insider of adjustment valve.
- END -
2/3
Operation Instruction Attachment
3/3
No. SS2-GTX00D-0100
(Rev.2)
AT9000 Advanced Transmitter

Differential Pressure Transmitters
OVERVIEW
AT9000 Advanced Transmitter is a micropro-
cessor-based smart transmitter that features high
performance and excellent stability. Capable of
measuring gas, liquid, vapor, and liquid levels, it
transmits 4 to 20 mA DC analog and digital sig-
nals according to the measured differential pres-
sure.
It can also execute two-way communications
between the CommPad (Handy Communicator)
or HART® 375 communicator, thus facilitating
self-diagnosis, range resetting, and automatic
zero adjustment.
FEATURES • A wide variety of corrosion-resistant materials

High performance and stability for wetted parts is also available.
• Unique characterization and composite semi- Remote communication
conductor sensors realize high accuracy up to • Two-way communication using digital output
0.04% F.S. facilitates self-diagnosis, range resetting, auto-
• Our proven sensor technology enables Long- matic zero adjustment, and other operations.
term stability up to 0.1% of URL per 10-year. • HART® protocol communication is available.
Wide measuring range (range ability) (Option)
• A wide measuring range is available from a
single model. This feature is highly effective in HART® is a registered trademark of the HART Communication Foundation.
taking measurement over a wide range and

reducing the need for inventory.
• Model GTX30D/31D/32D: 0.5 to 100 kPa
(range ability: 200 to 1)
A diverse lineup
• A wide range of models is available to meet
user requirements. They include draft range
differential pressure, standard differential pres-
sure, high differential pressure, standard differ-
ential pressure/high static pressure, and high
differential pressure/high static pressure mod-
els.
Specifications are subject to change without notice. -1-

No. SS2-GTX00D-0100 Yamatake Corporation
FUNCTIONAL SPECIFICATIONS Electrical Parameters: Ui=30V, Ii=100mA, Pi=1W,

Ci=13nF, Li=0.5mH
Type of protection Certificate No. GYJ071269
NEMA3 and 4X
IEC IP67 NEPSI Type n Certification
Ex nL IIC T4 Tprocess=110°C -40°C < Tamb < +60°C
FM Explosionproof and Dust Approvals Enclosure IP66 / 67
Explosionproof for Class I, Division 1, Groups A, B, C Electrical Parameters: Ui=30V, Ii=100mA, Pi=1W,
and D; Class I, Zone 1, AEx d IIC Ci=13nF, Li=0.5mH
Dust-Ignitionproof for Class II, III, Division 1, Groups E, Certificate No. GYJ071269
F and G
T5 -40°C < Tamb < +85°C
EMC Conformity
Hazardous locations 89/336/EEC, 92/31/EEC, 93/68/EEC Electromagnetic
Indoor / Outdoor Type 4X, IP67 Compatibility (EMC) Directive
Factory sealed, conduit seal not required for Division Measuring span / Setting range / Working
applications pressure range
Caution - Use supply wires suitable for 5°C above sur-
Mo
rounding ambient Measuring Span Measuring range Working Pressure Range
del
FM Explosion proof approval (draft, pending) GTX 0.1 to 2 kPa -1 to 1 kPa -70 to 210 kPa
Explosionproof for Class I (Gas, steam), Division 1, 15D {10 to 200 mmH2O} {-100 to 100 mmH2O} {-0.7 to 2.1 kgf/cm2}
Group A, B, C, D 0.5 to 100 kPa 2.0kPa abs to 3.5MPa
Dust-ignition for Class II (Inflammable dust), Division 1, GTX -100 to 100 kPa
{50 to 10160 {15 mmHg abs to 35 kgf/
30D {-10160 to 10160 mmH2O}
Group E, F, G mmH2O} cm2} *Note 1
Suitable for Class III (inflammable fiber), Division 1 2.0 kPa abs to 21 MPa
Nonincendive for Class I, Division 2, Group A, B, C, D 0.5 to 100 kPa {15 mmHg abs to 210 kgf/
GTX -100 to 100 kPa
FM Intrinsically safe approval (draft, pending) 31D
{50 to 10160
{-10160 to 10160 mmH O} cm2}*Note 1, *Note 2
mmH2O} 2
(For vacuum pressure, see
Intrinsically safe for Class I, II, III, Division 1, Group A, Figure 1, 2)
B, C, D, E, F, G 2.0 kPa abs to 42 MPa
ATEX Flameproof approval (draft, pending) GTX
0.5 to 100 kPa
-100 to 100 kPa
{15mmHg abs to 420 kgf/
2
{-10160 to 10160 mmH2O} cm } *Note 3
{50 to 10160
Certificate number: INERIS99ATEX0010 X 32D mmH2O} (For vacuum pressure, see
II 2 GD EExd IIC T6 at -20 < Tamb < +60°C Figure 1, 2)
2.0kPa abs to 3.5MPa
GTX 35 to 700 kPa -100 to 700 kPa
ATEX Intrinsic safety (draft, pending) 40D {0.35 to 7kgf/cm }
2 2
{15 mmHg abs to 35 kgf/
{-1 to 7kgf/cm }
Certificate number: KEMA03ATEX1225 X cm2} *Note 1
2.0 kPa abs to 21 MPa
II 1 G EEx ia IIC T4 at -20 < Tamb < +60°C {15 mmHg abs to 210 kgf/
GTX 35 to 700 kPa -100 to 700 kPa
Electrical data: Ui = 30V 41D {0.35 to 7kgf/cm }
2 2 cm2}*Note 1, *Note 2
{-1 to 7kgf/cm }
Ii = 100 mA (For vacuum pressure, see
Pi = 1W Figure 1, 2)
Ci = 3 nF 2.0 kPa abs to 42 MPa
Li = 0.5 mH {15mmHg abs to 420 kgf/
GTX 35 to 700 kPa -100 to 700 kPa
42D {0.35 to 7kgf/cm }
2 2 cm2} *Note 3
SPECIAL CONDITIONS FOR SAFE USE (X) {-1 to 7kgf/cm }
Because the enclosure of the Smart Pressure Transmitter is Figure 1, 2)
made of aluminium, if it is mounted in an area where the 2.0 kPa abs to 21 MPa
use of category 1 G apparatus is required, it must be {15 mmHg abs to 210 kgf/
installed such, that, even in the event of rare incidents, GTX 0.25 to 14MPa -0.1 to 14 MPa 2
71D {2.5 to 140kgf/cm2} {-1 to 140 kgf/cm2} cm }*Note 1, *Note 2
ignition sources due to impact and friction sparks are (For vacuum pressure, see
excluded. Figure 1, 2)
2.0 kPa abs to 42 MPa
NEPSI Flameproof and Dust Certifications {15mmHg abs to 420 kgf/
Ex d IIC T6 DIP A21 TA 85°C Tprocess=80°C -40°C < GTX 0.25 to 14MPa -0.1 to 14 MPa 2
Tamb < +75°C 72D {2.5 to 140kgf/cm2} {-1 to 140 kgf/cm2} cm } *Note 3
Ex d IIC T5 DIP A21 TA 100°C Tprocess=95°C -40°C < Figure 1, 2)
Tamb < +80°C Note) 1) With PVC wetted parts, the maximum working pressure
Ex d IIC T4 DIP A21 TA 115°C Tprocess=110°C -40°C <
is 1.5 MPa {15 kgf/cm2}.
Tamb < +80°C 2) With 304 SST bolts and nuts, the maximum working
ENCLOSURE TYPE IP66/67
pressure is 10MPa {100 kgf/cm2}.
Certificate No. GYJ071268
3) With 304 SST bolts and nuts, the maximum working
NEPSI Intrinsic Safety Certification (draft, pending) pressure is 23.3 MPa {233 kgf/cm2}.
Ex ia IIC T4 Tprocess=105°C -40°C < Tamb < +60°C
Enclosure IP66 / 67
-2-
Yamatake Corporation No. SS2-GTX00D-0100
Operative limit
Working pressure P (kPa {kgf/cm2})

210
Working Pressure P (kPa abs/{mmHg})

{2.1}
133.3 Normal
{1000} Normal operating range operating
101 range
0
80
Operative limit
53 -20
{-0.2}
27
-50
13 {-0.5}
8.0
5.3 -40 -10 0 40 65 70
2.0
{15} Unusable range Temperature of wetted parts ( C)
1.3
Figure 4 Working pressure and temperature of
wetted parts section (for model
-50-40 40 50 60 70 80 90 100110 115 GTX15D oxygen service)
Temperature of wetted parts ( C)
Figure 1 Working pressure and temperature of Supply voltage and load resistance
wetted parts section (for general pur- 17.9 to 42V DC. A load resistance of 250 Ω or more is
pose models) necessary between loops. See Figure 5.
1482
1345
Working pressure P kPa {mmHg}
Unusable range Load resistance (W)
Operative limit
Supply voltage - 12.5
=
Load resistance (Ω)
0.0219
133.3
{1000} Normal operating
range
101.3
{760}
Operating Range
53
{400} 245
0 12.5 17.9 42 45
-40 -20 0 40 75 80 Supply voltage (V DC)
Figure 2 Working pressure and temperature of Figure 5 Supply voltage vs. load resistance
wetted parts section (for oxygen and characteristics
chlorine service) Note) For communication with HART communicator or Comm-
Pad, a load resistance of 250 Ω or more is necessary.
Output
Working pressure P (kPa {kgf/cm2} )
210
{2.1} Analog output (4 to 20 mA DC) with DE protocol
Analog output (4 to 20 mA DC) with HART protocol
Operative limit
Operating limit
Output signal
Normal operating range
0 3.6 to 21.6 mA
3.8 to 20.5 mA (NAMUR NE43 compliant)
Failure Alarm
-70 Upper: 21.6 mA or more
{-0.7}
Lower: 3.6 mA or less
-40 -15 0 657080
Figure 3 Working pressure and temperature of

wetted parts section (for model
GTX15D regular type)
-3-
Ambient temperature limit Stability against supply voltage change

Normal operating range ± 0.005% FS/V
-40 to 85°C for general purpose models Response time
-15 to 65°C for general purpose model (model GTX15D) Below 100 msec.(model GTX30D/31D/32D, when damp-
-20 to 75°C for oxygen and chlorine models ing time is set to 0 sec.)
-15 to 65°C for oxygen and chlorine model (model
GTX15D) Damping time
-25 to 80°C for model with digital indicators Selectable from 0 to 32 sec. in ten stages
-15 to 65°C for model with digital indicators (model
GTX15D) Zero Stability
± 0.1% of URL per 10-year (model GTX30D/31D/32D)
Operative limits
-50 to 93°C for general purpose models Lightning protection
-40 to 70°C for general purpose model (model GTX15D) Applicable Standards; IEC 61000-4-5
-25 to 93°C for general purpose model (model GTX32D/ Peak value of current surge(80/20µ sec.): 6000A
42D/72D)
-40 to 80°C for oxygen and chlorine models Indicator
-30 to 85°C for models with digital indicators The digital LCD indicator (optional) indicates engineering
Transportation and storage conditions units and can be set freely between -99999 and 99999 (5
-50 to 85°C for general purpose models digits). For meter calibration, specify the following items
-15 to 65°C for general purpose model (model GTX15D) when placing your order
-15 to 85°C for general purpose model (model GTX32D/ • Meter calibration range
42D/72D) • Meter calibration unit
• Linear / Square-root for meter indication.
Temperature ranges of wetted parts Various kinds of data can be set using the CommPad or
Normal operating range
-40 to 110°C for general purpose models the HART®375 communicator.
-15 to 65°C for general purpose model (model GTX15D) Bolts and nuts materials (for fastening
-20 to 75°C for oxygen and chlorine models meter body cover)
-15 to 65°C for oxygen and chlorine model (model Carbon steel (SNB7), 304 SST, 630 SST
GTX15D)
Paint
Operative limits
-50 to 115°C for general purpose models Standard
-40 to 70°C for general purpose model (model GTX15D) Corrosion-resistant paint (Baked acrylic paint)
-40 to 80°C for oxygen and chlorine models Corrosion-proof finish
-15 to 115°C for general purpose model (model Corrosion-proof paint (Baked epoxy paint), fungus-
GTX32D/42D/72D) proof finish
Ambient humidity limits Corrosion-resistant finish (silver paint)
5 to 100% RH Transmitter case is coated with silver paint in addition to
the above corrosion-resistant finish.
-4-
OPTIONAL SPECIFICATIONS PHYSICAL SPECIFICATIONS

Oil free finish Materials
The transmitter is shipped with oil-free wetted parts. Fill fluid
Adapters for anticorrosion materials Silicone oil for general purpose models
These are adaptor flanges to connect 82 mm pipes made of Fluorine oil for oxygen and chlorine models
anticorrosion materials [excluding ASTM B575 (Equiva- Center body
lent to Hastelloy C-276)] to 54 mm general-purpose pipes. 316 SST
External zero/span adjustment function Transmitter case
The transmitter can be easily zero/span adjusted in the Aluminum alloy
field. Meter body cover flange
Elbow SCS14A (Equivalent to 316 SST) or 316 SST, PVC
This is an adaptor for changing the electrical conduit con- For Wetted parts
nection port from the horizontal to the vertical direction, if
Adapter flange (option)
required by wiring conditions in the field. One or two
SCS14A (Equivalent to 316 SST), PVC
elbows may be used as needed.
Center body
Conformance to Non SI units 316 SST (Diaphragm 316L SST)
We deliver transmitters set to any Non SI units as speci- ASTM B575 (Equivalent to Hastelloy C-276), Tanta-
fied. lum, 316L SST
Safety Transmitter Vents and plugs
Select this option to be used as a component of Safety 316 SST, PVC
Instrument System (SIS).
AT9000 is complied with IEC61508, certified according to Weight
Safety Integrity Level2 (SIL-2) Approx. 3.6 kg (model GTX30D)
Alarm Output (contact output) INSTALLATION

Contact output is prepared as alarm output when alarm
(Output Alarm/Sensor Temp. Alarm) condition is Electrical connection
detected. It can be set to Normally Open. (When alarm is 1/2NPT internal thread, M20 internal thread.
detected, Contact ON). Grounding
Custom calibration Resistance 100 Ω max.
Calibrate for the specified pressure range at the factory. Mounting
Can be installed on a 2-inch horizontal or vertical pipe
(can be directly mounted on a process pipe)
Process connection
Rc1/2, 1/2NPT internal thread and Rc1/4, 1/4NPT internal
thread.
-5-
PERFORMANCE SPECIFICATIONS
Accuracy
Shown for each item are the percentage ratio for χ (kPa), which is the greatest value of either the upper range value
(URV)*1, the lower range value (LRV)*2 or the span.
Model GTX15D
(Material of wetted parts: Diaphragm; 316L SST, Others; 316 SST)
Accuracy Linear output:  1.0
± 0.15 + 0.15 × ------- %
 χ
When output is 50 to 100%:same as linear output
Square-root output: 50
When output is 7.1 to 50%: linear output × -------------------------------------------------------- %
square – root ⋅ output
When output is less than 7.1%: dropout
Ambient Temperature Combined shift:
effect (Shift from the set (including zero and
1.0
range) span shifts) ±  0.19 + 0.56 × ------- %
 χ
Change of 30ºC
(Range from -5 to 55ºC)
Static pressure effect Zero shift: 1
(Shift with respect to Set- ±  0.03 + 0.4 × --- %
χ
ting range)
Change of 70 kPa {0.7 Combined shift:
1
(including zero and ±  0.03 + 0.45 × --- %
kgf/cm2}  χ
span shifts)
Model GTX30D/31D/32D
Accuracy (*3) Linear output: ± 0.04% (For χ ≥ 10.0kPa {1000mmH2O})
10
±  0.008 + 0.032 × ------ % (For χ < 10kPa {1000 mmH2O})
χ
Square-root output: When output is 50 to 100%: same as the linear output
50
Ambient Temperature Combined shift: ± 0.15% (For χ ≥ 12.5kPa {1250 mmH2O})
effect (Shift from the set (including zero and
12.5
range) span shifts) ±  0.075 + 0.075 × ---------- % (For χ ≤ 12.5kPa {1250 mmH2O})
 χ 
Change of 30ºC
(Range from -5 to 55ºC)
Static pressure effect Zero shift: 12.5
(Shift with respect to Set- ±  0.03 + 0.17 × ---------- %
χ
ting range) (*3)
Combined shift: 12.5
Change of 7 MPa {70 kgf/
(including zero and ±  0.03 + 0.37 × ---------- %
χ
cm2} span shifts)
Note) *1: URV denotes the process value for 100% (20 mA DC) output
*2: LRV denotes the process value for 0% (4 mA DC) output.
*3: Within a range of URV > 0 and LRV > 0.
-6-
Model GTX40D/41D/42D
Accuracy (*3) Linear output: ± 0.1% (For χ ≥ 140kPa {1.4 kgf/cm2})
140
±  0.025 + 0.075 × --------- % (For χ < 140kPa {1.4 kgf/cm2})
χ
50
Ambient Temperature Combined shift: ± 0.41% (For χ ≥ 210kPa {2.1 kgf/cm2})
effect (Shift from the (including zero and
210
set range) span shifts) ±  0.18 + 0.23 × --------- % (For χ < 210kPa {2.1 kgf/cm2})
χ
Change of 30ºC (*3)
(Range from -5 to
55ºC)
Static pressure effect Zero shift: ·
700
(Shift with respect to ±  0.03 + 0.15 × --------- %
χ
Setting range) (*3)
Change of 7 MPa {70 Combined shift: ± 0.33% (For χ ≥ 700kPa {7.1 kgf/cm2})
(including zero and
kgf/cm2} span shifts)
700
±  0.03 + 0.3 × --------- %(For χ < 700kPa {7.1 kgf/cm2})
χ
Model GTX71D/72D
Accuracy (*3) Linear output: ± 0.15% (For χ ≥ 3.5MPa {35 kgf/cm2})
3.5
±  0.1 + 0.05 × ------- % (For χ < 3.5MPa {35 kgf/cm2})
 χ
50
Ambient Temperature Combined shift: ± 0.41% (For χ ≥ 3.5MPa {35 kgf/cm2})
3.5
set range) span shifts) ±  0.18 + 0.23 × ------- %( χ < 3.5MPa {35 kgf/cm2})
 χ
(Range from -5 to
55ºC)
(Shift with respect to ±  0.03 + 0.17 × --- %
 χ
Setting range) (*3)
Change of 7 MPa {70 Combined shift: ± 0.4% (For χ ≥ 7MPa {70 kgf/cm2})
(including zero and
7
±  0.03 + 0.37 × --- % (For χ < 7MPa {70 kgf/cm2})
 χ
Note) *3: Within a range of URV > 0 and LRV > 0.
-7-
Model GTX31D
(Material of wetted parts: Diaphragm; ASTM B575 (Equivalent to Hastelloy C-276), Tantalum, 316L SST Others; ASTM
B575 (Equivalent to Hastelloy C-276), Tantalum, 316L SST)
Accuracy (*3) Linear output: ± 0.2% (For χ ≥ 10kPa {1000mmH2O})
10
±  0.125 + 0.075 × ------ % (For χ ≥ 10kPa {1000 mmH2O})
χ
50
Ambient Temperature Combined shift:
set range) span shifts) 20.0
±  0.55 + 0.65 × ---------- %
Change of 30ºC (*3)  χ 
(Range from -5 to
55ºC)
Static pressure effect Zero shift: 20.0
(Shift with respect to ±  0.03 + 0.62 × ---------- %
 χ 
Setting range) (*3)
Combined shift: 20.0
Change of 7 MPa {70
(including zero and ±  0.55 + 0.45 × ---------- % ( χ ≥ 20.0kPa {2000 mmH2O})
 χ 
20.0
±  0.18 + 0.82 × ---------- % ( χ < 20.0kPa {2000 mmH2O})
 χ 
Model GTX41D
(Material of wetted parts: Diaphragm; ASTM B575 (Equivalent to Hastelloy C-276), Tantalum, 316L SST Others; ASTM
B575 (Equivalent to Hastelloy C-276), Tantalum, 316L SST)
Accuracy (*3) Linear output: ± 0.2%( χ ≥ 140kPa {1.4 kgf/cm2})
140
±  0.125 + 0.075 × --------- % (For χ < 140kPa {1.4 kgf/cm2}
 χ 
50
Ambient Temperature Combined shift: ± 1.20%( χ ≥ 210kPa {2.1 kgf/cm2})
210
set range) span shifts) ±  0.55 + 0.65 × --------- % (For χ < 210kPa {2.1 kgf/cm2})
 χ 
(Range from -5 to
55ºC)
(Shift with respect to ±  0.03 + 0.62 × --------- %
χ
Setting range) (*3)
Combined shift: 700
Change of 7 MPa {70
(including zero and ±  0.03 + 0.50 × --------- %
χ
-8-
Model GTX71D
(Material of wetted parts: Diaphragm; 316L SST, Others; 316L SST)
Accuracy (*3) Linear output: ± 0.2% (For χ ≥ 3.5MPa {35 kgf/cm2})
3.5
±  0.15 + 0.05 × ------- % (For χ < 3.5MPa {35 kgf/cm2})
χ
50
Ambient Temperature Combined shift: ± 1.20% (For χ ≥ 3.5MPa {35 kgf/cm2})
3.5
set range) span shifts) ±  0.55 + 0.65 × ------- % (For χ < 3.5MPa {35 kgf/cm2})
χ
(Range from -5 to
55ºC)
(Shift with respect to ±  0.03 + 0.295 × --- %
 χ
Setting range) (*3)
Combined shift: 7
Change of 7 MPa {70
(including zero and ±  0.45 + 0.125 × --- % (For χ ≥ 7MPa {70 kgf/cm2})
 χ
7
±  0.08 + 0.495 × --- % (For χ < 7MPa {70 kgf/cm2})
 χ
-9-
MODEL SELECTION
Model GTX15D(Standard type for lowest differential pressure)
Model No.:GTX_ _D-Selection I(I II III IV V VI VII)-Selection II(I II III IV V VI)-Option
Basic Model No.

Measuring span 0.1 to 2.0 kPa (10 to 200 mmH2O) GTX15D
Selection I
I Output 4 to 20mA (SFN Communication) A
4 to 20mA (HART Communication) B
II Fill fluid Regular type (Silicone oil) A
For oxygen service (Fluorine oil) H
III Material (Meter Meterbody cover Vent / Drain plugs
body cover, Vent/
Drain plugs) SCS14A 316 SST A
IV Material (center 316 SST (Diaphragm:316L SST) A
body)
V Process connections Re 1/2, with adapter flange A
Re 1/4, with adapter flange B
Re 1/4, without adapter flange C
1/2 NPT internal thread, with adapter flange D
1/4 NPT internal thread, with adapter flange E
1/4 NPT internal thread, without adapter flange F
VI Process installation Vertical piping, top connection A
Vertical piping, bottom connection B
Horizontal piping, front connection C
VII Bolt/nut 304 SST B
Selection II -
I Electrical connection 1/2 NPT, Watertight A
M20, Watertight *1 B
II Explosion proof None XX
FM Explosion proof F1
FM Intrinsically safe F2
ATEX Explosion proof A1
ATEX Intrinsically safe A2
IECEx Explosion proof, E1
IECEx Intrinsically safe E2
NEPSI Explosionproof N1
NEPSI Intrinsically safe N2
NEPSI Type n N5
III Indicator None X
With indicator A
IV Paint Standard X
Corrosion-proof B
Corrosion-resistant (Silver coating) D
V Failure alarm Upper limit of output at abnormal condition A
Lower limit of output at abnormal condition B
VI Mounting bracket None X
Carbon steel (L form) 3
304 SST (L form) 4
Note) *1 Not applicable for the combination with code F1 “FM Explosion proof” of Explosion proof.
(Continued)
- 10 -
(Continued from previous page)
Option -
No options XX
Adapter flange for corrosion-resistant application (316L SST or Tantalum for the wetted parts of centerbody) A1
With external Zero/Span adjustment *11 A2
One elbow (left) *6*7*10 G1
One elbow (right) *6*7*10 G2
2 elbows *6*8*10 G3
Long vent/drain plugs G4
Side vent/drain top *6 G6
Side vent/drain bottom *6 G7
Oil and water free finish K1
Oil free finish *4 K3
Au Plating Diaphragm L1
Safety Transmitter *5 Q1
NAMUR NE43 Compliant Output Signal Limits:3.8 to 20.5mA (Output 21.6mA/selected upper limit, 3.6mA/selected lower Q2
limit)
Alarm Output (contact output) Q7
Custom calibration R1
Test report T1
Mill certificate T2
Traceability certificate T4
NACE certificate *9 T5
Non SI Unit W1
Note) *4 No need to select when Fill Fluid code H, or J is selected.

*5 Not applicable for the combination with code A2,or Q7 of Option.
*6 Not applicable for the combination with code A, or B of Process installation.
*7 Not applicable for the combination with code F1 “FM Explosion proof” of Explosion proof.
*8 Not applicable for any Explosion proof. Please select code F1 “None” of Explosion proof.
*9 Applicable for “ASTM B575”, code B of Material (center body).
*10 Not applicable for the combination with code B “M20, Watertight” electrical connection.
*11 Not applicable for the combination with code X “None” of Indicator. Please select “With indicator”.
- 11 -
Model GTX30D(Standard type for standard differential pressure)

Model GTX40D(Standard type for high differential pressure)
Basic Model No.

Measuring span 0.5 to 100kPa (50 to 10160mmH2O) GTX30D
35 to 700kPa (0.35 to 7kgf/cm2) GTX40D
Selection I
I Output 4 to 20mA (SFN Communication) A
4 to 20mA (HART Communication) B
II Fill fluid Regular type (Silicone oil) A
For oxygen service (Fluorine oil) H
III Material (Meter Meterbody cover Vent / Drain plugs
body cover, Vent/ SCS14A 316 SST A
Drain plugs)
IV Material (center 316 SST (Diaphragm:316L SST) A
body) ASTM B575 (Equivalent to Hastelloy C-276) B
V Process connections Rc 1/2, with adapter flange A
Rc 1/4, with adapter flange B
Rc 1/4, without adapter flange C
1/2 NPT internal thread, with adapter flange D
1/4 NPT internal thread, with adapter flange E
1/4 NPT internal thread, without adapter flange F
VI Process installation Vertical piping, top connection A
Vertical piping, bottom connection B
Horizontal piping, front connection C
VII Bolt/nut 304 SST B
Selection II -
I Electrical connection 1/2 NPT, Watertight A
M20, Watertight *3 B
II Explosion proof None XX
FM Explosion proof F1
FM Intrinsically safe F2
ATEX Explosion proof A1
ATEX Intrinsically safe A2
IECEx Explosion proof, E1
IECEx Intrinsically safe E2
NEPSI Explosionproof N1
NEPSI Intrinsically safe N2
NEPSI Type n N5
III Indicator None X
With indicator A
IV Paint Standard X
Corrosion-proof B
Corrosion-resistant (Silver coating) D
V Failure alarm Upper limit of output at abnormal condition A
Lower limit of output at abnormal condition B
VI Mounting bracket None X
Carbon steel (L form) *2 3
304 SST (L form) *2 4
Note) *2 Applicable for wetted parts of material (center body); 316 SST and ASTM B575.
*3 Not applicable for the combination with code F1 “FM Explosion proof” of Explosion proof.
(Continued)
- 12 -
10Ø BITE
CONNECTION
10Ø BITE
CONNECTION
®
ProMinent
Betriebsanleitung
Operating Instructions
Mode d’emploi
Instrucciones de servicio
ProMinent® CONCEPTPLUS
Part No. 987033 ProMinent Dosiertechnik GmbH · 69123 Heidelberg · Germany BA CO 013 03/04 G/GB/F/E
D Betriebsanleitung in Deutsch von Seite 3 bis 13
GB Operating Instructions in English from page 15 to page 25
F Mode d’emploi en francais de la page 27 à la page 37
E Instrucciones de servicio en español de página 39 hasta página 49
2 ProMinent
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Seite
Allgemeine Benutzerhinweise 4
1 Geräteübersicht .............................................................................. 5
2 Typenübersicht/Werkstoffangaben ............................................... 6
3 Sicherheit ......................................................................................... 6
4 Lagern und Transportieren ............................................................ 7
5 Montieren und Installieren ............................................................. 7
6 In Betrieb nehmen .......................................................................... 8
7 Wartung ........................................................................................... 8
8 Reparieren ....................................................................................... 9
9 Funktionsstörungen beheben ....................................................... 9
10 Außer Betrieb nehmen und Entsorgen .......................................... 10
11 Technische Daten ........................................................................... 10
12 Zubehör ........................................................................................... 11
Konformitätserklärung 13
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Anweisungen
Sicherheitshinweise:
WARNUNG
Bezeichnet eine möglicherweise gefährliche Situation. Wenn sie

nicht gemieden wird, sind Sie in Lebensgefahr und schwere
Verletzungen können die Folge sein.
ACHTUNG
Bezeichnet eine möglicherweise schädliche Situation. Wenn sie

nicht gemieden wird, können Sachschäden die Folge sein.
Diese Betriebsanleitung ist für Fachleute für Dosierpumpen und

deren Betrieb!
Falls dennoch ausführliche Installationshinweise benötigt werden,
die "Allgemeine Betriebsanleitung ProMinent® Magnetdosier-
pumpen" bestellen (Best.-Nr. 987126)!
4 ProMinent ®
Geräteübersicht
1 Geräteübersicht
8
2 7
1 Hublängen-Einstellknopf
2 Störungs-/Betriebsanzeige (Störung rot / Betrieb grün)
3 Multifunktionsschalter (Hubfrequenzen (in % von 180 Hüben/min),
Stop, Betriebsart "Extern" (Nachrüstsatz))
4 Netzkabel
5 Buchse "externe Ansteuerung" (in Betriebsart "Extern",
Ansteuerung über Kontaktsignal; Nachrüstsatz)
6 Buchse "Niveauschalter" (für 1-stufige Niveauschalter; Nachrüstsatz)
7 Saugventil
8 Druckventil
Die Leckagebohrung ist zwischen Saugventil und Antriebsgehäuse.
ProMinent
®
5
Typenübersicht/Werkstoffangaben / Sicherheit
2 Typenübersicht/Werkstoffangaben
Bestellnummern CONCEPTPLUS, CNPa, 230 V-Ausführung
Pumpentyp Werkstoff Fördereinheit

PP (mit EPDM*) NP** (mit Viton® *)
1000 1022452 1022476
1601 1022453 1022477
1002 1022474 1022478
0704 1022475 1022479
* Dichtungswerkstoff
** Ventilwerkstoff ist PVC
Die Ventilkugeln sind aus Keramik.
3 Sicherheit
Bestimmungs- • Die Pumpe darf nur zur Dosierung flüssiger Medien eingesetzt
gemäße werden!
Verwendung • Alle anderen Verwendungen oder ein Umbau sind verboten!
• Die Pumpe ist nicht dazu bestimmt, gasförmige Medien oder
Feststoffe zu dosieren!
• Die Pumpe nur durch hierfür ausgebildetes und autorisiertes Personal
betreiben lassen!
Das Personal muss mit Dosierpumpen und deren Betrieb vertraut
sein!
WARNUNG
• Sobald die Pumpe mit dem Netz verbunden wird, kann es sein,
dass sie zu pumpen beginnt!
Vermeiden Sie, dass gefährliche Dosiermedien austreten können!
Haben Sie dies versäumt, dann den Multifunktionsschalter auf
STOP stellen oder die Pumpe sofort vom Netz trennen!
• Die Pumpe lässt sich nicht stromlos schalten!
Bei einem elektrischen Unfall das Netzkabel vom Netz trennen!
• Vor Arbeiten an der Pumpe das Netzkabel vom Netz trennen!
• Gefahr eines Stromschlages!
Diese Pumpe ist mit einem Schutzleiter und einem Stecker mit
Schutzkontakt ausgerüstet. Um die Gefahr eines Stromschlages
zu verringern, ist sicherzustellen, dass sie nur an eine Steckdose
mit ordnungsgemäß verbundenem Schutzkontakt angeschlossen
ist.
6 ProMinent
®
Sicherheit / Lagern und Transportiern / Montieren und Installieren
• Vor Arbeiten an der Pumpe immer zuerst die Fördereinheit

druckentlasten!
• Vor Arbeiten an der Pumpe die Fördereinheit entleeren und
spülen, wenn gefährliche oder unbekannte Dosiermedien
verwendet wurden!
• Bei Arbeiten an der Fördereinheit die zu Ihrem Dosiermedium
passende Schutzausrüstung tragen!
• Die Dosierpumpe nie gegen erheblich überhöhten Betriebsdruck
oder ein geschlossenes druckseitiges Absperrorgan arbeiten
lassen! Die Druckleitungen können bersten!
• Überfördern vermeiden durch positive Druckdifferenz zwischen
Druck- und Saugseite! Deshalb z. B. bei freiem Auslauf ein
Druckhalteventil mit mindestens 1,5 bar Öffnungsdruck
verwenden (nicht möglich bei 0213)!
• Die Montage und Installation von ProMinent®-Dosierpumpen mit
Fremdteilen, die nicht von ProMinent geprüft und empfohlen
werden, ist unzulässig und kann zu Personen- und Sachschäden
führen, für die keine Haftung übernommen wird!
• Beachten Sie bei der Installation die gültigen nationalen
Vorschriften!
Schalldruck- Der Schalldruckpegel ist < 70 dB (A) in 1 m Abstand gemäß EN 23741

pegel oder EN 23742 bei maximalem Hub, maximaler Hubfrequenz,
maximalem Gegendruck (Wasser)
4 Lagern und Transportieren
Umgebungsbedingungen für Lagerung und Transport:

Lager- und Transporttemperatur: -10 bis +50 °C
Luftfeuchtigkeit: < 92 % rel. Feuchte, nicht
kondensierend
5 Montieren und Installieren
ACHTUNG
• Die Pumpe so befestigen, dass keine Schwingungen auftreten
können!
• Magnetdosierpumpen neigen bei geringem Gegendruck zum
Überfördern! In diesem Fall ein Druckhalteventil, ein Multifunktions-
ventil oder ein Dosierventil mit 1,5 bar Öffnungsdruck hinter die
Pumpe installieren (nicht möglich bei 0213)!
ProMinent®
7
Montieren und Installieren / In Betrieb nehmen / Wartung
• Verwenden Sie nur Original-Schläuche mit den angegebenen

Durchmessern und Wandstärken!
Andernfalls ist die Haltbarkeit der Verbindung mit den
Pumpenventilen nicht sicher gestellt!
• Für Tipps zum hydraulisch Installieren bestellen Sie die
"Allgemeine Betriebsanleitung ProMinent® Magnetdosier-
pumpen" (Best.-Nr. 987126).
• Übereinstimmung der Netzspannung und der Frequenz mit den
auf dem Typenschild angegebenen Werten überprüfen!
• Beachten Sie bei der Installation die gültigen nationalen
Vorschriften!
Dosierpumpe auf einen Behälter oder eine Konsole mit Schrauben

▲
und U-Scheiben (Ø 6 mm) montieren.

