Mm-14 Inst. Book For Aux. Boiler & Exh. Gas Economizer

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MARINE AUXILIARY BOILER

HB~oa, 1o, 12, 15, 1a
MANUAL
Introduction
Thank you very much for selecting HB Boiler.
This manual gives you instructions on how to use HB Boiler. In using the boiler, make sure you
choose a person in charge of handling the boiler (Engineer) and use the boiler after perusing the
manual and understanding the contents. In addition , we recommend that you always have this
manual at hand when you work.
The main contents of this manual are: Outline of HB Boiler, main functions, descriptions of the con-
trol system, operating procedure and maintenance. Precautions relating to operating method and
safety indicated in this manual from damages to measures only relate to usage for specified pur-
poses.
Do not use the boiler by methods that are not mentioned in this manual. Please be aware that we
cannot be held responsible if the boiler is used by methods not mentioned in this manual.
As a result of tireless research for improvement involving the design of HB Boiler," there are details
that do not correspond to the product you have purchased. Please note that the contents of the
manual may change without notice.
If you have any inquiries concerning the product you have purchased or about the contents on this
manual , please do not hesitate to contact us.
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CONTENTS
& 1. Terms ···············································································································5

& 2. Warning Label ·· · ··· ··· ·· · · ·· ··· · · · · ·· ··· ·· · ·· · · ·· ··· · ·· ·· · ··· · ·· · · · · ·· ·· · ·· · ·· · · · · · ·· ·· · ··· ··· · ·· ··· ··· ·· · ··· ···6
& 3. Basic Precautions······································· ···· ··· ········ ······· ······ ·············· ··············· 7
4. Boiler's outline drawing ··· ··· ·· · ··· ··· ··· ··· · ·· ·· · · · · · ·· · ··· ··· · ·· ·· · · ·· ·· · · ·· ··· · ·· ··· ·· · · ·· ··· · ·· ··· ··· · · · ·· ·8
5. Internal Structure ··· ··· ··· ··· ··· ······ ··· ··· ······ ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ··· ······ ··· ······ ··· ··· ··· ······9
6. Structure, part names, inspection and adjustment of each device···················· · ····· · ··· ···10
6-1 Burner Assembly (HB08-18) ···· ···················· ··· ···· ···································· ··············1 0
6-2 Burner Assembly (Boiler top) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·11
6-3 Burner element HB 08-15 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·12
Burner element HB 18 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·13
6-4 Fuel oil piping ····· ························· ································· ······ ··········· ·······················14
6-5 Flame funnel & Diffusers · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·15
6-6 Burner Nozzle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1 5
6-7 Primary Air Damper & Diffuser · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·17
6-8 Pilot Burner · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·17
Nozzle Tip for pilot burner · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·18
6-9 Combustion control unit · · ··· · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·19
(1) Control system · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·19
(2) Cam motor···························································· ·· ···· ···· ·· ··· ···· ······· ···· ··· ··· ····· ·20
(3) Oil flow control valve ······ ··················· ··········· ········· ··· ·· ··· ··········· ····· ············ ··· ·· ·21
(4) Air flow controller and Danper assembly ···· ········· ·· ····· ·· ····· ···· ························· ·· ····· 23
6-10 Blower ········ ·· ··· ··············· ········································ ·· ············ ·· ······ ·····················25
6-11 Solenoid Valve (HB08-18) ···· ··· ·· ····· ····························································· ····· ····26
6-12 Fuel Oil Pump ·························· ··· ················· ··· ·····················································29
6-13 Ignition Transformer ···················································· ··· ············ ····· ··· ·· ················30
6-14 Flame Eye ·· ········ ···· ···· ········· ······ ··· ··························· ····· ····· ······ ··· ···· ···················31
6-15 Fuel Oil Heater ············· ·· ······ ······································ ············ ············ ········· ··· ··· ·32
6-16 Fuel Oil Temperature Indication Regulator··· ······ ·· ·············· ··· ······· ············· ················· ·33
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6-17 Thermostat (For fuel oil) ··· · · · ·· · ·· · · · · ·· ··· · ·· · ·· · · · · ·· · · · ·· · · · · · ·· · ·· · · · · ·· · · · · ·· · · · · ·· · ·· · ·· · · · ·· · · · · · · · · · · ·34
6-18 Heavy oil Heating Temperature Chart ············ ···································· ············· ···· ·· ·····36
6-19 Water level gauge and Water level control cylinder · · · · · · · · · ·· · ·· · · · · ·· · ·· · · · · · · · · · · ·· · · · · ·· · ·· · · · · · · · ·· ·37
6-20 Exhaust gas thermostat··· ··············· ················· ····································· ........ .. ·.· ·· ··· ·39
6-21 Pressure switch (for steam and fuel oil) ·· · ·· · ·· · · · · · · · · · ·· · · · · · ·· · · · · · · · ·· · · · · ·· · · · · ·· · · · · · · · ·· · ·· · · · · · · · · · ·40
(1) SNS Type ·· · · · · · · · · · · ·· · ·· · · · · ··· ·· · · · · ·· ··· · ·· · ·· · · · · · · · · · ·· · · · · · · · ·· · · ·· · · · · · · · ·· · · · · · · ·· · · · · · ·· · · · · ·· · · · ·· · ·41
(2) RT Type · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·41
6-22 Safety valve · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·42
6-23 Duplex strainer (For fuel oil) · .... : · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · ·43

(1) Operation guide ... .... ................... ... ........................................................ .. ...... 43
(2) Y-Shaped strainer .. ··· .. ·· .. ··· .. ·· .. ··· .. ·· .. · .. · .. · .. ··· .. ·· .. · .. · .. ······· .. ···· .. ····· .... · .. ··· · .. ··· .. · ·44
(3) Oil Strainer for pilot burner .. · · · · .. · · · .. · · · · · · ... · · · · · · · · .. · .. · .... · · .. · · · .. . · · · · .. · .. · .. . .... · · .. · .. · .. · · · ·45
6-24 Feed water check valve·· .. ·· .. · .. ···· .. ··· .... ····· .. ····· .. · .. · .. ··· .. ·· .. ··· .. ······· .. ····· .. ··· .. ··· ·· .. · .. ·45
6-25 Sequencer (Programmable controller) · · · · · · · · .. · · · · · · · · .. · · · · · · .. · · .. · · · .. · · .. · · · ... · · · · · · · .. · .. · · · · · · · .. ·46
6-26 Flame detector (FS-1 00) · · · · · · · · · · · · .. · · · .. · · · · · · · .. · · · · · .. · .. · · · · · · .. · · .. · · · .. · · · · · · · · · · · · · · · · · .. · .. · · ···· · .. ·52

6-27 Water level detector (LM1-200) ....... ...... .. .. ........ .............................. ... ..... ..... .......... 53
7. Automatic operation of the boiler by the sequencer················································ ···54

7-1 Summary .................... , ................... ...... ............................ .... .... ... ..... .................. 54
7-2 Basic time chart ................... .. ... .. ............................ : ....................... ................. ... ... . 54
7-3 Flowcharts ..... ..... .......... ...................... ..... ............................................. ... ... .. .. ...... 58
7-4 4-Position control of the burner ............... .. .... .. · .................. ........... .. ................ · .. ....... 59
8. Safety Assurance System ··· · ·· · ·· · ·· ·· · · · · ··· · ·· · ·· ··· · ·· ··· · ·· ·· · ·· · · ·· · ·· · ·· · · · · · · · · · ··· · · · · · · · ·· ··· · · · · · ·60
9. Manual Combustion Circuit · ·· ·· · ··· ·· · ··· ··· ··· · ·· ··· · ·· ··· · ·· ··· ··· ··· ··· ··· ··· ·· · ·· · ··· ··· ·· · · ·· ··· ··· ···61
10. Inspection before operation and Operation ··· ··· ··· ··· ··· ··· ······ ··· ··· ··· ······ ··· ··· ··· ······ ··· ···64
10-1 Inspection of every check points before operation ................ ............................ .......... 64
10-2 Operation (in case of automatic burner operation) .. ...... ...... .............. ...................... · .. ·65
(1) Confirm operating switches for the boiler ..... ..........................................................65
(2) Feeding water to the boiler .. · .. · · .... · · · · · · · .. · · · · .. · .. .... · · .. · .. · · .. · · · .. · · · · .. · · .. · · · · · · .. · · .... · .. · · .. ·65

(3) Combustion ; Start from D.O (A heavy oil) .... ........................ .................. ............ .. 55
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(4) Termination with 0 .0 (Heavy oil A) ......... : ........................................................... 65
(5) Switching fuel ······ ·········· ···· ·········· ··················· ········:································· ·· ·· ·65
(6) Cold Start · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·66
(7) How to assure alarm bell·········· ····· ·········· ·· ················· ····· ······················· ·· ····· ·· ···66
11. Regular Maintenance · · · ··· ··· ··· ··· ··· ··· ··· ··· ·· · ··· ··· · ·· · ·· ··· ··· ·· · ··· ··· ·· · · · · ··· ··· · ·· · ·· ··· ··· ·· · ··· · ··67
11-1 Regular Maintenance · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·67
11-2 Inspection and Precautions Before Starting Operation··· ·············· ······ ····· .. ···· ··· ··· ··· ···· ··· ·68
11-3 Inspection and Precautions during operation············ ··· ·············· ···· ········ ··· ·········· ·· ······ ·68
11-4 Inspection After Operation ·· ·· ···· ··· ··· ·· ·········· ········ ·· ············· ··· ····· ····· ·· ······················ ·68
11-5 Water Treatment · · ·· · · ·· · ··· ·· · ·· · · · ··· ··· · ·· · ·· · ·· · · · ·· · · · · · · · · · · · · · · ·· · · · · · · · · · ·· · · · · ·· · · · · · · · · · · · ·· ·· · · ·· · · · ·· · ·68
11-6 Long-term Shut-down· ····· ······· ··· ······ ···· ···· ···· ··· ··· ·····: ··· ···· ···· ····· ·························· ···· ·69
12. Troubleshooting ··········································· ········ ······ ··· ········· ··· ······ ··· ···············70
12-1 Water Feeding System · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·70

12-2 Fuel System· ······················· ···· ············· · · ··· ········· ······· ··· ·· ·· ·· ····· · ·· ············ ~ · ·· · ··· ·· ··· · 71
12-3 Fuel System ···· ··· ········· ·· ····· ········ ············· ············ ·· ··· ········ ····· ·· ········ ·· ·· ··· ·· ········ ····71
12-4 Safety Control; Alarm Circuit · · ·· · ·· · · ·· · · · · ·· · · · ·· · · · · · ·· · ·· · · ·· · · · ·· · ·· · · · ·· · · · · · · · · · · ·· · · ·· · ·· · · · · ·· · ··· ·· ·73
ADDITIONS and CORRECTIONS 6-9 (4) Air volume adjuster and damper ········· ········· ·· ·······74
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1. Terms
The following terms are used in this manual for your safe and effective operation.
~ WARNING
1. Indicates a condition or practice which may cause death
or serious injury to the operator.
~ CAUTION
2. Indicates a condition or practice which may result in
damage or destruction of property and/or minor personal
injury.
NOTE
3. Indicates cautions for perventing the failure of the
devices, and points for effective operation .
4. Number in the pointing hand sign indicates the page for

related items.
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2. Warning Label
& Warning
The body of HB Boiler and its ancillary equipment have parts with the following warning label attached .
2-1. Scald warning label

Attached near parts with hazard of scalding or hot parts (Parts with surface temperature of over 6o·c ).
2-2. Catch warning label .
Attached on rotating parts with gaps in the structure that could catch fingers (Fingers might get trapped)
2-3. Electrification warning label

Attached on electric parts or around the parts that cannot be insulated (or covered) completely.
2-4. Trap warning label

Synonymous with the catch label, it is attached on moving parts.
2-5. Damage warning label

Attached on the water gauge as there is a possibility of damage by aged deterioration when it is used for
long periods.
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3. Basic Precautions
~ Warning
When operating HB Boiler, please comply strictly with all precautions relating with safety indicated in this manual.
There is a danger of serious physical injury if the precautions are not observed.
3-1. Carry out a check before using the device

Check the pipe system diagram of the completion drawing and the system of the vessel. Do not operate the
device with the wrong system as this could lead to serious accidents.
Moreover, refer to the completion drawing for specifications.
When handling the device, be sure to choose a person in charge of handling. The person in charge should not
operate or carry out maintenance of the device until they have perused the precautions .relating to safety
indicated in the manual and have a sufficient understanding of the precautions.
3-2. Wear proper outfit and protection gears

The device should not be operated or serviced wearing baggy clothes and accessories as they could catch on
the valve or machinery parts. Do not wear oil stained clothes as they could catch fire.
Do not forget to wear a helmet, protection eyewear, safety shoes and gloves when working on the device.
Protection gears must be worn as there is a particular danger of scalding near hot parts. Moreover, protection
eyewear and gloves must be worn as chemicals could splatter on hands and eyes while injecting chemicals.
3-3. Do not remodel the device, Use the genuine products for the parts.
Do not remodel the device without our approval. We may not be able to permit such remodeling by regulations.
Moreover, such remodeling could compromise safety. Use the manufacturer's genuine products for parts.
3-4. Use the designated fuel

Do not use fuels other than those designated. There would be a danger of the device exploding if other fuels are used.
3-5. Do not keep flammable goods near the boiler

Do not keep flammable goods near the boiler. There would be danger of fire.
It is highly dangerous as there would be a danger of fire if flame were brought near the boiler fuel.
Store flammable goods in a safe place away from flames, check where the fire extinguisher is kept, and learn
how to use it in case of emergency.
Dispose of cloths stained with fuel or oil. Such cloths could ignite spontaneously if kept in a wrong way.
Wipe up spilt fuel and oil immediately.
3-6. Keeping a fire extinguisher and first-aid kit

Keep a fire extinguisher in preparation for fire and learn how to use it.
Establish where to keep the first-aid kit.
Establish the contact numbers in case of fire or accident and how to handle such emergencies.
3-7. Advice on moving the boiler or selling the vessel

A correct installation and incidental work are required in operating the boiler. Please be sure to contact our
company when moving the boiler or selling the vessel.
Do not carry out incorrect installation or incidental work as there is a danger of such work leading to physical injury.
~ Warning
Always disconnect all electrical power at the main circuit breaker, close the main and pilot manual shut off valves
before performing adjustments and/or maintenance. f ailure to do so could cause electrical shock, explosion, fires
and/or burners which will result in serious personal injury and/or death. All adjustments and/or maintenance must
be performed by qualified and experienced personnel only.
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4. Boiler's outline drawing
2)
This photo shows the boiler of HB.
1 Main Steam Valve 8 Blower Unit & Motor

2 Burner Unit & Wind Box 9 Control Panel
3 Water Gauge and Controller 10 F.O. Pump Unit '
4 Fan Duct 11 Manhole (Lower Drum)

5 Manhole (Upper Dr.um) 12 Blow Down Valve
6 Surface Blow Off Valve 13 Steam Pressure Gauge Unit
7 Funnel Flange
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5. Internal Structure
& Warning
Make boiler inside and combustion chamber cool by boiler bottom blow and blower purge before internal
inspection, and confirm inside pressure is OMPa.Ventilate inside with ventilation duct and fan during inspection.
1) - - --. 1 Main Burner Details of water tubes fitting
2 Stay Tube
3 Upper Drum
4 Insulation
5 Expansion Ring
6 Inner Casing
7 Water Tube I
8 Casing
9
10
11
12
Wind Box
Castable
Funnel Flange
Lower Drum
w
After expander, bell finish
fig-1
The boiler has a structure with the donut shaped Lipper

drum (3) and water drum (12) linked by multiple water
tube (7) and the swaged ends of the water tube are
arranged as seen in the left diagram .
The fuel oil pressurized by the fuel pump is sprayed by
the burner after being heated up to be prescribed temper-
Exh.gas ature by the Fuel Oil Heater, which is mixed with air sent
outlet
in by the blower, ignited by the Ignition Transformer and
turns into a proper flame in the furnace .
The flame transfers its heat to the water inside the inter-
nal water tube, which transforms into fuel gas, separates
to left and right between the multiple water tube , con-
verges again at the exit and is expelled from the funnel.
Water tube arrangement is changed It is built so that heat is transferred to water efficiently by
for boiler type. heat being transferred by contact when heat passes
between the water tube.
The casing is double layered with the inner casing of a welded construction and the exteral casing , and heat
radiation is restricted by layering a Heat Insulator (4) between the water tube, inner casing and internal and
~-
external casings.
The lower part of the furnace and the swaged part of the water tube are insulated by refractory and short pass
of gas is also prevented.
At the upper and lower drums, there are manholes which allow you to check the interior. Check the state of
deposits (scaling) , corrosion, pitching , and reflect the results in processing boiler water. (For more details,
please refer to the separate manual: Manual for Water Treatment) . When you check the inside of the furnace,
look for deposits of soot, peeling of fire-resistant materials, fuel leakage on the furnace bottom , traces of water
leakage, accumulations of unburnable materials, and so on.
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-MARINE AUXILIARY BOILER
6. Structure, part names, inspection and adjustment of each device

6-1 Burner Assembly
7) 5) 6) 8) 9) 10) 11) 12) 14)

1)
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\
-··- -r--·---
- - - Z- ---
/ '
/
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2) 13)
/
1 Wind Box 6 Solenoid Valve(N .O.) 11 Expansion Joint

2 Insulator 7 Solenoid Valve Unit 12 Air Duct
3 Burner Element Assembly 8 Control Unit 13 Blower
4 Ignition Transformer 9 Primary Air Duct 14 Silencer
5 Solenoid Valve(N .C.) 10 Damper Unit
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6-2 Burner Assembly (Boiler top)
secondary pressure
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6-3 Burner element
HB-08,10,12,15
~ Warning
Before opening the burner and making the
inspection , you must first use the fan to make
a purge, and be sure the furnace chamber is
Rc 1/2
sufficiently cooled and ventilated. Turn off the
F.O. pump, F.O. booster pumps, and close the
main F.O. valve and pilot F.O. valve. Prepare
the oil receiving so that the fuel oil should not
2) - - - - - · - - leak. If fuel oil is leaking from the flexible tube ,
burner, or elsewhere, wipe it up immediately
and dispose it properly. The leakage oil to the
high temperature part might burn.
1) - ---
I i I
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Model a b
HB-08,10 870 350
HB-12 870 320
HB-15 850 320
1 Primary duct gun holder

2 Primary air manifold G7
3 Primary air damper 65A
4 Burner gun BG1520N
5 Nozzle ART152
6 Primary air diffuser DF80/30F
10)
7 Main diffuser
8 Middle diffuser
8) -· 9 Blast tube
10 Flame funnel FIC-13
11 Pilot burner
12 Electrode
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HB-18
Rc 1/8 "
4) 3) ~ Warning
Before opening the burner and making the
Rc 1/4 ....__
inspection , you must first use the fan to make
Rc 1/2 --,
a purge, and be sure the furnace chamber is
Rc 318- .i.-...,
"-,, sufficiently cooled and ventilated. Turn off the
F.O. pump, F.O. booster pumps, and close the
main F.O. valve and pilot F.O. valve. Prepare
the oil receiving so that the fuel oil should not
leak. If fuel oil is leaking from the flexible tube,
burner, or elsewhere , wipe it up immediately
1) ·-, -~ and dispose it properly. The leakage oil to the
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I
I
I I
I
high temperature part might burn.
i
12) I'
'
'·
I~ 1\)
en co
en
0
I
.l!J
1 Primary duct gun holder

2 Primary air manifold G7
3 Primary air damper 65A
4 Burner gun BG1520N
5 Nozzle ART152
6 Primary air diffuser DF80/30F
7 Main diffuser
8 Middle diffuser
9 Blast tube
10 Flame funnel FIC-13
11 Pilot burner
12 Electrode
13
lVI lURA
•
•
6-4 Fuel oil pipring diagram
I
BURNER
TC-1
A. F. 0. TAHI<
r
I
I
F . 0 . SlAG L1 NE : '--Jik11f.J...____j Hf-Loo>®f7+-wl-l~><>-\k
+-------- - --------~
M-1 STRAINER
M-2 F.O. PUMP (MAIN)
M-3 F.O.P. MOTOR (MAIN)
GLOVE VALVE SOLENOID VALVE M-4 AUTO STRAINER (PILOT)

1>4 00
BALL VALVE Y TYPE STRAINER M-5 F.O. PUMP (PILOT)
181 1-.;1
NEEDLE VALVE STRAINER M-6 F.O.P. MOTOR (PILOT)
~ KDI
--<>- COCK THERMOSTAT M-7 Y TYPE STRAINER
~
FLANGED JOINT PRESSURE SWITCH M-8 F.O. BOOSTER PUMP
-4-
~
__.._ ORIFICE ® PRESSURE GAUGE TC-1 THERMOCOUPLE (CONTROL)
PUMP THERMOCOUPLE TS-1 THERMOSTAT (LOW TEMP.)