Die Saughöhe und Saugleitungslänge möglichst kurz halten.
▲
Saugleitung steigend verlegen

Saug- und Druckschlauch auf das nötige Maß ablängen
▲ ▲ ▲
Überwurfmutter und Klemmring über die Schlauchleitung ziehen.

Das abgelängte Schlauchende bis zum Anschlag über die Tülle
Schlauch
schieben.
Schlauch anpressen und Überwurfmutter festziehen.
▲
Überwurf-
mutter
(Schnitt)
Klemmring
Fußventil montieren.
▲ ▲
Tülle
O-Ring
Hierzu freies Saugleitungsende so weit ablängen, dass Fußventil
knapp über dem Behälterboden hängt.
Saug- Bei Dosierlösungen mit Verunreinigungen oder Bodensatz freies
anschluss
Saugleitungsende so weit ablängen, dass Fußventil mind. 50 mm
über dem Behälterboden hängt.
6 In Betrieb nehmen
Präzises Dosieren ist nur in einem Hublängenbereich von 30–100 %

möglich.
7 Wartung
Wartungs- Vierteljährlich, bei normaler Beanspruchung (ca. 30 % vom

intervall Dauerbetrieb)
Die Dosiermembran auf Beschädigungen prüfen

▲ ▲
Den festen Sitz von Druck- und Saugventil und der Dosierleitungen
überprüfen.
8 ProMinent ®
Wartung / Reparieren / Funktionsstörungen beheben
Die Dichtigkeit der gesamten Fördereinheit prüfen (besonders
▲
Leckagebohrung zwischen Saugventil und Antriebsgehäuse)
den festen Sitz der Dosierkopfschrauben überprüfen.
▲
Anzugsdrehmomente für Dosierkopfschrauben: 4,5 bis 5 Nm
8 Reparieren
Reparaturmaßnahmen, die von qualifizierten Personen durchgeführt

werden dürfen (gemäß den Sicherheitshinweisen):
• Reinigen eines Ventils
• Membran austauschen (Montageanleitung ist der Ersatzmembran
beigelegt)
Wenden Sie sich für alle anderen Reparaturen an die für Sie zuständige
ProMinent®-Niederlassung!
9 Funktionsstörungen beheben
Pumpe saugt trotz voller Hubbewegung und Entlüften nicht an

Ursache: Kristalline Ablagerungen auf dem Kugelsitz durch
Austrocknen der Ventile.
Abhilfe: Saugschlauch aus dem Vorratsbehälter nehmen und die
Fördereinheit gründlich ausspülen.
Falls kein Erfolg, Ventile ausbauen und reinigen.
An der Kopfscheibe tritt Flüssigkeit aus

Ursache: Die Fördereinheit ist an der Dosiermembran undicht.
Abhilfe: Schrauben im Dosierkopf über Kreuz nachziehen
(Anzugsdrehmoment: 4,5 bis 5 Nm)
Falls kein Erfolg, Membran austauschen (Einbauanleitung ist Membran
beigelegt).
Störungs-/Betriebsanzeige leuchtet nicht

Ursache: Keine oder die falsche Netzspannung liegt an.
Abhilfe: Vorgeschriebene Netzspannung gemäß Spannungsangabe
auf dem Typenschild verwenden.
Störungs-/Betriebsanzeige leuchtet rot

Ursache: Flüssigkeitsspiegel im Vorratsbehälter hat "Stufe Niveau
Mangel" erreicht.
Abhilfe: Vorratsbehälter auffüllen.
Ursache: Elektronikfehler.
Abhilfe: Pumpe einschicken.
ProMinent
®
9
Außer Betrieb nehmen und Entsorgen / Technische Daten
10 Außer Betrieb nehmen und Entsorgen
ACHTUNG
• Bei Außerbetriebnahme einer Pumpe muss das Gehäuse und
besonders die Fördereinheit grundsätzlich von Chemikalien und
Schmutz gereinigt werden.
• Beachten Sie beim Entsorgen die z. Zt. in Ihrem Ort gültigen
Vorschriften! (besonders bezüglich Elektronikschrott!)
11 Technische Daten
Leistungstabelle 230 V-Ausführungen
Pumpen- mindest Förderleistung mindest Förderleistung max. Anschluß- Saug- Ansaug- Zulässiger
typ bei maximalem bei mittlerem Hubzahl größe höhe* höhe** Vordruck
Gegendruck Gegendruck äØ • iØ Saugseite
Hübe /
bar l/h ml/Hub bar l/h ml/Hub min mm m WS m WS bar
1000 10 0,6 0,07 5 0,8 0,08 180 6x4 6 1,8 8

1601 16 1,0 0,10 8 1,4 0,13 180 6x4 6 2,0 8
1002 10 2,0 0,18 5 2,6 0,24 180 6x4 5 2,5 5,5
0704 7 3,9 0,39 3,5 4,5 0,42 180 6x4 4 3,0 3
0308 3 8,0 0,74 1,5 10,8 1,00 180 8x5 2 2,0 1
0213 1,5 13,5 1,42 1,0 15,5 1,4 180 8x5 1,5 1,5 0,5
* Saughöhen bei befüllter Saugleitung und befüllter Fördereinheit

** Ansaughöhen mit sauberen sowie angefeuchteten Ventilen, bei
Dosiermedium Wasser (20 °C), bei 100 % Hublänge, 180 Hüben/min,
freiem Auslauf bzw. geöffnetem Entlüftungsventil und fachgerecht
installiertem Leitungssystem.
Werkstoffangaben
Fördereinheit: siehe Typenschlüssel

Gehäuse: PPE, glasfaserverstärkt
Elektrische Daten
Netzfrequenz: 50 Hz / 60 Hz
Variante 230 V/AC CNPa
Nennleistung: 10 W
Strom I eff: 0,12 A
Spitzenstrom 0,5 A
Einschaltspitzenstrom < 4 A für < 0,1 ms
Sicherung*: 0,16 AT
* Sicherungen müssen die Zulassungen nach VDE, UL und CSA aufweisen!
10 ProMinent ®
Technische Daten / Zubehör
Temperaturangaben
Lager- und Transporttemperatur: -10 °C...+50 °C
Funktion bei Umgebungstemperatur: -10 °C...+45 °C
zulässige Mediumtemperatur: -10 °C...+35 °C
Werkstoff Langzeitig bei max. max. 15 min

Fördereinheit Gegendruck bei max. 2 bar
PP 50 °C 100 °C
NP 45 °C 60 °C
Klima
Zulässige relative Luftfeuchtigkeit: 92 %, nicht kondensierend.
Beanspruchung im Feucht - Wechselklima: FW 24 gemäß DIN 50016.
Schutzart und Schutzklasse

Berührungs- und Feuchtigkeitsschutz: IP 65 gemäß IEC 529, EN 60529,
DIN VDE 0470 Teil 1 Schutzklasse 1 – Netzanschluss mit Schutzleiter
Schalldruckpegel
Schalldruckpegel: < 70 dB(A) in 1m Abstand gemäß EN 23741 oder
EN 23742 bei maximalem Hub, maximaler Hubfrequenz, maximalem
Gegendruck (Wasser)
Versandgewicht
Versandgewicht: 1,8 kg
12 Zubehör
Sauglanzen Sauglanze für 200 l-Fass, Behälteröffnung 2“ DIN 570, PPE 1022511
Sauglanze für 200 l-Fass, Behälteröffnung 2“ DIN 570, PCB 1022512
Sauglanze für Behälter 5 - 50 l-Fass, Behälteröffnung d50, PPE 1022645
Sauglanze für Behälter 5 - 50 l-Fass, Behälteröffnung d50, PCB 1022644
Variable Sauglanze mit 1-stufigen Niveauschalter, bei Chemikalien-

mangel schließend.
Der Lieferungumfang umfasst auch die erforderlichen Teile zum
Anschluss an die Pumpe.
Nachrüstsätze Nachrüstsatz Extern + Niveau CNP 1022099

Nachrüstsatz Niveauschalter CNP* 1022115
*Anschlussteile bei kundenseitig gestellten Sauglanzen und Behältern
ProMinent®
11
Technische Daten
85 CONCEPTPLUS (Maße in mm)
158,7
132,5
84,7
18,3
80
6
92,5
M20 x1,5
140 (156*)
70 (90*)
10,5 33,9
56,1
105,3 76
98 (110*)
* Maße für Pumpentypen 0308,0213
12 ProMinent
®
Konformitätserklärung
ProMinent
®
13
14 ProMinent
®
Table of Contents
Please read the opertaing instructions through completely before

commissioning this equipment!
Do not discard!
Any part which has been subject to misuse is excluded from the
warranty!
Page
General user instructions 16
1 Equipment overview .................................................................. 17
2 Type overview/material details ................................................. 18
3 Safety........................................................................................... 18
4 Storage and transport ............................................................... 19
5 Assembly and installation ......................................................... 19
6 Commissioning .......................................................................... 20
7 Maintenance ............................................................................... 20
8 Repair .......................................................................................... 21
9 Troubleshooting ......................................................................... 21
10 Decommissioning and disposal ............................................... 22
11 Technical data ............................................................................ 22
12 Accessories ................................................................................ 23
Declaration of Conformity 25
ProMinent
®
15
General user instructions
General user instructions
Please read through the following user instructions carefully! They will
help you get the best use out of the operating instruction manual.
The following are highlighted in the text:
• Enumerated points
Instructions
▲
Safety guidelines:
WARNING
Describes a potentialy dangerous situation. If not avoided, could

cause fatal or serous injury.
IMPORTANT
Describes a potentialy dangerous situation. If not avoided, could

cause damage to property.
This operating instructions manual is aimed at experts in metering

pumps and their operation.
If you require detailed installation instructions please order ”Gene-
ral Operating Instructions Manual, ProMinent® Solenoid Metering
Pumps” (Order No. 987057).
16 ProMinent ®
Equipment overview
1 Equipment overview
2 7
1 Stroke length adjustment knob

2 Error/operating indicator (error - red / operation - green)
3 Multifunction switch (stroke rates (in % of 180 strokes/min), stop,
operating mode ”external” (Retrofit kit))
4 Power cable
5 “External actuation” socket (actuation via contact signal in ”external”
operating mode; Retrofit kit)
6 “Float switch” socket (for 1-stage float switch; Retrofit kit)
7 Suction valve
8 Discharge valve
The leakage bore is between the suction valve and the drive housing.
ProMinent
®
17
Type overview/material details / Safety
2 Type overview/material details
Order No. CONCEPTPLUS, CNPa, 115 V versions

Pump type liquid end material
PP (with EPDM*) NP** (with Viton® *)
1000 1022480 1022484
1601 1022481 1022485
1002 1022482 1022486
0704 1022483 1022487
Order No. CONCEPTPLUS, CNPa, 230 V versions

Pump type liquid end material
PP (with EPDM*) NP** (with Viton® *)
1000 1022452 1022476
1601 1022453 1022477
1002 1022474 1022478
0704 1022475 1022479
* Seal material
** Seal material is PVC
The valve balls are made of ceramics.
3 Safety
Correct use of • The pump may be used only for metering liquid media!
equipment • All other uses or modifications are prohibited!
• The pump is not suitable for metering gaseous media or solids!
• The pump must be operated by appropriately trained and authorised
personnel!
The personnel must be familiar with metering pumps and their operation!
WARNING
• The pump may start to operate as soon as it connected to the mains
power supply!
Ensure that no hazardous metering chemical can leak out!
If you have not done so, set the multifunction switch to STOP or
disconnect the pump from the mains immediately.
• The pump cannot be switched off! In the case of an electrical failure,
disconnect the mains cable from the power supply.
• Disconnect the power cable from the mains before working on
the pump.
18 ProMinent ®
Safety / Storage and transport / Assembly and installation
• Risk of electric shock - This pump is supplied with a grounding

conductor and grounding-type attachment plug. To reduce the risk of
electric shock, be certain that it is connected only to a properly
grounding-type receptacle.
• Always depressurise liquid end before working on the pump.
• Always empty and rinse the liquid end before working on the pump
if used with hazardous or unknown feed chemicals.
• Wear safety equipment appropriate to the metering chemical when
working on the liquid end.
• Never let the pump work against a significantly increased operat
ing pressure or a closed stop tap on the discharge-side. This can
cause lines to burst.
• Avoid overfeed due to positive pressure difference between in take
and discharge sides. E.g. use a ball check valve with at least 1.5
bar opening pressure with an atmospheric pressure outlet (not 0213).
• Assembly and installation of ProMinent® metering pumps with non-
original parts, which have not been checked and recommended by
ProMinent is not allowed and can lead to harm to persons or
property for which no liability can be accepted.
• Note all national directives which apply to the installation.
Sound pressure level The sound pressure level is < 70 dB (A) at a distance of 1 m in accordance
with EN 23741 or EN 23742 at maximum stroke, maximum stroke rate, maxi-
mum back pressure (water)
4 Storage and transport
Ambient conditions for storage and transport:

Storage and transport temperature: -10 to +50 °C
Humidity: < 92 % rel. humidity,
non-condensing
5 Assembly and installation
IMPORTANT
• The pump must not vibrate when installed.
• Solenoid metering pumps tend to overfeed if the back pressure
is too low. In this case fit a ball check valve, a multifunction valve
or a discharge valve with 1.5 bar opening pressure downstream
from the pump (not 0213).
ProMinent®
19
Assembly and installation / Commissioning / Maintenance
• Use only original hoses with the specified diameter and wall
thickness! It is not otherwise possible to ensure the durability of
the connection to the pump valves!
• For tips on hydraulic installation, order the ”General Operating
Instructions Manual, ProMinent® Solenoid Metering Pumps”
(Order No. 987057).
• Check that the mains power supply and frequency match the
values specified on the rating plate!
• Note all national directives which apply to the installation!
Mount metering pump on a tank or bracket using screws and

▲
washers (Ø 6 mm).
Hose
Keep suction height and length of suction hose as short as possible.
▲
Union nut Install suction hose in an ascending position.

(section)
clamping
ring
Cut the suction and pressure pipe to the required length.

▲ ▲ ▲ ▲ ▲ ▲
grommet
O-Ring Push union nut and clamping ring onto the hose.
Push the cut hose onto the grommet up to the stop.
intake Press on hose and tighten the union nut.
connector
Mount the foot-actuated valve.
For this purpose, cut the free suction hose end such that the foot-
actuated valve is suspended close above the tank bottom.
In case of metering solutions with contaminations or residues, cut
the free suction hose end such that the foot-actuated valve is
suspended at least 50 mm above the tank bottom.
6 Commissioning
Precision metering is possible only within a stroke length range of

30-100 %.
7 Maintenance
Service interval Quarterly at normal load (approx. 30 % continuous operation)

▲ ▲
Check the pump diaphragm for damage

Check that the discharge and suction valves and the discharge lines
are seated firmly
▲
Check the overall tightness of the liquid end (in particular leakage
opening between suction value and drive housing)
▲
Check liquid end screws are tight

Tightening torque for liquid end screws: 4.5 to 5 Nm
20 ProMinent ®
Repair / Troubleshooting
8 Repair
Repairs which may be carried out by qualified persons (according to

safety instructions):
• Cleaning a valve
• Replacing the diaphragm (installation instructions included with
replacement diaphragm)
For all other repairs consult your ProMinent® Subsidiary.
9 Troubleshooting
The pump does not prime despite full stroke action and venting
Cause: Crystalline deposits on the ball seat due to valves drying out.
Remedy: Remove suction hose from the supply tank and rise liquid
end thoroughly.
If unsuccessful, dismantle valves and clean.
Fluid is leaking from the head washer

Cause: The liquid end is leaking at the pump diaphragm.
Remedy: Screw in the liquid end anti-clockwise (torque: 4.5 to 5 Nm)
If unsuccessful, replace the diaphragm (installation instructions
included with the diaphragm).
Error/operating indicator not lit

Cause: No or incorrect mains voltage.
Remedy: Use mains voltage as specified on the rating plate.
Error/operating indicator lit red

Cause: Liquid level in the supply tank has reached “low liquid level”.
Remedy: Top up supply tank.
Cause: Electronic failure.
Remedy: Send pump away for repair.
ProMinent
®
21
Decommissioning and disposal / Technical data
10 Decommissioning and disposal
IMPORTANT
• When decommissioning a pump, clean all traces of chemicals
and dirt from the housing and particularly the liquid end.
• Observe all relevant disposal directives for your area
(particularly with regard to electronic waste)
11 Technical data
Performance table 230 V version
Pump Minimum delivery rate Minimum feed rate Max. Connection Priming Priming Admissible
type at maximum at medium stroke size lift* lift** priming pressure
back pressure back pressure rate ext. Ø x int. Ø Intake
ml/ ml/ strokes/
bar l/h stroke bar l/h stroke min mm m Wc m Wc bar
1000 10 0.6 0.07 5 0.8 0,08 180 6x4 6 1.8 8

1601 16 1.0 0.10 8 1.4 0.13 180 6x4 6 2.0 8
1002 10 2.0 0.18 5 2.6 0.24 180 6x4 5 2.5 5.5
0704 7 3.9 0.39 3.5 4.5 0.42 180 6x4 4 3.0 3
0308 3 8.0 0.74 1.5 10.8 1.00 180 8x5 2 2.0 1
0213 1.5 13.5 1.42 1.0 15.5 1.4 180 8x5 1.5 1.5 0.5
* Suction lift with filled suction line and liquid end

** Priming lifts with clean and wetted valves, metering fluid, water
(20 °C), at 100 % stroke length, 180 strokes/min, atmospheric
pressure outlet and/or open venting valve and correctly installed lines.
Materials
Liquid end material specification: see type code

Housing: PPE, glass fibre reinforced
Electrical data
Mains frequency: 50 Hz / 60 Hz
230 V/AC version CNPa 115 V/AC version CNPa

Wattage: 10 W Wattage: 11 W
Current I eff: 0.12 A Current I eff: 0.26 A
Peak current 0.5 A Peak current 1.2 A
Switch-on peak current < 4 A for < 0.1 ms Switch-on peak current < 3 A for < 0.1 ms
Fuse*: 0.16 AT Fuse*: 0.315 AT
* Fuses must have approvals according to VDE, UL and CSA.
22 ProMinent ®
Technical data / Accessories
Temperature details
Storage and transport temperature: -10 °C...+50 °C
Function at ambient temperature: -10 °C...+45 °C
Admissible feed chemical temperature: -10 °C...+35 °C
Material Long term at max. back max. 15 min.

feed unit pressure at max. 2 bar
PP 50 °C 100 °C
NP 45 °C 60 °C
Climate
Admissible relative air humidity: 92 %, non condensing.
Load in wet and alternating climate: FW 24 in accordance with DIN 50016.
Enclosure rating and safety class

Contact and moisture protection: IP 65 in accordance with IEC 529,
EN 60529, DIN VDE 0470 Part 1 Safety class 1 - electric mains with earth
Sound pressure level

Sound pressure level: < 70 dB(A) at a distance of 1 m in accordance
with EN 23741 or EN 23742 at maximum stoke, maximum stroke rate,
maximum back pressure (water)
Shipping weight
Shipping weight: 1.8 kg
12 Accessories
Suction lances Suction lance for 200 l drum, tank opening 2“ DIN 570, PPE 1022511
Suction lance for 200 l drum, tank opening 2“ DIN 570, PCB 1022512
Suction lance for tank 5-50 l drum, tank opening d50, PPE 1022645
Suction lance for tank 5-50 l drum, tank opening d50, PCB 1022644
Adjustable suction lance with single-stage level switch, closing in the

event of lack of chemicals.
The delivery scope also includes the parts required for connecting the
pump.
Retrofit kits Retrofit kit External + level CNP 1022099

Retrofit kit level switch CNP* 1022115
*connecting parts given suction lances and tanks provided by the

customer
ProMinent ®
23
Technical data
85 CONCEPTPLUS (dimensions in mm)
158.7
132.5
84.7
18.3
80
6
92.5
M20 x1.5
140 (156*)
70 (90*)
10.5 33.9
56.1
105.3 76
98 (110*)
* dimensions for pump type 0308, 0213
24 ProMinent
®
Conformity declaration
ProMinent
®
25
26 ProMinent
®
Sommaire
Lisez d’abord entièrement le mode d’emploi !

Ne le jetez pas !
Les dommages consécutifs aux erreurs d’utilisation ne sont pas
couverts par la garantie !
Page
Informations générales destinées à l’utilisateur 28
1 Vue d’ensemble de l’appareil .................................................... 29
2 Vue d’ensemble des types / Informations concernant les matériaux .. 30
3 Sécurité ....................................................................................... 30
4 Stockage et transport ................................................................ 31
5 Montage et installation .............................................................. 31
6 Mise en service ........................................................................... 32
7 Entretien ...................................................................................... 32
8 Réparation ................................................................................... 33
9 Elimination de dysfonctionnement ........................................... 33
10 Mise hors service et élimination ............................................... 34
11 Caractéristiques techniques ..................................................... 34
12 Accessoires ................................................................................. 35
Déclaration de conformité 36
ProMinent
®
27
Informations générales destinées à l’utilisateur
Informations générales destinées à l’utilisateur
Lisez les informations suivantes destinées à l’utilisateur ! Leur

connaissance vous permettra de tirer un meilleur profit de la notice
technique.
Les parties suivantes sont mises en évidence :
• énumérations
▲
instructions
Consignes de sécurité identifiées par des pictogrammes :
AVERTISSEMENT
Identifie une situation potentiellement dangereuse. Si elle n’est pas

évitée, vous êtes en danger de mort et de graves blessures peuvent
en être la conséquence.
ATTENTION
Identifie une situation potentiellement dommageable. Si elle n’est

pas évitée, des dommages matériels peuvent en être la
conséquence.
Ce manuel d’utilisation est de tiné aux personnes spécialisées en

matière de pompes de dosage et de leur fonctionnement !
Toutefois, au cas où des informations d’installation détaillées
seraient requises, veuillez commander la „Notice technique
générale, ProMinent® pompes doseuses électromagnétiques “
(référence 987058) !
28 ProMinent®
Vue d’ensemble de l’appareil
1 Vue d’ensemble de l’appareil

8
2 7
1 Bouton de réglage de la longueur de course

2 Indicateur de dérangement/service (dérangements : rouge / service :
vert)
3 Commutateur multifonction (fréquence des impulsions (en % de 180
impulsions/min), Stop, mode de service «externe» (kit de rattrapage))
4 Câble secteur
5 Douille «commande externe» (en mode de service «externe» pilotage
via signal de contact ; kit de rattrapage)
6 Douille «Détecteur de niveau» (pour détecteur de niveau monoétagé ;
kit de rattrapage)
7 Vanne d’aspiration
8 Clapet de refoulement
L’alésage pour fuites est entre la vanne d’aspiration et le corps de

l’entraînement.
ProMinent
®
29
Vue d’ensemble des types / Informations les matériaux / Sécurité
2 Vue d’ensemble des types / Informations concernant

les matériaux
Référence CONCEPTPLUS, CNPa, exécution 230 V
Type de pompe matériau de l’unité de refoulement

PP (avec EPDM*) NP** (avec Viton® *)
1000 1022452 1022476
1601 1022453 1022477
1002 1022474 1022478
0704 1022475 1022479
* Matériaux du joint
** Vanne/clapet en PVC
Les billes de clapet sont en céramique.
Utilisation 3 Sécurité
conforme • La pompe doit être exclusivement utilisée pour le dosage de liquides !
• Toute autre utilisation ou une modification conceptuelle est stricte-
ment interdite !
• La pompe n’est pas destinée à doser des fluides gazeux ou des parti-
cules solides !
• L’utilisation de la pompe est strictement réservée à un pesronnel
autorisé, expérimenté et ayant reçu la formation requise à cet effet !
Le personnel doit s’être familiarisé avec les pompes de dosage et leur
mode fonctionnel et d’exploitation !
AVERTISSEMENT
• Dès que la pompe est reliée au secteur, il se peut qu’elle commence
à pomper !
Evitez que des produits à doser dangereux s’en échappent !
Si vous n’avez pas pensé à cette éventualité, positionnez alors
immédiatement le commutateur multifonction sur STOP ou
débranchez immédiatement la pompe du secteur !
• La pompe ne peut pas être mise hors tension !
En cas d’accident électrique, débranchez aussitôt le câble secteur
de l’alimentation en courant !
• Avant de travailler sur la pompe, débranchez le câble secteur de
l’alimentation secteur !
• Risque d’électrocution !
Cette pompe est équipée d’un conducteur de protection et d’un
connecteur pourvu d’un contact de protection. Pour diminuer le risque
d’électrocution, assurez-vous que le raccordement a exclusivement
lieu sur une prise femelle à contact de protection correctement relié.
30 ProMinent ®
Sécurité / Stockage et transport
• Avant de travailler sur la pompe, il est indispensable de toujours

mettre tout d’abord l’unité de refoulement hors pression !
• Avant de travailler sur la pompe, il est indispensable de purger et
de rincer l’unité de refoulement si des produits à doser inconnus
ou dangereux ont été préalablement utilisés !
• En cas de travaux sur l’unité de refoulement, portez un équipement
de protection adapté au fluide à doser spécifique !
• Ne laissez jamais la pompe de dosage travailler contre une
pression de service considérablement surélevée ou contre un
organe d’arrêt fermé côté refoulement ! En effet, les tuyaux de
refoulement risquent d’éclater !
• Evitez un refoulement exagéré en assurant une pression
différentielle positive entre le côté refoulement et aspiration !
Installez donc une vanne de maintien de pression avec une
pression d’ouverture de 1,5 bar min. s’il y a présence, par exemple,
d’une évacuation libre (pas possible pour 0213) !
• Le montage et l’installation de ProMinent® pompes de dosage avec
des pièces d’autres constructeurs (c’est-à-dire non d’origine) qui
n’ont pas été contrôlées, homologuées et recommandées par
ProMinent sont interdits et peuvent donner lieu à des dommages
aussi bien corporels que matériels et entraînent automatiquement
la perte de tout droit de garantie !
• Lors de l’installation, veuillez respecter les prescriptions et
réglementations nationales en vigueur !
Niveau de A 1 m de distance, conformément à EN 23741 ou à EN 23742, le niveau

pression de pression acoustique est < 70 dB (A) à impulsion (= course) maximale,
acoustique fréquence des impulsions maximale, contre-pression maximale (eau)
4 Stockage et transport
Conditions ambiantes pour le stockage et le transport :

Température de stockage et de transport : -10 à +50 °C
Humidité de l’air : < 92 % d’humidité relative,
sans condensation
5 Montage et installation
ATTENTION
• Fixez la pompe de manière à exclure les vibrations !
• A faible contre-pression, les pompes doseuses électromagnétiques
ont tendance à trop refouler ! Dans pareil cas, installez une vanne
de maintien de pression, une vanne multifonction ou une vanne de
ProMinent
®
31
Montage et installation / Mise en service / Entretien
dosage de 1,5 bar de pression d’ouverture en aval de la pompe !