~ ~
SAFETY VALVE STEAM TRAP TS-2 THERMOSTAT (HIGH TEMP.)
h ®
~ FLOW CONTROL VALVE -..J\1' FLEXIBLE TUBE SV-1 SOLENOID VALVE (PILOT)
N CHECK VALVE COMPOUND GAUGE SV-2 SOLENOID VALVE (STEAM)

©
SV-3 SOLENOID VALVE (N.C.)
SV-4 SOLENOID VALVE (N .O.)
RV RELIEF VALVE
FCV FLOW CONTROL VALVE
14
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•
•
6-5 Flame funnel & Diffusers
·J
The flame funnel is mounted on the blast tube. and has and oxidation resistance.
diffusers arranged internally. On the other hand, the diffusers play roll of stabilization
The flame funnel serves as a primary combustion chamber. of the flame due to a circulating flow of combustion gas
It makes a high temperature section above 1OOO'c inside produced in its backside. Thus a high loading combus-
to establish an ideal combustion condition by highly evap- tion is actualized.
orating the oil injected through the nozzle as well as mix- Since both the flame funnel and the diffusers play impor-
ing it with combustion air tranferred from the blower. tant parts in the combustion as mentioned above. Through
For this reason, the flame funnel is made of the special care must be taken for their installation and adjustment.
heat resisting chrome steel excellent in heat resistance
[& 6-3. Burner element
6-6 Burner Nozzle
The burner nozzle is to atomize the fuel oil pumped out by applying oil pressure on the piston provided in the burner
from the fuel pump. This burner employs a spill back nozzle. This is done by two solenoid valve.
type nozzle. That is in such manner that these solenoid valves are not acti-
The fuel from the pump may flow through the inside of vated during oil circulation so that the solenoid valve in tile
the nozzle and be given a circling flow by the flow disc pump delivery side is closing without oil pressure imposed on
at the nozzle tip. the piston, when the solenoid valves are energized simultane-
A part of the oil flow is atomized and burns. And the other ously with start of combustion •. the one in the pump delivery
part goes flowing towards the flow control valve passing side opens and the other in the return side closes, where the
)
through the outside of the nozzle. oil pressure is imposed on the piston which pull up the needle
The oil flow can be controlled by controlling return to start spraying.
pressure. All parts for the burner nozzle are of precisely machined.
On the other hand, this nozzle has a cutoff needle which cut Care must be used thoroughly for disassombling and
off the fuel oil at the nozzle tip during stopping combustion to reassombling them .
make a preheat circulation possible.
This cutoff needle is made to control opening I closing action
}
~) r-
s\
\~ )
Activated open
!/
- - · 1-- - - .
Normaly close
_f .1:1\j f=:::jl===::x:
( S ) Activated
' ~ close
Status :Combustion
15
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Structure of Burner nozzle
Because the nozzle is a very intricate part, please handle it carefully. Damage, deformation and abrasion
may cause the spray from the nozzle to be faulty, or it could even cause fuel to leak from the cut-off nee-
dle. In normal maintenance, turn the cap nut at the tip of the nozzle and remove the nozzle, then clean the
tip (24), flow disk (25), bore plug (26) and needle (27). After cleaning, screw the nozzle into the F.O. out-
let, flow general use air into the F.O. inlet (0.7MPa) , and make sure there is no leakage from the spray
opening on the cap nut (23). If there is leakage and damage, replace the flow disk set (No. 24, 25, 26, 27,
and 18). As the upper control part consists of an intricate arrangement of 0-ring, spring and lock nut, you
must NOT take apart. The burner nozzle should be adjusted once a year by authorized service.
LEAKAGE
t
COTROL
PRESSURE
F.O. OUTLET
TIP SIDE
Please make sure the direction and the order of

the flow disk set are correct.
1 ADAPTER 8 0-RING NUT 15 NEEDLE PISTON 22 0-RING

2 OUTER TUBE 9 NEEDLE CYLINDER 16 SPRING PIN A 23 CAP NUT
3 INNNERTUBE 10 NEEDLE CYLINDER HEAD 17 NEEDLE ROD 24 TIP
4 0-RING COLLAR A 11 NEEDLE PISTON STOPPER 18 SPRING PIN 8 25 FLOW DISK
5 0-RING COLLAR 8 12 STOPPER LOCK NUT 19 0-RING 26 BORE PLUG
6 HYDRO END 13 STOPPER PROTECTOR 20 0-RING 27 NEEDLE
7 SOCKET 14 SPRING 21 0-RING
16
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6-7 Primary Air Damper & Diffuser
For improving the condition of low combustion and protection from sticking of carbon , this burner is
applied with the air flow from the air duct to the primary air cylinder. This air flow is controlled by the pri-
mary air damper which employs a fixed type and usually provides 50% opening . (equipped to HBOS-12)
On the other hand , the primary diffuser provides a suitable rotation of the primary air introduced and
achieves a high mixing rate of fuel I air and maintenance of good combustion during the low combustion.
6-8 Pilot Burner
1 Diffuser for pilot

2 Spark rod
3 Nozzle Tip
4 Set bolt
For this burner. a pilot burner ignition system is

adopted as a standard and a pilot burner exclu-
sively used for diesel oil is equipped-with .
Please adjust the size of the parts of pilot burner
the way that is shown in the diagram .
• The ignition insulator and lead insulator cause the ignition transfer created by high voltage to be transmitted
to near the nozzle tip, causing a spark. Since they are made of ceramics, be careful when you handle them.
Make sure that the holder screw is not screwed too tight. If there is any cracking , please replace screw.
• If there is carbon sticking to any part, wash it off with cleaning oil.
~ Caution
Manual operation for a long time should be avoided as this burner provides a fewer combustion rate but is set in the
upstream side of the main burner.
17
•
Nil IURA
•
Nozzle Tip for pilot burner
(for pilot)
Body Screw Pin Filter
The oil coming into the nozzle passes through the cut off valve for prevention of oil leakage or the filter
(Except for tip with large capacity) and enters the spinning chamber through a thin channel of the distribu-
tor. This spinning chamber is conical and the tip has an orifice. The oil increases its velocity while it swirls
inside the spinning chamber, passes through the orifice and sprayed to the combustion chamber. As the
machine work of the nozzle is very precisely, care must be exercised in handling the nozzle. In addition, a
hard material is used for the nozzle as oil always frictions the orifice and other parts at a very high pres-
sure and speed, it should be exchanged in 3-12 months.
The size by the model differs slightly. Please check the notes on the final drawing .
• There is a cut-off valve attached to the nozzle tip of the pilot burner. When replacing the nozzle tip,
please remove the filter and attach the cut-off valve.
• The defuser for the pilot burner is attached to maintain the pilot flame as the main burner.
~ Caution
Nozzle tip can cause fuel defective if steam amount, angle and configuration are not correct. Because accident
such as backfire can be occured, please use Miura's genuine parts.
The cut off valves with the nets cannot be used for C heavy oil. Replace the valves after checking the nozzle stan-
dards.
~ Warning
Cool and ventilate air of combustion chamber completely. Stop F. 0 . pump and pressure pump,. and close fuel
valve of main and pilot. Prepare oil receiver or cloth not to fuel oil be leaked. Clean up fuel oil that is leaked from
flexible tube or burner immediately; oil leakage on high temperature area can cause fire .
18
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6-9 Combustion control unit
(1) Control system
Pz
Burner gun
---
'--r--~------ ----------02
Flow control valve
Air
Cam disc 0 '
A
[J_ a~rflo~Droller_ ~-~~

Cam motor
Dumper
Proportion control unit
Adjusting valve and damper is t:ontrolled with cam motor operation. The flow control valve is opened at
low combustion, and at this condition, P2 pressure is 40-50% of P1 pressure. The flowing amount of 02 is
smaller, and the flowing amount of 03 is larger.
At high combustion, it works toward closing and the P2 pressure increase to 75-90% of P1 pressure. 03
flowing amount decreases and 02 spray amount increase. Therefore, it is possible to adjust high-mid-low
combustion to requested oil amount after controlling the amount of combustion sprayed from a nozzle ,
changing P2 pressure by controlling flow control valve. To match the amount of air flow to an amount of
the oil at each combustion , air flow controller is installed. At this condition it is possible to adjust dumper
opening.
The steam pressure in the drum is sensed by pr-essure switches (low, middle, high) , which send signals to
the control panel. These signals make the cam motor control the flow control valve and the air flow con-
troller to provide for low, middle and high combustion .
19
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(2) Cam motor
The damper motor serves for setting the oil flow control valve and the damper at a matching position by
means of signals from the A.C.C., as well as for transnitting signal~ to the A.C.C. by means of cam switch .
The internal construction includes a high torque motor. A gear head and seven cam switches . By adjust-
ing these cam switches. The combustion can be changed optionally.
setting
OPEN LIMIT approx 10 degree
HIGH COMB approx 20 degree
MID COMB approx 45 degree
LOW COMB approx 70 degree
CLOSE LIMIT approx 80 degree
Clutch lever
Cam switch adjustment a) Each limit switch of "CL" and "OL" should never
The following five limit switshes are used for the be moved.
damper motor. Opening which can be adjusted by The motor could cause overdrive, that may
moving the red cam for each switch to change the result damage to burner equipment.
combustion flow and damper opening . You can b) The setting as being over than capacities of the
adjust the cam switch by turning off the boiler, boiler body and the blower capacity: as for the
pushing the clutch lever down toward you and "H" high combustion: and the setting as exceed-
manually operating the air flow regulator. ing the pilot ignition range. as for the "L" pilot low
If now one wants to increase the combustion flow in combustion. (Usually keep the presetting of the
. the middle combustion. He can easily change it by factory unchanged)
moving the can "M" in opening direction of the c) Use care in each opening setting for "L", "M" and
damper. (At go· of the damper scale. The damper "H" so that opening rates may not be set opposite.
goes fully closed.)
In making adjustment. Care must be taken thoroughly
to the following points:
~ Caution
Please return the clutch lever at the "Middle combustion" position of the air flow controller.
Note
To avoid the damage on a dumper motor, draw OPEN LIMIT and CLOSE LIMIT at 0 degree or 90 degree to
a center point closer than 5 degree.
Keep the difference between HIGH and Low open degree more than 50 degree in case of sudden decrease
of load demand which is on leaf spring board.
20
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(3) Oil Flow control valve
The fuel oil goes through inside a nozzle and reaches a tip of a nozzle. The part of the fuel oil gets
sprayed and combusts, and other part goes through inside a nozzle toward flow control valve.
By making a motion of the flow control valve connected with a cam motor, a flow rate is changed by the
piston valve , and the amount of spray is controlled .
---+ 0 1
Pz
P1 :circulation oil pressure

Flow control valve
P2:spray oil pressure
Cam motor
D.
Moving a notch up and down , decreases the resis-
tance inside and controls P2 pressure.
• • At low combustion , notch goes down and the resis-

tance inside will be small.
(P2 pressure is low)
P2
Inlet ----+ b'
I
At high combustion, notch goes up and the resistance
inside will be large .
(P2 pressure is high)
I
I • Notch has a groove which is a part the fuel oil goes
Return--D through .
Fuel flow control valve
21
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lVIII U RA
•
F.O. Oil Flow Adjustment
Once the damper opening determined. adjust the oil flow

with the oil flow control valve with following procedure.
(1) Oil flow control for the low combustion.
1. Check to see that the fuel pump delivery side primary
pressure has been set at 2.3MPa.
2. Loosen the 3) locknut securing the 2) notch with the burner
burnt under the low combustion. (During loosening the lock
nut, secure the notch end always with like a wrench.
3. Turn the 2) notch by inserting a 3mm hex. wrench into
the "groove under the notch.
By turn ing the 2) notch counter clockwise from top of
view. The secondary pressure rises up and the fuel con- 4) 6) 5)
sumption increases. Adjust the secondary pressure with-
in a range of 40 to 50% the primary pressure with the 1 F.C.V The high combustion
5
combustion condition and the secondary pressure gauge 2 Notch adjusting bolt
observing.
3 Locknut 6 Cam disc
(2) Oil flow control for the high combustion.
4. Loosen the lock bolt while placing the burner in the high 4 Lock bolt 7 Groove
combustion condition. (Do never remove the lock bolt.)
5. According as screwing (clockwise) the high combus- 6. Securely tighten the lock bolt after completion of adjustment.
tion adjusting bolt located in the backside of the cam Subsequently, shift the burner to the low combustion and if
disc. The secondary pressure rises up and the com- the secondary pressure indication on the pressure gauge is
bustion flow increases. indentical with that of previous setting, secure the lock nut, if
adjust the secondary pressure within a range of 75 to the secondary pressure has changed. Complete the adjust-
90% the primary pressure with the secondary pressure ment by repeating the procedure in the other of "2" through
gauge observing. Use the fuel flow meter to make sure "6" until the secondary pressure may be stabilized under
that fuel is not being consumed over the rated quantity. either the high combustion and the low combustion.
Note
If the adjustment range of the oil flow control valve deflects under the low combustion and the high combustion . Readjust
it after making revise of previous setting for the limit switch of the damper or making adjustment of the damper rod .
(3) Fuel consumption adjustment for middle consumption.
combustion Turning counterclockwise from top of view:increas-
If the fuel consumption for middle combustion is es fuel consumption.
stable and half-way between high and low combus- (5) When adjustment is needed for only high combustion
tion, there is no particular need to adjust it. Loosen the lock bolt 4) of the variable disk cam and
(4) When adjustment is needed for both low turn the high combustion adjustment bolt 5) that is
and high combustion behind the cam and slide the variable disk cam.
Loosen the lock nut 3) and stick a 3 mm hexagonal Turning clockwise :increases fuel consumption.
wrench into the notch groove and turn the notch. Turning counterclockwise :decreases fuel con-
Turning clockwise from top of view:decreases fuel sumption.
& Caution & Warning

Every time you lock with a lock nut, hold the notch in Please set oil consumption so that it does not exceed the
place with a hexagonal wrench ; otherwise, the lock rated level. Excessive oil consumption can cause improp-
nut and notch will turn together. er combustion and accelerate damage to the unit.
22
lVI lURA
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•
(4) Air flow controller and Danper assembly
An air flow controller is provided on this burner in order to cordinate the restriction characteristic of the oil
flow control valve with that of the damper, as well as to control the air flow at each opening rate.
This is made in such manner that a damper driving lever may move along a leaf spring to be bent in the
sector-shape. The restriction charasteristic is varied by changing the configuration of the leaf spring by
means of 8 pieces of setting bolte attached to the leaf spring .
This device makes it possible to change the combustion flow rate from Low combustion to high combustion .
Air flow adjustment

Once you have decided on the oil flow for the
open level of the dampers, you should adjust
the air flow.
(1) First, loosen the 8 lock bolts that are hold-
ing the adjustment bolt in place.
(2) Next, adjust the air flow in the order of
low, middle and high combustion using
the adjustment bolt. Loosening the adjust-
ment bolt will restrict the air flow.
(3) If air flow volume is either large or small
for all three (low, middle , high) combus- Lock bolt Adjusting Leaf spring
bolt
tion positions, adjust the overall air flow at
either the bush rod of the damper link mechanism , or the damper arm .
(4) To adjust the combustion positions, move the leaf spring of the air-fuel adjustment register up or down .
Beforehand, loosen the screw that is locking the 8 adjustment bolts, then turn the adjustment bolts.
Turning clockwise raises the leaf spring to increase air flow.
Turning counterclockwise lowers the leaf spring to decrease flow.
(5) After adjustment, tighten the lock screws. rT7:4?
ADDITIONS and CORRECTIONS
lLJ 6-9 (4) Air volume adjuster and damper
~ Caution
If you cannot adjust the air flow properly with this equipment, change the settings of the damper motor limit switch
and try again to adjust the air flow.
Damper Assembly
In order to control the air flow necessary for combustion to the boiler, a damper is installed in the inlet of
the wind box. The damper is operated by the cam motor.
Adjustment of opening of the darmper should be made using through attention, because it has an effects
on the combustion condition of the boiler.
Furthermore, as vibration or an external force is constantly acting on the damper, the damper opening
can easily change due to loose parts and other causes . In that case, further tighten the lock nut into the
link mechanism , and grease the link mechanism at regular intervals.
Turn off the power, push the clutch lever inside the cam motor down, turn the adjustment valve by hand,
and make sure the damper is working smoothly.
23
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•
Damper Assembly initial adjustment
Adjustment for HB-08 to 12

1. Make sure that damper lever A and damper lever D are parallel
{)_Atj_!>_E..R~.(B) . ~{
to one another. Damper lever A should also be parallel with
PUSH ROD \ ~i
[:)A_f:1f.I:;_R_1EVERJ QL\.·········\. \ ~: damper lever B.
9..1\.t:lf..E..~
... .I\.RM (A) \._··.. \ :;! 2. Set the distances between the attached rods to the both ends of
DAMPER LEVER .(A) \, \ ~~:3) ----=:.i
\ \ \klt-=:""-'111 the damper link and the center of the damper link to the value
\ ·' shown in the diagram or greater.
3. Air flow adjustment made during combustion adjustment should
be done at the bush rod . In most cases , damper arm A and
damper link B should be tight.
/ 4. In the damper opening range of 0-75 degrees (that is, the angle
!'.~tl.~.~~...l.-:I:YE.I'l. <?.> / of bending of the coil spring) , make your adjustment so that the
HB-08~12 link mechanism can move smoothly without locking up.
Adjustment for HB-15

PRO.P._()I'l.~..JQ.t;f.<.k CONTROL UN 1.!. 1. Make sure that damper lever A and damper lever D are parallel
DAMPER....~f<.t:l..~f'.!.._V.ERT I CAL ._ '\
Q.!\'.'IPER ARM (8) HQI'l_l_~.Q.N.. \ \
DAMPER
.... ................ LEVER (D) . ,
\ \
\ \ damper lever B.
DAM;;A;P:.:~::._;!\:~) \ \ \ ~~3) 2. Set the distances between the attached rods to the both ends
•. \ - and the center of the damper arm B to the value shown in the
\ \
diagram or greater.
be done by the dampe! arm B (horizontal ). In most cases ,
Q.i\.t:I.P..f::.R LE VER (8) /

/
HB-15
. damper arm B (vertical) and damper arm A should be fixed.
4. In the damper opening range of 0-75 degrees (that is, the angle
of bending of the coil spring) , make your adjustment so that the
link mechanism can move smoothly without locking up.
Adjustment for HB-18