(pas possible pour 0213)
• Utilisez exclusivement des tuyaux flexibles d’origine qui présen-
tent les diamètres et les épaisseurs de paroi prescrits !
Sinon, la durabilité des raccords entre les vannes et la pompe ne
sera pas assurée !
• Pour plus d’informations utiles quant à l’installation hydraulique,
veuillez commander la «Notice technique générale, ProMinent®
pompes doseuses électromagnétiques «(référence 987058).
• Vérifiez si la tension secteur et la fréquence coïncident bien avec
les valeurs indiquées sur la plaque signalétique !
• Lors de l’installation, veuillez respecter les prescriptions et régle-
mentations nationales en vigueur !
Monter la pompe doseuse sur un récipient ou une console en utilisant

▲
les vis et les rondelles en U (6 mm).

La hauteur d’aspiration et la longueur de la conduite d’aspiration doivent
▲
être les plus courtes possibles. Poser la conduite d’aspiration à la verticale.

▲
Tayau
Raccourcir le tuyau flexible d’aspiration et le tuyau flexible de
flexible refoulement sur la longueur requise.
▲
Ecrou-
raccord
Emmancher l’écrou-raccord et la bague de serrage sur le flexible.
(Coupe)
Bague de
serrage
Pousser l’extrémité raccourcie du tuyau jusqu’à la butée sur l’embout.
▲ ▲ ▲ ▲
Embout
Presser le tuyau contre l’embout puis le fixer avec l’écrou-raccord.
Joint
torique
Monter la crépine d’aspiration.
Raccordement A cet effet, raccourcir l’extrémité libre de la conduite d’aspiration sur une
d’aspiration
longueur assurant que la crépine d’aspiration plonge juste au-dessus du
fond du récipient sans le toucher.
Pour les solutions de dosage laissant des dépôts sur le fond ou contenant
des particules, raccourcir l’extrémité de la conduite sur une longueur telle
que la distance entre la crépine d’aspiration suspendue et le fond du
récipient soit au moins de 50 mm.
6 Mise en service
Un dosage précis est uniquement possible au sein d’une plage de

longueur de course de 30 à 100 %.
7 Entretien
Intervalle Trimestriel pour une sollicitation normale (env. 30 % du service continu)

d’entretien
▲
Vérifiez l’état impeccable de la membrane de dosage
32 ProMinent ®
Entretien / Réparation / Elimination de dysfonctionnements
Vérifiez si le clapet de refoulement, le clapet d’aspiration et les
▲
conduites de dosage sont correctement et fermement fixés
Vérifiez l’étanchéité de l’unité de refoulement complète (en particulier
▲
trous de fuite entre le clapet d’aspiration et le boîtier d’entraînement)
▲Vérifiez si les vis de la tête doseuse sont correctement serrées.
Couples de serrage pour les vis de la tête doseuse : 4,5 à 5 Nm
8 Réparation
Mesures de réparation que des personnes qualifiées ont le droit

d’exécuter (conformément aux consignes de sécurité) :
• Nettoyage d’une soupape/vanne/clapet
• Remplacement de la membrane (les instructions de montage
sont jointes à la membrane de rechange)
Pour toutes autres réparations, adressez-vous à la filiale ProMinent® de
votre région !
9 Elimination de dysfonctionnements
La pompe n’aspire pas malgré un mouvement de course et une

purge complets
Cause : Présence de dépôts cristallins sur le siège de bille du fait
d’une dessiccation des clapets / vannes / soupapes.
Remède : Retirez le tuyau d’aspiration du réservoir et rincez l’unité de
refoulement à fond.
Si cette opération n’est pas couronnée de succès, démontez et net-
toyez les clapets / vannes / soupapes.
Du liquide sort de la rondelle de tête

Cause : L’unité de refoulement n’est pas étanche au niveau de la
membrane de dosage.
Remède : Resserrez les vis dans le tête doseuse en mode croisé
(couples de serrage : 4,5 à 5 Nm)
Si cette opération n’est pas couronnée de succès, remplacez la mem-
brane (les instructions de montage sont jointes à la membrane).
L’indicateur de dérangement/service n’est pas allumé

Cause : Tension secteur appliquée erronée ou totalement absente.
Remède : Utilisez la tension secteur prescrite conformément aux
indications sur la plaque signalétique.
L’indicateur de dérangement/service est allumé en rouge

Cause : «Manque de liquide» dans le réservoir.
Remède : Remettez le réservoir à niveau.
Cause : Erreur de l’électronique.
Remède : Expédiez la pompe au service de réparation.
ProMinent
®
33
Mise hors service et élimination / Caractéristiques techniques
10 Mise hors service et élimination
ATTENTION
• Pour la mise hors service d’une pompe, il faut que le corps et
plus particulièrement l’unité de refoulement soient toujours net-
toyés avec une extrême précaution pour enlever toute trace de
produits chimiques et de salissures et pollutions quelconques.
• Pour l’élimination, veuillez respecter les prescriptions et législa-
tions locales actuellement en vigueur !
(Surtout quant à la ferraille et aux déchets électroniques !)
11 Caractéristiques techniques
Table des performances des exécutions 230 V

Type de débit de refoulement débit de refoulement nombre Taille de Hauteur Hauteur de Pression
d’alimentation
minimal à contre-pression minimal à contre-pression d’impulsions raccordement réamor- admissible
çage** côté aspiration
Impulsions
bar l/h ml/imp bar l/h ml/imp / mn min m de CE m de CE bar
1000 10 0,6 0,07 5 0,8 0,08 180 6x4 6 1,8 8

1601 16 1,0 0,10 8 1,4 0,13 180 6x4 6 2,0 8
1002 10 2,0 0,18 5 2,6 0,24 180 6x4 5 2,5 5,5
0704 7 3,9 0,39 3,5 4,5 0,42 180 6x4 4 3,0 3
0308 3 8,0 0,74 1,5 10,8 1,00 180 8x5 2 2,0 1
0213 1,5 13,5 1,42 1,0 15,5 1,4 180 8x5 1,5 1,5 0,5
* Hauteurs d’aspiration à tuyau d’aspiration rempli et unité de

refoulement remplie
** Hauteurs de réamorçage avec soupapes/vannes/clapets propres et
humidifiés ; fluide à doser : eau (20 °C), pour longueur de course
100 %, 180 impulsions/mn, évacuation libre ou soupape/vanne de
purge ouverte et réseau de conduites installé dans les règles de l’art.
Indications concernant le matériau
Informations concernant les matériaux de l’unité de refoulement :

cf. code type
Corps: PPE, renforcé par fibres de verre
Caractéristiques électriques
Fréquence secteur : 50 Hz / 60 Hz
Variante 230 V/CA CNPa
Débit nominal : 10 W
Courant I eff : 0,12 A
Courant de crête 0,5 A
Courant de crête d’activation < 4 A pour < 0,1 ms
Fusible* : 0,16 AT
* Les fusibles doivent être homologués selon VDE, UL et CSA !
34 ProMinent ®
Caractéristiques Techniques / Accessoires
Indications relatives aux températures

Température de stockage et de transport : -10 °C...+50 °C
Fonctionnement à température ambiante : -10 °C...+45 °C
Température admissible du fluide : -10 °C...+35 °C
Matériau de longue durée à maxi. max. 15 minutes

l’unité de refoulement contre-pression à 2 bar max
PP 50 °C 100 °C
Verre acrylique 45 °C 60 °C
Conditions climatiques
Humidité de l’air relative admissible : 92 %, sans condensation.
Sollicitation en atmosphère humide alternante : FW 24 conformément à
DIN 50016.
Degré de protection et classe de protection

Protection contre le contact et l’humidité : IP 65 conformément à
CEI 529, EN 60529, DIN VDE 0470, partie 1 Classe de protection 1 –
raccordement secteur avec conducteur de protection
Niveau de pression acoustique

Niveau de pression acoustique : < 70 dB(A) à 1 mètre de distance, con-
formément à EN 23741 ou à EN 23742 à impulsion maximale, fréquence
des impulsions maximale, contre-pression maximale (eau)
Poids d’expédition
Poids d’expédition : 1,8 kg
12 Accessoires
Armatures Armature d’aspiration pour fût de 200 l, ouverture du récipient 2” DIN 570, PPE 1022511
Armature d’aspiration pour fût de 200 l, ouverture du récipient 2” DIN 570, PCB 1022512
d’aspiration Armature d’aspiration pour récipient/fût 5 à 50 l, ouverture du récipient d50, PPE 1022645
Armature d’aspiration pour récipient/fût 5 à 50 l, ouverture du récipient d50, PCB 1022644
Armature d’aspiration variable avec détecteur de niveau mono-étagé,

fermeture à manque de produits chimiques. Le matériel fourni englobe
également les pièces requises pour le raccordement à la pompe.
Kits de Kit de rattrapage CNP externe + niveau 1022099

rattrapage Kit de rattrapage détecteur de niveau CNP* 1022115
*Pièces de raccordement pour armatures d’aspiration et récipients

fournis par le client
ProMinent ®
35
Croquis coté
85 CONCEPTPLUS (cotes en mm)
158,7
132,5
84,7
18,3
80
6
92,5
M20 x1,5
140 (156*)
70 (90*)
10,5 33,9
56,1
105,3 76
98 (110*)
* dimensions pour les types de pompes 0308, 0213
36 ProMinent
®
Déclaration de conformite
ProMinent
®
37
Lea primero las instucciones completas.
No las tire.
En caso de daños debidos a errores en el uso caducará la
garantia.
Página
Notas generales para el usuario 40
1 Cuadro sinóptico ....................................................................... 41
2 Esquema de tipos/datos de material ...................................... 42
3 Seguridad .................................................................................. 42
4 Almacenamiento y transporte ................................................. 43
5 Montaje e instalación ............................................................... 43
6 Puesta en servicio ..................................................................... 44
7 Mantenimiento .......................................................................... 44
8 Reparación ................................................................................ 45
9 Eliminación de fallos de funcionamiento ............................... 45
10 Puesta fuera de servicio y eliminación de residuos .............. 46
11 Datos técnicos .......................................................................... 46
12 Accesorios ................................................................................. 47
Declaración de conformidad 49
ProMinent
®
39
Notas generales para el usuario
Notas generales para el usuario
¡Por favor lea las siguientes notas para el usuario! Conociéndolas podrá
aprovechar mejor el manual de instrucciones.
Elementos especialmente destacados en el texto:
• enumeraciones
instrucciones
▲
Notas referentes a la seguridad:
ADVERTENCIA
Una advertencia denota una situación posiblemente peligrosa. Si

no se evita, existe peligro para la vida y el riesgo de graves
lesiones como consecuencia.
ATENCIÓN
Una Ilamada a la atención designa una situación posiblemente

perjudicial. Si no se evita, pueden ocurrir daños materiales como
consecuencia.
Estas instrucciones de servicio están destinadas a expertos en

bombas dosificadoras y para el uso de las bombas.
Si necesita, no obstante, instrucciones detalladas para la
instalación, pida las ”Instrucciones de servicio generales
ProMinent® bombas dosificadoras magnéticas” (referencia
987061)!
40 ProMinent ®
Cuadro sinóptico
1 Cuadro sinóptico
8
2 7
1 Botón de ajuste de longitud de carrera

2 Indicador de fallo/funcionamiento (fallo rojo / funcionamiento verde)
3 Mando multifuncional (frecuencias de carrera (en % de 180 carreras/
min), parada, modo operativo ”Externo” (kit de equipamiento
posterior))
4 Cable de red
5 Conexión “mando externo “ (en modo operativo ”Externo” mando
mediante señal de contacto; kit de equipamiento posterior)
6 Conexión “Interruptor de nivel” (para interruptor de nivel de 1
escalón, kit de equipamiento posterior)
7 Válvula de aspiración
8 Válvula de impulsión
El orificio de fugas está entre válvula de aspiración y caja de

transmisión.
ProMinent
®
41
Esquema de tipos/datos de material / Seguridad
2 Esquema de tipos/datos de material
Referencia: CONCEPTPLUS, CNPa, tipo 230 V

Tipo de bomba Material de la unidad de transporte
PP (con EPDM*) NP** (con Viton® *)
1000 1022452 1022476
1601 1022453 1022477
1002 1022474 1022478
0704 1022475 1022479
* Material de junta
** Material de válvula es PVC
Las bolas de válvulas son cerámicas.
3 Seguridad
Uso conforme • La bomba solamente puede ser utilizada para dosificar medios
a los fines líquidos.
previstos • Cualquier otro uso o transformación están prohibidos.
• La bomba no está destinada para la dosificación de medios
gaseosos o sólidos.
• La bomba debe ser utilizada exclusivamente por personas
cualificadas y autorizadas.
El personal debe estar familiarizado con bombas dosificadoras y su
funcionamiento.
ADVERTENCIA
• Puede ser que la bomba empiece a funcionar inmediatamente al
ser conectada a la red.
Evite que puedan salir medios dosificados peligrosos.
Si no lo ha hecho, ponga el mando multifuncional en STOP o
desconecte inmediatamente la bomba de la red.
• La bomba no se puede desconectar de la corriente eléctrica.
En caso de accidente eléctrico desenchufe el cable de la red.
• Desenchufe el cable de la red antes de efectuar trabajos en la
bomba.
• Peligro de descarga eléctrica.
Esta bomba incorpora un conductor de proteción y un conector
con contacto de seguridad. Para reducir el peligro de descarga
eléctrica, debe enchufarse solamente en un enchufe con
contacto de puesta a tierra correctamente instalado.
42 ProMinent ®
Seguridad / Almacenamiento y transporte / Montaje e instalación
• Antes de realizar trabajos en la bomba debe evacuarse siempre

primero la presión de la unidad de transporte.
• Antes de realizar trabajos en la bomba vaciar y lavar la unidad de
transporte si se han dosificado medios peligrosos o
desconocidos.
• En los trabajos en la unidad de transporte utilice el equipo de
protección personal apropiado.
• No haga trabajar la bomba dosificadora nunca contra una
presión de trabajo considerablemente excesiva o contra un
órgano de cierre cerrado en el lado de impulsión. Podrían
reventarse las tuberías de impulsión.
• Evite excesos de caudal mediante diferencia de presión positiva
entre lado de impulsión y lado de aspiración. Utilice por ello,
p.ej., en salida libre, una válvula presostato con presión de aper
tura de 1,5 bar, como mínimo (no es posible en 0213).
• No están permitidos el montaje y la instalación de ProMinent®
bombas dosificadoras con piezas ajenas que no hayan sido
comprobadas y recomendadas por ProMinent, y pueden generar
daños personales y materiales por los que no asumimos ninguna
responsablidad.
• Observe las normas nacionales vigentes en la instalación.
Nivel de El nivel de intensidad sonora es < 70 dB (A) en separación de 1 m

intensidad según EN 23741 o EN 23742 con carrera máxima, frecuencia de
sonora carrera máxima, contrapresión máxima (agua)
4 Almacenamiento y transporte
Condiciones ambientales para almacenamiento y transporte:

Temperatura de almacenamiento y transporte: -10 hasta +50 °C
Humedad atmosférica: < 92 % hum. rel., sin
condensación
5 Montaje e instalación
ATENCION
• Sujete la bomba de forma que no se produzcan vibraciones.
• Las bombas dosificadoras magnéticas tienden a excesos de
caudal en caso de contrapresión reducida.
En este caso, instale una válvula presostato, una válvula
multifuncional o una válvula dosificadora con presión de
ProMinent®
43
Montaje e instalación / Puesta en servicio / Mantenimiento
apertura de 1,5 bar detrás de la bomba (no es posible en 0213).

• Utilice solamente mangueras originales con los diámetros y
espesores de pared indicados.
En caso contrario, no se garantiza la resistencia de la unión con
las válvulas de la bomba.
• Para consejos para la instalación hidráulica pida las
”Instrucciones de servicio generales ProMinent® bombas
dosificadoras magnéticas”(referencia 987061).
• Compruebe la concordancia de la tensión de la red y la
frecuencia con los datos indicados en la placa de características.
• Observe las normas nacionales vigentes en la instalación.
Montar la bomba dosificadora en un recipiente o una consola con tornillos

▲
y arandeles (Ø 6 mm).
Mantener la altura de aspiración y la longitud de la tubería de aspiración lo
▲
manga más cortas posible. Instalar la tubería de aspiración en posición ascendente.

Cortar las mangueras de aspiración y de impulsión a la medida necesaria.
▲ ▲
tuerca de Introducir la tuerca racor y el anillo de apriete en la tubería de aspiración.

unión
(sección)
aro de
sujeción
Introducir el extremo cortado de la manguera hasta el tope en la boquilla.
▲ ▲ ▲ ▲
boquilla
Ajustar la manguera y apretar la tuerca racor.
anillo “O” Montar la válvula de pie.
Para ello, cortar el extremo libre de la tubería de aspiración de forma que
conneción de
aspiración la válvula de pie quede suspendida justo sobre el fondo del recipiente.
En soluciones de dosificación con impurezas o posos cortar el extremo
libre de la tubería de aspiración de forma que la válvula de pie quede
suspendida como mínimo 50 mm sobre el fondo del recipiente.
6 Puesta en servicio
La dosificación exacta sólo es posible en una gama de longitud de carrera

de 30–100 %.
7 Mantenimiento
Intervalo de Trimestral, bajo condiciones de servicio normales (aprox. 30 % de régimen

mantenimiento de funcionamiento continuo)
Controlar el estado de la membrana de dosificación.

▲ ▲
Controlar la fijación de las válvulas de impulsión y aspiración y de las

tuberías de dosificación.
Controlar la estanqueidad de la unidad de transporte completa (en especial
▲
el orificio de fugas entre válvula de aspiración y carcasa del accionamiento)
44 ProMinent ®
Mantenimiento / Reparación / Eliminación de fallos de funcionamiento
Controlar la fijación de los tornillos del cabezal dosificador.
▲
Par de apriete de los tornillos del cabezal dosificador: 4,5 hasta 5 Nm
8 Reparación
Medidas de reparación que pueden ser realizadas por personal

cualificado (según las instrucciones de seguridad):
• Limpiar una válvula
• Cambiar la membrana (las instrucciones para el montaje se
adjuntan en la membrana de recambio)
Para todas las demás reparaciones diríjase a su ProMinent®
representante
9 Eliminación de fallos de funcionamiento
La bomba no aspira a pesar del movimiento de carrera completa y

desaireación
Causa: Incrustaciones cristalinas en el asiento de la bola debidas
al secado de la válvula.
Eliminación: Sacar la manguera de aspiración del depósito y lavar bien
la unidad de transporte.
Si no obtiene el efecto esperado, desmonte las válvulas y límpielas.
Salida de líquido en el disco cabecero

Causa: Fuga en la membrana de dosificación de la unidad de
transporte.
Eliminación: Reapretar en cruz los tornillos del cabezal dosificador
(pares de apriete: 4,5 hasta 5 Nm)
Si no obtiene el efecto esperado, cambie la membrana (las
instrucciones para el montaje se adjuntan en la membrana).
El indicador de fallo/funcionamiento no se enciende

Causa: Falta tensión o tensión errónea.
Eliminación: Conecte la tensión correcta según se indica en la placa de
características.
El indicador de fallo/funcionamiento encendido rojo

Causa: El nivel de líquido en el depósito ha descendido por debajo
del “Nivel mínimo”.
Eliminación: Llene el depósito.
Causa: Fallo electrónico.
Eliminación: Envíe la bomba.
ProMinent
®
45
Puesta fuera de servicio y eliminación de residuos / Datos técnicos
10 Puesta fuera de servicio y eliminación de residuos
ATENCION
• En la puesta fuera de servicio de una bomba debe limpiarse
siempre la carcasa y especialmente la unidad de transporte de
restos de productos químicos y suciedad.
• Observe las normas nacionales vigentes en la eliminación de
residuos (en especial respecto a la basura electrónica).
11 Datos técnicos
Tabla de potencias de los tipos de 230 V

Tipo de Caudal mín. a Caudal mín. a Núm. de Conexión Altura de Altura de Presión previa
bomba contrapresión máx. contrapresión media carreras Ø ext. x Ø int. aspiración* aspiración** adm. lado de
máx. aspiración
ml/ ml/ Carreras /
bar l/h carrera bar l/h carrera min mm m.c.a. m.c.a. bar
1000 10 0,6 0,07 5 0,8 0,08 180 6x4 6 1,8 8

1601 16 1,0 0,10 8 1,4 0,13 180 6x4 6 2,0 8
1002 10 2,0 0,18 5 2,6 0,24 180 6x4 5 2,5 5,5
0704 7 3,9 0,39 3,5 4,5 0,42 180 6x4 4 3,0 3
0308 3 8,0 0,74 1,5 10,8 1,00 180 8x5 2 2,0 1
0213 1,5 13,5 1,42 1,0 15,5 1,4 180 8x5 1,5 1,5 0,5
* Alturas de aspiración con tubería de aspiración y unidad de trans-

porte llenas
** Alturas de aspiración con válvulas limpias y húmedas, con medio de
dosificación agua (20 °C), con longitud de carrera 100 %, 180
carreras/min, salida libre o válvula de desaireación abierta y
tuberías correctamente instaladas.
Datos de material
unidad de transporte: ver clave de tipos
Carcasa: PPE, reforzado con fibra de vidrio
Datos eléctricos
Frecuencia de la red: 50 Hz / 60 Hz
Variante 230 V/C.A. CNPa

Potencia nominal: 10 W
Corriente I eff: 0,12 A
Corriente de cresta 0,5 A
Corriente de cresta a la conexión < 4 A para < 0,1 ms
Fusible*: 0,16 AT
* Los fusibles deben estar homologados según VDE, UL y CSA
46 ProMinent ®
Datos técnicos
Datos de temperatura
Temperatura de almacenamiento y transporte: -10 °C...+50 °C
Función en temperatura ambiente: -10 °C...+45 °C
Temperatura del medio admisible: -10 °C...+35 °C
Material Larga duración máx. 15 min

de la unidad con contrapresión con máx. 2 bar
de transporte máx. 15 min.
PP 50 °C 100 °C
Vidrio acrílico 45 °C 60 °C
Clima
Humedad atmosférica relativa admisible: 92 %, sin condensación.
Solicitación en clima alterno de humedad: FW 24 según DIN 50016.
Modo y clase de protección

Protección contra contacto casual y humedad: IP 65 según IEC 529,
EN 60529, DIN VDE 0470 Parte 1 Clase de protección 1 – Conexión a
la red con conductor protector
Nivel de intensidad sonora

Nivel de intensidad sonora: < 70 dB(A) en separación de 1 m según
EN 23741 o EN 23742 con carrera máxima, frequencia de carrera
máxima, contrapresión máxima (agua)
Peso de envío
Peso de envío: 1,8 kg
12 Accesorios
lanzas de Lanza de aspiración para cuba de 200 l, abertura del recipiente 2“ DIN 570, PPE 1022511
aspiración Lanza de aspiración para cuba de 200 l, abertura del recipiente 2“ DIN 570, PCB 1022512
Lanza de aspiración para recipiente 5, cuba de 50 l, abertura del recipiente
d50, PPE 1022645
Lanza de aspiración para recipiente 5, cuba de 50 l, abertura del recipiente
d50, PCB 1022644
Lanza de aspiración variable con interruptor de nivel de 1 posición,

cierre en caso de falta de agente químico.
El suministro incluye también las piezas necesarias para la conexión a
la bomba.
kits de kit de equipamiento posterior Externo + nivel CNP 1022099

equipamiento kit de equipamiento posterior interruptor de nivel CNP* 1022115
posterior
*Piezas de conexión en lanzas de aspiración y recipientes suministrados
por el cliente
ProMinent®
47
Hoja de dimensiones
85 CONCEPTPLUS (Medidas en mm)
158,7
132,5
84,7
18,3
80
6
92,5
M20 x1,5
140 (156*)
70 (90*)
10,5 33,9
56,1
105,3 76
98 (110*)
* Dimensiones en tipos de bomba 0308, 0213
48 ProMinent
®
Declaración de conformidad
ProMinent
®
49
2
OPERATING INSTRUCTION SALINITY METER
SALINITY METER SYSTEM

( MODEL : SI - 30 )
Table of Contents
1 The Generals of System

1-1 Instruction
1-2 Measuring Principle
2 Installation of Salinity Meter
2-1 Controller Installation
2-2 The Sensor Installation
3 Operating the Salinity Meter
4 Technical Specifications of System
5 Drawing Inspection
6 Troubleshooting Guide
MODEL : SI-30 -1- Instruction Manual Rev. 1.0

1 The Generals of System
1-1. Instruction
Salinity Meter is an instrument, which measures the content of

natrium chloride in the evaporated water from a fresh water
generator displayed in PPM (parts per million), and ensures
that water containing a higher level of PPM, than what has been
keyed in at the salinity meter, is rerouted back to the fresh water
generator.
1-2 Measuring Principle
Measuring principle is that calculating the conductivity between

two electrodes submerged in evaporated water as means of
quantity of current on condition that constant voltage is
supplied.
Furthermore, measured value, that is substantially affected by
ambient temperature,is to be calibrated by additional temperature
compensation circuit to acquire reliable result.

2 Installation of Salinity Meter
2-1 Controller Installation

The Salinity Meter is consist of two parts :
A display part where from the connected sensors is shown as well as
installation part whitch is delivered in a plastic module in which
power supply and connection clips are mounted.
The display part is delivered in a cabinet for front installation in the
control cabinet and enclosed shape can be used for the installation.
The installation part is fastened. The cable is to be connected

through receptable & plug to the sensor and the sensor must be
connected to the terminal block, as described Fig 1.
* WIRING *
1 2 3 4 5 6 7 13 14 15
8 9 10 11 12 16 17 18
F
. NO COM NC
G Sensor Temp.
AC AC + - + - + - NO COM NC NO COM NC
1 2
F.G
Salinity Sensor 4~20mA Power Fail
AC Power
백 OUTPUT Alarm OUTPUT Sol'Valve
220V 백 적 적
색 색 색 색 OUTPUT OUTPUT
(outside)
( Figure 1. Connection diagram of the control box )
1) The white color cable of the sensor is connected to the terminal 4 (' Sensor + ')
2) The white color cable of the sensor is connected to the terminal 5 (' Sensor - ')
3) The red color cable of the sensor is connected to the terminal 6 (' Temp +')
4) The red color cable of the sensor is connected to the terminal 7 (' TEMP.- ')

2-2 The Sensor Installation
INSTALLATION & DISASSEMBLY METHOD
INSIDE OUTSIDE
TANK TANK
1. Insert the cell the way into the safety

valve body.
2. Turn the knob clockwise firmly holding

the cable gland in place to prevent
the cable from being twisted.
Turn the knob of the body clockwise
until it stops touching the flange.
3. This is the normal operating position.
4. When releasing the cell, turn the knob

of the cell counterclockwise all the way
out holding the cable gland in place to
prevent the cable from being twisted
and then turn the knob of the body
counterclockwise all the way out.
5. Take out the cell.

3 Operating the Salinity Meter
▶ On the front plate of the display part there are 4 keys

( MENU/ACK ,Increase(▲) ,Decrease(▼) ,ENTER ).
▶ When source ( AC 220V ) is supplied to this controller,

the process value(PPM & TEMP.) will be displayed(Option DC24V).
▶ If you want to alter the alarm setting value, press the '▲' + key and
▼' - key at the same time then the current setting value(PPM)
A-S
will be displayed while the ALARM lamp is turned on
80
after that set the alarm setting value as much as you want.
▶ After adjusting, Please make sure of saving the altered value

by means pressing the 'ENTER ' key. (Very Important)
▶ When occur the alarm, click the 'MENU/ACK' key once

then the alarming will be stopped
but the solenoid valve will be still on working.
▶ The Power Fail ,Alarm and Sol'valve output function is free contact.
(NO / COM / NC).
▶ To keep the salinity operating accurately all the time,

detach the electrode(cell) and clean the sensor at least once a month.
In cleaning the electrode, carefully wipe off dust and scale from its sur
with soft cloth. Do not use sandpaper or other material whitch may hu
the surface.

3 Specificaion Sheet

5 Drawing Inspection

6 Troubleshooting Guide
Condition Cause Solution Remark
Check the power cable or ,

Power fail No power or fuse trouble
replace the fuse.
Check the Alarm Setting Value

Alarm Setting Value is higher
(Refer to the
than normal state.
OPERATING MANUAL)
ALARM LED fail
Change the I/O Main-PCB
Caution output signal error
(Contact to the manufacturer)
Check the Alarm Setting Value

Alarm Setting Value is lower
(Refer to the
than normal state
ALARM LED is on OPERATING MANUAL)
continually
Change the I/O Main-PCB
Caution output signal error
(Contact to the manufacturer)
PPM valve is lower than

Inferiors on the senser serface Clean the sensor
normal
Inferiors on the senser serface Clean the sensor

PPM valve is higher
than normal
Wire cut or error of Main-PCB Change the I/O Main-PCB
in the control box. (Contact to the manufacturer)
Bad connect between Jack
Check the condition of
Cable
Cable Jack tightened
FND signal board error and Control Box Main-PCB
for the PPM and Temp..
PPM connect cable(white) is

Check the cable
unconnected or bad
ERR' and Alarm sign on
the PPM signal board Open the safety valve and
The sensor cell is exposured
contain water after insert the
in the air
sensor
ERR' and Alarm sign on TEMP connect cable(Red) is
Check the cable
the Temp. signal board unconnected or bad
Check the positive and

mA connect cable error
negative of mA connect cable.
Non output the mA value

INFORMATION ON CONTACTING US
Thank you very much for purchasing our products.

We always strive to maintain excellent quality and provide
exceptional products whitch satisfy our customer's requirement.
Please do not hesitate to call or e-mail regarding our products,
technical issues, inquiries, etc.
Our staff will immediately respond to your request.
The contact stations are as follows
SI-MAEINE Co.,Ltd.
ADD.:20-Dong,#129,Industrials Goods Center,

Gwaebeop-dong,Sasang-Gu,Busan,Korea
TEL.: +82-51-337-8877 / +82-51-319-1273
FAX.: +82-51-319-0097
http://www.simarine.co.kr
E-mail: [email protected]

CABLE DIA :
11.2mm
4. BURNER SPECIFICATION

LIST OF BURNER DATA

1 - Burner technical data & specification 0
2 Brner excess air ratio curve 0
3 Draft loss curve for register 0
4 Characteristic curve of “Y” jet type 0
atomizer
5 2066568-15A Burner arrangement drawing 0
6 MB-INT-001 Installation of mixing tube 0

Burner technical data & specification
A. Fuel oil data

Diesel oil Marine gas oil Heavy fuel oil
(M.D.O) (ISO 8217 “DMA”) (H.F.O)
Viscosity at 50℃ 10 2 (at 40℃) 380
(cSt)
Specific gravity 850 890 991
(kg/m3)
Low calorific value 10200 10400 9750
(kcal/kg)
B. Fuel oil consumption

Diesel oil Marine gas oil Heavy fuel oil
(M.D.O) (ISO 8217 “DMA”) (H.F.O)
Max. consumption 1250 1180 1315
Min. consumption 145 145 145
C. Burner specification
Number of burner /ship : 1 Set
Burner type (Steam atomizing) : SFDTU-405 (Osaka, Japan)
Burner range : 145~1450 Kg/h
Used atomizer : L590-9117G
(HFO/MGO common type)
Burner operation pressure at H.F.O : 2.5~20.0 Kg/cm2
Burner inlet fuel oil viscosity at H.F.O : 18 cSt
Atomizing steam and air pressure : 5 Kg/cm2
Atomizing steam consumption (MAX.) : 92 Kg/h
Atomizing air consumption (MAX.) : MAX 1.06 Nm3/min
Burner inlet air temperature : 45 ℃
Burner draft loss : 180 mmAq
Excess air ratio : 15%

D. Electric data
Power source : AC440, 60Hz, 3ph
Control source : AC220, 60Hz, 1ph
Motor insulation : F
Enclosure type : IP 54
 F.O PUMP
Motor power : 3.6 Kw
Motor specification : T.E.F.C. Insulation calss
“F/B” IP55
 Ignition pump
Motor power : 0.4 Kw
Motor specification : T.E.F.C. Insulation calss “F”
IP56
E. Paint color
Burner body : Maker standard

HM12063(SFDTU-405).docx
USER'S: SPP SHIPBUILDING CO.,LTD. H.NO.S5112/3/4/5/6/7

TO : KANGRIM HEAVY INDUSTRIES CO.,LTD.
*****************************************************
* ＯＩＬＢＵＲＮＩＮＧＡＰＰＡＲＡＴＵＳ *
* *
* （ SFDTU-405 ） *
* *
* *
*****************************************************
ＶＯＬＣＡＮＯＣＯＭＰＡＮＹ，ＬＴＤ
3-38,1-chome,Nonakakita,Yodogawa-ku,
Osaka, Japan
TEL.+81-6-6392-5541
FAX.+81-6-6396-5338
MARINE EQUIP,SECT. ENG'G. DESIGN DEPT.

COMBUSTION ENG'G. DIVISION
APPROVED H.ISHIMARU
CHECKED H.I
DRAWN T.SHIRAI
DATE 24th.NOV.2011
REVISIONS
No DESUCRIPTION DATE APPROVED CHECKED DRAWN
CONTENTS
FOR SPP S5112/3/4/5/6/7

No. DRAWING No. TITLE TYPE PAGE
1 HM12063 SPECIFICATION 1～6
2 2883A EXCESS AIR RATIO CURVES SFDTU-405 7
3 1282C DRAFT LOSS CURVE SFDTU-405 8
4 3323A CHARACTERISTIC CURVE L590-9117G 9
5 2065341-82 PIPING DIAGRAM SFDTU-405 10
6 2066796-47 OIL BURNER UNIT SFDTU-405 11
7 3088338-21 SPRAYER ASSEMBLY OB-22-1925 12
8 3020008-00A FLEXIBLE TUBE FTS-20-2(L=0.5M) 13
9 3019982-01 LIMIT SWITCH WLCA2-TH 14
10 3011644-01 QUICK CLOSING VALVE F.O. & STEAM UTKM-1 15
11 3065728-62 PILOT BURNER ASSEMBLY PBL-9-1-1685-270 16
12 3019990-00C FLEXIBLE TUBE FTSP-10 17
13 4092091-00 FLAME EYE AXV-260-33 18
14 E4-34238 FLAME DETECTOR RELAY RDV-1005-200 19
15 3047626-64 PILOT BNR'PUMP UNIT APS-44 20
16 DH-202RF-02-b-A 2-WAY BALL VALVE DHE-BL200 21,22
17 4078047-01 REDUCING VALVE UNIT COSR-16 23
Specification No.HM12063
SPECIFICATION OF FUEL OIL BURNING APPARATUS
24th.Nov. 2011
VOLCANO CO.,LTD.
Designing Sec.
Use for : SPP SHIPBUILDING CO.,LTD. H.NO. S5112/3/4/5/6/7

To : KANGRIM HEAVY INDUSTRIES CO.,LTD.
Quantity : 1 Boiler/Ship
1. Boiler specification
Type PB-18 Vertical Water tube boiler

Evaporation per boiler (MCR.) 18.0 t/h
Steam pressure Design 9.0 kgf/cm2 (0.88 MPa)
Working 7.0 kgf/cm2 (0.68 MPa)
Steam temperature SAT.
Burner inlet air temp. 45 ℃
Draft system Forced draft system
Furnace pressure (MCR.) ab.160 mmAq
Fuel oil consumption (MCR.) 1,315 kg/h
Furnace dimension Diameter ab.2,686 mm x Height ab.3,835 mm
1
2. Other Specification
2-1 Used Fuel
Plant start-up &
NOR. use
Pilot burner use
Marine Gas Oil
Species Heavy Fuel Oil Marine Diesel Oil
(ISO 8217,DMA)
Calorific value
9,750 kcal/kg
(L.H.V.)
Specific gravity
0.991 or less 0.85
(at 15/4 ℃)
Viscosity 380 cSt at 50℃ 1.5～6.0 cSt at 40℃ 10.0 cSt at 50℃
2-2 Steam Source

(for burner atomizing at port) :7.0 kgf/cm2 (0.69 MPa)× SAT.
(for burner atomizing at normal sea) :7.0 kgf/cm2 (0.69 MPa)× SAT.
2-3 Electricity Source

(power) :AC 440 V, 60Hz, 3φ
(control) :AC 220 V, 60Hz, 1φ
2-4 Air Source

(for burner atomizing) :7.0 kgf/cm2(0.69 MPa)× 45℃
2-5 Classification
DNV, JIS
2-6 Painting
* Oil burner unit :Heat-resistant silver paint
* Pilot burner pump unit :Munsel No.7.5BG7/2
* Igniter source unit :Munsel No.7.5BG7/2
2-7 Drawing and Literature

We shall present the followings after the order has been decided.
a) Decided specification
b) Application for approval
c) Descriptive booklet for handling
2-8 Inspection and Test

This apparatus should be subjected to the following tests and inspections,
based on the method determined by the rule, in the presence of your inspector,
at our expense, and must pass its inspection:
a) Hydraulic test (for each pressure apparatus)
b) Outside dimension
2
3. Burner Specification
Type SFDTU-405
VOLCANO steam jet oil burner
Quantity 1 set/ship
Fuel oil consumption (MCR.) 1,315 kg/h
Burner range 145～1,450 kg/h
Used atomizer L590-9117G (H.F.O./M.G.O. common using type)
Burner oil pressure range 2.5～20.0 kgf/cm2 (0.25～1.96 MPa)(for H.F.O. use)
2.0～20.0 kgf/cm2 (0.2～1.96 MPa)(for M.G.O. use)
Oil viscosity (burner inlet) 18.0 cSt (H.F.O.)
2.5～6.0 cSt (M.G.O.)
Burner inlet oil temp. 120 ℃ (H.F.O.)
room temperature (M.G.O.)
Atomizing steam pressure 5.0 kgf/cm2( 0.49 MPa) constant
Atomizing steam consumption (MAX.) 92 kg/h (H.F.O.)
106 kg/h (M.G.O.)
Burner inlet air temperature 45 ℃
Air register draft loss (MCR.) 180 mmAq
Atomizing air consumption MAX. 2.19 Nm3/min
Excess air ratio(MCR.) 1.15
Turn down range abt' 10:1
7-1) Air register × 1 SFDTU-405

7-2) Wind box × 1 WB-SFDTU-405
7-3) Sprayer with cap nut × 1 OB-22-1925
7-4) Atomizer × 1 L590-9117G
7-5) Swirler × 1 SWR-280×30×50-1LH-PR
7-6) Quick closing valve F.O. & steam × 2 UTKM-1
7-7) Flexible tube for F.O. & Steam × 2 FTS-20-2(L=0.5 M)
7-8) Limit switch for sprayer insert × 1 WLCA2-TH
7-9) Packing × 1 780×745×705×16-φ19×t3
7-10) Housing tube × 1
7-11) Metal throat × 1
3
4. Flame detector
Type Photo IC
Quantity 2 sets
Operating luminosity 3.5 Lx min.
8-1) Flame detector body × 2 AXV-260-33

8-2) Flame detector relay with socket × 2 RDV-1005-200, 11PFA
5. Pilot burner
Type Diesel oil pilot burner / electric ignition

Quantity 1 set
Burner capacity 25 kg/h
Burning pressure 14.0 kgf/cm2 (1.37 MPa)
Secondary voltage 10 KV
Electric capacity 200 VA
Used atomizer AP-5-60SS×HC
9-1) Pilot burner body × 1 PBL-9-1-1685-270

9-2) Ignition cable with plug × 1 N-EVS
9-3) Ignition transformer × 1 G10M23-ZC
9-4) Diesel oil solenoid valve × 2 EV210B3B (NOR. Close)
9-5) Escape valve × 1 SEV-3/8-20
4
6. Pilot burner pump unit
Type APS-44
Quantity 1 set
Capacity 30 kg/h
Delivery pressure 14.0 kgf/cm2 (1.37 MPa)
Suction pressure 0 kgf/cm2 (0 MPa)
Revolution 1670 R.P.M.
Motor power 0.4 kw, 4P
Motor specification T.E.F.C. Insulation Class “F” IP55
12-1) Pilot burner pump × 1 GFY-V3

12-2) Safety valve(contain in body) × 1 Set press. 14.0 kgf/cm2 (1.37 MPa)
12-3) Motor × 1 SY-5-15A(60MESH)
12-4) Y type strainer × 1 AU1/4×60×10K/MPa×76cm
12-5) Compound gauge (*1) × 1 AU1/4×60×50K/MPa
12-6) Pressure gauge (*1) × 1 KMKM 1/4×1/4
12-7) Root valve × 2
(*1) Green marked & Glycerin filled
7. Equipments on F.O. & Steam line in burner unit
10-3) 2-way atom. steam ball valve with limit switch × 1 DHE-BL200
10-4) 2-way burner purge steam ball valve with limit switch × 1 DHE-BL200
10-5) Check valve for burner purge × 1 M20K-FGC20
10-6) 3-way solenoid valves with manifold block × 1 set
10-8) Root valve for F.O. pressure PX & PS × 3 KMKM1/4×1/4
5
8. Atomizing steam reducing valve unit
Type COSR-16
Quantity 1 set
Primary pressure (steam) 7.0 kgf/cm2 (0.69 MPa)
(air) 7.0 kgf/cm2 (0.69 MPa)
Secondary pressure 5.0 kgf/cm2 (0.49 MPa) constant
Flow rate range (steam) 40～105 kg/h
(air) 0.87～2.17 Nm3/min
Max. ΔP 1.0 kg/cm2(0.098 MPa)
Size JIS 10K-15A RF
11-1) Strainer × 1 YF10K-15A

11-2) Drain separator × 1 DS10K-15A
6
9. Guarantees
-1. Volcano shall guarantee the products supplied by Volcano and approved by Purchaser
for a period of 12 months from the date of delivery of the Ships to Owner,
or 18 months from the date of delivery of the product to Purchaser, whichever comes earlier,
against any defect resulting from defects in workmanship and design.
-2. Purchaser shall notify Volcano in writing of any defect upon discovery,
informing the nature of the defect and/or the extent of the damage caused thereby.
Upon receipt of notification thereof and provided that the products has been installed
and maintained and operated in accordance with good shipboard practices
and any specific instruction of Volcano, Volcano shall remedy the such defect forthwith
at its own expenses by repair or replacement of the defective parts at its option.
Parts furnished as replacement or repairs for original parts under the guarantee
shall endure until the end of the original guarantee period, and no longer.
-3. Volcano shall not be responsible for costs of removal or installation of any parts
whether or not supplied by Volcano nor shall Volcano responsible for any transportation
charge.
-4. The guarantee shall not be applied to defects, malfunction, damages and missing caused
by operator's negligence and mishandling of the products and by an accident during
the transportation after delivery of the products to Purchaser.
-5. The effects of normal wear and tears and consequent supplement of the on board spare parts
shall be specifically excluded from this guarantee.
6a
3
3
5. F.O SYSTEM WITH EQUIPMENTS

LIST OF DRAWING (1 OF 2)
NO DRAWING NO. TITLE PART NO. REV. REMARK

1 PB08-PL-02 Part list of fuel oil piping system 0
2 PB0801DS38-60 Piping system diagram 0
3 MB-FO-TV-01 3-Way valve with limit switch FO-TV-01 0 16K-50A
4 MB-FO-01 Fuel oil supply pump unit FO-MPA-02 0 DMC-2400
5 MB-PS-01 Pressure switch FO-PS-03 0
Type : 904, 0~25kg/cm 2
FG-PS-09
6 BNR-NV-01 Needle valve FO-HV-04 0
FG-HV-07
7 Pressure control valve with control FO-PCV-05 0 30K-20A
panel FG-PCV-10
8 Pressure transmitter FO-PX-06 0
9 MB-TCV-01 Temp. control valve with control FO-TCV-08 0 16K-20A
panel
10 MB-TS-02 Temperature switch FO-TS-10 0
Type : 471, 20~150℃ FO-TS-11
11
12 Flowmeter FO-FN-19 0 VZF-25
13 MB-SS-01 Steam pressure reducing unit AS-SP-01 0
AS-ST-02
AS-RV-03
14
15 MB-IP-01 Ignition pump unit DI-ST-01 0
DI-MPA-02
DI-PI-03
DI-CI-04

LIST OF DRAWING (2 OF 2)
NO DRAWING NO. TITLE PART NO. REV. REMARK

16 MB-FAN-01 Boiler f.d fan CA-MO-01 0
CA-FAN-02
CA-AV-03
CA-EXP-05
17 MB-EXP-01 Expansion joint for windbox CA-EXP-06 0
18 MB-TB-01 Gun cleaning pack MT-00-01 0
19
20 FCV-20 Flow control valve FO-FCV-20 0 30K-20A

DOC. No. : PB-PL-02
PART LIST OF FUEL OIL PIPING SYSTEM ( 1 OF 3)

A. LOOSING EQUIPMENT OF H.F.O LINE
FO-TV-01 3-Way valve with limit switch 16K-50A 1 0 2006271
FO-MPA-02 H.F.O Supply pump unit DMC-2400 1 0 3006938
FO-PS-03 Pressure switch for H.F.O supply pump Type : 904 1 0 3000678
stand-by start 0~25kg/cm 2
FO-HV-04 Needle valve PF3/8” 2 0 2000015

FO-PCV-05 Pressure control valve with control panel 30K-20A 1 0 2091260
FO-PX-06 Pressure transmitter MBS3000 1 0 -
FO-HT-07 H.F.O Heater unit Ship yard supply -
FO-TCV-08 Temp. control valve with control panel 16K-20A 1 0 2093283
FO-ST-09 Y-Strainer 16K-20A 1 2093284
FO-TS-10 Temperature switch Type : 471 1 0 6005072
For H.F.O High temperature 20~150℃
FO-TS-11 Temperature switch Type : 471 1 0 6005072
For H.F.O Low temperature 20~150℃


B. LOOSING EQUIPMENT OF ATOMIZING STEAM LINE
AS-SP-01 Steam separator 10K-15A 1 0 BMK
AS-ST-02 Y-Strainer (100MESH) 10K-15A 1 0 BMK
AS-RV-03 Steam pressure reducing valve 10K-15A 1 0 BMK
AS-STV-04 Stop valve (JIS F7302) 10K-15A 3 0
UNIT
AS-STR-05 Steam trap 10K-15A 1 0
3004427
AS-ST-06 Y-Strainer 10K-15A 1 0
C. LOOSING EQUIPMENT OF D.O SUPPLY LINE

DI-ST-01 Bucket type strainer YS-5-15A 1 0 BMK
DI-MPA-02 Ignition pump GFY-V3 1 0 BMK
DI-PI-03 Pressure gauge (0~15kg/cm2) PT 1/4” 1 0 BMK
DI-CI-04 Pressure gauge (-76~6kg/cm2) PT 1/4” 1 0 BMK
D. LOOSING EQUIPMENT OF COMBUSTION AIR SUPPLY LINE

CA-MO-01 Motor (M2QA 315 L4A) 4P-63 KW 1 0 3004892
- Heating element(M2QA 315 L4A) 4P-63 KW 1 0 3004943
CA-FAN-02 F.D Fan 18TON 1 0 3010776
CA-AV-03 Actuator CNL 1 0 -
CA-EXP-05 Expansion joint for fan - 1 0 -
CA-EXP-06 Expansion joint for wind box - 1 0 3006195
E. LOOSING EQUIPMENT OF BURNER TOOS

MT-00-01 Gun cleaning pack - 1 0 -


F. BURNER EQUIPMENT
BF-BE-01~2 Flame detector Photo IC 2 0 BMK
BF-LS-03 Limit switch for sprayer location WLCA2-TH 1 0 BMK
FO-TI-12 Temperature indicator (I-TYPE, 200℃) PT1/2” 1 0 3001749
FO-TX-13 Temperature transmitter(PT100, 200℃) PF3/4” 1 0 3001197
FO-XV-14 3-Way shut off valve with limit switch 20K-20A 1 0 2093528
FO-LS-15 Limit switch - 2 0 -
FO-SV-16 Solenoid valve - 2 0 BMK
FO-STV-17 Stop valve for flow meter in/out, by pass 20K-20A 3 0 2N01733
FO-ST-18 Y-strainer 20K20A 1 0 2019000
FO-ST-19 Flow meter( 20K-25A, 180℃) VZF25 1 0 3005107
FO-FCV-20 Flow control valve 30K-20A 1 0 2090300
FO-XV-21 Fuel oil shut off valve 20K-20A 1 0 2093527
FO-HV-22 Quick closing valve UTKM-1 1 0 BMK
FO-FH-23 Flexible hose (FTS-20-2) L=0.5m 1 0 BMK
FG-XV-14 2-Way shut off valve with limit switch 20K-20A 1 0 2093527
FG-LS-15 Limit switch - 1 0 -
FG-SV-16 Solenoid valve - 1 0 BMK
AS-XV-07 Steam shut off valve 20K-20A 1 0 BMK
AS-LS-08 Limit switch - 2 0 -
AS-SV-09 Solenoid valve - 2 0 BMK
AS-XV-10 Purge shut off valve 20K-20A 1 0 BMK
AS-FH-11 Flexible hose (FTS-20-2) L=0.5m 1 0 BMK
AS-NRV-12 Globe check valve ( JIS F7409) FGU2020N 1 0 BMK
DI-ES-05 Escape valve PT1/2” 1 0 BMK
DI-SV-07 No.1 Solenoid valve PT 1/4” 1 0 BMK

DI-SV-08 No.2 Solenoid valve PT 1/4” 1 0 BMK
FO-OR-24 Orifice 1.5mm 1 0 BMK

PART NO.
FO-MPA-02
858
297
217
60
SAE 1 1/2" 18
G 1/2" 3000 PSI
90 270
500
CABLE GLAND SIZE :

664 DIA 13.5mm
376
551
573
130
500
550
600
Maße ohne Toleranzangabe: Schraubenspindelpumpe

Untolaranced dimensions:
DIN ISO 2768 - (m, c)
Screw-pump TMP
EN ISO 13920 - B DMC- 2400.BAAA.xxx Datum:
Date:
Gezeichnet von:
Drawn by:
M 20 + motor IEC72 - size 100 21.04.10 Laudien
"Für diese Zeichnung behalten wir uns gemäß DIN 34 alle Rechte vor" Maßstab:
"For this drawing all rights are reserved according to DIN 34" Scale: 1:10 A4 Blatt/Sheet 1 von/of 1
PART NO.
FO-MPA-02
Data sheet EMD 21B
Type description FCA 100 LA-2

Construction standard EN 60034-1
Size 100
Construction form B5
Rated output at 50/60Hz 3,0 / 3,6 KW
Duty type S1-100 %
No-load speed at 50/60Hz 2860/3432 1/min
Rated voltage at 50Hz 380-420/660-720 Volt, 50 Hz
Rated voltage at 60Hz 380-480/660-830 Volt, 60 Hz
Frequency 50/60 Hz
Rated current at 400 Volt 6,01 A
Starting current/rated current 7,5 IA/IN
Starting torque/rated torque 2,2 MA/MN
Pull-out torque/rated torque 2,3 MK/MN
Efficiency 82,8 %
Power factor 0,87 cos phi
Moment of inertia J = GD ² 0,01090
Protection mode IP 55
Insulation class F/B
Bearing type DE/NDE 6206.ZZ.C3/6206.ZZ.C3
Feature Marine execution
Weight 21,0 kg
AC-Motoren GmbH Telefon 06106-770280 Sparkasse Dieburg Handelsregister

Kronberger Str. 16 Telefax 06106-77028-20 BLZ 508 526 51 Konto 148011521 Langen HRB 34096
D-63110 Rodgau e-Mail: [email protected] Ust.-IdNr.: DE 812439558 Geschäftsführer: Peter Dieter
- 6616 -
PART NO.
FO-PCV-05
- 6618 -
- 6619 -
- 6620 -
- 6621 -
- 6622 -
- 6623 -
- 6624 -
- 6625 -
PART NO.
FO-PX-06
- 6626 -
- 6627 -
- 6628 -
CM2-AGV200-2001
CV3000 Alphaplus Series

Control Valves
Model : AGVB/AGVM
User’s Manual
Copyright, Notices and Trademarks
Printed in Japan - C Copyright 1998 by Yamatake Corporation
While this information is presented in good faith and believed to be acdurate,

Yamatake Corporation disclaims the implied warranties of merchantability and
fitness for a particular purpose and makes no express warranties except as
may be stated in tis written agreement with and for its customer.
In no event is Yamatake Corporation liable to anyone for any indirect, special

or consequential damages, The information and specifications in this
document are subject to change without notice.
Preface
Introduction Thank you for purchasing the Yamatake Corporation CV3000 Alphaplus con-
trol valve.
The model AGVB/AGVM top-guided single-seat control valve features accu-
rate flow control performance and reduced cost. It has a new lighter valve
body design and multi-spring loaded actuator and is 20% lighter and smaller
than conventional models. Minimize space, installation costs, and mainte-
nance are assured when you choose the CV3000 Alphaplus.
Additionally, the flow shutoff performance equals that of an emergency

shutoff valve. The CV3000 Alphaplus thus plays a dual role in your
process:control, normal flow control and emergency shutoff of process fluid.
i
Unpacking and Inspecting Your CV3000 Alphaplus
Unpacking the CV3000 Alphaplus is a precision instrument and should be handled with care
CV3000 Alphaplus to prevent damage or breakage.
After unpacking CV3000 Alphaplus, verify that the following items are in-
cluded:
• CV3000 Alphaplus
• Ordered accessories
Verifying the The specifications of your CV3000 Alphaplus are written on an name plate
specifications attached actuator.
Enquiries If you have any questions regarding the specifications of your CV3000
Alphaplus, contact your nearest Yamatake Corporation office or Yamatake
Corporation representative. When making an enquiry, make sure to provide
the model number and product number of your CV3000 Alphaplus.
ii
Storing your CV3000 Alphaplus
Precautions An unused CV3000 Alphaplus should be stored:
• indoors at normal temperature and humidity and in a place safe from vibra-
tion or shock.
• inthe same condition and container as shipped.
Procedure Used CV3000 Alphaplus valves must be treated before storage using the fol-
lowing procedure:
Step Action
Rinse the inside of the control valve body with water to
remove residual fluids, then allow to dry. Anti-corrosive
1
treatment is recommended for control valves with carbon
steel bodies.
Attach caps to air piping connections, electrical conduit

2 connections of accessories to prevent moisture from
entering.
3 Protect flange surface with flange-caps or other safeguards.

Store the CV3000 Alphaplus indoors at normal temperature
4 and humidity in a place safe from vibration or shock.
iii
Table of Contents
Section 1 - General Description ............................................................ 1

1-1 Scope .................................................................................... 1
1-2 Major Components ............................................................... 1
1-3 Structures ............................................................................. 2
Section 2 - Installation ........................................................................... 3

2-1 Maximum Lifting Loads of Eyebolts ...................................... 3
2-2 Installing the Valve on Process Pipe .................................... 4
2-3 Check After Installation and Before Starting Operation ........ 4
Section 3 - Inspection and Maintenance .............................................. 6

3-1 Inspection ............................................................................. 6
Section 4 - Disassembly and Assembly .............................................. 7

4-1 Detaching Actuator from Valve Body .................................... 7
4-2 Disassembly and Assembly of Valve Body ........................... 8
4-3 Disassembly and Assembly of Actuator ............................... 13
Section 5 - Adjustment .......................................................................... 38
Section 6 - Trouble-shooting ................................................................ 40
Section 7 - Recommended Spare Parts ............................................... 41
Appendix A DIMENSIONS ....................................................................... A-1
Appendix B PARTS LIST ......................................................................... B-1
iv
Section 1 - General Description
1.1 Scope
This manual contains the instructions for top-guided single-seated control

valves (model AGVB/AGVM).
For the valve positioner instructions, refer to the following Operator’s Manu-
als:
• OM2-8310-0200 (for model HTP)

• OM2-8313-0100 (for model HEP)
• OM2-8310-0410 (for model VPE)
• CM2-AVP300-2001 (for model AVP)
1.2 Major Components
Each control valve comprises two major components—a valve body and an
actuator. Combinations of valve body and actuator sizes, pressure ratings,
types of materials, and actuator sizes are selectable according to process re-
quirements.
1
1.3 Structures
A typical CV3000 Alphaplus series control valve is shown in Figure 1-1.
The valve body is connected to the bonnet by stud bolts and nuts. Gaskets
mounted between body and bonnet act as a seal for the internal fluid, making
the valve body a pressure vessel.
The valve plug is supported by the guide bushing and driven by the actuator.
The multi-spring actuator and a diaphragm convert the pneumatic control sig-
nal into a mechanical control action that positions the valve plug.
Figure 1-1 Model AGVB/ABVM
2
Section 2 - Installation
2.1 Maximum Lifting Loads of Eyebolts
The diaphragm case has a pair of eyebolts for lifting the valve. The allowable
maximum lifting loads are shown in Table 2-1, so before moving the valve
check that the total weight of the control valve (including accessories) is less
than the total allowable maximum lifting load of the eyebolts.
Table 2-1 Maximum Lifting Loads of Eyebolts

Weight(kg) (Standard Bonnet)
Body size Actuator Allowable maximum
(inches) model without with side lifting load of eyebolts (kg)
handwheel handwheel
1/2, 3/4, 1 PSA1D, R 18 25
160
PSA2D, R 21 28
1-1/2 PSA1D, R 28 35
PSA2D, R 31 38 160
PSA3D, R 51 78
PSA4D, R 69 96 220
2 PSA1D, R 29 36
PSA2D, R 32 39 160
PSA3D, R 52 79
PSA4D, R 70 97 220
2-1/2 PSA3D, R 76 103 160
PSA4D, R 94 121 220
PSA6R 196 231 220 (Actuator only)
3 PSA3D, R 80 107 160
PSA4D, R 98 125 220
4 PSA3D, R 105 132 160
PSA4D, R 123 150 220
NOTE
When lifting a CV3000 Alphaplus by its eyebolts, please use ex-
treme care to prevent shock to either actuator or valve body.
3
2.2 Installing the Valve on a Process Pipe
1. Before installing the valve, remove scales, welding chips or any other con-
taminants from both upstream and downstream sides of the process pipe.
2. Confirm that the direction of process fluid flow conforms to the arrowhead
mark on the valve body.
3. Ensure that the pipe connection gaskets do not intrude the process pipe.
Gasket materials suitable for the process fluid must be selected with care.
4. Ensure that excessive stress is not transferred from the process pipe to the
valve body. Uniformly tighten the bolts on the process pipe connection
flanges.
5. Before connecting pneumatic pipes to the actuator and positioner, blow
through the pipes to clean them.
6. Do not install any heating or cooling equipment on the bonnet.
2.3 Check After Installation and Before Starting Operation
1. Check for leakage from any air pipes.

2. Check that the bolts and nuts on the diaphragm case are tight.
3. Tighten the packing flange nuts to prevent leakage from the gland part.
Standard tightening torques are shown in Table 2-2.
4. Check for leakage at the process pipe.
Table 2-2 Tightening Torques of Packing Flange Nuts
Valve sem diameter Yarn packing N m PTFE chevron packing

(mm) {kgf-cm} N m {kgf-cm}
13 5 {50}
16 12 {125} 0.8 {8}
30 32{320}
Note: These tightening toques are only reference values, and may vary
depending on the packing used.
4
PTFE yarn packing PTFE chevron(Direct + Reverse)
(for regular service) (for vacuum service)
PTFE chevron packing Graphite packing
(for oil-proof service) (for high temperature service)
Figure 2-1. Gland section
5
Section 3 - Inspection and Maintenance
3.1 Inspection
Inspect and service the control valve as follows:
1. Tightening the gland:

Tighten the gland approximately every 6 months. Follow the tightening
procedures given in subsection 2.3.
2. Check for valve position hunting. Refer to Section 6, “Trouble-shooting.”
3. Check for abnormal noise and vibration. Refer to Section 6, “Trouble-
shooting.”
6
Section 4 - Disassembly and Assembly
This section covers the disassembly and assembly procedures for its overhaul
or modification.
4.1 Detaching Actuator from Valve Body
1. Apply air pressure to the actuator so that the valve position pointer is at
10% to 20% over fully closed position.
2. Loosen the clamping bolts on of the stem connector and remove it. Detach
the actuator stem from the valve stem.
3. Remove the yoke clamping nut.
4. Raise the actuator to detach it from the valve body.
Caution
1. Before detaching the actuator from a valve that has already
been installed on the process pipe, be sure to shut down the
process and release the process pressure.
2. Ensure that the valve body is cool before detaching.
3. Loosen all process piping bolt and nuts so that excessive stress
is not transferred to the eyebolts when detaching the control
valve from the process pipe.
Figure 4-1 Disassembling the actuator
7
4.2 Disassembly and Assembly of Valve Body
To disassemble or assemble the valve body, refer to Figures 4-2 through 4-4
and proceed as described below.
Disassembly 1. Loosen the hex nuts on the packing flange.