PROPORTIONAL CONTROL UNIT
··-···-·········· ········- ·····---,
1. Make sure that damper lever A and damper lever D are parallel
DAMPER ARM (f:l.l._,
DAMPER l,E.'J.E.R \9.)., ._ damper lever B.
DAMPER ARM (A) \
-·····--··················· \\ \
~3 2. Set the distances between the attached rods to the both ends
DA MPER LEVER (A) \ '..
------ -\ \ and the center of the damper arm B to the value shown in the
diagram or greater.
be done at damper arm A. However, if it is not possible to do th is
at only damper arm A, you can also move damper arm B.
4. In the damper opening range of 0-75 degrees (that is, the angle
DAMPER LE VEJ:<..!f3.)./ of bending of the coil spring) , make your adjustment so that the
HB-18 link mechanism can move smoothly without locking up.
This figure shows the damper opening range

of 45 degrees.
24
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•
lVII U RA
•
6-10 Blower (HB-08-18)
Note
Check the blower regularly.
The Blower that forced air into the burner ensures velocity, pressure and airflow by rotating the impeller by
a motor. In addition, as the HB-type allows for greater fuel gas velocity to improve the heat exchange with
the fuel gas, a high speed blower with high static pressure is used.
~ Regular Maintenance
If there is major vibration even after the impaler has been cleaned , you will need to either replace the
bearings or balance the impeller.
• Greasing the bearings
The bearings for the fan motor have a grease injection system . Please inject the correct amount of
grease at regular intervals. While injecting grease, be sure to read the caution plate on the motor.
• Inspections
Check for vibrations, strange noises, and abnormal bearing temperature during operation. When not in
operation, turn off the power, then move the impeller by hand to check for abnormalities.
• Insulation test
You should conduct an insulation test either once every three months, after the unit is being restarted
after a long period of being idle, or when otherwise necessary. If the value does not exceed 1M Q , you
should either replace the motor, or fix it once the ship has docked in port.
Notice of re-greasing
The following caution plate is put on the fan motor. The re-grease is to be done according to the caution
plate.
NOTICE OF RE-GREASI NG
j ' ') - :::z ti!i
~g 0) a :¥.
CAUTIOH :THE RE-GREASE IS TO BE DON£ AT RUHHIHG
N. D. E.
CONDITION Bl THE FOLLOIING PROCEDURE GREASE INLET
a:--· jtJ-J.li!gl~iifLr+w"F~~.Ql'fi?
- "t"F~~~ .
0
RE - GREASE QUANTITY ~jjg.t._ 20 g

INTERVAL Mtg;~ 1200 hrs
GREASE j 1)-). ESSO BEJ.CON 325
11'1 1:'-)J 325
1 .OPEN THE OUTLET COVER. l!~·t1JJ~-i:*'-' "t"F~~~.
2 . RE-FIL~ 1 HE1 GREASE llflf. OVE QUANTITY.
tijl,~l? J-J.~i.ll (J:! i) l-1:"F2"~l.
3.RAXE OUT OLD C"kEASE :t~'2')-J.~IIli'J.f., t, "Ll'_2(l,
4 .RE-FIT THE OUTLET CbYti.llt)I!1JJ~-U!'Yf.t 1Hl'~P.
OPERATE MOTOR AfTER RE-GREASIHG liTH ABOVE QUANTITY,
IF MOTOR HAS BEEN STOPPED DURING MORE THAN TWO MONTHS. N.D. E.
DON'T ~IX OTHER ONE IITK LITHIUW BASE. GREASE OUTLET
27 JH:l_l:I;J!:O)~~~t. l:~liiS.! ~V.. !Eii=;t~J..? "L"F~ b.
f,ii; , ;@? J -J.O)~J!lti~t:tl'f2" ~ '.
1
3MI4930P5
25
•
lVIII U RA
•
Re-grease quantity, interval and grease brand are decided by the motor capacity.
Refer to the following list or the caution plate. Don't mix other one with lithium base.
~
HB-08 HB-10/12 HB-15 HB-18
(37kW) (45kW) (75kW) (90kW)
Re-grease
20 20 50 50
quantity (g)
Interval
"" 1200 1200 1200 2000
(hrs )
Exxon Mobil : Beacon 325 Exxon Mobil : Mobilux No.2

Recommendable Nippon Oil Corporation : multinoc SDX Nippon Oil Corporation : multinoc No.2
Grease JOMO : LT Grease JOMO: Lisonix Grease No.2
Shell :Albania Grease HVQ Shell : Albania Grease S2
6-11 Solenoid Valve
The Solenoid Valve opens and closes by the electric activation and non-activation to control the supply of
fuel oil to the burner nozzle.
Take care in handing the Solenoid Valve as its style and valve opening action differ depending o·n the model.
Note
Clean and inspect t.he Solenoid Valve andY-type strainer regularly.
In either of the Solenoid Valves, ignition may fail when there is foreign particles on the seat as the oil
pressure will not rise due to oil leakage. Moreover, as obstruction may cause oil leakage inside the
combustion chamber, which could develop into ignition failure and other problems related to combustion ,
please carry out a regular inspection. Take care in disassembling the device, as internal parts, valve seat
and springs can easily be lost.
1. Solenoid Valve for main burner
On the window box at the top of the boiler, there are two switches for the nozzle control. Please refer to 6-
6 (Burner nozzle) for instructions for operation. Please inspect once every three months, or whenever
necessary. Since there are two types of switches (NORMALLY OPEN and CLOSED AT ACTIVATION },
please do not get them confused.
~ 6-6. Burner nozzle
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MARINE AUXILIARY BOILER I
1 Valve body
2 Plunger
14) 4) 7) 6)
3 Plunger spring
4 Packless assembly
9) 5 0-ring
6 Coil assembly
2)
7 Bonnet assembly
8 Name plate
12)
9 Lead connection line label
10 Bolt
11 Connector
12 Wave washer
13 Spacer
14 Adapter
15 Terminal box
Normaly close 16 Terminal
Open-at-activated
18) 17) 7) 10) 9)

1 Valve body
2 Needle valve
3 Spring
12) 4 Bottom plug
11 ) 5 Plunger
5)
6 Plunger spring
7 Packless assembly
15)
8 0-ring
9 Coil assembly
10 Bonnet assembly
11 Name plate
2)
12 Lead connection line label
13 Bolt
3) 14 Connector
15 Spacer
Normaly open .........____ 4)
Close-at-activated 16 Adapter
17 Terminal box
18 Terminal
Please set the valve after making sure the direc1ion of oil flow is correct.
27
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•
2. Solenoid Valve for Pilot Burner

This solenoid valve is used in the pilot system and its capacity is relativety small.lt opens when
activated and two valves are used for the pilot burner. During pre-purge, the solenoid valve is closed , and
fuel circulates in the fuel pump, and oil pressure keep rises . When pre-purge is completed , the solenoid
valves is activated and opens, and combustion is started.
9)
11)
16) 12)
13)
14)
~' Direction of the flow 15)

\ BEV Type
No. Part Name No. Part Name

1 External Cabinet Stop Bolt 10 Bottom Plate
2 Attractor 11 Coil Packing
3 Top Plate 12 Cover Plate
4 Coil 13 0 Ring
5 Label 14 Stopper
6 Plunger Spring 15 Body
7 External Cabinet 16 Spacer
8 Plunger Tube 17 Valve
9 Plunger
28
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6-12 Fuel oil Pump

Regarding the details about fuel oil pump for main burner please see separate instruction.
GFS Type (Used for the pilot)

To the nozzle
Strainer
Suction
Pressure
Regulating
Valve
The oil suctioned by the pump passes through the strainer, blown-off from the rotor .
When the discharge pressure reaches 0.7- 1.0MPa set by the Pressure Regulating Valve , the oil is
released from the Pressure regulating Valve, passes through the shaft seal and returns to the suction side
in the pump.
Pressure is adjusted by the "Pressure

Regulating Screw" and turned clockwise
with a hexagon wrench , the pressure
,
Discharge Opening PT1 /8
rises and the pressure drops when it is

turned counterclockwise , allowing for
Return
easy adjustment of pressure within a Opening PT1 /4
0.6-1 .2MPa range .
Tight locknut after adjustment.
Pressure
Regulating
Screw
~Suction \
Opening PT1/4
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6-13 Ignition Transformer
Primary side
AC100V
The Ignition Transformer is an important device for

creating sparks from the Ceramic Insulator for the
Ignitor by changing the 1OOV voltage on the primary
side to high voltage.(1 Okv)
The primary voltage of the transformer has dual
voltages; 100V and 200V. When the control circuit
voltage is 1OOV, install the wire on the primary side
as shown in the right diagram .
E
Primary side
~ Warning
Beware of electrification as the Ignition Transformer
conducts high voltage. AC200V
Avoid using it with rubber disconnected from the

boiler as it cannot be earthed, which would cause
the transformer to burn out.
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6-14 Flame Eye
1 Flame Eye
2 Fitting Box
3 Fitting Stand
4 Flame Eye Glass
5 Packing
The Flame Eye is a device that gives an indication to the combustion circuit by detecting the flame during
combustion and monitors the flame using its photosensitive characteristic (Normally, when a resistance of
1OOk 0 catches flame , it drops under 500 0) of CdS (Cadmium sulfide cell) .
The Flame Eye will not be able to catch the brightness of the flame inside the furnace when it is damaged
or the protection glass is blackened with soot. Such soiling could stop the burner as it produces the same
condition to failed ignition or mis-fire. The failure of the Flame Eye may be caused by soiled protection
glass if the flame dies out in about 3-4 seconds after combustion as the burner is ignited by turning the
burner switch to combustion while looking inside the furnace from the sight glass . Do not neglect cleaning
the protection glass at all times.
INote
Clean the protection glass regularly.
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6-15 Fuel Oil Heater
1. Electric Heater
A combination heater with electricity and steam as shown in the diagram is used as a standard to heat
up the heavy fuel oil to an appropriate temperature.
F.O. Exit Steam Inlet

I Safety Valve
Steam Outlet I
F.O. Inlet - ···11
Drain
The sheathed heater has a coiled nichrome wire in the center of the pipe and filled up with special
powders that have good heat conductivity and the electrical insulation at high temperature, and these wire
and powders are both solidified at high temperature.
In order to save the capacitance , the device is structured to heat up the outside of the heater body with
steam , and it preforms heater ability with the combination of steam and electrical heaters.
The volume of steam is controlled at the same time with the sheathed heater by switching the steam
solenoid valve On and Off in the Fuel Oil Temperature controller.
If sludge sticks to the heater, it wi ll become hard to control the unit, which could lead to incomplete
combustion, overheating, or other problems. Therefore, once a year you should clean the interior.
2. Solenoid Valve for the Steam Heater

CD
1 Coil
@
2 Spring
3 Plunger Assembly
4 Bonnet
5 Valve Body
6 Spring
7 Main Valve
8 Disc
The Steam Solenoid Valve installed to control the fuel heater's steam volume fo"r heating , and its structure
and part names are as shown in the above diagram.
When the Solenoid Valve is leaky or does not shut properly, it would cause problems, as the fuel oil
temperature would not be controlled.
Check to see if there is no damage to the valve or sheet and whether the coil itself has burnt out and carry
· out regular cleaning and check ups.
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6-16 Fuel Oil Temperature Indication Regulator
The appropriate heating temperature of fuel oil diffe rs by the viscosity of the oil. Determine the
temperature following the Heavy Oil Heating Temperature Chart.
[§} 6-18 Heavy Oil Heating Temperature Chart
Control Output Indicator Lamp

C. Green
Lights up when the control
~ ·c
output is ON .
CO HO LO
Reading Indicator Lamp

~ [ I D D Dj
PV. Red The value is decreases
Lights up when a reading is by 1 when pressed once.
indicated. The value decreases
when continuously
pressed.
Set Value Indicator Lamp
SV. Green
Lights up when a set value is
indicated. The value increases by 1
when pressed once.
Select Key The value increases
Used in changing the set when continuously
value. pressed.
Note
• Set up the data by pressing the key steadily with the fingertip .
• The data is automatiGally registered 3 seconds after it is set up.
• The indicator automatically reverts to indicate reading in approximately 30 seconds after set up.
• Do not press SEL key for one second or more. The data in the controller may chage .
How to set up the set value (SV)

Example : Changing the set value (SV) from 120°C to 130°C .
Key Operation Explanation Indication

SEL Reading indicated (PV)
~
The SV indicator lamp lights up when SEL is pressed once to indicate the
PV 'o' I ltl 21Ol
,...._ current set value.
SV 'o' I ltl21 Ol
~ Keep pressing until the changed value reaches 130.
(The value is automatically registered 3 seconds after set up)
SV'o' I ltl 3101
Reading is indicated (PV) when pressed once.
SEL {The reading is also indicated automatically in approximately 30 seconds
~
after set up without this operation) PV 'o' I lti 2IOI
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6-17 Thermostat (For fuel oil)
For High Temperature Alarm For Low Temperature Alarm
The Fuel Oil Thermostat (Automatic Temperature Regulator) switches the electrical switch on and off by
sensing the temperature, and uses a fluid with high expansion co-efficiency in its thermos sensor. When it
senses temperature, the expanded fluid and pressure inflates the diaphragm inside the body, releases the
lever to open the electrical contact and when the diaphragm deflates, the electrical contact closes .
The following thermostat is used for the HB-type boiler.
The Low Temperature Alarm Thermostat raises an alert when the temperature of the fuel drops below the
heating set temperature.
Set the temperature of the Low Temperature Alarm Thermostat 2o·c-3o·c lower than the heating
temperature.
The High Temperature Alarm Thermostat raises an alert when the temperature of the fuel rises above the
As the set temperature of the High Temperature Alarm Thermostat differs by the boiler specification and
combustion, refer to the completion drawing for correct temperature.
Once every three months, turn the dials to change the settings and perform a check of the electrical
system .
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Thermstat Adjustment
RTType Use the RT model shown at the left based on

your specifications.
Q) Adjusting Range
Rotate the Setting Knob to adjust to the specific
figure on the Graduated Dial.
1) Setting Knob
2) Setting scale plate
3) Differential Setting Disk
(g)Differential Control
Adjust differential pressures by using the Differential Setting Disk. The specified value should be
decided using the nomogram . Connect the main preset value (A) with preset differential value (B)
by straight line, and locate where it crosses with the differential value (C). This value should be
identified as preset value of the disk.
Nomogram to set differentials.

A. = Main preset value Note
B. = Preset differential value
Since the thermostat has been adjusted, do not try to
C. = Differential value
adjust freguently.
'C 'C
'C 'C 1.8
1.8 120 2
?0
130
00
I
140
I
90 150 10
12
100 A 10 160 A 14
8 1?0 16
110 .!!;> 8
.!!;> 18
15 180
120 20
190 22
130 24
20 200
26
140
210 28
RT 10? 25 215 RT120 30
150
35
6-18 Heavy Oil Heating Temperature Chart
Temperature ·c
100.000 - 10.000 10 0 10 20 25 30 3840 50 60 70 80 90 99 110
10,000
50.000 5.000
1.000 5.000
20.000 2.000
500 2,000
~
10.ooo ..: ·1.000
1.000
200
5.000 500 j:}
400 500 'cij
. 300 100
300
8
II)
2.000 200 5o 2oo e>

40 250 ::J
1.000 - .. 100
30 100 ~
-
700 .. .. 70 :g
20 70 ~
500 Vl
. ·. 50
100 50
300 40
u
Q)
u ~
Q)
25 200
~
(\J
d
z hl
zd
Q)
'0
w
0)
'0
0
0
100 -
0
0
;:
'0
"'
w
c
;: 90 Q)
0::
3-· 100
'0
Q) 80 ; 90
0::
70 .: 80
60 ..
2-
60
50 -
1.7 55
45 ~. 50
Viscosity of the heavy oil in
1.5
45 the burner'needs to be below
40
this line.
1.4
35 -
How to use this chart

To find out the required temperature of the
weight of viscosity in the burner nozzle at 50°C
(122"F);
1. First, find the point of viscosity of the used
oil and level it horizontally to 50'C (122"F) .
2. Next, draw a parallel line besides the
viscosity temperature line to Redwood No.1 60. 33 ot:t:,~oJtj2o=i=3~o=ti4o=i=5Lo±=sto:t±7o=tij8o:±=sloi=,o~o±=,~,oi=,H2~o=,t3oi=,4~o±,d5=o±,~s~o1,17=ol,~8o~19~oJ2~o~o62~1o~22~oL2~3lo2J4~o~2~5o~2s~o~27~o~2~8}o~2s~o~3oo
3. The vertical line drawn from the intersecting
point indicates th e required heating
temperature. Temperature "F
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6-19 Water level gauge and Water level control cylinder
~ Warning
As the water level gauge glass may be damaged due to aged deterioration , replace it on regular basis
(once a year)
The water level gauge is built in with the water level control cylinder as an integral-type as shown below.
1 Water Level Gauge Box 6 Hexagon Bolt

2 Gauge Glass Seat 7 Hexagon Nut
3 Gauge Glass Cover 8 Connecting Pipe
4 Gauge Glass 9 Water Level Control Cylinder Cover
5 Gauge Glass Packing 10 Drain Valve
Water level control cylinder is installed in the top and the bottom (on the steam side and water side) of the
steam drum by the valve and combines the water level gauge and water level control cylinder with the
gauge glass attached on the body.
The water level gauge is an important device for safety to check if the prescribed water level is kept in the
boiler. As the glass of the water level gauge always needs to be kept clean , clean it by blowing the water
level gauge at least once a day.
The water level gauge glass uses the reflective type and the size is different depending on boiler models.
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In addition to the water level gauge to check water level by eyesight, the level control cylinder has four (or
five) water level detecting rods (3) with different lengths inside the cylinder to electrically detect water level
and put out a signal to automatically start/stop the feed pump and stop the burner when the level is low.
The stainless detecting rod is screwed in the electrode holder and further tightened with setscrews.
As the water level detecting rod may get dirty with concentrated boiler water and cause malfunction , pull
the water out and clean it at least once a month .
1 Electrode Holder
2 Water Level Gauge Box
1 ) ----n~ ~
3 Water Level Detecting Rod
4 Drain Valve Flange
3
3)
s
M
L
Continuity and insulation check of the Electrode Holder LL

Check continuity and insulation of the
electrode holder every three months.
Continuity check @ --- @ 0 Q
4) :J .'==J
Insulation check @ --- @ 0.1 M Q or more
Replace the electrode holder periodically
(once/2 years) as it causes insulation and
continuity failure due to aged deterioration.
How to blow the water level gauge
1. Close the steam valve of the water level

gauge and open the drain valve to discharge
water in the gauge.
2. Close the drain valve and open the steam
valve.
3. Close the water valve and open the drain
valve to discharge steam and clean the water
level gauge.
4. Open the water valve and close the drain
valve.
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6-20 Exhaust gas thermostat
A thermostat is installed on the exhaust pipe of the boiler to detect the exhaust gas temperature and
electrically stop the boiler by raising an alarm when it detects abnormal temperature.
The thermostat is set to 450"C at factory shipment. The temperature can increase to 450"C or more due to
aging boiler, reduced efficiency by internal and external dirt and the exhaust gas temperature rise . When
the thermostat work in other condition , it can be faulty or something may be wrong in the combustion
chamber. Check is required inside the furnace . As is described in the internal structure section , water tube
is specially structured in the combustion chamber to enhance heat efficiency in the boiler and the upper
and lower water tube ends are filled with castable refractory. The castable refractory may drop if the boiler
frequently vibrates and backfires. As combustion gas will directly escape to the exhaust pipe from where it
dropped and cause exhaust gas temperature rise , periodically check the inside of the combustion
chamber.
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6-21 Pressure switch (for steam and fuel oil)
Steam pressure switch

ON-OFF control Oil Pressure switch
Pressure switch for steam

The pressure switch for steam is used for combustion control (high setting , middle setting , low setting).
The pressure switch for low setting cuts off the contact to stop high combustion when the pressure
reaches the preset level and puts on the contact again to start high combustion when the pressure falls
down to the differential preset level. The pressure switch for middle setting cuts off middle combustion
when the preset level and puts on the contact again to start middle combustion when the pressure falls
down to the differential preset level. The pressure switch for high setting cuts off the contact to stop low
combustion and the boiler when the pressure reaches the preset level. It puts on the contact again to start
low combustion when the pressure falls down to the differential preset level.
Pressure switch for fuel oil

The pressure switch for fuel oil is used for oil pressure drop alarm. It cuts off the contact, raises an alarm
and stop combustion when the pressure drops the preset level.
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Pressure Switch Adjustment

1. Range Adjustment
(1) SNS Type
Connection pressure goes up as scale shows
when pressure adjustment screw is turned left-
Spring regulator for Spring regulator
handed (Pressure adjustment spring is pressed.)
pressure difference for pressure
When connection pressure goes up , section
pressure goes up logically. Pressure adjustment
Pressure pointer
screw can adjust connection pressure and open-
Differential pressure pointer
close pressure difference cannot be adjusted .
Scale plate
2. Differential Pressure Adjustment
The difference between connection pressure and
section pressure can be widened when pressure
difference adjustment screw is turned right-handed
(Pressure difference adjustment spring is pulled) .
Pressure adjustment screw can adjust connection
pressure and pressure difference adjustm ent
screw can adjust section pressure . Pressure
difference pointer shows connection pressure on
scale plate and pressure difference pointer shows
open-close pressure difference.
(2) RT Type Section pressure = connection pressure - open-
close pressure ; because scale reading of above
adjustment procedure is based on A point, B
point is opposite.
1)
2)
3)
(RT Type)
1. Range Adjustment
Rotate setting knob to adjust to specific figures
on setting scale plate .
1) Setting knob
2. Differential Pressure Setting
Adjust differential using setting disk. Refer to the
3) Differential setting disk
left table to see the appropriate value.
1 2 3 4 5 6 7 8 9 10
1
RT 5 1} 1' 6 '2.
I
I
o'' 2. '4
:
2. 8 T3 . 2
I
3. 6 ~ . 0
I ba r
I I
o.13 1 o. p
I
.0. 7
I i I I I
i.I 1 I
I "l
RT 116 I I P· 91
1.; 3
ba r
I I "I I I I l
I l T
1 1 I I
1.
I I
1. 0 I 5 I 2 0 I2. 5 3. 0 I3. 5 4.0
RT 117 I ba r
I l l I I I l I T l
MIN. MAX .
1 2 3 4 5 6 7 8 9 10
I I I I I I I I I I
Relation between differential disk scale and differential pressure
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6-22 Safety valve
jt Warning
It is not allowed to change the outlet pressure of the safety valve .
The safety valve is a safety device implemented to prevent the boiler steam pressure from rising to the
maximum allowable working pressure and the full-bore safety valve is used for HB type. Normally, the
safety valve will not operate as the steam pressure switch work. ·In case the pressure switch does not
work for some reason , combustion continues and the steam pressure abnormally or abruptly rises due to
rapid load change, it protects the boiler by blowing steam off and lowering the steam pressure. Two or
more safety valve are installed and an adequate margin of safety is provided to the total relieving capacity
with more than the maximum amount of evaporation of the boiler.
The boiler's safety valve is set at the presence of
an auditor, so as to blow off at the strictly limited
pressure ; nobody should be allowed to make an
attempt of further adjustment on board. However,
only in case of emergency, such as when the safety
valve leaks , or some kind of appropriate
countermeasure can be taken on the judgment of
chief engineer discretion . In that case , the
following procedure should be followed to adjust
blowout pressure of the safety valve .
1 Valve Casing
2 Valve Seat
3 Valve Body
4 Adjusting Ring
5 Valve Body Cylinder
6 Lift Limiting Bush
7 Spring
8 Valve Stem
9 Adjusting Bolt & Nut
10 Cap
11 Lift Valve Lever
How to Adjust
1) Unlock the shaft on the (11) lift valve lever lever arm , pull off the shaft and take off the lever.
2) Take off the cap by loosening its setscrew.
3) Activate safety valve, while (9) adjusting nut is loose. (Check blowout pressure when the boiler gets
shifted to manual operation and steam goes up)
4) Rotate the (9) adjusting bolt to the left, if blowout pressure is higher than limited pressure , to the right ,
if it is lower, so that it blows off at the limited pressure.
5) After the adjustment, fasten the (9) adjusting nut tightly to fix it securely.
6) Put back the cap, restoring (11) lift valve lever, lock it and fix it.
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6-23 Duplex strainer (for fuel oil)
( ll Body
(il Cover
<._§) Cock Plug
(_4 ) Gland
(_5) Handle
(§) Gland
<j! Cock Shaft
(!l) Cup Nut
('l) Bridge
Qdi Adjusting Handle
on Screw Bush
oZI Column
(lJ) 0-ring
o4l 0-ring
QSl Nut
()Sl Pin Bolt
()7l 0-ring
Qffl Filter
Q9l Gauze Wire
(2(}) Bridge
~j) Bolt
The strainer is used to remove impurities such as dust
~ Gasket
and sand in fuel used for the boiler and to prevent them (2] Air Vent Plug
from entering the fuel pump, the electromagnetic valve (24} Gasket
and the burner nozzle and damaging them. It is installed (£5> Drain Plug
on the inlet side of the pressure pump.
(1) Operation guide

1) Close the line valve first before switching.
2) Then, rotate the@)Adjusting Handle counter-clockwise
a half-turn and lift the@Cock Plug .
3) Turn the@Cock Plug to the required direction with the®
Handle. Namely, if you turn the@Handle clockwise (see
diagram 1), "A" strainer stops oil while "B" strainer
Diagram 1
passes oil. If you turn it counter-clockwise (see diagram
2), "A" strainer passes oil while "B" strainer stops oil.
4) After switching , turn the @Adjusting Handle clockwise
to contact the@Cock Plug to theCDBody.
5) Open the line valve gradually to its fullest.
6) When "A" and "B" strainers pass oil, air accumulates
on the top of theQ)Body. Loosen the @Air Vent Plug
and check if air slightly flows out before closing .
Diagram 2
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Notes on operating and disassembling the strainer Removing and cleaning the filter
1) Check if the line valve is closed. Disassemble the strainer on the stationary side
2) Do not switch and disassemble the strainer according to the following steps.
without operating the Oadjusting handle. 1) Loosen the @air vent plug.
a) You may not operate the @handle to switch 2) Leave the @drain plug open.
when the @) adjusting handle is kept 3) Loosen @bolts after the oil has been drained
tightened. and remove the ® bridge and the @cap.
b) You may not disassemble the strainer due to 4) Hold the handle of the @filter to take out the
oil leakage on the stationary side when the tube.
@adjusting handle is kept loose 5) Clean the @gauze wire.
3) Turn the @ handle to the required position , 6) Assemble the strainer in the reverse order after
namely to the stopper position on the top of the cleaning . Build the filtering tube in the strainer
® column to switch it. Leaving t he handle body.
somewhere in-between causes oil leakage and 7) Close the @drain plug.
lets oil pass through both strainers . 8) Open the line valve gradually to its fullest and fill
4) Fully check if oil passes or stops by the position oil in the stationary side . Close the @air vent
of the @handle before disassembling . Then, plug if oil leaks from it.
loosen the @ air vent plug and check that there
is no internal pres~ure. Leave the @! drain plug
open and check if oil has been drained before
disassembling.
5) Never operate the @handle and the @adjusting
handle during disassembling.
6) After cleaning the filter, keep the stationary side
ready to pass oil anytime by assembling the
(filtering tube and the @cover and operating the
@handle and the @adjusting handle.
(2) Y-type strainer

There is a Y-type strainer at the fuel heater outlet and burner inlet. This is for removing contaminants in
the fuel oil that could prevent damages of solenoid valves and other parts. Depending on the condition of
the fuel oil, approximately once every three months, you should open the strainer, clean it, and check to
make sure there is no deformation or other damage to the element. If the element is damaged or
deformed , replace it.
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(3) Oil strainer for pilot burner
1) Draining Handle
Close the supply valve of the oil tank , then
loosen the drain release bolt at the bottom of the
strainer and flush out any water or contaminants
that have collected on the bottom.
2) Disassembly and cleaning
After making sure that the valve of the oil tank is
closed , remove the bolt at the top of the oil
Drain cock plug
strainer, then remove the cup section and flush
out any gunk on the filter plate with cleaning oil.
3) Air release
Open the valve of the oil tank and slightly tighten
the air release screw at the top of the oil burner.
Note
If, after releasing the air, oil starts to come out
from the place where the screw was loosened, Clean the oil strainer periodically.
then tighten the screw.
6-24 Feed water check valve

A check valve is provided in front of the feed water inlet valve to prevent boiler water from flowing back.
If the check valve leaks, the steam pressure lowers. Furthermore, when the feed water pump is activated,
high temperature in the pump generates air bubbles due to cavitation, disables pump operation and feed
water to the boiler and finally causes abnormal low water level. It is important to periodically check the
valve seat and valve element of the check valve and exercise care to reduce wear and tear. A set of feed
water check valve and feed water valve is attached on the upper and the lower drums. Use the upper feed
water valve under normal conditions.
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6-25 sequencer (Programmable controller)
1. Outline of the sequencer
The conventional sequencer is the one called hard wired logic (for short, hard logic) to compose a logic
(logical circuit) by wiring among devices composed of relays and timers.
A computer does nothing with the hardware alone and takes advantage of its function with software called
programs. It can also have various functions depending on how software is created. Namely, logic can
change by software even on the same hardware and the computer logic is subject to software logic.
Applying the same idea to the sequence control , we can replace "wiring" assembly of relay circuit logic
with software called programs. As software plays a role of wiring , it is called soft wired logic (for short, soft
logic).
To realize the sequence control with soft logic, we install a storage device (memory) on the hardware to
be able to load various programs on it exactly like a computer. Such devices designed for sequence
control is called a programmable controller or simply a sequencer.
2. CQM1 H unit explanation
CQM1H
Output unit
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- ~1 ___________M_~_R_IN_E__A_U_X_IL_~__R_Y_B_O~I_LE_R__________~
CD Names and explanation of parts of CPU unit
CQM1 H-CPU11
Battery storage cover / .......·-·-------.........................--~-- Slider

If you open the cover, you will Fix adjacent units.
find a battery and a front dip
switch .
Install the memory cassette
inside the cover. . LED display
Peripheral port
This is for connection with
mainly peripheral tools (CX-
Mate connectors of adjacent
Programmer, programming
units to connect them .
console) . Upward link and
NPP communication are also
available. CPU unit built-in 16-point input
If you open the cover, you will
find a 16-point input terminal
block.
How to open the battery storage cover
Insert your finger tip or a small slotted screwdriver into the ga_Q on the
bottom of the battery storage CD and open the cover upward (b).
Status of the dip switch
1 OFF
2 ON
3 OFF
4 OFF
5 OFF
6 OFF
7 ON
Battery I
Dip switch I
8 OFF
!
Memory cassette (option)

You will find a slot to install a
memory cassette on the back.
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Installing the memory cassette
CPU unit
Memory cassette
Insert a memory cassette along the slot and tuck it in until the connector is
engaged.
Turn off the boiler power to replace the memory cassette.
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1
® Replacement procedure of the built-in battery

Replace the built-in battery according to the following steps.
1 . Turn off the boiler power.

If the power is already OFF, turn ON the power once and leave it at least for 5 minutes.
2. Pull off the connector of the battery in the cover of COM1 H and replace the battery with a new one.
Once you have removed the old battery, install a

new battery within five minutes. If the power is not
supplied to the CPU for five minutes or more , the
stored data may be lost.
@Battery
A battery is built in the CPU unit.
The following data will be backed up by the battery.
• 1/0 memory (including PC system configuration)
• User programs
• Clock data (when the memory cassette with clock function is installed)
The battery lasts for 5 years in 25·c ambien ~ temperature . When the battery runs out, the front
ERR/ALM LED flashes. You need to replace it with a new one within a week , please contact to our
service engineer. Prepare a spare battery in advance.
@Input unit
An operation switch, a pressure switch on the detector and the thermostat will be connected to work
as a joint.
@ Output unit
An electromagnetic relay, an electromagnetic valve and indication lights are connected. Relay contact
output is adopted. You can check the operation status of output points with LED on the unit surface.
(The light is on when the output relay is on)
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3.Display function
I CPU unit built-in input relay (0-15) I (Yellow)

This indicates the ON/OFF status of the
input relay OCH built in the CPU unit (lights
H Error(ERR/ALM) I (Red) ..
r - - - - - - - - - - , up when the relay is on).
-·--·j Load rejection (INH)I (Yellow)
The light is on. ·I The light is on when the load rejection relay (25215) is on .
, Operation stops. ,; i1 All outputs of the output unit will be shut off.
I RUN LED lights out.
i L...........J Peripheral port (PRPHL) I (Yellow)
Y Alarm(ERR/ALM) I (Red) I Unavailable
The light flashes.
Operation eontinues. L_n····---1Built-in RS-232C port (COMM)I (Yellow)
Unavailable
LED Color Status Condition
CPU unit is running a program in "Monitor "

RUN Green D and "Run" mode.
• Under operation stop and irregular stop
CPU stops operating when an operation stop
D error is detected by self-diagnosis.

All outputs will be shut off.
ERR/ALM Red CPU continues operating when an operation

~ continuation error is detected by self-diagnosis.
• CPU is operating normally .

However, this LED lights out when WDT error occurs.
When the auxiliary relay for load rejection is on,

INH Yellow D all outputs of the output unit will be shut off.
D :Light on ~
•
:Flashing •
When the auxiliary relay for load rejection is off.
Light out
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4.Errors and their measures
Abnormal phenomenon Probable cause Measures
f POWERJ LED does not Loose connection of the power Terminal block: Correctly insert
1
light up. terminal block connector the connector.
Power line failure Replace CPU unit.

2 fRUNJ LED does not light up.
Program mistake Correct the program .
Loose connection of the unit Correctly insert the unit.

All output (input) units does not
3 Loose connection of the terminal Correctly insert the terminal
turn on .
block connector block connector.
All output (input) units does not Input circuit failure Replace the output (input) unit.
4
turn off.
External voltage is low. Use rated external voltage.

Output (input) units turn on Loose terminal screw Fasten the screw.
5
and off irregularly. Loose connection of the terminal Correctly insert the terminal
block connector block and lock it.
Output (input) operation indicator LED

6 LED failure Replace output (input) units.
does not light up.(normal operation)
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6-26 Flame detector (FS-100)
The flame detector is the relay to detect burner flame and take it out as an electric signal and includes
built-in operational amplifier, electrolytic capacitor, transistors, diodes, auxiliary relay and many other
electronic parts.
Terminal
Terminal block
Rating
1. Rated voltage : AC1 00/11 OV 50/60Hz
2. Permissible ambient temperature :-5·c -+55·c
3. Action
Output
..--,-----i ON
' I
----~~~~~ OFF
15 10.5
Flame eye resistance(k 0)
* Flame eye (Flame detecting sensor)·· · ···Cadmium sulfide cell (CdS)P621-03 type
4. Output :1 a relay contact

5. Basic connection
u
Power Flame detecting circuit
FR
4
I I
I I
b!
Output ~
Flame eye
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6-27 Water level detector (LM1-200)
(1) Outline
Q) Summary
LM1-200 is a water level detector which is an integral type of the conventional level detector
consisting of two switches and sequencer output without changing the sequencer program and major
connections.
~ Characteristics
LM1-200 is characterized as follows.
• 1OOV /200V voltage available
• No relay is used and open collector is used for output.
• IC(TC4584) for detection can be replaced .
(2) Rating
Q) Rated Voltage : 1 <!> AC1 OOV /200V 50/60Hz
Voltage variation : +10%~-15%
~ Permissible ambient temperature : -1 o·c ~+6o ·c
® Basic connection
......
..-
-
OFF
Water level detector LM1-200

-u
0
I :E
' 1-- ~
Logic circuit Q.
Level detecting circuit
n
c:
~ ;:::;:
; Semiconductor ciont~ct
I I I
} ,) f NPN-type
I
000 001 lOS 004 A. A, II C c. o. o. TC ! ov '•• 10~

T
TCIOH
'
.-.~
: ~OOY
f h
;o..~~
IDC: • .Ja
101 001 OOJ ... I
I
Sequencer input terminal I I - A,

Note) Irrelevant terminals are A.-
omitted . 8.
I L f - - 8,
C• c.
o. o.
BOILER WATER LEVEL
-
~
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7. Automatic operation of the boiler by the sequencer

7-1 Summary
Sequence control is an automatic control to sequentially perform a series of different operations different
from the set-point control that allows the feedback control to maintain controlled variable during operation
and the proportional control that maintains the ratio of two controlled variables at a constant level.
Speaking of this boiler, it activates the timer and relay to sequentially and automatically performs a series
of actions such as starting the feed water pimp and the fan motor, activating the ignition device after full
pre-purge , opening the fuel valve to ignite the burner, shutting off the ignition device and gradually
steaming up to terminate startup with a press of button .
7-2 Basic time chart

The following shows basic patterns for the steady operation , accidental fire during operation , ignition
mistake and safety activation in operating the boiler.
(1) Steady operation
!46s,l
Ignition transformer
Pilot solenoid valve ----+~
rl
=...,cJ....__ _ _ _ _ _ _ _ _ _ _ __
. : I~ 4S
Combustion solenoid valve -------;.--:1:"'"'--'""'~'""'

1
"<p_·_ r·"' "·"···"""""""---'""""""""'-'"""""="""---"'-

1
I
: Flame detection
(2} Flame failure during operation
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(3) Ignition failure
Combustion SW
Fan motor
lghition transformer
Pilot solenoid Valve I
I
I
I
I flame failure
Flame eye
Alarm bell
Turn off the combustion switch once or press the alarm reset button to reset operation when you
experienced the situation stated (2) and (3) .
Note
Time charts varies depending on specifications. See the final drawing for details.
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7-3 Flowcharts
HB Flow chart
NFBON Power lamp ON
YES Low Water

Low level lamp ON
Feed Water Pump Level
Run
NO
Combustion (B)
f-----+-1 Oil pump and
start button Fan Motor on
3-4B ON
Boiler Running Lamp on
Oil Heater SW
A Position is at...
Manual Reset
A/C C
Normal Temp
(A)
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(A) (B)
YES Alarm lamp

ON
""'0
.....
CD
-oc
.....
(!)
CD
Stand by
is
CLOSE
Reset SW Reset
ON
Misfire lamp ON
Ignition Trans OFF f----.-1
Pilot Solenoid
Valve OFF
YES Post-purge
Low Oil Pressure Post-purge

lamp ON
Pressure rise? Pilot Solenoid
Valve OFF
YES
('")
=! 0
3 3
rr
::::J c
(!) !!l.
w a·
:::J
0 U>
=!»
(f)
CD CD
()
('")
::r
~
=:::J
CD
(C)
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(C)
High Combustion
Middle Combustion
Low Combustion
(B)
CLOSE
Combustion stop
SW 3-48 ON
NFB OFF Running Lamp OFF
j
END
it CAUTION
When burner interlock alarm lamp illuminates, It will not have an automatic reset. Reset the unit manually.
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7-4 4-position control of the burner
Steam pressure regulated with Steam Pressure

(MPa) Steam Pressure Lines
a pressure switch (Instance)
Maximum pressure :0.9 :MPa