Procedure
2. Remove the hex nuts (1) on the bonnet.
3. Raise and detach the bonnet from the valve body.
4. A seat ring is threaded in to the valve body. To remove the seat ring
special tools (available as an options) are required.
Caution
If the valve plug comes out together with the bonnet, remove the
plug from the bonnet by rotating the plug. When doing this, be care-
ful not to damage the valve stem.
Inspection Inspect the disassembled parts for damage before assembly. If any damage is
found, replace the parts. When ordering parts, refer to the PROD. No. of the
valve indicated on the nameplate.
1. Do not reuse the gland packing once it has been removed, but use new
packing when reassembling the valve. In case of vacuum service, verify
the gland packing composition as shown in Fig. 2-1.
2. Check that the seating surfaces of the plug and seat ring are not damaged.
3. Check that the gasket-contacting surfaces of valve body and bonnet are
not damaged. Do not reuse the same gasket, but use a new gasket when
reassembling the valve.
4. Check that the plug guide section, the stem, and the internal guiding sec-
tions of the guide bushing are not damaged.
8
Assembly 1. Securely fasten the seat ring onto the threaded valve body, using the spe-
Procedure cial (optional) tools. For the tightening torque, see Table 4-1. Apply lu-
bricant “Neverseize” to the threaded sections, except for oil free valves.
2. Place the plug on the seat ring.
3. Put the bonnet on the valve body and check that the bonnet is properly
mated with the indented section of the valve body. Tighten the nuts alter-
nately and evenly. For the tightening torque, see Table 4-2.
4. Insert the gland packing as shown in Figure 2-1.
Note: When yarn packing sheets are used, overlap the sheets so that their cut
ends are alternately positioned.
5. Install the packing follower and packing flange, and tighten the nuts. For
the tightening torques, see Table 2-2.
6. Check that the external O-Ring of the packing follower is installed to the
bonnet gland box.
Table 4-1 Seat Ring Tightening Torques
Body size (inches) Torque N • m {kgf-cm}

1/2, 3/4, 1 140 {1400}
1-1/2, 2 210 {2100}
2-1/2, 3 340 {3500}
4 590 {6000}
Table 4-2 Tightening Torque of Bonnet Stud Bolts.
Body size (inches) Bolt size Torque N • m {kgf-cm}

1/2, 3/4, 1 M10 140 {1400}
1-1/2, 2 M16 210 {2100}
2-1/2, 3 M16 340 {3500}
4 M16 590 {6000}
9
Figure 4-2 Model AGVB Control Valve
(Available body sizes: 1/2 inches, 3/4 inches, 1 inch)
10
(Available body sizes: 1-1/2 inches, 2 inches)
11
(Available body sizes: 2-1/2 inches, 3 inches, 4 inches)
12
4.3 Disassembly and Assembly of Actuator
Normally, the actuator should require no adjustment. However, at certain

times the actuator should be disassembled and reassembled. Reassembly is
recommended when installing it on a valve body, when modifying its specifi-
cations, or when replacing damaged parts. The disassembly and reassembly
procedures for the actuator in such cases are covered in subsections 4.3.1 and
4.3.2
Notes Before 1. Only the nuts for the eyebolts are made of stainless steel. Keep these nuts
Disassembly separate from the other nuts when assembling the diaphragm case.
2. Make locating marks on the top and bottom diaphragm cases before disas-
sembling the valve. This will help you to easily find the air piping connec-
tor location.
3. Store the removed parts in a clean place.
Caution
Use extreme care when removing the bolts and nuts form the ac-
tuator. The actuator contains powerful compressed springs that
may cause injuries or other damage. When removing the bolts and
nuts, be sure to closely follow the instructions given for disassembly
and assembly procedures of the actuator and top handwheel.
13
4.3.1 Disassembly and Assembly of Model PSA 1, 2, 3, 4
Disassembly A. Direct Action model (see Figure 4-5 or 4-6)

Procedure
1. Disconnect the air piping and detach the accessories from the actuator.
2. Remove the stem connector.
3. Remove the clamping bolts (except the pair of eyebolts) form the dia-
phragm case.
4. Alternately and evenly loosen the pair of eyebolts. The initial setting
of the springs is achieved using these eyebolts.
5. Remove the diaphragm case. Pull the actuator rod out and upward
together with the diaphragm.
6. Take out the springs.
B. Reverse Action model (see Figure 4-7 or 4-8)

1. Disconnect the air piping and detach the accessories from the actuator.
2. Remove the stem connector.
3. Remove the clamping bolts (except the pair of eyebolts) from the dia-
phragm case.
4. Alternately and evenly loosen the pair of eyebolts. The initial setting
of the springs is achieved using the eyebolts.
5. Remove the diaphragm case. Take out the spring.
6. Pull the actuator rod out and upward together with the diaphragm.
14
Figure 4-5 Direct Action model Figure 4-6 Direct Action model
(PSA1D, PSA2D) (PSA3D, PSA4D)
15
Figure 4-7 Reverse Action model Figure 4-8 Reverse Action model
(PSA1R, PSA2R) (PSA3R, PSA4R)
16
Assembly Before assembly, check the parts for scratches, damage, deformation, peeling
Procedure paint and other abnormalities. To assemble the actuator, proceed as follows:
A. Direct Action models

• See Figures 4-5 and 4-6.
1. Secure the diaphragm case (bottom) with the four bolts to the yoke.
At the some time, set the air vent hole as shown in Figure 4-9.
For PSA1D and PSA2D actuators, secure the spring plate to the dia-
phragm case and yoke.
2. Fasten the spring plate and install springs in the spring plate (see Fig-
ure 4-9.)
3. Insert the actuator rod (with diaphragm connected) into the bushing.
Be careful to prevent the bushing’s inside surface or dust seal from
being damaged by the threaded section of the rod. If possible, cover
the threaded section with adhesive tape.
4. Rotate the actuator rod, locating the diaphragm plate stopper as shown
in Figure 4-9.
5. Place the top diaphragm case and secure it with the pair of eyebolts.
Notes: Set the air pipe connection port in the location shown in Figure
4-9.
Tighten the pair of eyebolts uniformly and alternately. The
initial setting of the springs is completed by tightening these
eyebolts.
6. Clamp the diaphragm case with clamping bolts.
7. Install the stem connector. Connect the air pipe to its connection port
in the top diaphragm case.
8. After completing assembly, check the following:
• Apply air pressure of 490kPa{5 kgf/cm2} through the air pipe con-
nection port in the top diaphragm case, and check the diaphragm
periphery for air leakage with soapy water.
• Check that the actuator operates smoothly through its full stroke by
operating it as an independent unit.
Caution
Install packing for the rod and dustseal in the correct direction.
Refer to Figures 4-5 and 4-6.
17
Figure 4-9-1 Model PSA1D Actuator
Figure 4-9 Direct Action models
18
Figure 4-9 Direct Action models
19
A. Reverse Action models
• See Figures 4-7 and 4-8.
1. Secure the bottom diaphragm case with the four bolts to the yoke.
At the same time, set the air pipe connection port in the location shown
in Figure 4-10.
2. Insert the actuator rod (with diaphragm connected) into the bushing.
Be careful to prevent the bushing’s inside surface or dust seal the
threaded section of the rod. If possible, cover the threaded section with
adhesive tape.
3. Rotate the actuator rod, locating its diaphragm plate stopper as shown
in Figure 4-10.
4. Fasten the spring plate and install springs in the spring plate (see Fig-
ure 4-10).
5. Place the top diaphragm case and secure it with the pair of eyebolts.
Notes: Set the air vent hole in the location shown in Figure 4-10.
Uniformly and alternately tighten the eyebolts. The initial set-
ting of the springs is completed by tightening these eyebolts.
6. Clamp the diaphragm case with clamping bolts.
7. Install the stem connector.
8. Install the rain cap on the air vent port.
9. Connect the air pipe to its connection port in the bottom diaphragm
case.
10. After completing of assembly, check the following.
• Apply air pressure of 490kPa{5kgf/cm2} through the air pipe con-
nection port in the bottom diaphragm case, and check the diaphragm
periphery for air leakage with soapy water.
• Check that the actuator operates smoothly through its full stroke by
operating the actuator as an independent unit.
Caution
Install packing for the rod and dustseal in the correct direction.
Refer to Figures 4-7 and 4-8.
20
Figure 4-10-1 Model PSA1R Actuator
Figure 4-10 Reverse Action models
21
Figure 4-10 Reverse Action models
22
Direct Action model Reverse Action model
Figure 4-11 Bolts and Nuts of Actuator
Table 4-3 Tihtening Torques of Bolts and Nuts of Actuator

[N • m {kgf • cm}]
Key No. Material PSA1, 2 PSA3 PSA4
S45C 45 to 70 160 to 215 265 to 358
① M14
{460 to 710}
M20
{1,600 to 2,200}
M20
{2,700 to 3,650}
SK5
35 to 50 90 to 120 90 to 120
② S30C M12
{360 to 510}
M16
{920 to 1,220}
M16
{920 to 1,220}
15 to 20 15 to 20 50 to 60
③ S30C M8
{150 to 200}
M8
{150 to 200}
M12
{510 to 610}
15 to 20 50 to 60 50 to 60
④ SUS304 M8
{150 to 200}
M8
{510 to 610}
M12
{510 to 610}
10 to 15 30 to 40 30 to 40
⑤ S30C M8
{100 to 150}
M10
{300 to 400}
M10
{300 to 400}
Note: Install the rain cap on the reverse actuator as follows. Drive the cap into the
diaphragm case until the shoulder (brim) of the cap is brought into contact with
the diaphragm case, then drive the cap further into the diaphragm case by half a
turn.
23
Direct Action model Reverse Action model
Figure 4-12 Model PSA Actuator
No. Item Material

1 Nut S45C, SK5
2 Diaphragm case (top) SAPH370
3 Diaphragm EPDM, Polyaimid
4 Eyebolt S20C
5 Nut SUS304
6 Bolt SUS304
7 Diaphragm case (bottom) SAPH370
8 Bushing SPCC, bronze, PTFE, lead
9 Dust seal NBR
10 Yoke S25C
11 Stem connector S25C
12 Bolt S30C
13 Diaphragm retainer SS400
14 Diaphragm plate AC4A/AC4C
15 Spring SWOSM-B/SWOSC-V
16 Bolt S30C
17 Nut S20C
18 Spring plate SPCC
19 Bolt S30C
20 Seal washer NBR, SPCC
21 Packing for rod NBR
22 O-Ring NBR
23 Rod SUS304
24 Truss screw SUS304, SK5
25 Scale plate SUS304
26 Drive screw SUS304
27 Name plate SUS304
28 Rain cap SUS304
29 Washer SUS304
24
4.3.2 Disassembly and assembly of Model PSA6 Actuator
1.General
Structure This actuator consists of cylinder, spring unit, lift stopper, spring retainer,
hexagon stay, yoke, manual handwheel and single action positioner.
For external appearance of the actuator, refer to Fig.4-13, External Appear-
ance of PSA6R.
(1)Without manual handwheel (2) With manual handwheel
Fig.4-13 Exterior of PSA6R
Assembly on valve Assembling nuts integral to the valve body assembles yoke and valve body.
body Stem connector connects actuator’s rod and valve stem.
Air piping The tubing is connected to single action positioner when used as control
connection
valve. Refer to the following instruction manuals for details of single action
positioner.
Pneumatic positioner (Model HTP) No. OM2-8310-0200
Electro-pneumatic positioner (Model HEP) No. OM2-8310-0100
Electro-pneumatic positioner (Model AVP300/301)
No. CM2-AVP300-2001
25
Calibration This actuator does not need calibration.
When connecting valve stem of the valve body with actuator’s rod with
stem connector, due adjustment should be made to seat the valve plug on the
seat ring. Then screws on actuator’s scale plate are loosened, stroke and
index matched to properly position the scale plate.
Caution in operation
and handling Caution
• When automatically operating an actuator with manual
handwheel, verify that the AUTO/MANUAL switchover pin is
inserted into pin holder, chain is engaged on the handwheel and
the indicator is in AUTO position before start of operation.
• When disassembling and assembling, always hold the actuator
in upright position (spring unit on top and yoke on bottom)
• While eyebolts are used to suspend actuator, assembled valve
should not be suspended by eyebolts only
26
2. AUTO/MANUAL switchover of manual handwheel
Refer to Fig.4-14 for details of AUTO/MANUAL switchover of handwheel.

With an actuator with AUTO/MANUAL switchover functions, switchover
between automatic operation and manual operation by handwheel are avail-
able.
AUTO/MANUAL switchover can be made at any optional moment during
operation.
Fig.4-14 AUTO/MANUAL switchover scheme
Fig.4-15 Operator’s instruction label
27
Step Procedure
1 Pull out AUTO/MANUAL switchover pin out of holder and

disengage chain, which binds handwheel from the wheel.
2 Verify operating label on handwheel and turn the handle to

thedirec tion of SHUT and lower slide screw.
3 Match the round holes of slide screw and actuator’s rod, and
insert pin. Push it all the way in and fix it there.
4 Verify OPEN, SHUT arrows on label, and turn the handwheel to

either direction to open or close the valve. The turning torque
should be under 127N (13kgf)
5 When the handwheel does not turn any further, check valve
opening and end operation.
Caution
Do not apply undue force on valve when
it reaches mechanical stop. Otherwise
valve stem may be damaged. Refer to
10. Trouble shooting for remedial action.
6 To resume automatic operation, remove the switchover pin, turn

handwheel until
The slide screw stop reaches AUTO position (refer to Fig. 4-16
below).
Run the chain on the pin through in order to restrict handwheel
movement and fix the pin on holder. Resume automatic
operation after verifying this condition.
Fig. 4-16
28
3. Disassembly and assembly of actuator
Disassembly and assembly procedures are described herein. Refer to it when-

ever necessary for periodic maintenance or malfunction which may call for
disassembly or assembly of the actuator.
Before disassembly 1.Only the nus for the eye bolts ae made of stainless steel. Keep these nuts
separte from the other nuts when assembling the diaphragm case.
2. Make locating marks on the top and bottom diapragm cases before disas-
sembling the valve. This will help you to easily find the air piping connector
location.
3. Store the removed parts in a clean place.
Caution
Use extreme care when removing the bolts and nuts from the
actuator. The actuaor contains powerful compressed springs that
may cause injuries or other damage. When removing the bolts
and nuts, be sure to closely follow the instructions given for disas-
sembly and assembly procedures of the actuator and top hand
wheel.
Detaching Actuator Refer to 4-1, page 7.

from Valve Body
29
Disassembly of <disassembly procedure>
actuator Disassembly procedure of actuator is described herein.
Refer to and Figures 4-17 and 18 or Table 4-4 for information.
① Marking and protection

Step Procedure
1 Match mark on spring retainer on the top of actuator, lift stopper,
cylinder and cylinder assembling yoke boss.
2 Wrap PVC tape on rod bushing to protect sealing parts, guide
bushing.
≠ Removing slide screw detent

Step Procedure
1 Loosen hexagon head bolt No.50 and hex nuts No.51 which
fasten slide screw detent No.49
2 Remove slide screw detent No.49
➂ Removing spring retainer

Step Procedure
1 Loosen hexagon nuts No.2 and eye nut No.1 on the top of
actuator and remove.
2 Lift spring retainer No.17 straight up and remove.
√ Removing lift stopper and spring unit

Step Procedure
1 Loosen hexagon stay No.4, No.9 (four stays) which fasten lift
stopper No.20 and cylinder No.21 and remove
2 Raise lift stopper No.20 straight up and remove.
3 Install eyebolts on threaded holes on the spring retainer No.59
which is located on the top of spring unit (M12 x 2) and lift
spring unit (approximately 120 kg) up with a crane.
4 While suspended by crane, remove piston’s No.57 sealing parts
(tape liner No.7, O-ring No.8)
➄ Removing slide screw and cylinder

Step Procedure
1 Turn slide screw No.34 by hand and extract from the bottom
2 Loosen hexagon head bolts No.12 (four bolts) which fasten
cylinder and manual handwheel and remove.
3 Lift cylinder up straight and remove.
≈ Removing worm unit

Step Procedure
1 Remove in the sequential order of bearing holder No.27, single
column angular bearing, (upper) No.32, worm wheel No.33, and
single column angular bearing (lower) No.32.
2 Loosen hexagon head bolts No.12 (four bolts), which fasten gear,
case No.30 and yoke and remove.
30
Fig.4-17. PSA6R
31
Table 4-4. Parts reference List
No. Parts description No. Parts description
1 Eye nut 33 Worm wheel
2 Hexagon nut 34 Slide screw
3 Spring washer 35 Locking pin
4 Hexagon stay (long) 36 Handwheel
5 O ring 37 Operating instruction label
6 Piston unit 38 Spring washer
7 Tape liner 39 Locknut
8 O ring 40 Single column bearing
9 Hexagon stay (short) 41 Worm shaft
10 Seal washer 42 Key
11 Spring washer 43 Gear case cap
12 Hexagon head bolt 44 Dust seal
13 Round bushing 45 Hexagon head bolt
14 Dust seal 46 Spring washer
15 Wearing 47 Truss screw, small
16 Name plate 48 Indicator
17 Spring retainer 49 Slide screw lock
18 Rain shield cap 50 Hexagon head bolt
19 O ring 51 Hexagon nut
20 Lift stopper 52 Hexagon nut
21 Cylinder 53 Stopper retainer
22 Rod packing 54 Spring (large)
23 Guide bushing 55 Spring (small)
24 Dust seal 56 Spring stopper
25 Scale plate 57 Piston
26 Truss screw, small 58 Rod
27 Index 59 Spring receptacle
28 Stem connector 60 Stopper
Fig.4-18. Spring Unit
29 Yoke 61 Detent nut
30 Gear case 62 Spring washer
31 Bearing holder 64 O ring
32 Single column angular bearing
32
Disassembling spring <disassembly procedure>
unit
Disassembly procedure of spring unit is described herein.
Refer to page 32 , Figure 4-18 for disassembling information.
Disassembling is not required if only piston’s sealing parts (tape liner, O
ring) are replaced.
① Removing spring unit

Step Procedure
1 Loosen hexagon nuts No.52 (four nuts on top) and remove
2 Remove stopper retainer No.53
3 Evenly loosen hexagon nuts No.52 (four nuts on bottom) until
tension of springs No.54 and No.55 becomes zero.
Caution
Follow disassembly procedure of spring unit when re
moving bolts and nuts. Otherwise, flying out of spring
may cause injury.
4 Remove spring retainer No.59

5 Remove springs (large No.54, small No.55)
≠ Removing piston unit

Step Procedure
1 Loosen stopper No.60 and remove
2 Loosen detent nut No.61 and remove, using flat faces of rod No.58.
3 Remove spring washer No.62, O-ring No.61.
Exercise care so as not to damage O ring with rod’s screw.
4 Separate rod No.58 from piston No.57.
33
Assembling <caution during assembly>
actuator
• Refer to the chapter of inspection items during disassembly and check,
and ensure that no abnormality is found on parts. If found, replace or
repair as required.
• O-ring of sliding parts should always be replaced at the time of periodic
disassembly. Whenever O-ring on the fixed part is deformed or damaged,
or scarred during disassembly, replace it.
• Clean O ring, oil seal, wearing, tape line O-ring recess and apply plenty of
lubricant.
• Ensure that no dust or dirt from maintenance work prior to disassembly
remains on sliding part of cylinder and guide bushing.
Assembly of actuator <assembly procedure>

with manual
Refer to pages31 , Figure 4-17 for assembly information.
handwheel
① Assembly procedure, manual handwheel and cylinder assembly
Step Procedure
1 While yoke is in upright position, place gear No.30 and temporarily
fasten with hexagon head bolts No.12 (four bolts)
2 Apply lubricant on single column angular bearing (top and bottom)
and assemble in the sequential order of bearing (lower) No.32,
worm wheel No.33, bearing (upper) No.32 and bearing holder
No.31. Refer to the Figure 4-19 below for details.
Fig. 4-19
3 Insert and screw in from the bottom slide screw No.34 with tape
liner No.13 assembled on. Apply lubricant on threaded parts of
slide screw No.34.
4 Assemble slide screw No.34 with slide screw detent No.49, hexagon
head bolt No.50 and nut No.51.
5 Apply lubricant on rod packing No.22 and dust seal No.24 and
assemble on cylinder No.21.
34
Step Procedure
6 Place cylinder No.21 on gear case No.30 and temporarily fasten by
hexagon head bolts No.12 (four)
7 Use rod No.58 to set the position of cylinder by ensuring that the rod
moves smoothly and tighten by the torque as shown in page 37,
table 2.
If the rod does not move smoothly, tap cylinder or gear case with
plastic hammer and set the position.
≠ Assembling piston unit, lift stopper and spring retainer

Step Procedure
1 Install eyebolts on threaded hole (M12 x 2) on the top of spring
retainer No.59 on the piston unit, suspend by crane and lift upright.
2 While suspended upright, assemble lubricated O ring No.8 and tape
liner No.7 on piston No.57.
3 Assemble piston unit in cylinder No.21 from the top. See to it that
the round hole of rod No.58 appears front.
4 Assemble lift stopper O-ring No.5 in the slot on the top of cylinder
No.21.
5 Insert lift stopper No.20 from the top and fix by hexagon stay No.4,
No.9 (four). Screw on the ones of same length diagonally.
6 Assemble so that the hexagon stays No.4, No.9 are fit into holt holes
of spring retainer No.17.
7 Fix spring retainer No.17 with hexagon head nuts No.2 (four)
8 Install eye nuts No.1 (two) on hexagon stay No.4
Assembly of actuator When assembling actuator without manual handwheel, follow the proce-
without manual
handwheel dure in “Assembly of actuator with manual handwheel” on page 34 except
the applicable parts to actuator.
35
4. Major replacement parts
Actuator’s parts have been designed to withstand prolong usage. However,

it is recommended that the following parts be replaced in the interval as
shown below:
Tape liner --------Every five years
Busing ------------ ˝
Wearing ---------- ˝
Seal washer ------ ˝
Dust seal --------- ˝ (to be replaced when disassembled)
Rod seal ---------- ˝ ( ˝ )
O ring ------------ ˝ ( ˝ )
Tightening torque of actuator assembly

Table below shows tightening torque of actuator assembling. Refer to Fig.
4-20, tightening torque of actuator’s threaded parts.
Table. 4-5
Key No. Size Tightening torque [N-m{kgf.cm}]
① M14 80~120 {800 – 1200}
≠ M20 270~360 {2700 – 3650}
➂ M24 300~410 {3050 – 4150}
√ M14 80~120 {800 – 1200}
➄ M12 50~60 {500 – 600}
Fig. 4-20. Tightening torque of actuator threads
36
Section 5 - Adjustment
As a general rule, diaphragm control valves do not require adjustment. How-

ever, adjustment of travel (stroke) is necessary when coupling an actuator to a
valve body, after removing the actuator for overhaul, or for other purposes.
For this adjustment, refer to Figures 4-1 and 5-1 and proceed as follows:
1. Connect the actuator to the valve body by securely tightening the yoke
clamping nut use a chisel and hammer.
2. Connect an adjustable air pressure source (with a pressure regulator) to
the actuator—to the top diaphragm case (direct action) or to the bottom
diaphragm case (reverse action).
3. Lower the valve seat and check that it comes into contact with the
valve seat.
A. Direct Action models

4. Apply the maximum air pressure to the actuator corresponding to the
spring range indicated on the nameplate.
5. Increase the air pressure to the supply pressure and check that the ac-
tuator stem responds by moving 1 to 2 mm. This movement represents
the stroke allowance.
6. Decrease the air pressure once. Then increase it again to the maximum
value corresponding to the spring range, in the increasing direction.
7. In the above state, align the actuator stem and valve stem on a straight
line, adjust so that the thread of the stem connector mates with those of
the actuator stem and valve stem, and securely tighten the clamping
bolts of the stem connector. (See Figure 5-1.)
B. Reverse Action models

4. Apply the minimum air pressure to the actuator corresponding to the
spring range indicated on the nameplate, and check that the actuator
stem moves by 1 to 2 mm in response.
5. Increase the air pressure once. Then decrease it again to the minimum
value corresponding to the spring range, in the decreasing direction.
6. Perform a procedure identical with that of Step (7) of Item A “Direct
Action models.” (See Figure 5-1.)
37
Figure 5-1 Adjustment for Direct or Reverse Action models
38
Section 6 - Trouble-shooting
This section covers the symptoms, causes, and remedies of problems. Parts
may need to be replaced. For further assistance, please contact your
Yamatake Corporation representative.
Table 6-1 Troubleshooting
Symptom Cause and Remedy

Unstable Valve Operation • CV value is too large.
• Reduce CV value.
Valve hunts when almost fully • For a single seat valve, the valve is installed in the reverse flow
closed direction.
• Large pneumatic equipment is hooked up to the same air supply

line.
• Check air supply capacity, piping capacity, and restriction capacity
Air supply pressure is unstable are appropriate.
• Supply air pressure regulator is inadequate or not operating
properly.
• Controller is not properly tuned.

• Properly tune the controller (properly set the proportional band and
Signal pressure is unstable other parameters).
• Check that the controller output does not change abnormally.
• Hunting output of positioner itself.

Valve hunts even when signal • Check and repair or replace the positioner.
pressure is stable • Being affected by pressure change of process fluid as power of the
actuator is insufficient. Replace the actuator with a larger model.
Vibration of valve • Piping vibrates.

• Securely fasten the piping.
Valve vibrates (generates • Check for other sources of vibration.
noise) at any position of valve • Worn valve plug or guides.
plug • Check the parts and replace them as required.
Valve vibrates (generates • Check for changes in process fluid flow conditions (change in
restriction orifice, CV value, etc.)
noise) only when valve plug is • Check for changes in plug configuration (change in flow control
set at a certain position characteristics.)
• Air leak from piping.

• Air leak from actuator.
Sluggish valve operation or • Foreign matter trapped in guide section of valve plug.
inoperative valve Aged and hardened gland packing, causing increased hysteresis.
• Malfunctioning positioner (check the positioner by operating it
directly on an air supply known to be operating normally).
Fluid leakage from gland • Check for loose nuts of bonnet.

section • Check for damaged valve shaft.
• Air leak at actuator section.

• Apply the air supply pressure or atmospheric pressure to the
Even when valve plug is in actuator. Check the air supply source and positioner.
closed position, large flow leak • Check whether the valve plug is actually in the closed position.
to downstream side • Check the plug seat ring for corrosion and erosion.
• Check the guide sections for binding.
39
Section 7 - Recommended Spare Parts
It is recommended to replace the folowing parts when servicing the control

valve.
1. Valve Body
Be sure to replace the following parts whenever the valve body is disas-
sembled:
• Gland packing
• Gaskets
2. Actuator
Replace the following parts every 5 years or so:
• Diaphragm
• Bushing
• Seal Washer. Be sure to replace whenever the actuator is disassembled.
• Dust Seal and Rod Seal. Be sure to replace whenever the actuator is
disassembled.
40
Appendix A DIMENSIONS
Table A-1, 2 shown the dimensions and weight of the control valves. Note that the addition of any optional
specifications will change their installed dimensions and weights.
Table A-1. Main dimensions and product weights
Dimensions (mm)
A H Classified by positioner C
Valve size
Actuator AVP
(inches) JIS10K JIS20K,30K General φB
Extension
ANSI150 JIS16K ANSI300 Use VPE HTP HEP with w/o
bonnet
JPI150 JPI300 bonnet Air Set Air Set
PSA1D, R 420 545 218 145
1/2, 3/4 184 190 194
PSA2D, R 450 575 267 ——
225 290 312 221
PSA1D, R 420 545 218 145
1 184 193 197
PSA2D, R 450 575 267 ——
PSA1D, R 420 605 218 145
225 290 312 221
PSA2D, R 450 635 267 ——
1-1/2 222 231 235
PSA3D, R 630 760 350 ——
270 330 318 227
PSA4D, R 680 815 470 ——
PSA1D, R 420 605 218 145
225 290 312 221
PSA2D, R 450 635 267 ——
2 254 263 267
PSA3D, R 630 760 350 ——
270 330 318 227
PSA4D, R 680 815 470 ——
PSA3D, R 675 800 350 ——
318 227
2-1/2 PSA4D, R 276 288 292 725 855 470 —— 270 330
PSA6R 1145 1275 470 —— 348 257
PSA3D, R 675 800 350 ——
318 227
3 PSA4D, R 298 313 317 725 855 470 —— 270 330
PSA6R 1145 1275 470 —— 348 257
PSA3D, R 680 800 350 ——
318 227
4 PSA4D, R 352 364 368 730 860 470 —— 270 330
PSA6R 1150 1275 470 —— 348 257
Table A-2. Product Weight (kg)
Valve size
1/2 3/4 1 1-1/2
(inch)
JIS 10K JIS 20K JIS 10K JIS 20K JIS 10K JIS 20K JIS 10K JIS 20K
Pressure
rating ANSI 150 ANSI 300 ANSI 150 ANSI 300 ANSI 150 ANSI 300 ANSI 150 ANSI 300
JPI 150 JPI 300 JPI 150 JPI 300 JPI 150 JPI 300 JPI 150 JPI 300
PSA 1 15 16 16 19 17 19 27 32
PSA 2 18 19 19 22 20 22 30 35
Actuator
PSA 3 —— —— —— —— —— —— 50 55
PSA 4 —— —— —— —— —— —— 68 73
PSA 6 —— —— —— —— —— —— —— ——
Valve size
2 2-1/2 3 4
(inch)
JIS 10K JIS 20K JIS 10K JIS 20K JIS 10K JIS 20K JIS 10K JIS 20K
Pressure
ANSI 150 ANSI 300 ANSI 150 ANSI 300 ANSI 150 ANSI 300 ANSI 150 ANSI 300
rating
JPI 150 JPI 300 JPI 150 JPI 300 JPI 150 JPI 300 JPI 150 JPI 300
PSA 1 30 33 —— —— —— —— —— ——
PSA 2 33 36 —— —— —— —— —— ——
Actuator
PSA 3 53 56 71 77 73 81 89 106
PSA 4 71 74 89 95 91 99 107 124
PSA 6 —— —— 190 197 192 201 208 225
Figure A-1. face-to-face dimension and
overall dimensions
Appendix A - 1
Figure A-2. VPE positioner mounted Figure A-3. HTP positioner mounted
Figure A-4. HEP positioner mounted Figure A-5. SVP positioner mounted
*When applying a presureproof packing, add 105 mm
The overall dimensions and the valve weight will change when a manual handwheel is mounted. Ins
standard mounting, the position of operation of the side handwheel is at the back of the actuator (on the
side opposite that where the valve positioner is mounted).
Table A-3. Hand wheel dimensions
Dimension (mm)
Maximum
driving force of Weight
Type of handwheel Actuator
I max ØF K handwheel (kg)
N (kgf)
PSA1D, R ― 200 80 (8)

215 7
PSA2D, R ― 200 150 (15)
Side handwheel PSA3D, R ― 355 260 (27)
345 27
PSA4D, R ― 355 450 (46)
PSA6R ― 380 310 127 (13) 35 Figure A-6. Side handwheel
Appendix A -2
Appendix B PARTS LIST
1. Bonnet
1-1. Bonnet for fluid temperature -17 to 230 deg.C : Standard Actuator
Connection
Body Material Trim Material Actuator Additional Condition Parts No.
Size
1/2inch SCPH2 SUS440C PSA1,2 82-553462 - 111
3/4inch SUS316 316Soft Seat PSA1,2 82-553462 - 111
1inch SUS316 316Soft Seat PSA1,2 Oil free 82-553462 - 131
SUS316Stellite Stellite face PSA1,2 82-553462 - 121
SCS13A SUS440C PSA1,2 82-553462 - 112
SUS316 316Soft Seat PSA1,2 82-553462 - 101
SUS316 316Soft Seat PSA1,2 Oil free 82-553462 - 132
SCS14A SUS316 316Soft Seat PSA1,2 82-553288 - 102
1-1/2inch SCPH2 SUS440C PSA1,2 82-553462 - 211
2inch SUS316 316Soft Seat PSA1,2 82-553462 - 211
SCS13A SUS440C PSA1,2 82-553462 - 212
SUS316 316Soft Seat PSA1,2 82-552993 - 101
SUS316Stellite PSA1,2 82-553462 - 223
SCS13A SUS440C PSA3,4 82-553462 - 312
SUS316 316Soft Seat PSA3,4 82-553290 - 101
4inchinch SCPH2 SUS440C PSA3,4 82-553462 - 411
SUS316 316Soft Seat PSA3,4 82-553462 - 411
SCS13A SUS440C PSA3,4 82-553462 - 412
SUS316 316Soft Seat PSA3,4 82-553291 - 101
Appendix B-1
1-2. Bonnet for fluid temperature -17 to 230 deg.C : Standard
Connection
Body Material Trim Material Actuator Additional Condition Parts No.
Size
SCS13A SUS440C PSA3,4 82-553939 - 212
SUS316 316Soft Seat PSA3,4 82-553887 - 101
2-1/2inch SCPH2 SUS440C PSA6R 82-553939 - 311
3inch SUS316 316Soft Seat PSA6R 82-553939 - 311
SUS316 316Soft Seat PSA6R Oil free 82-553939 - 331
SUS316Stellite Stellite face PSA6R 82-553939 - 321
SCS13A SUS440C PSA6R 82-553939 - 312
SUS316 316Soft Seat PSA6R 82-553910 - 101
SCS14A SUS316 316Soft Seat PSA6R 82-553910 - 102
4inch SCPH2 SUS440C PSA6R 82-553939 - 411
SCS13A SUS440C PSA6R 82-553939 - 412
SCS14A SUS316 316Soft Seat PSA6R 82-553882 - 102
Appendix B-2
2. Valve plug with stem
Plug is packed with the stem attached
2-1. Connection Size 1/2inch~1inch
* of these part’s numbers means the following materials.
for Cv value=0.25 or under, the material is only SUS316 Stellite face.
* Material Table
5 SUS316 Stellite face
Standard: For fluid temperature -17 to 230 deg.C
6 SUS316L Others: Lower than -17 deg.C, higher than 230 deg.C
7 SUS316L Stellite
Flow Additional
Connection Size (inch) Cv value Material Actuator Part No.
characteristic Condition
1/2 3/4 1 0.1 Refer to linear PSA1,2 Standard 82-553274 ― 0 1 *
Material linear PSA1,2 Others 82-553764 ― 0 1 *
0.16 table linear PSA1,2 Standard 82-553274 ― 0 2 *
linear PSA1,2 Others 82-553764 ― 0 2 *
0.25 linear PSA1,2 Standard 82-553274 ― 0 3 *
linear PSA1,2 Others 82-553764 ― 0 3 *
2-2. Connection Size 1/2inch to 1inch Cv0.4 or upper : Metal Seat

The "*" mark in the column of parts No. means materials.
For the details, please refer to the following table.
* Material Table
2 SUS316
5 SUS316 Stellite (For Cv value=0.25 or under chose"8")
6 SUS316L
7 SUS316L Stellite
8 SU316 Stellite face
Flow
Connection Size (inch) Cv value Material Actuator Additional Condition Parts No.
characteristic
0.4 Refer to equal percent PSA1,2 Standard 82-553274 ― 0 4 *
Material equal percent PSA1,2 Others 82-553764 ― 0 4 *
0.63 table equal percent PSA1,2 Standard 82-553274 ― 0 5 *
equal percent PSA1,2 Others 82-553764 ― 0 5 *
1.0 equal percent PSA1,2 Standard 82-553274 ― 0 6 *
1/2 3/4 1 4 equal percent PSA1,2 Standard 82-553274 ― 0 9 *
3/4 1 6.3 equal percent PSA1,2 Standard 82-553274 ― 1 6 *
8 equal percent PSA1,2 Standard 82-553274 ― 1 0 *
1 10 equal percent PSA1,2 Standard 82-553274 ― 1 1 *
14 equal percent PSA1,2 Standard 82-553274 ― 1 2 *
Appendix B-3
2-3. Connection Size 1/2inch~1inch Material SUS440C : Metal seat
Connection Size(inch) Cv value Material Flow characteristic Actuator Additional Condition Parts No.
1/2 3/4 1 0.1 SUS440C linear PSA1,2 Standard 82-553471 - 0 1 1

linear PSA1,2 Others 82-553766 - 0 1 1
0.16 linear PSA1,2 Standard 82-553471 - 0 2 1
0.25 linear PSA1,2 Standard 82-553471 - 0 3 1
0.4 equal percent PSA1,2 Standard 82-553471 - 0 4 1
equal percent PSA1,2 Others 82-553766 - 0 4 1
4 equal percent PSA1,2 Standard 82-553471 - 0 9 1
3/4 1 6.3 SUS440C equal percent PSA1,2 Standard 82-553471 - 1 6 1
1 10 SUS440C equal percent PSA1,2 Standard 82-553471 - 1 1 1
Appendix B-4
2-4. Connection Size 1-1/2inch~4inch : Bonnet for fluid temperature -17 to 230 deg.C
Port size
Connection Size (inch) Material Flow characteristic Actuator Additional Condition Parts No.
(inch)
1-1/2 1 SUS316 equal percent PSA1,2 Standard 82-553274 - 1 2 2
equal percent PSA3,4 Standard 82-553912 - 0 1 2
SUS316Stellite equal percent PSA1,2 Standard 82-553274 - 1 2 5
SUS316Stellite face equal percent PSA1,2 Standard 82-553274 - 1 2 8
SUS440C equal percent PSA1,2 Standard 82-553471 - 1 2 1
SUS316L equal percent PSA1,2 Standard 82-553274 - 1 2 6
SUS316LStellite equal percent PSA1,2 Standard 82-553274 - 1 2 7
1-1/2 2 1-1/4 SUS316 equal percent PSA1,2 Standard 82-553274 - 1 4 2
2 2 SUS316 equal percent PSA1,2 Standard 82-553274 - 1 5 2
Appendix B-5
Port size
(inch)
2-1/2 1-1/2 SUS316 equal percent PSA3,4 Standard 82-553277 - 0 3 2
equal percent PSA6R Standard 82-553941 - 0 3 2
2-1/2 3 2 SUS316 equal percent PSA3,4 Standard 82-553277 - 0 2 2
2-1/2 3 4 2-1/2 SUS316 equal percent PSA3,4 Standard 82-553277 - 0 1 2
3 4 3 SUS316 equal percent PSA3,4 Standard 82-553277 - 0 4 2
Appendix B-6
Port size
(inch)
2-5. Connection Size 1-1/2inch~4inch : Bonnet for fluid temperature higher than 230 deg.C
Port size
(inch)
1-1/2 1 SUS316 equal percent PSA1,2 Others 82-553771 - 1 3 2
SUS316Stellite equal percent PSA1,2 Others 82-553771 - 1 3 5
SUS316Stellite face equal percent PSA1,2 Others 82-553771 - 1 3 8
SUS440C equal percent PSA1,2 Others 82-553766 - 1 3 1
SUS316L equal percent PSA1,2 Others 82-553771 - 1 3 6
SUS316LStellite equal percent PSA1,2 Others 82-553771 - 1 3 7
1-1/2 2 1-1/4 SUS316 equal percent PSA1,2 Others 82-553771 - 1 5 2
Appendix B-7
Port size
(inch)
1-1/2 2 1-1/2 SUS316 equal percent PSA1,2 Others 82-553771 - 1 4 2
2 2 SUS316 equal percent PSA1,2 Others 82-553771 - 1 6 2
2-1/2 1-1/2 SUS316 equal percent PSA3,4 Others 82-553765 - 0 3 2
equal percent PSA6R Others 82-554039 - 0 3 2
2-1/2 3 2 SUS316 equal percent PSA3,4 Others 82-553765 - 0 2 2
Appendix B-8
Port size
(inch)
2-1/2 3 4 2-1/2 SUS316 equal percent PSA3,4 Others 82-553765 - 0 1 2
3 4 3 SUS316 equal percent PSA3,4 Others 82-553765 - 0 4 2
4 4 SUS316 equal percent PSA3,4 Others 82-553765 - 0 5 2
Appendix B-9
2-6. Three-face Cut off plug
2-6-1. Connection Size 1/2inch to 1inch under CV0.25 : metal seat
* Material Table
8 SUS316 Stellite face
6 SUS316L
7 SUS316L Stellite
Flow
Connection Size (inch) Cvvalue Material Actuator Additional condition Parts No.
characteristic
1/2 3/4 1 0.1 Refer to linear PSA1,2 Standard 82-554885 - 0 1 *
0.16 Material linear PSA1,2 Standard 82-554885 - 0 2 *
0.25 Table linear PSA1,2 Standard 82-554885 - 0 3 *
2-6-2. Connection Size 1/2inch to 1inch over Cv0.4 : Metal Seat

* Material
2 SUS316
5 SUS316 Stellite (For Cv value=0.25 or under chos e"8")
6 SUS316L
7 SUS316L Stellite
8 SU316 Stellite face
Flow
Connection Size (inch) Cv value Material Actuator Additional condition Parts No.
characteristic
1/2 3/4 1 0.4 Refer to equal percent PSA1,2 Standard 82-554885 - 0 4 *
0.63 Material equal percent PSA1,2 Standard 82-554885 - 0 5 *
1.0 Table equal percent PSA1,2 Standard 82-554885 - 0 6 *
1.6 equal percent PSA1,2 Standard 82-554885 - 0 7 *
2.5 equal percent PSA1,2 Standard 82-554885 - 0 8 *
4 equal percent PSA1,2 Standard 82-554885 - 0 9 *
3/4 1 6.3 equal percent PSA1,2 Standard 82-554885 - 2 5 *
1 10 equal percent PSA1,2 Standard 82-554885 - 1 1 *
Appendix B-10
2-6-3. Three-face Cut off plug
Connection Size 1-1/2inch to 4inch : Bonnet for fluid temperature -17 to 230 deg.C
Port Additional
Connection Size (inch) Material Flow characteristic Actuator Parts No.
size(inch) condition
1-1/2 1 SUS316 equal percent PSA1,2 Standard 82-554885 - 1 2 2
SUS440C equal percent PSA1,2 Standard Refer to factory
equal percent PSA3,4 Standard Refer to factory
Appendix B-11
Port Additional
2-1/2 1-1/2 SUS316 equal percent PSA3,4 Standard 82-554885 - 0 3 2
equal percent PSA6R Standard Refer to factory
2-1/2 3 2 SUS316 equal percent PSA3,4 Standard 82-554885 - 0 2 2
2-1/2 3 4 2-1/2 SUS316 equal percent PSA3,4 Standard 82-554885 - 0 1 2
3 4 3 SUS316 equal percent PSA3,4 Standard 82-554885 - 0 4 2
Appendix B-12
Port Additional
Appendix B-13
3. Seat ring
3-1. Connection Size 1/2inch to 1inch
* of these parts’ numbers means the following materials.
* Material
2 SUS316
3 SUS440C
5 SUS316Stellite
6 SUS316L
7 SUS316LStellite
Connection Size (inch) Cv value Material Additional condition Parts No.

1/2 3/4 1 0.1 Refer to 82-553264 - 0 1 *
0.16 Material 82-553264 - 0 1 *
0.25 Table 82-553264 - 0 1 *
0.4 82-553264 - 0 2 *
0.63 82-553264 - 0 2 *
1 82-553264 - 0 3 *
1.6 82-553264 - 0 3 *
2.5 82-553264 - 0 4 *
4 82-553264 - 0 4 *
3/4 1 6.3 82-553264 - 0 5 *
8 82-553264 - 0 5 *
1 10 82-553008 - 1 0 *
14 82-553008 - 1 0 *
Appendix B-14
3-2. Connection Size 1-1/2inch to 4inch
Connection Size Port size Material Additional condition Parts No.
1-1/2 1 SUS316 82-553010 - 0 4 2
SUS316Stellite 82-553010 - 0 4 5
SUS440C 82-553010 - 0 4 3
SUS316L 82-553010 - 0 4 6
SUS316LStellite 82-553010 - 0 4 7
1-1/2 2 1-1/4 SUS316 82-553010 - 0 3 2
SUS316Stellite 82-553010 - 0 3 5
SUS440C 82-553010 - 0 3 3
SUS316L 82-553010 - 0 3 6
SUS316LStellite 82-553010 - 0 3 7
1-1/2 2 1-1/2 SUS316 82-553010 - 0 2 2
SUS316Stellite 82-553010 - 0 2 5
SUS440C 82-553010 - 0 2 3
SUS316L 82-553010 - 0 2 6
SUS316LStellite 82-553010 - 0 2 7
2 2 SUS316 82-553010 - 0 1 2
SUS316Stellite 82-553010 - 0 1 5
SUS440C 82-553010 - 0 1 3
SUS316L 82-553010 - 0 1 6
SUS316LStellite 82-553010 - 0 1 7
2-1/2 1-1/2 SUS316 82-553012 - 0 4 2
SUS316Stellite 82-553012 - 0 4 5
SUS440C 82-553012 - 0 4 3
SUS316L 82-553012 - 0 4 6
SUS316LStellite 82-553012 - 0 4 7
2-1/2 3 2 SUS316 82-553012 - 0 3 2
SUS316Stellite 82-553012 - 0 3 5
SUS440C 82-553012 - 0 3 3
SUS316L 82-553012 - 0 3 6
SUS316LStellite 82-553012 - 0 3 7
2-1/2 3 2-1/2 SUS316 82-553012 - 0 2 2
SUS316Stellite 82-553012 - 0 2 5
SUS440C 82-553012 - 0 2 3
SUS316L 82-553012 - 0 2 6
SUS316LStellite 82-553012 - 0 2 7
3 3 SUS316 82-553012 - 0 1 2
SUS316Stellite 82-553012 - 0 1 5
SUS440C 82-553012 - 0 1 3
SUS316L 82-553012 - 0 1 6
SUS316LStellite 82-553012 - 0 1 7
Appendix B-15
3-2. Connection Size 1-1/2inch to 4inch
Connection Size Port size Material Additional condition Parts No.
4 2-1/2 SUS316 82-553013 - 0 3 2

SUS316Stellite 82-553013 - 0 3 5
SUS440C 82-553013 - 0 3 3
SUS316L 82-553013 - 0 3 6
SUS316LStellite 82-553013 - 0 3 7
3 SUS316 82-553013 - 0 2 2
SUS316Stellite 82-553013 - 0 2 5
SUS440C 82-553013 - 0 2 3
SUS316L 82-553013 - 0 2 6
SUS316LStellite 82-553013 - 0 2 7
4 SUS316 82-553013 - 0 1 2
SUS316Stellite 82-553013 - 0 1 5
SUS440C 82-553013 - 0 1 3
SUS316L 82-553013 - 0 1 6
SUS316LStellite 82-553013 - 0 1 7
Appendix B-16
4. Gasket
Gasket : Gasket between bonnet and valve body
4-1. For general use Seat Gasket : Gasket between seat ring and valve body
Connection Size Parts Material Parts No. Qty
1/2 3/4 1 Gasket V543(PTFE) 82-553016 - 1 0 1 1
1-1/2 2 Gasket V543(PTFE) 82-553016 - 2 0 1 1
2-1/2 3 Gasket V543(PTFE) 82-553016 - 3 0 1 1
4 Gasket V543(PTFE) 82-553016 - 4 0 1 1
4-2. For oil free treatment

1/2 3/4 1 Gasket V543(PTFE) 82-553016 - 1 0 1 1
Seat Gasket V543(PTFE) 82-660153 - 1 0 1 1
1-1/2 2 Gasket V543(PTFE) 82-553016 - 2 0 1 1
2-1/2 3 Gasket V543(PTFE) 82-553016 - 3 0 1 1
4 Gasket V543(PTFE) 82-553016 - 4 0 1 1
4-3. For high temperature

1/2 3/4 1 Gasket V543 82-553757 - 1 0 1 1
Seat Gasket V563(Monel) 82-553756 - 1 0 1 1
1-1/2 2 Gasket V543 82-553757 - 2 0 1 1
2-1/2 3 Gasket V543 82-553757 - 3 0 1 1
4 Gasket V543 82-553757 - 4 0 1 1
Appendix B-17
5. Gland packing
5-1. PTFE Yarn packing : For general use
Connection Size Actuator Model No. Additional condition Parts No. Qty
1/2inch to 2inch PSA1,2 P4519 82-553327-101 5
2-1/2inch to 4inch PSA3,4 P4519 82-553328-101 5
5-2. V type PTFE packing : For oil free

1/2inch to 2inch PSA1,2 V-PTFE 82-553020-101 4
2-1/2inch to 4inch PSA3,4 V-PTFE 82-509693-001 4
5-3. V type PTEF packing : For vacuum service

1/2inch to 2inch PSA1,2 V-PTFE Direct/Reverse 82-553020-101 6
2-1/2inch to 4inch PSA3,4 V-PTFE Direct/Reverse 82-509693-001 6
5-4. Graphite yarn packing : For high temperature

1/2inch to 2inch PSA1,2 P6610CL 82-554274-101 3
P6722 82-554275-101 4
2-1/2inch to 4inch PSA3,4 P6610CL 82-554274-102 3
P6722 82-554275-102 4
6. Surrounding parts of grand packing

6-1. PTFE Yarn packing (P4519) used : For general use
Actuator PSA1,2
Parts Actuator Material Additional condition Parts No. Qty
Packing follower PSA1,2 SUS316 82-553026-101 1
O-ring (P18) PSA1,2 Aflas 82-592221-801 1
O-ring (P12.5) PSA1,2 Aflas 82-592221-401 1
Spacer PSA1,2 SUS316 82-553331-125 1
Actuator PSA3,4
O-ring (P22.4) PSA3,4 Aflas 82-592222-401 1
O-ring (P16) PSA3,4 Aflas 82-592221-701 1
Spacer PSA3,4 SUS316 82-553331-254 1
Appendix B-18
6-2. V type PTFE packing : For general use
Actuator PSA1,2
O-ring (P18) PSA1,2 Aflas 82-592221-801 1
O-ring (P12.5) PSA1,2 Aflas 82-592221-401 1
Retaining ring upper PSA1,2 SUS316 82-553272-101 1
Retaining ring lower PSA1,2 SUS316 82-553273-101 1
Spring PSA1,2 82-553329-101 1
Packing ring PSA1,2 SUS316 82-509712-166 1
Spacer PSA1,2 SUS316 82-553331-111 1
Actuator PSA3,4
O-ring (P22.4) PSA3,4 Aflas 82-592222-401 1
O-ring (P16) PSA3,4 Aflas 82-592221-701 1
Retaining ring upper PSA3,4 SUS316 82-509683-166 1
Retaining ring lower PSA3,4 SUS316 82-509703-166 1
Spring PSA3,4 82-553329-102 1
Packing ring PSA3,4 SUS316 82-509653-166 1
6-3. V type PTFE packing : For oil free use

Actuator PSA1,2
Packing follower PSA1,2 SUS316 Oil free 82-553026-101 1
O-ring (P18) PSA1,2 Biton Oil free 82-592221-897 1
O-ring (P12.5) PSA1,2 Biton Oil free 82-592221-497 1
Retaining ring upper PSA1,2 SUS316 Oil free 82-553272-101 1
Retaining ring lower PSA1,2 SUS316 Oil free 82-553273-101 1
Spring PSA1,2 Oil free 82-553329-101 1
Packing ring PSA1,2 SUS316 Oil free 82-509712-166 1
Spacer PSA1,2 SUS316 Oil free 82-553331-111 1
Actuator PSA3,4
Packing follower PSA3,4 SUS316 Oil free 82-553027-101 1
O-ring (P22.4) PSA3,4 Biton Oil free 82-592222-497 1
O-ring (P16) PSA3,4 Biton Oil free 82-592221-797 1
Retaining ring upper PSA3,4 SUS316 Oil free 82-509683-166 1
Retaining ring lower PSA3,4 SUS316 Oil free 82-509703-166 1
Spring PSA3,4 Oil free 82-553329-102 1
Packing ring PSA3,4 SUS316 Oil free 82-509653-166 1
Appendix B-19
6-4. V type PTFE packing (direct/reverse) use : For vacuum service use
Actuator PSA1,2
Packing follower PSA1,2 SUS316 For vacuum 82-553026-101 1
O-ring (P18) PSA1,2 Aflas For vacuum 82-592221-801 1
O-ring (P12.5) PSA1,2 Aflas For vacuum 82-592221-401 1
Retaining ring upper PSA1,2 SUS316 For vacuum 82-553272-101 2
Retaining ring lower PSA1,2 SUS316 For vacuum 82-553273-101 2
Packing ring PSA1,2 SUS316 For vacuum 82-509712-166 2
Actuator PSA3,4
Packing follower PSA3,4 SUS316 For vacuum 82-553027-101 1
O-ring (P22.4) PSA3,4 Aflas For vacuum 82-592222-401 1
O-ring (P16) PSA3,4 Aflas For vacuum 82-592221-701 1
Retaining ring upper PSA3,4 SUS316 For vacuum 82-509683-166 2
Retaining ring lower PSA3,4 SUS316 For vacuum 82-509703-166 2
Spacer PSA3,4 SUS316 For vacuum 82-553331-228 1
6-5. V type PTFE packing (direct/reverse) use : For vacuum service and oil free use
Actuator PSA1,2
Packing follower PSA1,2 SUS316 For vacuum • Oil free 82-553026-101 1
O-ring (P18) PSA1,2 Biton For vacuum • Oil free 82-592221-897 1
O-ring (P12.5) PSA1,2 Biton For vacuum • Oil free 82-592221-497 1
Retaining ring upper PSA1,2 SUS316 For vacuum • Oil free 82-553272-101 2
Retaining ring lower PSA1,2 SUS316 For vacuum • Oil free 82-553273-101 2
Packing ring PSA1,2 SUS316 For vacuum • Oil free 82-509712-166 2
Actuator PSA3,4
Packing follower PSA3,4 SUS316 For vacuum • Oil free 82-553027-101 1
O-ring (P22.4) PSA3,4 Biton For vacuum • Oil free 82-592222-497 1
O-ring (P16) PSA3,4 Biton For vacuum • Oil free 82-592221-797 1
Retaining ring upper PSA3,4 SUS316 For vacuum • Oil free 82-509683-166 2
Retaining ring lower PSA3,4 SUS316 For vacuum • Oil free 82-509703-166 2
Spacer PSA3,4 SUS316 For vacuum • Oil free 82-553331-228 1
Appendix B-20
6-6. Graphite yarn packing used : For high temperature service use
Actuator PSA1,2
Packing follower PSA1,2 SUS316 High temperature 82-553026-101 1
SUS316L High temperature 82-553026-201 1
O-ring (P18) PSA1,2 Biton High temperature 82-592221-897 1
O-ring (P12.5) PSA1,2 Biton High temperature 82-592221-497 1
Lantern ring PSA1,2 SUS316 High temperature 82-553862-101 1
SUS316L 82-553862-201 1
Packing ring PSA1,2 SUS316 High temperature 82-509712-166 1
SUS316L 82-509712-201 1
Actuator PSA3,4
Packing follower PSA3,4 SUS316 High temperature 82-553027-101 1
SUS316L 82-553027-201 1
O-ring (P22.4) PSA3,4 Biton High temperature 82-592222-497 1
O-ring (P16) PSA3,4 Biton High temperature 82-592221-797 1
Lantern ring PSA3,4 SUS316 High temperature 82-553863-101 1
SUS316L 82-553863-201 1
Packing ring PSA3,4 SUS316 High temperature 82-509653-166 1
SUS316L 82-509653-201 1
7.Other parts
Packing flange PSA1,2 SCS13 82-553028-201 1
Packing flange PSA3,4 SCS13 82-509513-264 1
Stud bolt PSA1,2 SUS304 82-592002-264 2
Nut PSA1,2 SUS304 82-592103-264 2
Stud bolt PSA3,4 SUS304 82-592004-264 2
Nut PSA3,4 SUS304 82-592103-464 2
Nut to fasten york PSA1,2 S25C 82-509501-126 1
Nut to fasten york PSA3,4 S25C 82-509503-126 1
Appendix B-21
8.Actuator
8-1.Chaging actuator action : Chaging from direct action to reverese action.
Actuator Parts Connection Size Additional condition Parts No. Qty
Rod 1/2, 3/4, 1inch 82-553314-103 1
PSA1D Seal washer 1/2, 3/4, 1inch 82-521069-101 4
to O-ring 1/2, 3/4, 1inch 82-592235-596 1
PSA1R Rod packing 1/2, 3/4, 1inch 82-521067-102 1
Washer 1/2, 3/4, 1inch 82-553318-101 1
Rain cap 1/2, 3/4, 1inch 82-553334-101 1
Rod 1/2, 3/4, 1inch 82-553314-103 1
PSA2D Seal washer 1/2, 3/4, 1inch 82-521069-101 4
to O-ring 1/2, 3/4, 1inch 82-592235-596 1
PSA2R Rod packing 1/2, 3/4, 1inch 82-521067-102 1
Washer 1/2, 3/4, 1inch 82-553318-101 1
Rain cap 1/2, 3/4, 1inch 82-553334-101 1
Rod 1-1/2, 2inch 82-553315-103 1
Diaphragm retainer(reverse) 1-1/2, 2inch 82-553313-101 1
Seal washer 1-1/2, 2inch 82-521069-102 4
O-ring 1-1/2, 2inch 82-592235-896 1
Rod packing 1-1/2, 2inch 82-521067-103 1
Washer 1-1/2, 2inch 82-553318-102 1
PSA3D Rain cap 1-1/2, 2inch 82-553334-101 1
connectionRc1/4
to Diaphragm case (upper) 1-1/2, 2inch
Standard finish
82-562893-101 1
connection1/4NPT
PSA3R Standard finish
82-562893-102 1
connectionRc1/4
82-562893-103 1
corrosion resistant
connection1/4NPT
82-562893-104 1
corrosion resistant
Rod 3, 4inch 82-553315-103 1
Diaphragm retainer(reverse) 3, 4inch 82-553313-101 1
Seal washer 3, 4inch 82-521069-102 4
O-ring 3, 4inch 82-592235-896 1
Rod packing 3, 4inch 82-521067-103 1
Washer 3, 4inch 82-553318-102 1
Rain cap 3, 4inch 82-553334-101 1
Rod 1-1/2, 2inch 82-553315-104 1
Diaphragm retainer(reverse) 1-1/2, 2inch 82-553313-101 1
Seal washer 1-1/2, 2inch 82-521069-102 4
O-ring 1-1/2, 2inch 82-592235-896 1
Rod packing 1-1/2, 2inch 82-521067-103 1
Washer 1-1/2, 2inch 82-553318-102 1
PSA4D Rain cap 1-1/2, 2inch 82-553334-101 1
connectionRc1/4
to Diaphragm case (upper) 1-1/2, 2inch
Standard finish
82-562564-101 1
connection1/4NPT
PSA4R Standard finish
82-562564-102 1
connectionRc1/4
82-562564-103 1
corrosion resistant
connection1/4NPT
82-562564-104 1
corrosion resistant
Rod 3, 4inch 82-553315-104 1
Diaphragm retainer(reverse) 3, 4inch 82-553313-101 1
Seal washer 3, 4inch 82-521069-102 4
O-ring 3, 4inch 82-592235-896 1
Rod packing 3, 4inch 82-521067-103 1
Washer 3, 4inch 82-553318-102 1
Rain cap 3, 4inch 82-553334-101 1
Appendix B-22
8-2.Changing actuator action : Changing from reverse action to direct action
Actuator Parts Connection Size Additional condition Parts No. Qty
PSA1R Rod 1-1/2, 2inch 82-553314-101 1
to
PSA1D Washer 1-1/2, 2inch 82-553318-101 1
PSA2R Rod 1-1/2, 2inch 82-553314-102 1
to
PSA2D Washer 1-1/2, 2inch 82-553318-101 1
Rod 1-1/2, 2inch 82-563133-101 1
Washer 1-1/2, 2inch 82-553318-101 1
PSA3R Diaphragm retainer (direct) 1-1/2, 2inch 82-553312-101 1
connectionRc1/4
to Diaphragm case 1-1/2, 2inch
Standard finish
82-521022-101 1
connection1/4NPT
PSA3D Standard finish
82-521022-102 1
connectionRc1/4
82-521022-103 1
corrosion resistant
connection1/4NPT
82-521022-104 1
corrosion resistant
Rod 3, 4inch 82-553315-101 1
Washer 3, 4inch 82-553318-101 1
Diaphragm retainer (direct) 3, 4inch 82-553312-101 1
Rod 1-1/2, 2inch 82-563133-102 1
Washer 1-1/2, 2inch 82-553318-102 1
PSA4R Diaphragm retainer (direct) 1-1/2, 2inch 82-553312-101 1
connectionRc1/4
to Diaphragm case 1-1/2, 2inch
Standard finish
82-521024-101 1
connection1/4NPT
PSA4D Standard finish
82-521024-102 1
connectionRc1/4
82-521024-103 1
corrosion resistant
connection1/4NPT
82-521024-104 1
corrosion resistant
Rod 3, 4inch 82-553315-102 1
Washer 3, 4inch 82-553318-102 1
Diaphragm retainer (direct) 3, 4inch 82-553312-101 1
8-3.Actuator diaphragm
Actuator Parts Additional condition Parts No. Qty
PSA1 Diaphragm 82-553306-101 1
8-4.Actuator spring
Actuator Spring Range Parts No. Qty
PSA1 Spring 20 to 100kPa 0.2 to 1.0kgf/cm2 82-553617-103 4
80 to 240kPa 0.8 to 2.4kgf/cm2 82-553310-101 4
80 to 240kPa 0.8 to 2.4kgf/cm2 82-553617-101 4
80 to 240kPa 0.8 to 2.4kgf/cm2 82-553310-103 8
80 to 240kPa 0.8 to 2.4kgf/cm2 82-553617-102 8
Appendix B-23
[1] Temperature Adjustment : The sensor was initially set at a temperature (Available range : ±60℃)
which was a mid-temperature of the requested temperature by a customer. Please reset precisely the
threshold temperature which the customer demands in yard.
Resetting Method : In order to reset the sensor temperature which

should be of the same scale to the thermometer installed in
equipment, work loose the slotted screw (S32) and then arrange the
temperature scale (S33) at the end of the indicating block (S16).
Tighten the slotted screw.
A. For higher temperature setting : As shown the figure, rotate slowly

the Adjusting Handle (S15) clockwise(CW) for the precision
temperature setting. The temperature changes at range of ±10℃ per
two revolutions of Adjusting Handle.
B. For lower temperature setting : It is the same of the case for

higher temperature setting, except to rotate counter-clockwise(CCW).
※ In changing the temperature from the higher to the lower because

the pressure expansion of a inner liquid into perception part (TV44,
C43) of the temperature becomes, there is need for the high rotation
force to rotate the Adjusting Handle. In this time please pay attention to avoid the sensor fracture.
To set the temperature from high to low, the present temperature should be reduced sufficiently less 5℃
than desired(threshold) temperature by means of cooling (Air, Water, etc). And then increase gradually
the temperature to the desired temperature.
[2] The inlet of the temperature control valve must set up a strainer to avoid the fracture by impurities at
a valve seat and a disc.
[3] To protect the sensor a sensor pocket must be installed.
[4] The capillary tube (TV38) which was attached to the sensor must be installed not to bent seriously.
[5] Install the general-purpose temperature gauge adjacent to the control sensor to confirm the correct
operation of the control sensor.
[6] Least eighty percent (80%) of the perception part (TV44, C43) should be soaked in the internal fluid
of the pipe line.
[7] The end point in the perception part (TV44, C43)
of the temperature must install to become the vertical
direction.
[8] The capillary tube (TV38) must be fixed strong

not to affect the vibration. Above all, it have not to
contact directly the steam line with high temperature.
[9] Install the sensor at the position which maintains

the homogeneous distribution of the temperature and
which is easily able to perceive the mean temperature
of an equipment.
[10] Before the valve fitting, the inner of the pipe

has to make clean.
[11] In case of the operation at the high temperature (200~250℃), The temperature control valve is
installed at the bottom of the equipment and the sensor must be cooled down by the cooling adapter to
minimize the heat transmit rate to the sensor.
[12] To facile the repair and the maintenance of the valve, it needs the space to work and the by-pass
line.
[13] The valve and the coupling of actuator (S1) must be fastened and have not to disassemble at the
vibration.
[14] In assembly working, the sensor and the valve should be installed as perpendicular as possible to
each other.
[15] The sensor part should be settled tightly and not be worked loose in the vibration.
[16] Injection method of sensing liquid : If the valve works for long time, there is a leakage of the
sensing liquid and it cannot close completely the valve. In this case, the sensing liquid should be filled
up. The procedure of injecting the sensing liquid is as follow.
A. Firstly, the position of the Adjust Handle is set at the desired threshold temperature plus 30℃ and
then the set-screw (S30) is disassembled. inject the sensing liquid. (At this time, the air within the
sensor should be removed.)
B. After the Injection of the sensing fluid, the set-screw (S30) should be strongly fastened and unable
to leak the sensing fluid.
C. Precision setting is equivalent to criteria of the temperature setting.