0.8
0.67 I
I ,1\ ;I!\
<
: / / / !''
} L
Normal pressure :0 . 6~0.8 :MPa 0.66 /• ' \7 .\ A 7 · i__ I

with Adjuster at High Pressure Setting
0.65
0.6 ' '
'
'
'
'
'
'
' '
: l JM
0.59 I I : '' ' : •"-7 : '' jE
--;-'
:
0
-r T
~·
:0.8 :MPa '' '' ''
''
''
'' ''
'
''
'
''
Differential :0.15 :MPa ''
''
''
''
'B• c:
''
! D c :! j : ::
i i) CBC~EA;3 c :
with Adjuster at Middle Pressure Setting U) C ® @ ~~ time
:0.67 :MPa
Differential :0.07 :MPa A:High Combustion B:Middle Combustion
with Adjuster at Low Pressure Setting C:Low Combustion D:Stop of combustion
:0.66 :MPa
Differential :0.07 :MPa
For boilers where the pressure is set as shown above, do the following:
1) When you start the boiler when it's low pressure, the burner will ignite after pre-purge .
For 30 seconds after ignition, conduct low combustion (C) so that there will not be a heavy load on the
unit. Once 30 seconds have passed , switch over to start Middle-High combustion (A) until the unit
reaches the set value of 0.66 MPa of the low pressure setting of the pressure switch, then go back to
middle combustion (B). After the pressure increases and the pressure on the middle-pressure setting
reaches the set value of 0.67 MPa, the unit will start low combustion (C). The steam pressure will
further increase, then when the pressure on the high pressure setting reaches the set pressure of 0.8
MPa, stop the burner and conduct post-purge for 60 seconds.
2) When the steam consumption increases on the load side , the pressure decreases, and the differential
(0.15 MPa) of the switch on the high-pressure side goes down (to 0.65 MPa) , the burner will ignite after
pre-purging , and low combustion will start (C) .
3) When there is rapid steam consumption on the load side and the differential of the middle pressure
switch (0.07 MPa) goes down to 0.6 MPa, combustion will occur so that steam consumption will be like
that at middle combustion.
4) When steam consumption continues to increase and the differential of the low pressure switch (0.07
MPa) goes down to 0.59 MPa, the steam generation will further increase to that at high combustion.
This cycle will repeat itself.
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8. Safety Assurance System

Lt Caution
The main boiler system is always alert for the
The specifications of your warning apparatuses may vary.
following malfunctions
Status Response by system How to reset
Ignition failure to burner Shut off burning appliances (ignition Reset button On
Burner flame out transformer, solenoid valve) in 3.5 seconds
1
False flame detected during burner Mis-fire, flame failure lamp lights on,Activate
stand-by (pre-purge) alarm bell. Post purge start
Lower water level Shut off burning appliances, Reset button On

2 (burner cut the water level) lower water level lamp lights on, (Reset after the
Activate alarm bell , Post purge start water level recovered)
Fuel oil temperature drop Shut off burning appliances, Reset button On
{lower than specified oil temperature F.O temp drop lamp lights on
3
set by thermostat) Activate alarm bell , Post purge start
F.O pressure drop (lower than specified Shut off burning appliances in 2 Reset button On
pressure set by F.O pressure switch, during seconds , Indicator light up for lower
4
burner ignition.) F.O press drop lamp lights on, Activate
alarm bell, Post purge start
Abnormal rise of exhaust gas Shut off burning appliances , Reset button On
temperature (higher than specified Exhgas high temp lamp lights on ,
5
temperature set by exhaust gas Activate alarm bell ,
thermostat) Post purge start
Fan stop {when thermal trips Shut off burning appliances, Operate thermal
6 due to overload upon draft fun) Fan abnormal stop lamp lights on , relay reset button ,
Activate alarm bell Reset button On
Abnormal rise of feeding water Shut off burning appliances in 2 seconds, Reset button On
discharging pressure {higher than Stop feed water pump ,
7 specified pressure set by feeding F.W press high lamp lights on, Activate
water pressure switch) alarm bell, Post purge start
Flame detected during post Shut off burning appliances , Reset button On
8 purge operation Abnormal fire lamp lights on , Activate
alarm bell , Extend post purge operation
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Abnormal rise of fuel oil temperature

Shut off fuel heater,
(higher than specified temperature
9 F.O temp high lamp lihjts on Automatic restoration
set by high temperature thermal alarm )
Activate alarm bell
F.O high temperature thermostat
Low water level lamp lights on

10 Low water level (Alarm level) Automatic restoration
Activate alarm bell
Abnormal CPU , Other abnormality Shut off every sequencer output such as
11 Power restoration
of the sequencer the feeding water pump,burning appliances
9. Manual Combustion Circuit
& Warning
In the manual combustion circuit, ignition error may cause dangers such as backfire, or over heat ; do not use
unless in emergency. In case of using , the following rules should be followed .
The manual combustion circuit is given as an option for emergency measure, in case the boiler is not
operated in the right order, or not operated , due to some control error of the sequencer, so that motors,
electric valves, ignition transformers, etc. can be operated to keep the boiler operation temporarily. The
following steps should be strictly followed during operation , and the malfunction should be detected as
soon as possible to return to normal, automatic operation .
The manual combustion circuit is divided into the following four circuits;
(1) Operation circuit
(2) Feed water circuit
(3) Combustion circuit
(4) Alarm circuit

Confirm that the power indicator (WL-1) lights up, by turning on a no-fuse breaker.
The feed water pump can be operated manually, by switching the feed water circuit (43WA) to the
above status. Originally, the On-Off of the feeding water pump is controlled automatically according to
the boiler water level.
In manual operation, where the feeding water pump can be operated regardless of the boiler water
level , the water level should always be checked using the water level gauge.
By shifting cam switch gradually, manual combustion can be established. Cam switch is positioned in
order at Off, F.O pump/heater, fun , ignition, Pri-combustion (combustion using the ignition transformer
pilot burner and main burner) and combustion (main burner only). Additionally, there is other
combustion switch , such as 4-position control , which can shift between low combustion, middle
combustion and high combustion. Single operation of any one appliance only should be prohibited for
safety; check operation by shifting cam switch into order.
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(3)-1. How to Use CAM Switch
(Figure) CAM Switch Sufficient Combustion

pre-purge Changeover
IGNmON lamp Switch
FAN MIDDLE
RUNNING
F.O.PUMP
HEATER
OFF
AUTO
COMB.
(Regarding Switches) 6. Pri-Combustion (Pre Comb.)

1. Auto (Auto Comb.) When you set the switch to PRI.COMB, the
Turn the CAM switch to this position and main burner will commence combustion .
turn on Auto Comb . Switch , to start Both the pilot burner and main burner will
automatic combustion using the sequencer. combust in this state.
2. Off (Stops combustion related operation.) 7. Combustion (COMB)
3. F.O. Pump/heater The pilot motor stops and the pilot
Dial the switch to F.O . Pump/heater, to solenoids valve close.
activate main F.O.P. and heater. The activation of the main burner solenoid
*Heater stops , either when fuel oil valve is held.
temperature exceeds the specified After established the low fire and then turn
temperature measured by the temperature the combustion change over switch to
adjustor, or when fuel shifting switch is middle and high fire position to get high fire .
turned to A heavy oil.
4. Fan Running
Turn the CAM switch to this position makes
draft fan start.
5. Ignition
~ Warning
Turning the CAM switch to this position The combustion change over switch should be
activates ignition transformer and pilot turned back to low position before restart the
· solenoid valve, to start pilot burner ignition . manual combustion.
Please change to middle or high combustion
after the low combustion is completely stabilized .
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(3)-2. Manual Combustion by CAM Switch
~ - Warning
In the manual combustion , ignition error may cause dangers such as backfire , or over heat ; do not use
unless otherwise emergency. In case of using , the following rules should be followed .
Start Combustion Stop operation

1) Turn Cam Switch to off position , to stop a) Return combustion change over switch to
automatic combustion. (Low Comb.) to reverse the above-
2) Shift fuel heater switch to A. Confirm that mentioned operation , and turn Cam Switch
combustion shifting switch is set at (Low counter-clockwise.
Comb.) . Keep running more than 60 seconds at
3) Turn Cam Switch to (F.O .Pump/heater) FAN position .
position. At this point, check that fuel is
properly circulating . (by pressure gauge) In manual operation as well , combustion is
4) Shift fuel heater switch to C, in case of C restricted by interlocking of safety system as
heavy oil , and make sure the temperature follows:
goes up to the specified level properly. If not, a) in case of flame-out, or ignition failure
stand-by until it reaches the proper level. b) when steam pressure rises
(A heavy oil should not require this step) . c) when the water level of the boiler goes
5) Turn Cam Switch to (Fan Running) position. down to lower water level
Make sure that draft fun is running properly. d) when the temperature of exhaust gas rises
6) Sufficient prepurge lamp should be e) when the fan motor stops
confirmed on. Combustion will be possible
after lighting the sufficient pre-purge lamp. In manual operation where there is not enough
7) Turn Cam Switch to (Ignition) position. Pilot inter-locking system for safety, pay attention to
burner combustion should be confirmed the boiler status carefully.
through sight glass, and combustion lamp. a) Take sufficient time for pre-purge before
If there is no combustion , immediately set manual operation and post-purge after
the switch to FAN RUNNING . operation . (more than 70 seconds)
8) Turn Cam Switch to (Pre . Comb) position . b) Run/or stop the feed water pump , while
After confirming combustion through sight checking the water level of the boiler.
glass, turn Cam Switch to (Comb.) position .
If it is not burning , return Cam Switch to
(Fan Running) right away.
9) Turn combustion change over switch to
(High Comb) , after confirming the right
status of combustion.
~ Warning
Sufficient purge should be conducted before igni-
tion ; lack of pre-purge can cause accidents such
as backfire .
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10. Inspection before operation and Operation

10-1 Inspection of every check points before operation
6. Are there any clogging or loosened parts at the
~ Warning connections throughout the fuel piping?
7. Are there any air in the fuel line?
The following points should be examined to pre- 8. Is not the fuel strainer clogged?
vent accidents. 9. Is oil properly running from every tank through
the fuel pump?
(1) Around The boiler 1O.ls the F.O booster pump working properly?
1. Is area around the boiler cleaned thoroughly? 11. Check thoroughly tor any leaks from the fuel
2. Is there any obstacles on the way? plumbing above the boiler.
3. Is there any flammable around the boiler? 12.1s every needle of the pressure gauge and
4. Is there air inlet, or proper ventilator? thermometer all right?
5. Is air pressure in engine room appropriate? It it (5) Burner
is negative, make it positive by adding another 1. Is installment of every equipment around the
ventilator. burner all right?
6. Is tire distinguishing system equipped? 2. Is the glass or flame eye not contaminated?
(2) The boiler and its Accessories 3. Is the ignition rod dirty, or is the size of each
1. Is equipment installation such as inspection part all right?
holes, covers , valves all right? 4. Is the lead wire from the ignition transformer
2. Is valve opening/closing , or switching of every through the rod , and each attachment all right?
drain valves all right? 5. Is the nozzle tip not clogged?
3. Is draining direction out of safety valve all right? 6. Are there any oil leaks before the injection?
4. Is not glass stained or broken on the water 7. Is a solenoid valve running properly? Are there
level gauge? any oil leaks, or is the installment of the exiting
5. Are needles of each pressure gauge all right? open/close type all right?
(3) Feed water system 8. Are there any deviance in the damper caused
1. Is the Cascade Tank filled with water? by loose screws or levers?
2. Is it dirty, or is there any oil in it? 9. Does the cam motor run properly?
3. Is automatic teed water valve (ball tap) function (6) Electricity
normal? 1. Does every motor of the draft tun , the water
4. Is switching of every valve tor teed water line all feeding pump, fueling pump, etc. run properly?
right? And/Or, does it turn to the right direction?
5. Does the switch No. on the control panel match 2. Is every value tor the thermostat (exhaust gas,
with teed water pump tor actual use? and fuel heater) , fuel oil temperature adjustor
6. Is there any clogging , air, leaking , or loose part and pressure switch specified correctly?
in pipes? 3. Is ignition transformer running normally? Does
7. Is not strainer tor sucking clogged? it generate any sparks?
8. Is not there any leaking from mechanical seal 4. Is the control panel not broken , or is every
of the teed water pump? attachment tool all right?
9. Are needles of pressure gauge and compound 5. Are there any disconnected lead wires , loose
gauge all right? screws, broken lumps or switches?
(4) Fuel oil system 6. Is voltage 440V(220V) provided tor regular
1. Is there oil in the service tank tor the boiler operation, and 1OOV tor operating the circuits?
(D.O tank and F.O tank)? 7. Are there not any disconnections throughout
2. Is the F.O tank heated properly? the external wiring of all equipment?
3. Is the F.O purified by the purifier? 8. Is every relay on the control panel running
4. Is the tank drained properly? properly? Or flame detector, every timer
5. Is every valve switching through the fuel piping running all right?
from the tank to the boiler all right? 9. Is the sequencer running?
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(7) Steam 4. Has the valve for excess steam dump va Lve
1. Is every valve line opening/closing of the boiler been installed? Or, is it set at the specified
all right? pressure properly?
2. Is overboard discharge valve closed? 5. Thoroughly examine other valve switching for
3. Is coding sea water flowing through the drain steam pipes , loosened parts around flange ,
cooler? before operation .
10-2 Operation (in case of automatic burner operation)

(1) Confirm operating switches for the boiler 6. Stop combustion , if there is any problem.
Make sure all the switches (incl. N.F.B) are set Check oil pressure, oil temperature, the damper
at the OFF position; if not, set it OFF. opening and buner nozzle.
(2) Feeding water to the boiler 7. If steam pressure rises , check for any leaking
' Always before starting burner operation, feed water from any parts.
to the boiler, following the procedures below: 8. When steam pressure rises up to specified level
1. Open all valves throughout systems from the set by pressure switch , examine combustion
cascade tank through the boiler. control if it works by following the order, from low
2. Let out air from the feeding water pump and combustion middle combustion high combustion
systems. middle combustion low combustion - stop.
3. The boiler power on. (NFB) 9. Stop combustion ... ... confirm . Is pressure
4. Set the feeding water pump at automatic (auto gauge running all right?
vs. manual shifting) and set No. 1 and No. 2 10.Suspend fan motor after 60 seconds post-
shifting switch at arbitrary ; to activate the purge .... Confirm .
feeding water pump, light up operation indicator 11 . Open main steam valve little by little, not to cause
lump, low and lower water level lamp, and bell water hammer, to supply through systems.
for low water level. ..... press on stop bell button. 12.Examine if there is any leakage in pipes of
5. Alert for noise of feed water pump/motor, and steam system .
overheat. (4) Termination with D.O (A heavy oil)
6. Are compound gauge and pressure gauge 1. Raise steam pressure close to the maximum
running properly? pressure for general.
7. Is it easy to view the water level gauge? Did 2. Close main steam valve.
the water feeding stop at the proper level? 3. Press down combustion stop button .
8. Double check against any leaking water around 4. Blow off the water surface, bottom of the water,
boiler body. and water level control cylinder.
9. Lower water level lump turns off by pressing 5. Close valve in the feed water system and 0 .0
reset the switch. valve.
(3) Combustion; Start from 0.0 (A heavy oil) 6. Close the valve , checking the amount of the
1. Close the air vent valve of the air separator, open cascade tank/oil service tank.
the booster pump return line valve to the D.O.tank 7. Turn off the boiler (NFB) .
and close the return line valve to the F.O.tank. (5) Switching fuel
2. Open the supply valve of the D.O. tank, close the e Switching from 0.0 (A heavy oil) to F.O
supply valve of the F.O. tank, open the inleVoutlet (C heavy oil)
valve of the booster pump and run the booster 1. Operate with 0.0 properly.
pump. 2. Raise F.O service tank to 80- 9o·c
3. Turn the heater switchover switch to the A side. 3. Open steam trace valve in the boiler fuel oil pipe.
4. Press combustion button . Be careful for F.O
pump motor, noise of draft fun , and temperature.
Pre-purge ... confirm ~ Warning
Start combustion ... combustion indicator lump lights on
Alarm bell for low temperature of fuel oil is can-
5. Pay attention to the following points during
combustion: celed , the moment heater switch shifted into
o Color of flame, expansion , stability "A/C". Stop the combustion , when inappropriate
o Color of smoke, any gas leak from its path fuel oil temperature causes faulty combustion.
o No vibration
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4. Temporarily turn off the boiler and booster (6) Cold Start
pump . Close the D.O . return valve of the When the water in the water heater body cools
booster pump, and open the F.O. return valve. down , or especially during test drive and using
5. Open slightly the air vent valve of the oil air new body, the following attention should be paid.
separator. 1. Do not raise steam drastically, when the entire
6. Close the supply valve of the D.O. tank, open the boiler cools down; it should take enough
the supply valve of the F.O. tank, and run the time before steam pressure is raised to
booster pump. 0.1MPa. Raise steam pressure gradually up to
7. Set the boiler to automatic operation , then 0.1 MPa by repeating 1 minute combustion and
when the oil in the pipe between the booster 4 minute purge. Hold 10 minutes at steam
pump outlet and the boiler F.O. pump unit pressu re 0.1 MPa. Between 0.1 MPa and 0.2
switches over to fuel oil (F.O.), turn the heater MPa (lkgf/cm 2 -2kgf/cm 2 ) repeat 2 minute
switchover switch to A/C. combustion and 3 minute purge to raise
8. Confirm that F.O temperature is raised up to the pressure.
proper level and that pressure is stable. 2. When it reaches around 0.2MPa (2kgf/cm 2 ) ,
stop the boiler, and retighten the screws and
9. Open slightly drain valve of oil air separator, to
nuts around connecting pints of each valves
check outgoing of F.O.
onto the water water heater body, manhole
10.When F.O temperature reaches close to the
packing and the water level gauge.
specified temperature, shift heater switch to "C".
3. Blow off the water level gauge to give the clear
11 . Confirm that there is no smoke in normal
sight of gauge .
operation.
4. Blow off the water in the water heater body, and
e Shifting from F.O (C heavy oil) to D.O
purify the water.
(A heavy oil)
5. When the above process is all done , t.urn on
1. Operate normally with F.O. the combustion switch to combustion again.
2. Open D.O supply valve , and then close F.O 6. When steam pressure reaches the maximum
supply valve quickly. pressure for general use , check if any steam
3. Close steam trace valve in the boiler fuel oil leaking .
piping . 7. Open main steam valve, to start automatic operation.
4. Shift the heater switch to "A", exactly when D.O (7) How to assure alarm bell
fills pipes from D.O valve through F.O pump unit. 1. Bell and lump for ignition failure
5. Open the D.O. return valve of the booster punp, Before burning burner, take off lead wire extending
then close the F.O. return valve. from transformer at upper burner, by pulling off the
6. Confirm that temperature at heater outlet drops cap. Burner flame out occurs due to no spark from
and pressure is stable. ignition rod. When it happens , check to see if
7. Close fully the air vent valve of the oil air flame off lamp lights up, switching off on burner
separator. circuit, and alarm bell rings after post purge.
8. Confirm outgoing D.O by opening slightly drain 2. Burner Cut for lower water level
valve of oil air separator. Drain the water inside , by opening drain valve
9. Confirm that there is no smoke in normal and closing upper and lower detective piping
combustion . valve on one of the water level control cylinder
the combustion. Make sure alarm bell goes off
in 10 seconds and burner is cut. After
~ Warning restoration of each valve , examine other side
for proper operation. Then restore each valve.
Stop combustion right away, when alarm bell
·rings or faulty combustion occurs at shifting
fuels . If any appropriate fuel oil temperature and ~ CAUTION
pressure is not given , manual operation should
be activated to operate heater, oil pump to reach Switch fuel to D.O (Heavy oil A) when the boiler is
the proper temperature and pressure. No manu- suspended for a long time. Low temperature F.O
al combustion should be attempted at switching (Heavy oil C) should lead to damaging oil pump,
fuels ; it causes accidents such as backfire. its mechanical seal, solenoid valve and heater.
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11. Regular Maintenance
~ CAUTION
Carry out conduct the following maintenance regularly.
11-1 Regular Maintenance

Item Maintenance Point Frequency
Feeding Water 1. Cleaning of inside of the cascade tank When docked

System 2. Cleaning of filter of the cascade tank inside Every 6 months
3. Cleaning of strainer/suction side of feeding water Every 2 months
4. Over hauling and inspection of the feed water check valve Every 6 months
5. Checking of'feed water pressure compound gauge On demand
6. Cleaning of water level detecting rod, electrode holder. insulation and resistance check Every 3 month
Fuel System 1 . Examination/cleaning of the inside of the fuel service tank When docked
2. Drainage of the fue l service tank Every day
3. Cleaning of the fuel strainer Every 1 week
4. Cleaning of the strainer inside fuel oil pump (Pilot pump) Every 1 month
5. Inspection/cleaning of fuel oil heater element On demand
6. Opening fuel oil pump (contact manufacturer) On demand
7. Major cleaning/exam of the fuel heater Every 1 year
8. Inspection/adjustment of the fuel oil thermostat and Temperature indicator/adjustor Every 3 months
9. Inspection/adjustment of the coupling for fuel pressurized pump Every 2 months
10. Cleaning of Y-type strainer Every 3 months
Burner system 1. Inspection of the fuel oil solenoid valve Every 3 months
2. Check for any leakage of the burner nozzle Every 3 months
3. Maintenance of the burner body (baffle and rectifier grid) Every 1 week
4. Inspection/adjustment for ignition rod Every 1 week
5. Inspection of the nozzle tip Every 1 week
6. Inspection of the air register Every 3 months
7. Inspection/adjustment of the motor related parts of the damper Every 1 month

8. Inspection of the dirt on flame eye/glass Every 1 month
9. Inspection of the draft fan and ball bearing On demand
10. Window box insulation On demand
Storage Water 1. Inspection within the boiler (from manhole) Every 1 year
Heater Body
2. Inspection within combustion chamber When burner is extracted
3. Inspection within exhaust line Every 1 year
4. Every type of valve attachment Every 1 year
5. Blow ·of the water level gauge and control cylinjer Every day
6. Blow of the surface/bottom of the boiler Every day
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Electricity 1 . Check insulating resistance of the relative motors over 1M Q Every 3 months
2. Inspection of the ball bearing of the each motors Every 1 month
3. Check resistance of the water level detector and holder Every 3 months
4. Operative test for burner interlocking Every 3 months
Burner Control Panel

Cut Alarm Bell Display
Ignition failure and/or mis-fire 0 0 0
draft fan suspended 0 0 0
heavy oil pressure goes down 0 0 0
heavy oil temperature goes down· 0 0 0
water level drops specified low water level X 0 0
exhaust gas temperature abnormally goes up 0 0 0
the feeding water pump delirery pressure abnormally rises 0 0 0
water level drops specified lower water level 0 0 0
heavy oil temperature abnormally rises X 0 0
Sequencer malfunction 0 X 0
Power shut off 0 X X
Refer to the final drawing archive of each boiler for details Every 3 months
5. Various automatic control test Every 3 months
*Automatic start/stop of the feed water pump Every 3 months
*Check 4-position control of the boiler Every 3 months
*Oil temperature control of the F.O. heater
11-2 Inspection and Precautions Before Starting 11-41nspection After Operation

Operation
1. Be aware of the oil level, heating temperature 1. Check for every water or oil reservoir
and drainage in the fuel tank 2. Check water level gauge instruction and steam
2. Check the cascade tank level and cleanliness · pressure
3. Gating of the valves for water feeding and fueling 3. Check fuel tank level.
4. Check the water level of the storage water tank. 4. Check gating of every system valve
5. Check steam pressure 5. Check the power switch.
6. Make sure every switch on the control panel is OFF.
11-31nspection and Precautions during 11-5 Water Treatment
operation
1 . Be aware of overheat, motor sound, vibration of accessories The details are shown in the accompanied "Manual
2. Be aware of pipes/tubes leaks for Water Treatment".
3. Be aware of flame color, sound of burning, vibration Be aware that most of the water tube accidents come
4 . Ensure if pressure gauge, pressure switch, and from faulty water treatment. Through understanding
thermostat are working properly. of the instruction book it should contribute to good
5. Examine if the water level gauge is visible, and management. The instruction book refers to how to
be aware of the water level change .
preserve the water tank, in case of a long-term shut-
6. Check against earth in the motor system .
down, as well.
7. Check against any vibration of the control panel
8. Ensure that the water feed pump stops/starts normally.
9. Check if there is any overheat around the boiler [7 Refer to the "Manual for Water Treatment" .
body or other parts.
10. Check condensed water temperature and see if
there is any condenser overheat
11 . Ensure that the ampere meter gauges correctly.
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11-6 Long-term Shut-down
~ Warning
Be aware that non-compliance of the proper procedures may damage the boiler rapidly or cause corrosion.
Details should be consulted with MIURA's service engineers.
The following shut-down procedures should be conducted , when the boiler will not be used for a long
time. Put the boiler compounds directly into the cascade tank. Make sure that water PH is higher than
11 . Then , start the boiler to raise its steam pressure up to 0.2MPa(2kgf/cm 2 ) . Upon reaching that level ,
close the water feeding valve and the main steam valve. Then , stop the boiler operation .
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12. Troubleshooting
~ CAUTION
Details should be consulted with MIURA's service engineers.
12-1 Feed water system

(1) When the water feed pump does not run. blocked
0 The power is not on. o Malfunction of the pressure gauge
0 Failure of 88W1 or 88W2 (Magnetic contactor 0 When the boiler is full due to feeding water
water feeding pump switch), or 43W (shifting control failure
switch); when thermal relay (49WI or 49W2) is (6) Water leaks from the feeding water pump
activated. o Failure of the mechanical sealing
o Stain on electrode rod or lead wire disconnected o Failure of the 0 ring of each cover
from electrode rod 0 Failure of the cock to let air, connection
o Motor burnout or disconnected coil failure of the pipes around pressure gauge
0 Burnout of the bearing , mechanical seal , or (7) When the water feeding pump does not
impeller start/stop correctly or respond to the
0 Failure of the feed water change over switch specified water level.
(2) When the water feed pump run, but pilot o Disconnection or fault in the wiring of the
lamp does not. lead wire and the water level detective rod
o Failure of lamp and socket o Failure in conduction at crossing point of the
0 Failure of 88w1 or 88w2 of magnetic water level detective rod and lead wire , due
contactor for feeding pump. to its corrosion (in some cases tester cannot
0 Disconnection and connection failure . show faulty conduction and it seems all right ;
(3) When the water feeding pump generates still may lead to failure , due to small current.)
abnormal noise or heat. 0 Loosened attachment of the terminal block
0 Burn of bearing . o When the water level detective rod is dirty
o Burn of mechanical seal or impeller, and object and/or it touches the cylinder body.
mixing. o When the water detective rod falls off holder,
o Elimination of impeller key. due to vibration etc.
0 Impeller and guide plate are not balanced. o Failure of 88W1 , W2 (feeding water switch)
o Single operation by insulation failure of motor o When valve of the water level control tube is
and magnetic contactor failure . blocked
(4) Failure in the water feeding pump suction 0 When the water level control stand pipe is
0 When air is mixed in out during suction, or blocked
air is not completely out o When the water level cannot be indicated
0 No water in the cascade tank correctly, due to dirty glass of the water level
0 Clogged water feeding line and/or strainer, gauge
etc. , or big resistance from suction o When priming or foaming is incurred by
0 When the cascade tank is installed lower concentrated water, etc.
than the water feeding pump 0 Failure of LM1-200 (water level detector)
0 When cavitation is incurred due to reversed (8) When the water level cannot be identified
water or abnormally high water temperature o Dirty glass of the water level gauge
0 Lack of capacity due to abnormally weary 0 When the boiler water is fully filled in the
impeller or/and guide plate of the feeding water level gauge .
water pump o When the valve of the water level gauge is
o Low alarm bell may go off against lack of blocked or not open
feeding water in time when priming is (9) the water level gauge leaks
incurred by concentrated water o Failure of the glass packing
(5) When blowout pressure of the feeding o Failure in attachment of the water level
pump is too high. gauge glass or fastened unevenly
o When valves or pipes on blow-out side are
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12-2 Fuel System

(1) Fuel oil pump does not run. (4) Fuel oil temperature does not rise.
0 Fuel oil pump magnet contactor 880 is defective. 0 Mixing of air.
0 Fuel oil pump switch thermal relay 490 is actuated. o Temperature setting of thermostat 23T is too low.
0 Push the start button 3-48 is defeotive or not 0 Defective thermostat 23T.
turned ON . 0 Disconnection of heater heating coil.
0 Rotor is seized or foreign matter is present. 0 Defectfve steam heater solenoid valve.
o Bearing is seized or shaft is locked . o Fuel heater swrtch 43H is defective.
o Defective coupling. 0 Defective combustion start button 3-48 or
o Motor main body burned , single-phase not being pushed ON .
operation or disconnection of external wiring . o Decrease in capacity of heater due to its
(2) Fuel oil pump sounds loud or is overheated. stained inside.
0 Pump cavitation or excessively-high (5) Fuel does not spray.
discharge pressure. 0 Defective fuel solenoid valve (for circulation
o Clogging of discharge piping , valve, or so on . or combustian) .
0 Air mixing from suction side. 0 Clogging of nozzle tip (Filter, screw pin, etc)
0 Shaft locking or rotary section seizure. o Leakage from fuel piping or joint or clogging
o Vapor locking due to excessively-high fuel oil of pipe.
temperature. o Improper discharge pressure of fuel booster pump.
o Excessive draining of fuel oil. o Excessively-high fuel viscosity ... lock of
0 Misalignment of pump and motor center lines. heating .
o Damage of shock absorbing rubber coupling. o Defective fan switch 88F or defective contact.
(3) Discharge pressure of booster pump is too (6) Will not go on high fire.
high. o Defective steam pressure switch 63.SL
0 Defective pressure gauge. (Defective contact) .
o Improper pressure adjustment. o Defective fan switch 88F or defective contact.
0 Clogging of discharge side piping or valve . 0 Defective of damper motor and link adjustment.
0 Clogging of nozzle pipe.
o High fuel viscosity... Excessively-low heating
temperature.
12-3 Combustion
(1) Fan does not run. o Oil pressure drop in about 10 seconds due to
o Defective fan switch 88F. defective solenoid valve.
0 Thermal relay 49F of fan switch 88F is actuated. 0 Wrong flame detecting position of flame eye.
o Steam pressure rises above steam pressure 0 Flame blowout due to excessive airfow.
switch set pressure. 3. Oil pressure drops and fire goes aut.
0 Defective combustion start button 3-48 or 0 Defective fuel solenaid valve and oil pressure
not being pushed ON . switch.
0 Motor burned out , disconnection , or 0 Oil leakage from fuel piping . Clogging of filter
defective bearing . or strainer.
(2) Ignition failure o Water evaporation in fuel (vapor locking) .
1. Fire goes out after burning far 2 or 3 seconds. o Long distance between fuel tankand booster
0 Defective flame eye or stained lens. pump and small diameter of piping makes
0 Improper ai.r flow adjustment (Imp roper high viscosity oil ditficult to flow and causes
damper adjustment). oil pressure drop.
0 Defective fuel solenoid valve. 0 If no steam trace is provided on the above
o Improper position between nozzle tip and piping , oil in line is cooled and becomes
baffle plate. ditficult to flow. This causes oil pressure drop
2. Fire goes out aftef burning for about 10 seconds. Therefore , pay special attention to high
o Improper position relative to the nozzle tip, viscosity oil.
baffle plate, and flame funnel.
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4. No firing at all (8) Dark purple flame, dark furnace inside, and
0 Improper air flow adjustment (Flame blowout black exhaust gas.
due to excessive air flow) . o lnsufticient air flow rate.
0 Improper of damper motor limit switch and o Excessively-large nozzle tip or widely-varied
adjustment. spray angle.
0 Improper dimensions of burner main body. o Low oil temperature.
0 Inadequate fuel supply and no oil pressure o Air register is burned.
rise (Refer to Item 12-2 (5).) o Combustion chamber is sooted inside and
0 Boiler not filled to specified water level. high furnace pressure.
o Clogged . nozzle tip and no fuel spraying . o Damper is closed Even if damper mechanism
(Defective oil pressure switch). functions properly, damper main body does
0 No ignition spark emitted. Defective ignition not work or slips out of position.
transformer or lead wire . Or leakage from 0 Improper burne r adjustment Improper
lead wire and spark rod . positional adjustment with regard to the
o Improper gap at end of ignition rod or spark baffle plate, ignition insulator, nozzle tip and
emitted at position other than end of ignition rod . air register.
0 Defective solenoid valve or dust present. o Negative air pressure in engine room.
(3) Mis-fire during combustion o Reverse rotation of fan .
0 Oil temperature drop and actuation of low- (9) Abnormal white smoke.
temperature alarm thermostat 220. o Excessive air flow.
0 Lower water level condition. 0 Fuel consumption too small or clogged.
0 Damaged flame eye or stained lens. o Improper burner adjustment Improper positional
0 Inadequate fuel supply. adjustment with regard to the baffle plate ,
0 Clogging of fuel system . (Oil pressure drop ignition insulator, nozzle tip and air register.
or no spraying). o Excessive opening of damper. (Even if damper
(4) Being burned but combustion indicator functions properly, it has some slippage from
lamp does not illuminate . damper main body during movement.)
0 Damaged indicator lamp or defective socket o Excessively-high oil pressure.
or poor contact. (10) Vibration during combustion.
(5) The steam pressure rises to specified 0 Air mixing in fuel.
pressure, but the combustion does not o Improper burner ignition position. (Ignition
stop. Or it stops at pressure different from delay occurs .)
specified pressure. 0 Excessively-high or -low oil heating temperature.
0 Steam pressure does not reach pressure 0 No adaption of fuel consumption size to air
switch set pressure. flow.
o Steam pressure switch is not in accordance o Oil leakage and burning in combustion
with pressure gauge indication. chamber.
o Defective steam pressure switch . 0 Damaged flame funnel.
o Defective contact of steam pressure control 0 Oil leakage from burner nozzle during
auxiliary relay 63SX. circulation .
o Defective solenoid valves 20VR, 20VL and 20VH . 0 Improper main solenoid valve (N.O)
(6) Unstable flame (Uneven flame) o Slow oil pressure rise (Ignition delay occurs.)
o Low fuel heating temperature. 0 Insufficient air flow.
0 Excessive air flow. o When the fuel quality changes significantly,combustion
o Improper size selection or stain of nozzle tip. condition rriay also be easily aftected.
o Improper fitting or misalignment of burner.
0 Misalignment of baffle plate to air register.
o Low fuel pressure or unstable pressure.
(7) Flame contacts against water tube wall.
o Improper selection of flow disc set or widely-
varied spray angle.
o Excessive air flow or excessively-high oil
pressure.
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12-4 Safety control and alarm circuit
(1) NFB is ON, but the boiler does not start. (4) When ship rolls, water level becomes lower
o Power is not turned ON . one and burner stops immediately.
o Damaged NFB. 0 Defective water level detector LM1-200.
(2) Combustion start button is pushed, but the 0 If both water level control cylinders are
combustion does not start. biased to port or starboard side due to boiler
0 Low low watef level (LOW low water level installation position , electric wiring should be
alarm lamp illuminates.) changed .
o Burner switch 438 is set at Manual. Or o Wrong connection of lead wire with water
manual operation switch is not turned OFF. level detecting rod terminal or disconnection.
o Steam pressure rises to set pressure of high (5) Ignition tails, but ignition failure lamp does
set pressure switch 63S. not iliuminate. Alarm does not sound either.
0 Refer to Item 13-3 Combushon. o Detective flame deteotor FS-1 00.
(3) Water is low low level, but no indicator lamp 0 Defective lamp or socket. Detective bell.
illuminates. Alarm bell does not sound o Defective bell stop switch 3-288.
either.
o Defective lamp or socket.
o Defective bell stop pushbutton switch 3-288.
0 Defective mainbody bell.
Simple causes of problems are described above During boiler operation, unexpected troubles may occur
including troubles with the sequencer itself which is in charge at control. Therefore, pay special attention
to a meter value, pressure gauge indication, heating and abnormality of components , so that abnormal
symptoms can be discovered in the early stages.
With regard to electric items, check terminal screws for looseness, lead wires for damages regularly to
prevent any possible troubles.
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ADDITIONS and CORRECTIONS to INSTRUCTIONS

6-9 (4)Air volume adjuster and damper
An air volume adjuster is provided to adjust the air volume according to respective combustion volume.
The conventional air volume adjuster has used a plate spring for its mechanism , however, a plate type,
which allows for easier adjustment, is employed for the HB-15/18 type . Adjustment procedures for the
plate type are described.
For adjusting procedures for the plate spring type, refer to page 23 in the Instructions.
Procedure for air volume adjustment (HB-15/18)

1) Loosen two screws the fixing the adjusting plate.
2) Turn on the burner fan to check damper opening at low combustion position.
Adjust damper arm (A) so that the damper opening degree is 10 to 12· .
3) Make burner burn to adjust air volume for high combustion.
For air volume adjustment, slide the position of the adjusting plate with the adjusting screw located on
the side of the adjusting plate .
Turning the adjusting screw to the right increases the combustion air volume.
Turning the adjusting screw to the left decreases the combustion air volume.
4) After adjusting combustion , tighten the right and left fixing screws fixing the adjusting plate.
NOTE
For tightening the fixing screw on the adjusting screw side, fix at a position where the end of the fixing
bolt is flush with the nut surface. Excessive tightening may cause damage to the adjusting screw.
Air volume adjusting plate Fixing screw(A)

PROPORT J9.~~.1:: ...-~0NTRO L UN LL
\
\
' \
DAMPEfL_ _~~~J!~L_ \
DAMPER LE VER (0) \ \
-·-----·--·--···----~
DAMPER ARM (A)

···-··-··········--\
\
\
DAM~-~R. .....l::.£:.:..\/ ER (A ) \ ·: .
t;~~g-~--1}'-F----x
Adjust screw
/
I
Fixing screw
DAMPER LEVER (B) /
HB-18
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DOMESTIC SERVICE STATION