Trouble Causality Trouble-shooting
◆ The direction of pipe line is -Exchange the direction of pipe line.
exchanged each other. -Readjust according to its procedure.
◆ Adjusting is incorrect. -Interchange the valve with
◆ The capacity of the valve is smaller acceptable capacity.
than that of the used equip. -Verify the temperature range of the
◆ Temperature range establishment at name plate and re-select the
No temperature
perception part is incorrect. perception part.
rising.
◆ The circumference temperature of -Reduce the surrounding
control valve is higher than setting temperature.
temperature. -Open and identify the trouble of the
◆ The trap constructed in the by-pass valve and change or repair
heat-exchanger has small capacity or the trap.
breaks down.
-Exchange the copper tube and the
◆ In the carelessness of handling a sensor.
small quantity of chemicals leaks at the -Readjust according to its procedure.
copper tube. -Through the disassembly, remove
E x c e s s i v e
◆ Temperature establishment is incorrect. the impurities and in case of
temperature rising.
◆ A leakage between disc and seat due scratches grind or exchange the
to impurities or scratches. part.
◆ A leakage of the by-pass valve. -Repair or exchange the by-pass
valve.
◆ Because the packing nut is excessively -Loose appropriately the packing
tighten, the piston rod do not smoothly nun.
move. -The thermometer and the sensor
Large error from ◆ The construction of the sensor is construct as the same position as
t h r e s h o l d incorrect or the location of thermometer possible and refer the construction
temperature. stands isolated. manual of the sensor.
◆ The capillary tube is in direct contact -Separate from the steam line and
with the steam line or it is under the do not influence the surrounding
influence of the surrounding temperature. temperature.
FN
Electrical connections E
Our different output functions are available:
• Pulser for volume pulses with programmable pulse value (for external totaliser)
• Analogue current output 4...20 mA corresponding to flow rate
• Frequency output 0...100 Hz corresponding to flow rate
• Switching function (limiting value switch) specified by programmable upper and lower flow rates
Except for the analogue output function, any two of the remaining three functions can always be used simultaneously.
This results in two types of connection; the desired one must be set in the Parameter Menu.
• 1 potential-free digital output (Rel.1), freely parameterisable to one of the three functions mentioned below.
• passive current output, 4…20 mA (Analog), used to power the meter at the same time.
Current Output
Resistance RL : (U-5)V/0,0215 [Ω]
Exemple 24 V : (24-5)/0,0215 = 883 Ω
Sensor area!
Pulse output No cables, wires or other installation
material must be present in this area.
Frequency output
This can lead to incorrect measurements
Switching output and damage to the meter.
Solid state relay

RON < 100 Ω, ROFF > 10 MΩ
Umax < 48 V AC/DC, Imax < 50 mA
• 2 potential-free digital outputs (Rel.1+Rel.2), each freely parameterisable to one of the three functions mentioned below.
• the current output is not available here, but the power is provided via its terminals.
Pulse output Sensor area!

No cables, wires or other installation
Frequency output material must be present in this area.
This can lead to incorrect measurements
Switching output and damage to the meter.
Solid state relay

Factory setting: 2 digital outputs

Output 1: Rel.1 – Volume pulses: 250 ms, 1 Ltr/pulse (DN40-50: 10 Ltr/pulse)
Output 2: Rel.2 – Limiting value switch: Limit min = Qmin , Limit max = Qmax , Hysteresis 1%
16 CONTOIL®
Setting the display
The display can be rotated 360° in 90° steps during installation to improve readability.
Data preservation
All data are saved periodically, and every time a key is pressed, in a non-volatile memory (EEPROM). This means that the last value is saved
even if the power supply is interrupted.
Operating notes
The 7-segment display can show 8-digit measured values with a decimal point or text messages using letters in a special presentation
mode. Units of measurement and additional items of information are shown with symbols or index indicators. The references to these in the
text are shown in square brackets, e.g. [LIMIT MAX]
Step key Enter key
To operate, use the Step key (triangle) and the Enter key (hooked arrow).
The display data and parameters are split into three menu groups:
• Main Menu: displays measured data, accesses other menus, tests display segments and displays error messages (if present).
• Information Menu: displays additional information about the meter and operating status
• Parameter Menu: displays parameter settings for the display and output signals. To set these parameters, the device must be unlocked
with the Service key. This is located in the connections compartment and is only accessible after the display module has been opened
or unscrewed.
Service key
used to unlock parameter
settings
Sensor area!
keep clear of cables,
wires and other
installation material
Connection terminals
CONTOIL® 17
Operation and parameterisation
Main Menu: displays most important measured data, accesses other menus, tests display
The standard display of the Main Menu is the total volume. Use the Step key to go to the measured value for the resettable volume or the
flow rate and other menu items, as follows:
Main Menu
Total volume [TOT] cannot be reset
Standard display adopted by the meter after a time-out. The flow indica-
tor bar corresponds to the meter measuring range. It shows the flow rate
by means of graduation marks, in steps of 5 per cent up to Qmax.
Subtotal volume [SUBTOT] can be reset

4s Reset: press the Enter key for 4 seconds.
Reset must be enabled in the Parameter Menu.The flow indicator bar cor-
RESET
responds to the meter measuring range.It shows the flow rate by means
of graduation marks, in steps of 5 per cent up to Qmax.
Current flow rate

Besides being displayed numerically, this value is also shown in the dis-
play by a bar with graduation marks, each mark representing 5% of the
maximum permitted flow rate.
Entry portal for the Information Menu

Display additional information about the device and operating status
4s (For details, see next page).
To access: press the Enter key for 4 seconds.
Time-out: 60 seconds
Entry portal for the Parameter Menu

Display and settings for device and operating parameters for display and
8s outputs (for details, see page 21).
To access: press the Enter key for 8 seconds.
Time-Out: 60 seconds
Display test
All the segments are shown for 2 seconds for monitoring. This test is
also performed after switching on the unit.
Device errors
If a device error is detected during the periodic self-test, this message
is briefly shown on the display every 2 seconds. Measuring accuracy
is impaired.
CAUTION! Meter may supply incorrect values.
The Information Menu gives more information on the error.
The value diplayed in "subtotal volume" [SUBTOT] can be reset to zero by pressing the Enter key for about 4 seconds, unless this function
has been disabled in the Parameter Menu.
If a meter error is present, the [ERROR] warning appears on the display every 2 seconds. Details about the error are shown in the Informa-
tion Menu.
18 CONTOIL®
Information Menu: display additional information about meter and operating status
Select the [INFO] item from the Main Menu and then press the Enter key for approx. 4 seconds to enter the Information Menu. Use the Step
key to view the following additional information about the meter and the operating status:
Information Menu
This is only shown when an error has been detected. CAUTION! Meter may supply incorrect measured values
Error status [E- . . .]

[E-FLOW] flow overload
[E-EEP] data error in EEPROM
[E-ROM] data error in ROM
[E-POWER] error in power supply
[E-SENSOR] signal error
For details, see "Error messages" page 29.
Hours in operation [H0]

Total hours in operation for the meter in HH:MM format

Hours in operation (HH:MM) in the optimal flow range, Qmin - QN

Hours in operation (HH:MM) in the upper flow range, QN - Qmax

Hours in operation (HH:MM) above Qmax
Duration [H4]
Duration (HH:MM) since last recorded flow
Peak flow rate [MAX Q]

Maximum value of flow rate since starting operation
Nominal size DN15 … DN50

[CAL] calibrated nominal size of the flow sensor
Measuring chamber volume [VC]

[CAL] calibrated volume of the flow sensor
Status display for outputs

2 relay outputs
1 analogue current output
Details on next page
Calibration date [DD.MM.YYYY]

[CAL] calibrated in factory
[UNCAL] delivered in uncalibrated state (spare part)
Serial number of electronics module [EN]

Main Menu
Consecutive number to identify the hardware
Firmware Version [FW]

Version number of electronics module firmware
CONTOIL® 19
Information Menu - Detailed view, outputs
Status of RELAY 1
Only the function that is enabled in the parameter setting is shown
volume pulses or frequency signal or limiting value switch
Status of pulse output [R1] Status of frequency output [R1 . . . Hz] Status of limiting value
[PULSE] appears as long as the displays the current flow output frequency switch [R1 . . . ]
pulse signal is present at the output displays the current relay status
[ON] switch closed
[OFF] switch open
(With very fast pulse trains “PULSE” will be displayed continuously)
Only the second output enabled in the "Output selection" parameter setting is shown (relay 2 or analogue)
Status of RELAY 2
Function as for relay, 1 see above
Status of pulse output [R2] Status of frequency output [R2 . . . Hz] Status of limiting value
switch [R2 . . . ]
or
ANALOG status display
Status of current output [ANA ...mA]

Displays the current value of the current output
Main Menu
If both keys are pressed at the same time, or if no key is pressed for 60 seconds, the device returns to the standard display.
20 CONTOIL®
Parameter Menu: show parameter settings for display and output signals
Select the [PARAMETER] item from the Main Menu and press the Enter key for approx. 8 seconds to enter the Parameter Menu.
The menu structure for reading out parameters is shown below. Use the Step key to display all the parameters that are set. Submenus are
available for the relay and power output menus; to enter them, press the Enter key.
Parameter Menu
Unit of measurement for volume [UNIT VOL]
to display volume and flow rate:
[L] litres (factory setting), [M3] m3, [G] US gallons
Unit of measurement for time [UNIT TI]

to display hours in operation and flow rate:
[H] hours (factory setting), [MIN] minutes
Nominal size DN15 … DN50

[CAL] calibrated nominal size of the flow sensor
Measuring chamber volume [VC]

[CAL] calibrated volume of the flow sensor
Parameter and status display of output, relay 1

Only the second output enabled in the "Output selection" parameter setting is shown.
Parameter and status display of output, relay 2

or
Parameter and status display for current output
Main Menu
Disable volume subtotal reset [SUBTOT]

[SUB RES] Subtotal can be reset (factory setting)
[SUB.NO.RES] Subtotal cannot be reset
If both keys are pressed at the same time, or if no key is pressed within 15 minutes, the device returns to the standard display.
CONTOIL® 21
Parameter Menu - detailed view of outputs
Parameter display, RELAY 1

Only the function enabled in the "Output selection" parameter setting is shown.
volume pulses (page 27) or frequency signal (page 27) or limiting value switch (page 28)
pulse width lower flow rate value for lower flow rate limiting value
of volume pulses in ms frequency output Q1 for f1 Limit Qmin
pulse value of one volume pulse lower frequency of upper flow rate limiting value
[LPP] in litres per pulse for volume frequency output f1 for Q1 Limit Qmax
unit [L] or [m3]
[PPG] pulses per US gallon for volume
unit [G]
upper flow rate value of hysteresis [HYST]

frequency output Q2 for f2 in percent of limiting values
pulse indication
[PULSE] appears as long as the pulse
upper frequency of Working position of contacts
signal is present at the output
frequency output f2 for Q2 [ACT ON] closed at limiting value
[ACT OFF] open at limiting value
(With a very fast pulse train,

"PULSE" may be displayed continuously.) current frequency output
frequency for flow rate in Hz
current position of contact
[ON] contact closed
[OFF] contact open
Only the second output enabled in the "Output selection" parameter setting appears (relay 2 or analog)
Parameter display, RELAY 2
Only the function that is enabled in the parameter setting is shown:
volume pulses or frequency signal or limiting value switch (for details see relay 1)
or ANALOG parameter display
lower flow rate value

Qmin for 4mA
upper flow rate value

Qmax for 20mA
Attenuation of current output [DAMP]

[1] no damping [10] high damping
Current output in case of an error [ERR...]

[HIGH] 21,5mA, [LOW] 3,5mA, [OFF] no output
Main Menu
current status of current output [ANA]

displays the current value of the current output
If both keys are pressed at the same time, or if no key is pressed within 15 minutes, the device returns to the
standard display.
22 CONTOIL®
Parameter setting
In order to set the parameters, the device must first be unlocked with the Service key.
This puts the device into Edit mode.
This is located in the connections compartment and is only accessible after the display module
has been opened or unscrewed. The power supply must not be interrupted when this is done.
This unlocking procedure is only possible within the Parameter Menu and is done by pressing the
Service key. Once the parameter setting is enabled, symbol will be shown in addition to all the
displays. On exiting the Parameter Menu, the Edit mode is automatically discontinued.
Parameter Menu
Press Service key = select = save =
Measuring unit for volume [UNIT VOL]

[L] litre - [M3] m3 - [G] US gallon
Measuring unit for time [UNIT TI]

[H] hours - [MIN] minutes
Nominal size DN15 … DN50, see section

"Parameterising the measuring sensor data"
Measuring chamber volume [VC], see section

"Parameterising the measuring sensor data"
Output selection [OUTP SEL]

[2REL 0AN] 2 relays, no current output
[1REL 1AN] 1 relay, 1 current output
Only the second output enabled in the output selection is shown
Parameter setting for relay 1

Only the function enabled in the output selection is shown
Parameter setting for relay 2

or
Parameter setting for current output
Main Menu
Disable subtotal volume reset [SUBTOT]

[SUB RES] Subtotal can be reset
[SUB.NO.RES] Subtotal cannot be reset
[DO.RESET] Perform reset
CONTOIL® 23
24
Parameter Menu - set outputs
Press the Service key select = save =
RELAY 1
Volume pulses
Pulse width
5 – 50 – 250 – 500 ms
Pulse value of one volume pulse

Only the function en- 0.1 – 1 – 10 – 100 – 1000 [LPP]
abled in "Parameter 10 – 1 – 0.1 – 0.01 – 0.001 [PPG]
setting" is shown
Current pulse output
[PULSE] appears when a pulse signal is
present at the output
Frequency signal
Lower flow rate value Q1 for f1
decimal value: 0...Q2
Lower frequency f1 for Q1

decimal value: 0...f2
Upper flow rate value Q2 for f2

decimal value: Q1... Qmax
Upper frequency f2 for Q2

decimal value: f1...100 Hz
Current frequency output

output frequency for flow rate in Hz
CONTOIL®
Limiting value
Lower flow rate limiting value Limit min
[OFF] - decimal value: 0... Limit max
CONTOIL®
Upper flow rate limit value Limit max
[OFF] - decimal value: Limit min...Qmax
Hysteresis [HYST]
in percent of limiting values
Working position of contact

[ACT ON] closed at limiting value
[ACT OFF] open at limiting value
Actual position of contact
[ON] contact closed
[OFF] contact open
Only the second output enabled in the 'OUTP SEL' parameter setting is shown (Relay 2 or Analog).
RELAY 2 setting - function as for relay 1, see above
or Analog
Lower flow rate value Qmin for 4mA
decimal value: 0...Q(20mA)
Upper flow rate value Qmax for 20mA

decimal value: Q(4mA)...Qmax
Damping of current output [DAMP]

damping value 1...10
Current output in case of an error [ERR...]

[HIGH] 21,5mA, [LOW] 3,5mA, [OFF] value
Actual status of current output [ANA]:
Main Menu
displays the current value of the current
output
25
In order to set the individual parameters, the relevant menu item in the Parameter Menu must be found, as above. Press the Enter key to
enable editing. The value to be set starts flashing and may be changed.
Selections are available for most of the menu items. Use the Step key to select a desired value and press the Enter key to save it. A saved
value no longer flashes.
If discrete numerical values are to be entered as individual digits (e.g. flow rate values), proceed from the smallest decimal place to the largest.
The digit to be set will flash. Use the Step key to select the value (0-9) and press the Enter key to accept.Then set the next higher decimal place.
The number of decimal places is fixed. For litres and gallons, one decimal place is specified; four decimal places are specified for m3.
For the limiting value settings, the function of the upper or lower limiting value switch can be disabled if necessary. To do this, an "OFF" selec-
tion is also offered when the lowest decimal value for the flow limit is entered.
If no key is pressed within 15 minutes, the device returns to the standard display and the Edit mode is discontinued. Any entries that have not
been completed by pressing the Enter key are rejected.
Parameterising the display
In order to set the parameters, the device must be unlocked with the Service key. See the section on Parameter setting, page 23.
Setting the unit of measurement for volume [UNIT VOL]

Possible settings and subsequent parameters derived from them are as follows:
• litre [UNIT LIT]: pulse value in litres per pulse [LPP], flow in [l/time]
• cubic metres [UNIT M3]: pulse value in litres per pulse [LPP], flow in [m3/time]
• US gallons [UNIT USG]: pulse value in pulses per gallon [PPG], flow in [gal./time]
The set unit of measurement is shown as an index.
Setting the unit of measurement for time [UNIT TI]

Possible settings and subsequent parameters derived from them are as follows:
• hour [UNIT TI h]: flow rate in [Volume/h]
• minute [UNIT TI min]: flow rate in [Volume/min]
The set unit of measurement is shown as an index.
Parameterising the flow sensor data
In order to guarantee accurate measurement, the electronics on the flow sensor require adjustment. During calibration in the factory, the
data for nominal size and the exact measuring chamber volume are entered for this purpose. These parameters cannot usually be changed
again. They are displayed with the index [CAL] to document the calibrated condition of the instrument.
If the measurement transducer has to be replaced, it is possible to enter these two parameters manually in order to "marry" a new meas-
urement transducer with the flow sensor. For spare parts for which the nominal size or measuring chamber volume can be changed, this
is shown by the [UNCAL] index.
CAUTION: the settings for the nominal size or the measuring chamber volume can be changed within a maximum time window of 7 days
after the first change, and a maximum of 4 changes can be made. After the time window has expired or after the fifth change to these two
parameters, NO FURTHER CHANGES ARE POSSIBLE.
26 CONTOIL®
Parameterising the outputs
The outputs to be used must be enabled in the 'Output selection [OUTP SEL] in the Parameter Menu.
Only enabled outputs can be parameterised. The following alternatives are possible:
• 2 relay outputs (factory setting) or
• 1 relay output and 1 current output
Pulse output for summing the flow volume (totaliser)
Parameter Menu: volume function [R1VOLUM]
T
Parameters that can be set:
Pulse width (t): 5 – 50 – 250 – 500 ms
=> The pulse width determines the smallest possible pulse value.
Pulse value for litres, m3 [LPP]: 0,1 – 1 – 10 – 100 – 1000 m3 or Ltr/pulse

Pulse value for US gallons [PPG]: 10 – 1 – 0.1 – 0.01 – 0.001 Pulses/USG
(Factory setting: 250 ms, 1 Ltr/pulse; DN40-50: 10 Ltr/pulse)
t ms
=> Based on the pulse width shown above, only those values are offered that can
also display the maximum possible flow rate. If a lower pulse value is required
other than those, a smaller pulse width must be selected.
Signal behaviour:
When the pulse value is reached, the solid state relay is closed for the duration of the
set pulse width.
Frequency output depicting flow rate
Parameter Menu: flow rate function [R1 FLOW]
Hz Parameters that can be set:

100 Frequency range and proportionality of the signal over the desired flow rate measure-
f2 ment range Q1...Q2
Lower flow rate [MIN]: Q1 ≥ 0 (factory setting: Qmin )
Lower frequency [Hz]: f1 ≥ 0 (factory setting: 10 Hz)
Upper flow rate [MAX]: Q2 ≤ Qmax. (factory setting: QN )
f1 Upper frequency [Hz]: f2 ≤ 100 Hz (factory setting: 80 Hz)
0 => The upper frequency must be larger than the lower frequency.
Q1 Q2 Vol/h
The upper flow rate value must be larger than the lower flow rate value.
Qmin, QN and Qmax are dependent on the nominal size of the meter.
Signal behaviour:
a) Value falls below the set lower flow rate value Q1:
• proportional decrease to 0 Hz, which is then maintained.
b) Value exceeds set upper flow rate value Q2:
• proportional increase to 100 Hz, which is then maintained.
No provision is made for error signals.
CONTOIL® 27
Switching output to signal a limiting value (Limit)
Parameter Menu: limiting value output [R1LIMIT]
Parameters that can be set:

H H
Lower flow rate limiting value [LIMIT MIN]: [OFF] or Q Limmin ≥ 0
(factory setting: Qmin )
Upper flow rate limiting value [LIMIT MAX]: [OFF] or Q Limmax ≤ Qmax.
(factory setting: QN )
=> The upper flow rate limiting value must be larger than the lower flow rate limiting
value. Qmin and Qmax are dependent on the nominal size.
Q Lim min Q Lim max Vol/h
Hysteresis [HYST] (H): 0…10% of Q Lim

(factory setting: 1%)
Working position of the semiconductor switch: active on – active off
Signal behaviour:
a) For a flow rate lying between the lower and upper flow rate limiting values, the
semiconductor switch is open in the "active on" working position. In the "active
off" working position, it is closed.
b) If the upper flow rate limiting value is reached or exceeded, the contact switches
to the closed position. It switches back again as soon as the value falls below the
upper flow rate limiting value by the hysteresis amount.
c) If the lower flow rate limiting value is reached or if the value falls below this limit,
the contact switches to the closed position. It switches back again as soon as the
lower flow rate limiting value is exceeded by the amount of the hysteresis.
Analogue current output (4…20mA) depicting flow rate
Parameter Menu: analogue output [ANALOG]
mA Parameters that can be set:

21,5
Proportionality of the signal over a flow rate-range Q1 to Q2
20,8
I 20 20 flow rate at 4mA [MIN mA] (I4): Q1 ≥ 0
(factory setting: 0)
flow rate at 20mA [MAX mA] (I20): Q2 ≤ Qmax.
(factory setting: QN )
I4 4
3,8 => The upper flow rate value must be larger than the lower flow rate value.
3,5
Qmin, QN and Qmax are dependent on the nominal size.
Q1 Q2 Vol/h
Damping of the signal on rapidly changing measured values

Damping value [DAMP] 1 (none) …10 (maximum)
=> The higher the damping, the larger the relative error.
Signal level when a relevant meter error occurs

Error behaviour [ERR …]: HIGH (21,5mA), LOW (3,5mA), OFF
Signal behaviour:
a) Value falls below the set lower flow rate value Q1:
• proportional decrease to 3.8mA which is then maintained.
b) Value exceeds set upper flow rate value Q2:
• proportional increase to 20.8mA which is then maintained.
c) Error signal for measurement-relevant meter error
(sensor, ROM, supply voltage, etc.):
• For HIGH error behaviour: output 21.5mA
• For LOW error behaviour: output 3.5mA
• For OFF error behaviour: no error signal, continued output of computed value.
28 CONTOIL®
Error messages
The electronics perform a self-test about every 5 minutes. If an error is detected which impairs the reliability or accuracy of the measure-
ment, the [ERROR] warning will appear every 2 seconds on the display.
The error is shown in detail in the Information Menu:
[E-FLOW] maximum permitted flow rate (Qmax) exceeded

The meter is mechanically overloaded and is no longer measuring accurately.
Action: reduce the flow rate or use the next higher nominal size.
[E-POWER] supply voltage is too low

Faulty data processing, meter supplies incorrect measured values.
Action: check the voltage supply and eliminate the cause of the error (if applicable).
[E-EEP] error when reading or saving data to EEPROM, faulty data backup.
Totaliser value may be incorrect.
Action: measurement transducer must be replaced. Please contact the supplier.
[E-ROM] error when reading data from the ROM

Faulty data processing, meter supplies incorrect measured values.
[E-SENSOR] signal error from flow sensor to measurement transducer

Meter supplies incorrect measured values.
Dimensional drawings
DN15, 20, 25: with threaded ends DN40: with threaded ends
DN15, 20, 25: with flanges (DIN 2501/SN 21843) DN40, 50: with flanges (DIN 2501/SN 21843)
h2
h2
ØF
H
H
ØF
h1
h1
b
b
B L B L
Nominal size L B a ØF b h1 h2 p r
DN15 165 105 260 95 45 65 90 G ¾” G ½”
DN20 165 105 260 105 54 74 90 G 1” G ¾”
DN25 190 130 305 115 77 101 90 G 1¼” G 1”
DN40 300 210 440 150 116 153 90 G 2” G 1½”
DN50 350 280 – 165 166 209 90 – –
Diemnsions in mm
CONTOIL® 29
Raccordements électriques F
Quatre fonctions différentes sont à disposition pour les sorties :
• émetteur d’impulsions volumétriques (pour totalisateur à distance)
• courant analogique 4...20 mA proportionnel au débit
• fréquence 0...100 Hz proportionnelle au débit
• commutateur de valeur limite pour débit max. et min.
Deux fonctions peuvent toujours être utilisées simultanément: soit la sortie de courant analogique et une sortie numérique, soit deux
sorties numériques. Les deux variantes de connexion possibles sont les suivantes. La variante souhaitée doit être choisie dans le menu de
paramétrage.
• 1 sortie digitale libre de potentiel (Rel.1), librement paramétrable sur l’une des trois fonctions mentionnées ci-dessous.
• 1 sortie analogique passive 4…20 mA, proportionnelle au débit; elle sert en même temps d’alimentation pour le compteur.
Sortie analogique
Résistance RL : (U-5)V/0,0215A [Ω]
Exemple 24 V : (24-5)/0,0215 = 883 Ω
Capteurs
Sortie d’impulsions Ne faire passer aucun câble, fil ou autre
accessoire de montage en cet endroit.
Sortie-fréquence
Vous risquez sinon de provoquer des
Alarme valeurs-limites erreurs de mesure et d’endommager le
compteur.
Relais semi-conducteur
• 2 sorties digitales libre de potentiel (Rel.1+Rel.2), chacune étant librement paramétrable sur l’une des trois fonctions mentionnées
ci-dessous.
• La sortie analogique n’est pas disponible ici. L’alimentation du module se fait toutefois via ses bornes.
Sortie d’impulsions Capteurs

Ne faire passer aucun câble, fil ou autre
Sortie de fréquence accessoire de montage en cet endroit.
Vous risquez sinon de provoquer des
Alarme valeurs-limites erreurs de mesure et d’endommager le
compteur.
Relais semi-conducteur
Réglage par défaut: 2 sorties digitales

Sortie 1: Rel.1 – Impulsions volumétriques: 250 ms, 1 Ltr/imp (DN40-50: 10 Ltr/imp)
Sortie 2: Rel.2 – Valeur limite: Limite inférieure = Qmin , Limite supérieure = Qmax , Hystérèse 1%
30 CONTOIL®
Confort de lecture
Possibilité de rotation de l’affichage par fractions de 90° pour un meilleur confort de lecture.
Sauvegarde des données

Mémorisation périodique de toutes les données dans une mémoire non volatile (EEPROM). Ceci signifie que la dernière valeur déterminée
reste enregistrée même en cas de coupure de courant.
Instructions d’utilisation
L’affichage à 7 segments permet d’afficher des valeurs de mesure à 8 chiffres avec décimales ou des indications textuelles au moyen de
lettres spéciales. Les unités de mesure et les informations complémentaires sont représentées au moyen de symboles et d’index. Les in-
dications qui s’y rapportent sont mentionnées en clair entre crochets, par ex. [LIMIT MAX].
Touche Touche
d’avancement de saisie
La commande se fait au moyen de la touche d’avancement (triangle) et de la touche de saisie (flèche coudée).
Les données d’affichage et les paramètres se subdivisent en trois groupes de menus :