*HEAD OFFICE:
MIURA CO.,LTD.
SHIP MACHINERY DEPT. 7,Horie, Matsuyama, Ehime, TEL: (+81)89 979 7066
Japan, 799-2696 FAX : (+81 )89 979 7067
*BRANCH:
TOKYO MAINTENANCE DIV. 2-15-35 Takanawa, Minato-Ku , TEL: (+81)3 5793 1047
Tokyo, Japan 108-007 4 FAX: (+81)3 5793 1045
SHIMANAMI MAINTENANCE DIV. 5-1-9 lmazu-Cho, Fukuyama, TEL: (+81 )84 930 0740
Hiroshima, Japan 729-0111 FAX : (+81)84 930 0741
KYUSHU MAINTENANCE DIV. 3-21-45, Naka, Hakata-ku, TEL: (+81 )92 432 3277
Fukuoka, Japan 812-0893 FAX : (+81 )92 432 3278
*AUTHORIZED DISTRIBUTORS:
N.Y.CO.,LTD. 1-4-26, Takanawa Minato-Ku, TEL: (+81)3 3449 3821
Tokyo, Japan, 108-0074 FAX : (+81 )3 3440 0944
CHUOKIKI CO. ,LTD. 4-28-2, Abraya-Cho, Minato-Ku, TEL: (+81)52 383 3166
Nagoya, Aichi , Japan, 455-0824 FAX: (+81 )52 383 3607
OVERSEAS SERVICE STATION
MIURA SOUTH EAST ASIA PTE. LTD. 26 Boon Lay Way #01-81 Tradehub21, TEL: (+65)6465 1147
Singapore 609970 FAX : (+65)6465 1148
OVERSEAS NETWORK
1.CHINA 6.TAIWAN
IHI MARINE (SHANGHAI) CO., LTD. HU CHERNG (HU CHWAN) MARINE
Room No.706-707, Information Tower No.1403 ENGINEERING CO.,LTD.
Minsheng Ad , Pudong New Area, Shanghai, 200135, No.18, Lane 5, Chung Chwan Rd . Keelung , Taiwan
P.R.China Tel : (+886) 2 24225747
Tel : (+86)21 6351 8029 Fax: (+886) 2 24261018
Fax: (+86)21 6351 8028 MING VUNG MACHINERY.,LTD.
2.GERMANY 27.Shin Shing St. , Van Cherng District Kaohsiung ,
TAKNAS MARINE ENGINEERING GMBH Taiwan
"Fruchthof" Oberhafenstr.1 20097 Hamburg~, Germany Tel : (+886)7 521 6266
Tel : (+49)40 32 1305 Fax : (+886)7 521 9368
Fax: (+49)40 33 0608 7.THE NETHERLANDS
3.KOREA NICOVERKEN HOLLAND B.V.
DONG YANG ENGINEERING Algerastraat 20 3125 BS Schiedam, The Netherlands
#1 0-11 ,2Ka Myeong-Ryun-Dong Dongrae-Ku Susan, Tel : (+31)10 2380999
Korea Fax : (+31)1 0 2380990
Tel : (+82)51 552 6503 FUJI TRADING (MARINE) B.V.
Fax: (+82)51 557 4830 Kortenoord 2-8 3087 AR Rotterdam , The Netherlands
MSK (MIURA SERVICE KOREA) Tel : (+31 )1 o 429 8833
103-1 , Sando Skyview 122 Gwangjang-5Gil, Dong-Gu, Fax : (+31)10 429 5227
Susan 601-836, Korea 8.UAE (DUBAI)
Tel : (+82)51 961 7771 MIDDLE EAST-FUJI (L.L.C.)
Fax: (+82)51 961 7772 P. 0 . Box 19227, Dubai, U.A.E.
4.PHILIPPINES Tel: (+971)4 347 4444
PHIL-NIPPON KYOEI CORP. Fax : (+971 )4 347 2771
S-705 Royal Plaza Twin Towers 684 Romedios St. , 9.USA
Malate Manila, Philippines CISCO BOILER SERVICE CO., INC.
Tel : (+63)2 400 5778 5709 Old Spanish Trail Houston, TX 77023, U.S.A.
Fax: (+63)2 400 9130 Tel : (+1)713 928 5700
5.SINGAPORE Fax : (+1)713 928 5795
TAKNAS ENGINEERING PTE.LTD. INDUSTRIAL BOILER SERVICE, INC.
102, Pandan Loop, Singapore 12831 0 23132 East Echo Lake Rd ., Snohomish, WA 98296,
Tel : (+65)6777 5856 U.S.A.
Fax: (+65)6779 6711 Tel: (+1)206 6241171
FUJI HORIGUCHI ENGINEERING PTE.LTD. Fax: (+1)206 483 9112
24 Chia Ping Rd ., Singapore 619976 10.VIETNAM
Tel : (+65)6863 6368 SHM-VLK CO. ,LTD
Fax : (+65)6863 8310 64 D2 Street, Van Thanh Sac Precinct, Ward 25,
Binh Thanh District, Ho Chi Minh, S.R. Vietnam
Tel : (+84)8 3512 8379
76
SAFETY, OPERATING & MAINTENANCE INSTRUCTIONS
MARINE AUXILIARY BOILER - HB-08, 10, 12, 15,18
Published by MIURA Co .,Ltd. Ship machinery Dept. September 2003.
11 'h edition May. 2009 . No. E990-0309-11
All rights reserved , Copyright © 2009 MIURA Co ., Ltd.

No part of this publication may not be reproduced , transmitted , distributed or
modified, in any form or by any means, without the written permission of the
publisher MIURA Co ., Ltd .
Visit us at www.miuraz.co .jp and get the latest information and Service News!
Printed in Japan
SAFETY,OPERATING&MAINTENANCE .
INSTRUCTIONS

H8-0ST, 1OT, 12T, 1ST, 1ST
STEAM ATOMIZING BURNER
E990-0706-05
MIURA
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HB-08T, 1OT, 12T, 15T, 18T
STEAM ATOMIZING BURNER

MANUAL
Introduction
Thank you very much for selecting HB-T Boiler.
This manual gives you instructions on how to use Steam Atomizing Burner for HB-T Boiler. In using the
boiler,. make sure you choose a person in charge of handling the boiler (Engineer) and use the boiler after
perusing the manual and understanding the contents. In addition, we recommend you to have this manual
at hand whenever you work.
The main contents of this manual are: Main specification of steam atomizing burner only, of HB-T Boiler,
Adjustment procedure, Maintenance, Trouble and countermeasure.
Please refer to the Instruction of Boiler about maintenance of equipments that is not mentioned.
Do not use the boiler by methods that are not m~ntioned in this manual.
Please be aware that we cannot be held responsible if the boiler is used by methods not mentioned in this
manual.
As a result of tireless research for improvement involving the design of Boiler, there are details that do not
correspond to the p~oduct you have purchased. Please note that the contents of the manual may change
without notice.
If you have any inquiries concerning the product you have purchased or about the contents on this manual,
please do not hesitate to contact us.
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CONTENTS
1. Basic Precautions · · · · · · · · · · · · · · · · · · · · · · 3
2. Terms · · · · · · · · · · · · · · · · · · · · · · 4
3. Part name and function · · · · · · · · · · · · · · · · · · · 6
3-1 Burner Assembly
3-2 Fuel piping, Atomize steam , Atomize air piping Assy details
3-3 Main Burner Nozzle
3-4 Pilot Burner
3-5 Ignition Transformer
3-6 Nozzle Tip for pilot burner
3-7 Fuel piping drowing around Burner
3-8 Proportional ·control of Burner
4. Operation · · · · · · · · · · · · · . . . . . . . . . . 13
4-1 Inspection before operation and Operation
4-2 Operation (Automatic Operation)
4-2-1 Cooling Start
4-2-2 Switching fuel
4-3 Stop
4-4 Operation in emergency
4-5 Poeration (Manual Operation)
5. Regular Maintenance · · · · · · · · · · · · · · · · · · · · 19
6. Troubles, Causes and Countermeasures · · · · · · · · · · · 21
7. Equipment name, function and Adjustent · · · · · · · · · · · 22
7-1 Combustion control unit
(1) Control system
(2) Flow control valve and Air flow controller
(3) Cam. motor
(4) Steam Pressure Controller
7-2 Solenoid Valve 26
7-3 Fuel block valve (Main)
7-4 Pressure equaizing valve
7-5 Fuel Pump
7-6 Auto cleaner
7-7 Flame Eye
7-8 Fuel Heater
7-9 Fuel Oil Temperature Indication Regulator
7-1 0 Thermostat (For fuel oil)
7-11 Heavy oil Heating Temperature Chart
7-12 Pressure Switch (for steam Atomizing, Fuel Oil)
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MARINE AUXILIARY BOlLEA.
1. Basic Precautions
1-1. Carry out a check before using the device

Check the pipe system diagram of the completion drawing and the system of the vessel. Do not operate
the device with the wrong system as this could lead to serious accidents. Confirm the boiler installing
condition.
Moreover, refer to the completion drawing for specifications.
When handling the device, be sure to choose a person in charge of handling. The person in charge
should not operate or carry out maintenance of the device until they have perused the precautions relating
to safety indicated in the manual and have a sufficient understanding of the precautions.
1-2. Wear proper outfit and protection gears
The device should not be operated or serviced wearing baggy clothes and accessories as they could
catch on the valve or machinery parts. Do not wear oil stained clothes as they could catch fire .
Do not forget to wear a helmet, protection eyewear, safety shoes and gloves when working on the device.
Protection gears must be worn as there is a particular danger of scalding near hot parts. Moreover,
protection eyewear and gloves must be worn as chemicals could splatter on hands and eyes while
injecting chemicals.
1-3. Do not remodel the device, Use the genuine products for the parts.
Do not remodel the device without our approval. We may not be able to permit such remodeling by
regulations . Moreover, such remodeling could compromise safety. Use the manufacturer's genuine
products for parts.
1-4. Use the designated fuel
Do not use fuels other than those designated . There would be a danger of the device exploding if other
fuels are used.
1-5. Do not keep flammable goods near the boiler
Do not keep flammable goods near the boiler. There would be danger of fire.
It is highly dangerous as there would be a danger of fire if flame were brought near the boiler fuel.
Store flammable goods in a safe place away from flames , check where the fire extinguisher is kept, and
learn how to use it in case of emergency.
Dispose of cloths stained with fuel or oil. Such cloths could ignite spontaneously if kept in a wrong way.
Wipe UR spilt fuel and oil immediately.
1-6. Keeping a fire extinguisher and first-aid kit
Keep a fire extinguisher in preparation for fire and learn how to use it.
Establish where to keep the first-aid kit.
Establish the contact numbers in case of fire or accident and how to handle such emergencies.
1-7. Advice on moving the boiler or selling the vessel
A correct installation and incidental work are required in operating the boiler.
Please be sure to contact our company when moving the boiler or selling the vessel, and give manuals to
new user.
Do not carry out incorrect installation or incidental work as there is a danger of such work leading to
physical injury.
1-8. Performing adjustments and/or maintenance
Always disconnect all electrical power at the main ci rcuit breaker, close the main and pilot manual shut off
valves before performing adjustments and/or maintenance. Failure to do so could cause electrical shock,
explosion, fires and/or burners which will result in serious personal injury and/or death. All adjustments
and/or maintenance must be performed by qualified and experienced personnel only.
1-9'. Warning Label
Dangerous part has warning labels on the baby. Refer to 3.
Part name and Function about the attached. P ~
Change new warning labels when labels are come off or teased . art ~
Please contact with Miura service engineer about warning labels. (Refer to information on back cover)
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2. Terms
The following terms are used in this manual for your safe and effective
operation.
I& WARNING
1. Indicates a condition or practice which may cause death or
serious injury to the operator.
I& CAUTION
2. Indicates a condition or practice which may result in damage
or destruction of property and/or minor personal injury.
NOTE
3. Indicates cautions for preventing the failure of the devices,
and points for effective operation.
4. Number in the pointing hand sign indicates the page for

related items.
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Followling special terms are in this manual ; please confirm the teams and meanings.
Ventilating boiler combustion chamber before boiler

Pre-Purge
combustion.
Ventilating boiler co mbustion chamber after boiler
Post Purge
combustion.
Stopping combustion or interrupting ignition when troubles
Inter lock
are happened with boiler and burner.
Requrgitate phenomenon of flame to inlet side of combustion
'Backfire
air.
i
Atomize fluid Supplied fluid for fuel atomize of main burner.
Atomize air Air as atomize fluid
Atomize steam Steam as atomize fluid
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3. Part name and function
3-1 Burner Assembly

Warning Panel (Burn)
•&
J-
& WARNING
00 NOT TOl X:H
HOT SU<FIICE
..,,ll)bll\)l..~m),
rr
\'llt t ·OJ:::ns v
0{ cv
\ . \
\ '
I
Ignition Transformer: Warning Panel (Electric shock)
~WARNING ~S
(II
~
HAZARDOUS VQ TAGE
Wll l CAUSE SEVERE INJ.RY
.._, • • co:cttif)tJ
1 Main Assy
2 Pilot Burner Assy
3 Fuel Piping Assy
4 Atomize Air Piping Assy
5 Atomize Steam Piping Assy
6 Tube
7 Baffle Plate
8 lginition Transformer
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3-2 Fuel Piping Atomize Steam Atomize Air Piping Assy details.
Fuel Shift valve for emergency (Main side)
Flow control Fuel shift valve from F.O to D.O in

emergency stop during combustion.
Valve for oil amount
adjustment according
to steam pressure. Fuel shift valve for emergency (Pilot side)
Fuel shift valve from F.O to D.O in

emergency stop during combustion.
Filter Regulator
Valve for supply
pressure adjustment of
compressed air to
solenoid valve.
Atomize Air Valve

Valve for atomize fluid
shift to air I steam.
Atomize Steam Valve

Valve for atomize
shift to air I steam.
Relief Valve for circulation
Oil detect cook of pressure Valve for oil pressure

equalizing valve adjustment.
Cook for detection of oil pressure to

pressure equalizing valve.
Pressure equalizing valve
Valve for atomize steam

adjustment according to air
amount.
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3-3 Main Burner Assy
Main Burner Nozzle can change atomize fluid (air I steam) to mist mixing fuel oil from fuel
oil.
Assembly consists of cap, mixer, nozzle, check valve , socket and burner gun body. Fuel oil
that is supplied from burner nozzle and atomize fluid that is supplied from the outer are
erupted from nozzle, and they are atomized from atomizing outlet on cap, after they are
mixed in mixer.
Fuel oil inlet

--""
__. ._#___ _-------(~.)
D.O inlet
1 Guide Pipe
2 Burner Gun Body
3 Pilot Burner
4 Cap
5 Mixer
6 Nozzle
7 Check Valve
8 Socket
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3-4 Pilot Burner
Pilot Burner ignition is taken as standard, and pilot burner, that is exclusive to light oil
and A heavy oil combustion , is installed.
Pilot Burner consists of Baffle plate, nozzle tip, nozzle holder, check valve , spark rod
and nozzle pipe. ~
Baffle plate
2 Nozzle Tip
3 Nozzle Holder
4 Check Valve
5 Spark Rod
6 Nozzle Pipe
3-5 Nozzle tip for Pilot Burner
Oil that comes into Pilot burner nozzle goes through strainer and thin distributor
channel to turning room. Turning room is cone and the point is orifice. Oil circles in
turning room speeding the pace, and it is atomized to combustion chamber through
orifice.
Nozzle tip needs to be replaced about once a year although it is made of hard
material, because oil wears orifice with high pressure and speed.
Confirm the size referring to Final Drawing.
Body Distributor Strainer
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3-6 Ignition Transformers
Ignition Transformer is import and equipment to produce spark from spark rod ,
changing 1OOV electric pressure of primary side to 1OkV high electric pressure.
Ignition Transformer is for both of 1OOV and 200V of primary electric pressure. Be
careful with variation of wiring that depends on electric pressure.
E E
Primary side Primary $ide
AC100V AC200V
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3-7 Fuel Piping Drawing around Burner
Atomize Steam Valve
Atomize Steam Inlet
SV- 4
Atomize Air Inlet
'~~------~----~IX I--~ x·~--~----~~
Fuel Shift Valve

for emergency
*Do not operation at normal
D.O Inlet F.O Inlet F.O Return
. flj# !
1>4 GLOBE.Y~.i,Y~.·-----;
¥=!~#
!181 BALL VALVE
'-<>- :J,:;?
·-···-- COCK
7-5-:ti!jf . - - -- -···i
~ FLANGED JOINT M-1 Y Strainer

--®-··- -•;-r··-·············-··················
·------~
i
~ SOLENOID VALVF SV-1 Solenoid Valve (Pilot)
N CHECK VALVE SV-2 Solenoid Valve (Air Drive Valve)
;,If#
~ REDUC I NG VALVE
····-··-·---··· ·:;c:r71iv7 .1-1 fsusr·- ·
SV-3 Solenoid Valve (Atomize Air)
,.f\f\- FLEX l BLE TUDE (SUS)

SV-4 Solenoid Valve (Atomize Steam)
- j JC::f;Ji~i~·:::fTTia"'/)e.=o.._ AC-1 Air Drive Valve (Main)
-.::A:P- I FLEXiBLE TU BE (TEFLON)
9. ! ~u RV Circulation Relief Valve
~ ]CONSTANT PRESSURE VALVE
; J!J J~ ::\ - FCV Oil Amount Adjustment Valve
-Q- . ORIF I CE
.... i if}JJ.-i ~7
Y l PRESSURE SWJ TCH
® \ lE:iJ:i
! PRESSURE GAUGE
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3-8 Proportional control of Burner
Steam Pressure t\djuster
Boiler Steam Pressure
High Pressure side
Usual Pressure
Low Pressure Side
Time
(])Boiler is not received high load with low combustion (Load 20%) for 30 seconds in
ignition start. After 30 seconds, combustion proportion is started to keep usual pressure
according to steam consumption (pressure) change by proportional control.
(2)Burner is stopped with high pressure side and post purge is started when steam
consumption is decreased and boiler steam pressure is increased.
@Combustion is started again after boiler steam pressure is decreased to low pressure
side, and combustion proportional control is started to keep usual pressure.
* 1 : Boiler steam pressure is risen to 0.7 MPa with atomize fluid air (Fuel : 0.0) at
start. Afterward, stop combustion and shift atomize fluid to steam (Close
atomize steam valve, open atomize steam).
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4. Operation
4-1 Inspection before operation and Operation
(1) Switch boiler power on.
(2) Confirm that boiler condition is ready to operation. *Prepare operation following
manual. ·
(3) Open fuel beginning valve after confirm that oil is in oil tank. *Open fuel
beginning valve of D. 0 line only at start. *Confirm that fuel piping has no leakage.
(4) Close air vent of air separator, open D.O tank of return line on booster pump and
close F.O tank.
(5) Switch F.O booster pump of boiler control panel on. *Confirm that fuel piping has
no leakage, again.
(6) Open compressed air valve for fuel, and confirm that it has 0.6'""0.9Mpa
pressure.
4-2 Operation (Automatic)

4-2-1 Cooling start
Operation with no boiler steam pressure

* Combustion Fuel: 0.0, Steam Fluid: Air, in this case.
(1) Confirm that Fuel heater shift switch on boiler control panel is I AJ , atomize fluid shift
switch is I AI RJ .
(2) Close main steam valve and atomize steam valve, and open atomize air valve.
(3) Open fuel shift valve (Main side) for emergency, and close fuel shift valve (Pilot side).
(4) Set filter regulator pressure 0.4 Mpa.
(5) Press combustion button on boiler control panel.
*After pre-purge, ignition and combustion is started.
* I CombustionJ lamp is turned on after combustion starts.
(6) Be careful with followings.
*Color, area and stability of fire
*Confirm color of smoke and that smoke way and some other parts have no leakage.
*Confirm that indicator of pressure gauge does no shake extremely.
When there are problems, press combustion stop button on boiler control panel to stop
combustion and investigate oil temperature, oil pressure and damper open.
(7} Confirm that boiler steam pressure is raised over 0.7 Mpa and press combustion stop
button on boiler control panel to stop combustion.
(8) Close atomize air valve and.atomize steam valve and open atomize steam valve.
(9) Shift atomize fluid switch on boiler control panel to ISTEAMJ .
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(1 0) Press combustion button on boiler control panel and start combustion again.
*After pre-purge, ignition and combustion is started.
*After low combustion for 30 seconds, high combustion is started according to steam
pressure.
(11) Be careful with followings. ·
*Confirm that there is no shaking.
(12) Open main steam valve gradually. *Confirm leakage of steam piping.
4-2-2 Switching Fuel
(1) Start operation with atomize fluid: steam, normally according to 4-2-1.
(2) Shift fuel according to facility on the vessel.
(3) Confirm that heater shift switch on boiler control panel is corresponding to fuel that is
elected.
* Fuel shift does not need adjustment of burner side.
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4-3 Stop
(1) Press combustion stop button on boiler control panel.
* Combustion lamp is turned off and post-purge is started.
(2) Confirm that wind bo.x is stopped.
4-4 Operation in emergency
Boiler steam can be started immediately shifting atomize fluid to air, when re-start is needed
because boiler steam pressure is decreased temporarily; for example, when boiler alarm is
started during F.O combustion
(1) Close main steam valve.
(2) Open atomize air valve and close atomize steam valve.
(3) Close fuel shift valve (Main side) for emergency and open fuel shift valve (Pilot side) for
emergency.
(4) Shift atomize fluid switch on boiler control panel I AI RJ .
(5) Press combustion button on boiler control panel and start combustion.
combustion and investigate oil temperature , oil pressure and damper open.
(7) Press combustion stop button on boiler control panel to stop combustion after boiler
steam pressure is confirmed that it is raised over 0. 7Mpa.
(8) Close atomize air valve and open atomize steam valve.
(9) Open fuel shift valve (Main side) for emergency and close fuel shift valve (Pilot side) for
emergency.
(1 0) Shift atomize fluid switch on boiler control panel ISTEAMJ .
(11) Press combustion button on boiler control panel and start combustion.
*Confirm that there is no shaking . .
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4-5 Operation (Burner manual operation)
The manual ~ombustion circuit is given as an option for emergency measure, in

case the boiler is not operated in the right order, or not operated , due to some
control error of the sequencer, so that motors, electric valves, ignition transformers,
etc. can be operated to keep the boiler operation temporarily. The following steps
should be strictly followed during its operation , and the malfunction should be
detected as soon as possible to return to normal, automatic operation.
The manual combustion ci rcuit is divided into the following four circu its;