• Menu principal : affichage des données de mesure, accès aux autres menus, test d’affichage et, le cas échéant, affichage des
messages d’erreur
• Menu d’information : affichage d’informations complémentaires sur le compteur et fonctionnement
• Menu de paramétrage : affichage du réglage des paramètres pour l’affichage et les signaux de sortie. Pour pouvoir régler ces
paramètres, l’appareil doit être déverrouillé à l’aide de la touche de service. Celle-ci se trouve dans la zone de raccordement et n’est
accessible qu’après ouverture du module d'affichage.
Touche de service
déverrouillage pour le
réglage des paramètres
Capteurs
Ne faire passer aucun
câble, fil ou autre
accessoire de montage
en cet endroit.
Bornes de
raccordement
CONTOIL® 31
Mode d'emploi et paramétrage
Menu principal : Affichage des principales données de mesure, accès aux autres menus, test d’affichage
L’affichage standard du menu principal est la quantité totale mesurée. La touche d’avancement permet d’accéder à la fonction « volume
avec remise à zéro », au débit instanté et à d’autres sous-menus comme suit :
Menu principal
Quantité totale [TOT] sans remise à zéro
Information standard remise automatiquement à l’affichage au bout d’un
intervalle de temps défini. Le diagramme à barres représente le débit
instantané en % du Qmax du compteur; chaque barre correspond à 5%.
Quantité partielle [SUBTOT] avec remise à zéro

4s Remise à zéro : appuyez sur la touche de saisie pendant 4 secondes.
La remise à zéro doit être activée dans le menu de paramétrage.
REMISE A ZÉRO Le diagramme à barres représente le débit instantané en % du Qmax
du compteur; chaque barre correspond à 5%.
Débit instantané
Cette information est également reprise par le diagramme à barres;
100% = Qmax du compteur; chaque barre correspond à 5%.
Portail d’accès au menu d’information

Affichage d’informations complémentaires sur le compteur et son fonc-
4s tionnement (détails à la page suivante).
Accès : appuyez sur la touche de saisie pendant 4 secondes.
Temps de maintien de l’affichage : 60 s
Portail d’accès au menu de paramétrage

Affichage et saisie des paramètres pour l’affichage et les sorties
8s (détails à la page 35).
Accès : appuyez sur la touche de saisie pendant 8 secondes.
Temps de maintien de l’affichage : 60 s
Test d’affichage
Tous les segments s’affichent pendant 2 secondes pour contrôle.
Ce test est également exécuté après la mise sous tension.
Erreur
Si l’autodiagnostic périodique détecte un défaut dans de l’appareil, ce
message apparaît brièvement dans l’affichage toutes les 2 secondes.
La précision de mesure n’est plus garantie.
ATTENTION ! Il se peut que le compteur indique des valeurs de
mesure incorrectes.
Renseignements complémentaires dans le menu d’information.
La valeur d’affichage « quantité partielle » [SUBTOT] peut être remise à zéro en maintenant la touche de saisie enfoncée longtemps (env.
4 secondes), sauf si cette fonction a été désactivée dans le menu de paramétrage.
En cas de défaut du compteur, le message [ERROR] apparaît toutes les 2 secondes sur l’affichage. Les détails relatifs à cette erreur sont
indiqués dans le menu d’information.
32 CONTOIL®
Menu d’information : Affichage d’informations complémentaires sur le compteur et son fonctionnement
Accès au sous-menu [INFO] à partir du menu principal en maintenant la touche de saisie enfoncée longtemps (env. 4 secondes). La touche
d’avancement permet d’afficher les informations complémentaires suivantes sur le compteur et son fonctionnement :
Menu d’information
Ne s’affiche que lorsqu’un défaut a été détecté. ATTENTION ! Il se peut que le compteur indique des valeurs de
mesure incorrectes.
Statut d’erreur [E- . . .]
[E-FLOW] Surcharge de débit
[E-EEP] Erreur de données dans EEPROM
[E-ROM] Erreur de données dans ROM
[E-POWER] Défaut dans l’alimentation
[E-SENSOR] Défaut capteurs de signaux
Pour plus de détails, voir le chapitre « Messages d’erreur ».
Heures de service [H0]

Nombre total d’heures de fonctionnement du compteur en
format HH:MM
Nombre d’heures de fonctionnement (HH:MM) dans la plage de
débit optimale Qmin - QN

Nombre d’heures de fonctionnement (HH:MM) dans la plage de débit
supérieure QN - Qmax

Nombre d’heures de fonctionnement (HH:MM) en surcharge au-delà
de Qmax
Durée [H4]
Temps écoulé (HH:MM) depuis la dernière saisie du débit
Valeur de pointe du débit [MAX Q]

Débit maximal enregistré depuis la mise en service du compteur
Diamètre nominal DN15 … DN50

[CAL] diamètre nominal du mesureur étalonné avec ce module
d’affichage
Volume de la chambre de mesure [VC]

[CAL] volume de la chambre de mesure du mesureur étalonné avec
ce module d’affichage
Affichage du statut des sorties

2 sorties relais
1 sortie courant analogique
Détails à la page suivante
Date d’étalonnage [TT.MM.JJJJ]

[CAL] étalonné en usine
[UNCAL] fourni non étalonné (pièce de rechange)
Menu principal
Numéro d’électronique [EN]

Numéro de série du module électronique
Micrologiciel [FW]
Numéro de la version du micrologicie / firmware du module
d’affichage
CONTOIL® 33
Menu d’information - Détail des sorties
Statut du RELAIS 1
Seule la fonction activée lors du réglage des paramètres apparaît
Impulsions volumétriques ou Signal de fréquence ou Valeur limite
Statut de la sortie d’impulsions [R1] Statut de la sortie fréquence Statut du commutateur de valeur
[PULSE] apparaît lorsque l’impulsion [R1 . . . Hz] limite [R1 . . . ]
est en train d'être émise Affichage de la fréquence de sortie Affichage de l’état actuel du relais
actuelle pour le débit [ON] Contact fermé
[OFF] Contact ouvert
(Si les impulsions se suivent de façon très rapprochée, l’indication “PULSE” apparaît en permanence.)
Seule la deuxième sortie activée dans le réglage des paramètres « Sélection des sorties » apparaît
(Relais 2 ou courant analogique).
Statut du RELAIS 2
Idem relais 1 ci-dessus
Statut de la sortie d’impulsions Statut de la sortie fréquence Statut commutateur de valeur limite
[R2] [R2 . . . Hz] [R2 . . . ]
ou
Affichage de l'état ANALOG
Statut de la sortie analogique [ANA ...mA]

Affichage du courant de sortie correspondant au débit actuel
Menu principal
En appuyant simultanément sur les deux touches, ou si aucune touche n’est actionnée pendant 60 secondes, l’appareil retourne en
affichage standard.
34 CONTOIL®
Menu de paramétrage : Affichage des paramètres sélectionnés pour l’affichage et les signaux de sortie
Accès au sous-menu [PARAMETER] à partir du menu principal en maintenant la touche de saisie enfoncée longtemps (env. 4 secondes).
La structure du menu pour la lecture des paramètres est représentée ci-dessous. La touche d’avancement permet d’afficher tous les
paramètres réglés. Les menus pour les relais et la sortie analogique comportent des sous-menus. On y accède en appuyant sur la touche
de saisie.
Menu de paramétrage
Unité de mesure du volume [UNIT VOL]
pour l’affichage du volume et du débit :
[L] litres (réglage par défaut), [M3] m3, [G] gallons US
Unité de temps [UNIT TI]

pour l’affichage des heures de fonctionnement et du débit :
[H] heures (réglage par défaut), [MIN] minutes
Diamètre nominal DN15 … DN50

[CAL] diamètre nominal du mesureur étalonné avec ce module
d’affichage
Volume de la chambre de mesure [VC]

[CAL] volume de la chambre de mesure du mesureur étalonné
avec ce module d’affichage
Affichage des paramètres et de l'état des sorties Relais 1

Seule la deuxième sortie activée dans le réglage des paramètres « Sélection des sorties » apparaît.
Affichage des paramètres et de l'état des sorties Relais 2

ou
Affichage des paramètres et de l'état de la sortie analogique
(réglage par défaut : sortie inactive)
Menu principal
Blocage de la remise à zéro [SUBTOT]

[SUB RES] sous-total avec remise à zéro (réglage par défaut)
[SUB.NO.RES] sous-total sans remise à zéro
Si aucune touche n’est actionnée pendant 15 minutes, l’appareil retourne en affichage standard.
CONTOIL® 35
Menu de paramétrage - Détail des sorties
Affichage des paramètres RELAIS 1

Seule la fonction activée dans le réglage des paramètres apparaît.
Impulsions volumétriques (page 41) ou Signal de fréquence (page 41) ou Valeur limite (page 42)
Largeur des impulsions limite de débit inférieure pour valeur limite inférieure du débit
volumétriques en ms la sortie fréquence Q1 à f1 Limit Qmin
Valeur de chaque impulsion limite de fréquence inférieure pour valeur limite supérieure du débit
volumétrique la sortie fréquence f1 à Q1 Limit Qmax
[LPP] en litres par impulsion si unité
de volume [L] ou [m3]
[PPG] impulsions par gallon US si unité
de volume [G]
limite de débit supérieure pour la Hystérèse [HYST]
sortie fréquence Q2 à f2 en pour cent des valeurs limites
Statut actuel limite de fréquence supérieure pour Position des contacts

[PULSE] apparaît pendant la durée la sortie fréquence f2 à Q2 [ACT ON] fermé à la valeur limite
d’émission de l’impulsion [ACT OFF] ouvert à la valeur limite
fréquence actuelle
fréquence de sortie en Hz
(Si les impulsions se suivent de façon correspondant au débit actuel
très rapprochée, « PULSE » peut rester Position actuelle des contacts
affiché en permanence.) [ON] Contact fermé
[OFF] Contact ouvert
Seule la deuxième sortie activée dans le réglage des paramètres « Sélection des sorties » apparaît. (Relais 2 ou Analogique)
Affichage des paramètres RELAIS 2
Seule la fonction activée dans le réglage des paramètres apparaît :
Impulsions volumétriques ou signal de fréquence ou valeur limite (voir Relais 1)
ou affichage des paramètres ANALOG
limite de débit inférieure

Qmin à 4mA
limite de débit supérieure

Qmax à 20mA
Lissage de la sortie courant [DAMP]

[1] Pas de lissage [10] Facteur de lissage élevé
Sortie courant en cas de défaut [ERR...]

[HIGH] 21,5mA, [LOW] 3,5mA, [OFF] Pas de signal
Menu principal
Courant analogique actuel [ANA]

Affichage du courant de sortie correspondant au débit actuel
Si aucune touche n’est actionnée pendant 15 minutes, l’appareil retourne en affichage standard.
36 CONTOIL®
Réglage des paramètres
Pour la saisie des paramètres, l’appareil doit d’abord être déverrouillé à l’aide de la touche de service.
Celle-ci se trouve dans la zone de raccordement et n’est accessible qu’après ouverture du
module d’affichage. Ne pas couper l’alimentation électrique lors de cette opération.
Le déverrouillage ne peut être réalisé qu’au départ du menu de paramétrage. Pour cela, appuyez sur la
touche de service. Lorsque la fonction de réglage des paramètres est activée, le symbole apparaît
pour toutes les données affichées. Dès que vous quittez le menu de paramétrage, la fonction
de réglage se verrouille automatiquement.
La structure de menu pour le réglage des paramètres est représentée ci-dessous.
Menu de paramétrage
Appuyez sur la touche de service = sélectionner = sauvegarder =
Unité de mesure du volume [UNIT VOL]

[L] litres - [M3] m3 - [G] gallons US
Unité de temps [UNIT TI]

[H] heures - [MIN] minutes
Diamètre nominal DN15 … DN50, voir le chapitre

« Paramétrage des données du mesureur ».
Volume de la chambre de mesure [VC], voir le chapitre

« Paramétrage des données du mesureur »
Sélection des sorties

[2REL 0AN] 2 relais, 0 analogique
[1REL 1AN] 1 relais, 1 analogique
Seule la deuxième sortie activée dans le réglage des paramètres "Sélection des sorties" apparaît.
Réglage des paramètres Relais 1

Seule la fonction activée apparaît.
Réglage des paramètres Relais 2

ou
Réglage des paramètres de la sortie analogique
Menu principal
Blocage de la remise à zéro [SUBTOT]

[SUB RES] sous-total avec remise à zéro
[SUB.NO.RES] sous-total sans remise à zéro
[DO.RESET] effectuer une remise à zéro
CONTOIL® 37
Menu des paramètres – Réglage des sorties
38
Appuyez sur la touche de service = sélectionner = sauvegarder =
RELAIS 1
Impulsions
volumétriques Largeur d’impulsion
5 – 50 – 250 – 500 ms
Valeur de chaque impulsion volumétrique

Seule la fonction 0,1 – 1 – 10 – 100 – 1000 [LPP]
activée dans le réglage 10 – 1 – 0.1 – 0.01 – 0.001 [PPG]
des paramètres appa-
raît. Statut de sortie
[PULSE] apparaît pendant la durée
d’émission de l’impulsion
Signal de
fréquence
Limite de débit inférieure Q1 à f1
Valeur décimale : 0...Q2
Limite de fréquence inférieure f1 à Q1

Valeur décimale : 0...f2
Limite de débit supérieure Q2 à f2

Valeur décimale : Q1... Qmax
Limite de fréquence supérieure f2 à Q2

Valeur décimale : f1...100 Hz
Fréquence actuelle
fréquence de sortie pour le débit en Hz
CONTOIL®
Valeur limite
Valeur limite inférieure du débit Limit min
[OFF] - Valeur décimale : 0... Limit max
CONTOIL®
Valeur limite supérieure du débit Limit max
[OFF] - Valeur décimale : Limit min...Qmax
Hystérèse [HYST]
En pour cent des valeurs limites
Position des contacts

[ACT ON] fermé à la valeur limite
[ACT OFF] ouvert à la valeur limite
Position actuelle des contacts
[ON] contact fermé
[OFF] contact ouvert
Seule la deuxième sortie activée dans le réglage des paramètres « Sélection des sorties » apparaît (Relais 2 ou analogique).
Fonction de réglage de RELAIS 2 identique à RELAIS 1 ci-dessus
ou sortie analogique
Limite de débit inférieure Qmin à 4mA
Valeur décimale : 0...Q(20mA)
Limite de débit supérieure Qmax à 20mA

Valeur décimale : Q(4mA)...Qmax
Lissage de la sortie courant [DAMP]

Facteur de lissage 1...10
Sortie courant en cas de défaut [ERR...]

[HIGH] 21,5mA, [LOW] 3,5mA,
[OFF] Pas de signal
Courant analogique actuel [ANA]
Menu principal
correspondant au débit actuel
39
Pour régler les différents paramètres, sélectionnez le sous-menu correspondant dans le menu de paramétrage comme décrit ci-
dessus. Appuyez sur la touche de saisie pour accéder au mode d’édition. Le paramètre réglable se met à clignoter et peut être modifié.
La plupart des sous-menus disposent de listes de sélection. Choisissez la valeur souhaitée à l’aide de la touche d’avancement et validez avec
la touche de saisie. Le paramètre mémorisé cesse de clignoter.
Si des valeurs numériques telles que le débit doivent être saisies, entrez les chiffres un par un en commençant par la plus petite décimale. Le
chiffre à saisir clignote. La touche d’avancement permet de sélectionner la valeur (0-9) et la touche de saisie de la valider. Le chiffre suivant se
met alors à clignoter. Le nombre de décimales est prédéfini. Ainsi, une décimale est prévue pour les litres et les gallons et quatre décimales
pour les m3.
Pour le réglage des valeurs limites, le commutateur de valeur limite inférieure ou supérieure peut si nécessaire être désactivé. La sélection
« OFF » est également proposée pour la plus petite décimale de la valeur limite de débit.
Si aucune touche n’est actionnée pendant 15 minutes, l’appareil retourne en affichage standard et la saisie des paramètres est verrouillée.
Les données qui n’ont pas été validées à l’aide de la touche de saisie sont rejetées.
Paramétrage de l’affichage
Pour pouvoir procéder au paramétrage, l’appareil doit être déverrouillé à l’aide de la touche de service. Voir le chapitre « Réglage des
paramètres », page 37.
Sélection de l’unité de mesure volume [UNIT VOL]

Les unités à disposition et les réglages qui en découlent sont :
• Litres [UNIT LIT] : valeur d’impulsion en litres par impulsion [LPP], débit en [l/unité de temps]
• Mètres cube [UNIT M3] : valeur d’impulsion en litres par impulsion [LPP], débit en [m3/unité de temps]
• Gallons US [UNIT USG] : valeur d’impulsion en impulsions par gallon [PPG], débit en [gal./unité de temps]
L’unité choisie apparaît à l’affichage en tant qu’index.
Sélection de l’unité de mesure de temps [UNIT TI]

Les unités à disposition et les réglages qui en découlent sont :
• Heure [UNIT TI h] : débit en [volume/h]
• Minute [UNIT TI min] : débit en [volume/min.]
L’unité choisie apparaît à l’affichage en tant qu’index.
Paramétrage des données du mesureur
Pour garantir la précision de mesure, le module électronique doit être adapté au mesureur. A cet effet le diamètre nominal et le volume
exact de la chambre de mesure sont programmés dans le module lors de l’étalonnage en usine. Ces paramètres ne peuvent par principe
plus être modifiés. Ils sont mis à l’affichage avec l’index [CAL] et sont la preuve que le compteur a été étalonné.
Si le module d’affichage doit être remplacé, il est possible d’introduire manuellement ces deux paramètres afin de l’adapter au mesureur.
Un module de rechange, où le diamètre nominal et le volume de la chambre de mesure peuvent être modifiés, affichera les paramètres
avec l’index [UNCAL].
ATTENTION : Après une saisie manuelle du diamètre nominal et/ou du volume de la chambre de mesure, 4 modifications sont possibles
dans un intervalle de temps de max. 7 jours après la première intervention. Passé ce délai ou après la cinquième modification, ces deux
paramètres ne peuvent PLUS ETRE MODIFIES.
40 CONTOIL®
Paramétrage des sorties
Les sorties à utiliser doivent être activées dans le menu de paramétrage « Sélection des sorties » [OUTP SEL].
Seules les sorties activées peuvent être paramétrées. Les variantes suivantes sont possibles :
• 2 sorties à relais [2REL 0AN] (réglage par défaut) ou
• 1 sortie à relais et 1 sortie de courant [1REL 1AN]
Impulsions pour la totalisation à distance du volume mesuré (totalisateur)
Menu de paramétrage :
Fonction volume [R1VOLUM]
Paramètres réglables :
T
Largeur d’impulsion (t) : 5 – 50 – 250 – 500 ms
=> La largeur d’impulsion détermine la plus petite valeur d’impulsion possible
Valeur d’impulsion pour les litres, m3 [LPP]: 0,1 – 1 – 10 – 100 – 1000 l/imp
Valeur d’impulsion pour les gallons US [PPG] : 10 – 1 – 0.1 – 0.01 – 0.001 imp / USG
(Réglage par défaut: 250 ms, 1 Ltr/imp; DN40-50: 10 l/imp)
=> Seules les valeurs possibles en tenant compte du Qmax du compteur et de la largeur
t ms
d’impulsion choisie sont proposées. Si une valeur d’impulsion plus petite est
nécessaire, il faut sélectionner une largeur d’impulsion plus faible.
Caractéristiques du signal :
L’émission d’impulsion se fait par fermeture du contact semi-conducteur pour une durée
correspondant à la largeur d’impulsion sélectionnée.
Sortie fréquence proportionnelle au débit
Menu de paramétrage : Fonction débit [R1 FLOW]
Hz
100 Plage de fréquence et proportionnalité du signal par rapport au débit
f2
Q1...Q2
Limite de débit inférieure [MIN]: Q1 > 0 (réglage par défaut : Qmin )
Limite de fréquence inférieure [Hz]: f1 > 0 (réglage par défaut : 10 Hz)
Limite de débit supérieure [MAX]: Q2 < Qmax. (réglage par défaut : QN )
f1
Limite de fréquence supérieure [Hz]: f2 < 100 Hz (réglage par défaut : 80 Hz)
0 => La fréquence supérieure doit être plus élevée que la fréquence inférieure.
Q1 Q2 Vol/h La limite de débit supérieure doit être plus élevée que la limite de débit inférieure.
Qmin, QN et Qmax dépendent du diamètre nominal du mesureur.
a) En-dessous de la limite de débit inférieure sélectionnée Q1 :
• diminution proportionnelle jusqu’à 0 Hz et rester sur cette valeur.
b) Au-dessus de la limite de débit supérieure sélectionnée Q2 :
• élévation proportionnelle jusqu’à 100 Hz et rester sur cette valeur.
Un signal d’erreur n’est pas prévu.
CONTOIL® 41
Sortie de commutation pour la signalisation d’une valeur limite (Limite)
Menu de paramétrage : signalisation d’une valeur limite [R1LIMIT]
H H
Valeur limite de débit inférieure [LIMIT MIN] : [OFF] ou Q Limmin > 0
(réglage par défaut : Qmin )
Valeur limite de débit supérieure [LIMIT MAX] : [OFF] ou Q Limmax ≤ Qmax.
(réglage par défaut : QN )
=> La valeur limite de débit supérieure doit être plus élevée que la valeur limite de
débit inférieure. Qmin et Qmax dépendent du diamètre nominal du mesureur.
Q Lim min Q Lim max Vol/h
Hystérèse [HYST] (H): 0…10% de Q Lim
(réglage par défaut : 1%)
Fonction du contact
semi-conducteur : active on – active off
a) Lorsque le débit se trouve entre les valeurs limites inférieure et supérieure, le
contact semi-conducteur est ouvert si la fonction « active on » (contact de travail)
a été sélectionnée. Si la fonction « active off » a été sélectionnée, il est fermé
(contact de rupture).
b) Lorsque le débit atteint et dépasse la valeur limite supérieure, le contact passe
dans la position sélectionnée pour sa fonction. Il revient à sa position de départ
dès que le débit est inférieur à la valeur limite supérieure moins l’hystérèse.
c) Lorsque le débit atteint ou est inférieur à la valeur limite inférieure, le contact
passe dans la position sélectionnée pour sa fonction. Il revient à sa position de
départ dès que le débit est supérieur à la valeur limite inférieure plus l’hystérèse.
Sortie de courant analogique 4…20mA proportionnel au débit
Menu de paramétrage : sortie analogique [ANALOG]
mA
21,5
Proportionnalité du signal par rapport au débit Q1...Q2
20,8 Débit à 4mA [MIN mA] (I4): Q1 > 0
I 20 20 (réglage par défaut : 0)
Débit à 20mA [MAX mA] (I20): Q2 ≤ Qmax.
(réglage par défaut : QN )
I4 4 => La limite de débit supérieure doit être plus élevée que la limite de débit
3,8
3,5 inférieure. Qmin, QN et Qmax dépendent du diamètre nominal du mesureur.
Q1 Q2 Vol/h
Lissage du signal en présence de variations rapides du débit
Facteur de lissage [DAMP] 1 (néant) …10 (maximal)
=> Plus le facteur de lissage est élevé, plus l’erreur relative est importante.
Niveau du signal en cas de défaut détecté sur l’appareil

En cas de défaut [ERR …]: HIGH (21,5mA), LOW (3,5mA), OFF
a) En-dessous de la limite de débit inférieure sélectionnée Q1:
• diminution proportionnelle jusqu’à 3,8 mA et rester sur cette valeur.
b) Au-dessus de la limite de débit supérieure sélectionnée Q2:
• élévation proportionnelle jusqu’à 20,8 mA et rester sur cette valeur.
c) Signal d’erreur en cas de défaut détecté sur l’appareil : capteur, ROM, tension
d’alimentation etc.…
• Fonction HIGH : courant de 21,5mA
• Fonction LOW : courant de 3,5mA
• Fonction OFF : pas de signal d’erreur, courant proportionnel au débit mesuré.
42 CONTOIL®
Messages d’erreur
Le système électronique effectue un autodiagnostic toutes les 5 minutes environ. Si une erreur qui influence la fiabilité ou la précision de
la mesure est détectée, le message [ERROR] apparaît toutes les 2 secondes dans l’affichage.
L’erreur est affichée en détail dans le menu d’information :
[E-FLOW] Dépassement du débit maximal autorisé (Qmax)

Le compteur est en surcharge mécanique et ne mesure plus avec précision.
Mesure : réduisez le débit ou utilisez un compteur d’un diamètre plus grand.
[E-POWER] Tension d’alimentation insuffisante

Traitement des données incorrect, le compteur fournit des valeurs de mesure incorrectes.
Mesure : vérifiez la tension d’alimentation. Eliminez les causes du défaut.
[E-EEP] Erreur de lecture ou de mémorisation des données dans l’EEPROM

Sauvegarde incorrecte des données. La valeur du totalisateur est peut-être incorrecte.
Mesure : le convertisseur doit être remplacé. Veuillez prendre contact avec le fournisseur.
[E-ROM] Erreur de lecture des données de la ROM

Sauvegarde incorrecte des données, le compteur fournit des valeurs de mesure incorrectes.
[E-SENSOR] Erreur de signal entre le capteur et le convertisseur

Le compteur affiche des valeurs de mesure incorrectes.
Schémas d’encombrement
DN15, 20, 25 à embouts filetés DN40 à embouts filetés
DN15, 20, 25 à brides (DIN 2501/SN 21843) DN40, 50 à brides (DIN 2501/SN 21843)
h2
h2
ØF
H
H
ØF
h1
h1
b
b
B L B L
Diamètre nominal L B a ØF b h1 h2 p r
DN15 165 105 260 95 45 65 90 G ¾” G ½”
DN20 165 105 260 105 54 74 90 G 1” G ¾”
DN25 190 130 305 115 77 101 90 G 1¼” G 1”
DN40 300 210 440 150 116 153 90 G 2” G 1½”
DN50 350 280 – 165 166 209 90 – –
Dimensions en mm
CONTOIL® 43
1 Analogue Output
1 Digital Output
Sensor area
(keep clear of wiring etc.)
2 Digital Outputs
Sensor area
(keep clear of wiring etc.)
Modification rights reserved / Copyright © Aquametro AG

Änderungen vorbehalten / Sous réserve de modifications
AQUAMETRO AG AQUAMETRO SA AQUAMETRO AQUAMETRO AQUAMETRO s.r.o.

MESSTECHNIK GmbH BELGIUM SPRL
Ringstrasse 75 Rue du Jura 10 Zum Panrepel 24 Dallaan 67 Prosecká 811/76a
Art. Nr. 20313
CH-4106 Therwil CH-1800 Vevey D-28307 Bremen B-1933 Sterrebeek CZ-190 00 Praha 9
Tel. 061 725 11 22 Tel. 021 923 51 30 Tel. 0421 / 871 64-0 Tel. 02 / 241 62 01 Tel. 02 / 86 88 77 78
Fax 061 725 15 95 Fax 021 922 58 44 Fax 0421 / 871 64-19 Fax 02 / 216 22 63 Fax 02 / 86 88 95 59
[email protected] [email protected] [email protected] [email protected] [email protected] www.aquametro.com
MOTOR CABLE GLAND SIZE :
37.6 mm X 1 EA
11.7 mm X 1 EA
PART NO.
MT-00-01
6. CONTROL PANEL

7. SPARE PARTS AND TOOLS

Spare parts Date 01.01, 2011
Rev.
for DMC-1800 / 2400 / 3300 / 5000 / 6500 -
Position : Drafted by:
KANGRIM F.O Pump Berchtold
Qty Pos. no. Description Art. no. Material Sketch
1 018 Filter Basket BAS 05 0,5mm, 580cm2
116 x 3
2 739 O-ring for Filter cover DDO 145
FKM 70º Shore A
6304
3 817 Bearing DLR 04
20 x 52 x 15
4 457 Mechanical Seal UED 261A SiC / SiC

S5114-Mm09-Aux. Boiler

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S5114-Mm09-Aux. Boiler

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Customer : SPP Shipbuilding CO.

1. BOILER DESIGN DATA

0 2011.11.16 FOR APPROVAL H.W.NOH K.J.AHN B.J.KIM

KANGRIM HEAVY INDUSTRIES CO., LTD.

1. BOILER DESIGN DATA

KANGRIM HEAVY INDUSTRIES CO., LTD.

LIST OF BOILER DESIGN DATA

NO DRAWING NO. TITLE REV. REMARK

KANGRIM HEAVY INDUSTRIES CO., LTD.

Boiler design data

KANGRIM HEAVY INDUSTRIES CO., LTD.

FIG 1] PB type boiler lay out.

KANGRIM HEAVY INDUSTRIES CO., LTD.

Information table of instruments

High water level - - - +165 ●

Too low water level - - - -145 ● ●

KANGRIM HEAVY INDUSTRIES CO., LTD.

Information table of instruments

25 Salinity indicator ppm 0~200 W03 80 ● F/W line

KANGRIM HEAVY INDUSTRIES CO., LTD.

Proposal water level

Low Water Level (9.2 mA)

KANGRIM HEAVY INDUSTRIES CO., LTD.

Proposal drum pressure setting point

 9.0 Safety valve open / Design pressure

 8.5 High steam pressure trip / alarm

 8.0 Dump valve open

 7.5 Burner stop

 7.0 Boiler working pressure

 6.5 Burner start

 5.0 Boiler low pressure

PRESSURE UNIT : kg/cm2G

KANGRIM HEAVY INDUSTRIES CO., LTD.

Thermal expansion of boiler

KANGRIM HEAVY INDUSTRIES CO., LTD.

KOREA (CHANGWON FACTORY) KOREA (POHANG FACTORY)

KOREA (SNINPYUNG FACTORY) KOREA (DADAE FACTORY)

CHINA (CHANGZHOU FATORY) CHINA (SHANGHAI OFFICE)

Operation and maintenance for PB boiler 1

3. Treatment of feed and boiler water

5. Plugging and replacement of tubes in PB boiler

6. Boiler check list

Operation and maintenance for PB boiler 2

The auxiliary boiler generates steam required for tanker service,

When the main engine is out of service, the exhaust gas

Astheengine load increases, the exhaust gas economizer

Such an independent operation of the exhaust gas economizer is

(1) Auxiliary boiler alone to be operated.Tanker Service Mode

(2) Auxiliary boiler and exhaust gas economizer Eco. Back-up

(3) Exhaust gas economizer alone to be operated. Economizer

Operation and maintenance for PB boiler 3

2.1 General notes on boiler operation

The following notes on boiler operation are of general nature to be

a) The boiler is designed to deliver steam at required pressure and

b) The concentration of solids entrained in the steam leaving the

c) If each heating surface of the unit is kept clean, the temperature

Operation and maintenance for PB boiler 4

e) The temperature and analysis of gases leaving the boiler are

b)The time required to bring the boiler up to pressure and