(4) Alarm circuit

Confirm that the power indicator (WL-1) lights up, by turning on a no-fuse
breaker.
The feed water pump can be operated manually, by switching the feed water
circuit (43WA) to the above status. Originally, the On-Off of the feeding water
pump is controlled automatically according to the boiler water level.
In manual operation, where the feeding water pump can be operated regardless
of the boiler water level, the water level should always be checked using the
water level gauge.
By shifting cam switch gradually, manual combustion can be established. Cam
switch is positioned in order at Off, F.O pump/heater, fun , ignition, Pri-combustion
(combustion using the ignition transformer pilot burner and main burner) and
combustion (main burner only). Additionally, there is other combustion switch ,
such as 3-position control , which can shift between low combustion and high
combustion . Single operation of any one appliance only should be prohibited for
safety; check operation by shifting cam switch into order.
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(4) How to Use CAM Switch
Combustion beginning
Figure
CAM Switch Combustion Shift Switch
(Regarding Switches)
1. Auto (Auto Comb.) 6. Pre-Combustion (Pre Comb.)
Turn the CAM switch to this position and turn on When you set the switch to PRI.COMB, the main
Auto Comb. Switch, to start automatic combustion burner will commence combustion. Both the
using the sequencer. pilot burner and main burner will combust in this
2. Off (Stops combustion related operation.) state.
3. F.O. Pump/heater
Dial the switch to F.O. Pump/heater, to activate main 7. Combustion (COMB)
F.O.P. and heater. The pilot motor stops and the pilot solenoids
*Heater stops, either when fuel oil temperature valve close.
exceeds the specified temperature measured by the The activation of the main burner solenoid valve
temperature adjustor, or when fuel shifting switch is is held.
turned to A heavy oil. After established the low fire and then turn the
4. Fan Running combustion change over switch to middle and
Turn the CAM switch to this position makes draft fan high fire position to get high fire.
start.
5. Ignition
Turning the CAM switch to this position activates
ignition transformer and pilot solenoid valve, to start
pilot burner ignition.
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(Stop Combustion)
a) Return combustion change over switch to (Low Comb.) to reverse the above-mentioned
operation, and turn Cam Switch counter-clockwise.
Keep running more than 60 seconds at FAN position.
In manual operation as well , combustion is restricted by interlocking of safety system as follows:

a) in case of flame-out, or ignition failure
b) When steam pressure rises
c) When the water level of the boiler goes down to lower water level
d) When the temperature of exhaust gas rises
e) When the fan motor stops
In manual operation where there is not enough inter-locking system for safety, pay extra
attention to the boiler status.
a) Take sufficient time for pre-purge before manual operation and post-purge after operation.
(More than 70 seconds)
b) Run/or stop the feed water pump, while checking the water level of the boiler.
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5. Regular Maintenance
Regular Maintenance
Item Maintenance Point Frequency
Clean oil and soot on cap top with wire brush and waste
cloth, and replace it with new spare part when hole is Every 1
Burner Gun worn or transformed. month
Clean inside parts, too, so that F.O is not hardened in
mixer and nozzle tip inside. w
Clean oil and soot on diffuser surface with wire brush Every 3
Main Diffuser
and waste cloth.
wmonths
Clean oil and soot on spark rod , baffle plate and nozzle tip Every 1
Pilot Diffuser month
with wire brush and waste cloth.
[@r
Y Strainer net on main, pilot and atomize steam line with Every 4
Strainer
wire brush and waste cloth months
Every 1
Flame Eye Clean flame eye and flame eye·glass with waste cloth . month
[@r
Confirm that pressure gauge of F.O, Pilot, atomize steam
Pressure Gauge Every day
and atomize air is not waggled extremely.
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Refer to drawing as below for size adjustment of pilot burner each parts.
Spark rod and lead insulator guides high pressure by ignition transformer to nozzle tip
around, and spark rod is occurred. Be careful to handle spark rod because it is made of
ceramic. Do not fasten screw of holder strongly. Replace it with new spare part when it has
cracks. Clean carbon on each part with cleaning oil completely.
3 ±1
4±1 ~ I
+I I
m l l
7±1
20
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MARINE AUXILIARY BOILER I
6. Trouble Shooting
Condition I Alarm Contents Cause Countermeasure
Dirt and damage of spark rod Cleaning · Replacing of spark rod
Spark trouble
Confirmation of spark rod size [@r
20
Replacing of ignition transformer
No ignition with
pilot burner Confirmation of fuel root valve
No fuel, lack of oil pressure
Air pulling and replacing of pump
·----- ···-·--·--·- -··--
s:: Dirt of nozzle tip S?.lea~!ng · Replacin~J_~~ no~~_l_e ti.e__
~ Solenoid valve operation trouble Parts replacing
~-
Dirt of main burner nozzle Main burner cleaning
)>
() Dirt of main diffuser Main diffuse cleaning
()
0: Air drive valve operation trouble Parts replacing
CD
::l Solenoid valve for air drive valve
~ Main diffuser cleaning
No switch to operation trouble
-Cil - main burner Lack of air drive valve supply air
Parts replacing
)> ___pressure --·· ·----···--··--·-····----·-··-- ······--·--
iii" ·-··--·--····-~
Atomize fluid solenoid valve operation

3 trouble
Parts replacing
No fuel, lack of oil pressure Confirmation of air root pressure

Dirt of main burner nozzle Main burner cleaning
··-
Fade fire during Dirt of main diffuser Main diffuser cleanino
mail
combustion
burner Trouble and damage of flame eye Cleaning · Replacing of flame eye ll2:r
No fuel, lack of oil pressure Confirmation of air root pressure
Fuel oil pressure changes Adjustment · Pump replacing
·-·------
Low oil temperature Heater set temperature adjustment [s~
Smoke Dirt of main burner nozzle Main bur_ner cleaning ---
Dirt of main diffuser -~§lin diffu~f?.!:.E.!~~r]ing ______________
······-·····--·----------·-·····---------···· .
Tube inside burning Tube inside replacing

Operation mistake of atomize fluid shift
Confirmation of atomize fluid shift switch
switch on control panel
Atomize steam I Air Operation mistake of atomize fluid root Confirmation of atomize fluid root
Pressure low Alarm valve valve
Pressure decrease of atomize steam I Confirmation of boiler steam pressure,
air compressed air pressure
Simple causes of problems are described above during boiler operation, ·unexpected
troubles may occur including troubles with the sequencer itself which is in charge of control.
Therefore, pay attention to meter valve, pressure gauge indication, heating and abnormality
of components and so on, so that abnormal symptoms can be discovered in the early
stages.
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7. Equipment Name, Function and Adjustment
7-1 Combustion control equipment
(1) Control system

Pressure transmitter senses inside steam pressure, and pressure transmitter sends signal
to steam pressure controller on control box. The signal, that is proportion controlled from
steam pressure controller, is sent to CAM motor and combustion is proportion controlled .
Oil flow control valve and damper are linked with CAM motor and controlled.
Change of opening degree of oil flow control valve by linking with CAM motor changes
burner inlet pressure P2 and control combustion amount that is atomized ·from burner gun,
and it is adjusted to set flow of low combustion'"'-'high combustion. Damper opening is
controlled by installing Air flow controller and link system to adjust proper air proportion
according to combustion amount. Relief valve for circulation can always circulate oil, and
it keeps fuel as proper stick .
. Equalizing valve senses burner inlet oil pressure P2 and adjust P3 to control necessary
amount of steam for atomize.
Drain Pot
Atomize steam
Relief Valve for circulation
Burner Gun/
Fuel A/S
Oil flow control Valve "'I ...____ _____, ~
F.O Pump
D---+1
·-0
Ai' flow Contmlle' ~
Damper
D--O--
Pressure
Transmitter
Steam
pressure
CAM Motor
Controller
*Drain pot contains special oil inside.

Recommended specification: Ethylene Glycol
Purity: more than 99.5%
Density (20°C): 1.12-1.15g/ml
Moisture: less than 0.2%
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MARINE AUXILIARY BOILER _._.
(2) Oil flow control valve and Air flow controller
Fuel oil enters from control valve, and control flow by changing gap of oil flow control valve
inside. Revolving oil flow control valve shaft that is on the same steam with CAM motor
turns cut trench by shaft, and inside gap is changed.
Air flow controller is installed to join squeeze quality of oil flow control valve with squeeze
quality of damper.
This equipment can change proper combustion amount according to best air proportion
from low combustion to high combustion.
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(3) CAM Motor
CAM Motor can set oil flow adjustment and damper on proper position of each fuel
condition by signal from steam pressure adjuster, and send signal to control panel by CAM
switch inside.
(4) Steam pressure adjuster
Steam pressure adjuster can send signal from pressure dispatch to CAM motor with
proportion control to control steam pressure control. Steam pressure adjuster can control
combustion amount and proportion control, and send signal of combustion stop and start, at
the same time. Steam pressure adjuster can also change combustion amount set.
Steam pressure adjuster

Pressure Transmitter (On control panel)
(Installed on steam pressure Unit)
Manual (MAN) mode lamp [Green] . - - - - Remote (REM) mode lamp (Green]
PV ~AN REN AT Autotuning (AT) lamp [Green]

Measured value (PV) display --~·18888
AREA sv~otv ----++- Manipulated output (MV) lamp [Green]

Memory area display ----~ B =!B.BB.B set value (SV) display
fOUTI OUT2 DOl D02 003 DO~
l---------~1
Output (OUT1, OUT2) lamps [Green]
Digital output (D01 to D04) lamp
Bar graph display ooooo·ooooo
I Ml- -NON- -AID, [Green]
Direct keys -----tt•~Q__Q __ OJ Alarm (ALM) lamp [Red]
@r) l<wca I V IA
Set (SET) key --~=u=:=U:::::::J-_L~~- Up key
Shift key _ _ _ _ __ _ J
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7-2. Solenoid valve
Solenoid valve opens and closes by electric activation and non-activation to control each
flu id. Take care in handling solenoid valve as its style and valve opening action differ
depending on the model.
In either on solenoid valves, ignition may fail when there are foreign particles on the seat as
the oil pressure will not rise due to oil leakage. Moreover, as obstruction may cause oil
leakage inside the combustion chamber, that could develop into ignition failure and other
problems related to combustion, please carry out regular inspection. Take care in
disassembling the device, as internal parts, valve seat and springs can easily be lost.
7-3 Fuel Interception Valve (Main)
Air Drive Valve is installed on fuel interception valve (Main) . Be careful that air drive is
closed when air is not supplied.
Air Drive Valve Outlook
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.MARINE AUXILIARY BOILER
7-4 Equalizing Valve
Steam amount adjustment is needed according to combustion amount when steam is atomized .
Equalizing valve adjusts steam amount according to each fuel amount. Equalizing valve
inspects oil pressure and equalizes pressure gap between oil pressure and steam .
Equalizing Valve Outlook
26
-.... '" ...., ................
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MARINE AUXILIARY BOI{ER
7-5 Fuel Oil Pump
(1) For main burner

Refer to separate manual about details of fuel oil pump for main burner
(2) For pilot burner (Type GO)
Return Opening
Pressure Adjusting Valve
Discharge Outlet _...,.___
<Adjustment>
Pressure is adjusted with pressure adjusting valve. Pressure is increases by turning
right and pressure is decreased by turning left. Adjust discharge outlet pressure
regularly.
*Refer to commissioning test report about pressure adjustment set.
<Maintenance>
Check leakage from cover and oil seal every day. Strainer is not installed inside;
land it and ·repair when it is damaged without resolution.
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7-6 Fuel Oil Strainer (Fuel System)
The oil strainer removes dust and impurities from the fuel entering the boiler and prevents them from
entering into and damaging the fuel pump, solenoid valve, or burner nozzle.
It is installed on the suction side of the fuel pump. Since it is an oil strainer, its element can be cleaned
during operation. Turn the handle once a day to prevent it from clogging.
Open the plug then drain all water and sludge out once a month .
23)
1 Cleaner Cover 9 Air Plug 17 Square Rod

2 Oil Tank 10 Packing 18 Round Rod
3 Handle 11 Upper End 19 Plug
4 Main Shaft 12 Lower End 20 Packing
5 Gland 13 Fixing Plate 21 Washer
6 0-ring 14 Packing 22 Nut
7 Ring 15 Filter Plate 23 Cap Nut
8 Packing 16 Scraper Plate
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7-7 Flame Eye
~ Warning
Furnace inside is very high just after combustion stop.
Do not start flame eye glass cleanig until it is cooled ; it causes burn .
1 Flame Eye
2 Fitting Box
3 Fitting Stand
4 Flame Eye Glass
5 Packing
The Flame Eye is a device that gives an indication to the combustion circuit by detecting the flame during
combustion and monitors the flame using its photosensitive characteristic (Normally, when a resistance of
100kQ catches flame, it drops under 5000) of CdS (Cadmium sulfide cell).
The Flame Eye will not be able to catch the brightness of the flame inside the furnace when it is damaged
or the protection glass is blackened with soot. Such soiling could stop the burner as it produces the same
condition to failed ignition or mis-fire. The failure of the Flame Eye may be caused by soiled protection
glass if the flame dies out in about 3-4 seconds after combustion as the burner is ignited by turning the
burner switch to combustion while looking inside the furnace from the sight glass. Clean protection glass
regulary.
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7-8 Fuel Oil Heater
& Caution
If sludge sticks to the heater, it will become hard to control the unit, which could lead to incomplete
combustion, overheating , or other problems. Therefore, once a year you should clean the interior.
1) Electric Heater
A combination heater with electricity and steam as shown in the diagram is used as a standard to heat
up the heavy fuel oil to an appropriate temperature.
F.O. Exit Steam Inlet
! Safety Valve
Steam Outlet
F.O. Inlet- ·
Drain
The sheathed heater has a coiled nichrome wire in the center of the pipe and filled up with special
powders that have good heat conductivity and the electrical insulation at high temperature, and these wire
and powders are both solidified at high temperature.
In order to save the capacitance, the device is structured to heat up the outside of the heater body with
steam , and it preforms heater ability with the combination of steam and electrical heaters.
The volume of steam is controlled at the same time with the sheathed heater by switching the steam
solenoid valve On and Off in the Fuel Oil Temperature controller.
2) Sole.noid Valve for the Steam Heater
Q)
1 Coil
2 Spring
3 Plunger Assembly
4 Bonnet
5 Valve Body
6 Spring
7 Main Valve
8 Disc
The Steam Solenoid Valve installed to control.the fuel heater's steam volume for heating , and its structure
and part names are as shown in the above diagram.
When the Solenoid Valve is leaky or does not shut properly, it would cause problems, as the fuel oil
temperature would not be controlled.
Check to see if there is no damage to the valve or sheet and whether the coil itself has burnt out and ·carry
out regular cleaning and check ups.
30
'-
•
NIIURA
• ...
'
7-9 Fuel Oil Temperature Indication Regulator '

The appropriate heating temperature of fuel oil differs by the viscosity of the oil. Determine the
temperature following the Heavy Oil Heating Temperature Chart.
Control Output Indicator Lamp

C. Green
Lights up when the control
output is ON .
LO
Reading Indicator Lamp

PV.Red
'n un
'u o] The value is decreases
Lights up when a reading is by 1 when pressed once.
The value decreases
- --- ------
indicated.
-- -
------~
---
-
-
~
. -- - - when continuously
pressed.
Set Value Indicator Lamp
SV. Green
Lights up when a set value is
indicated. The value increases by 1
when pressed once.
Select Key The value increases
Used in changing the set when continuously
value. pressed.
~ Caution
• Set up the data by pressing the key steadily with the fingertip.
• The data is automatically registered 3 seconds after it is set up.
• The indicator automatically reverts to indicate reading in approximately 30 seconds after set up.
• Don't press SEL key for one second or more. The data in the controller may change .
How to set up the set value (SV)

Example : Changing the set value (SV) from 12o·c to 13o·c .
Key Operation Explanation Indication

SEL Reading indicated (PV)
~
The SV indicator lamp lights up when SEL is pressed once to indicate the
PV 'o' I 11121Dl
current set value .
SV 'o' I 11121Dl
/">.
~ Keep pressing until the changed value reaches 130.

(The value is automatically registered 3 seconds after set up)
SV 'o' I 11131Dl
Reading is indicated (PV) when pressed once.
SEL (The reading is also indicated automatically in approximately 30 seconds
~
after set up without this operation) PV 'O' I 11121 Dl
31
•
Nil IURA
•
· MARINE AUXILIARY BOILER
7-10 Thermostat (For fuel oil)
1. Dial Type
Thermostat Type Thermostat for Heater Protection
For High Temperature Alarm

For Low Temperature Alarm
The Fuel Oil Thermostat (Automatic Temperature Regulator) switches the electrical switch on and off by
sensing the temperature, and use'S a fluid with high expansion co-efficiency in its thermos sensor. When it
senses temperature, the expanded fluid and pressure inflates the diaphragm inside the body, releases the
lever to open the electrical contact and when the diaphragm deflates, the electrical contact closes.
Three thermostat is used for the GK-type boiler.
The Low Temperature Alarm Thermostat raises an alert when the temperature of the fuel drops below the
< Adjustment >

This is dial type. After dial set metal is losen, adjust dial point to set temperature point and fix it with set metal.
CD Thermostat for Low temperature alarm :Set the temperature of the Low Temperature Alarm
Thermostat 2o·c -3o·c lower than the heating
temperature.
(2) Thermostat for High temperature alarm : Set the temperature of the High temperature Alam
Thermostat 3o·c -4o·c higher than the heating
temperature.
@ Thermostat for Heater protection :Set 1ao·c .
< Maintenance>
Check operation test of each alarm i once every th ree month. Confirm that operation temperature and dial
set is almost equal.
32
NIIURA
•
•
Thermstat Adjustment
RTType Use the RT model shown at the lett based on

your specifications.
CD Adjusting Range
Rotate the Setting Knob to adjust to the specific
figure on the Graduated Dial.
1) Setting Knob
3) Differential Setting Disk
@Differential Control
Adjust differential pressures by using the Differential Setting Disk. The specified value should be
decided using the nomogram . Connect the main preset value (A) with preset differential value (B)
by straight line, and locate where it crosses with the differential value (C) . This value should be
identified as preset value of the disk.
Nomogram to set differentials.

A. = Main preset value Note
B. = Preset differential value
Since the thermostat has been adjusted. Do not try to
C.= Differential value
adjust freguently.
"C "C
"C "C 1.8
1.8 12U 2
70
130 4
80 6
I
140
I
90 150 10
12
100 A 10 160 A .14
B 170 16
110 ~ B
~ 18
15 180
120 2U
100 22
130 24
20 100
26
140
210 28
RT107 25 c15 RT120 30
\50
33
7-11 Heavy Oil Heating Temperature Chart
Temperature "C
100,000 - · 10.000 10 0 10 ' 2025 30 3840 50 60 70 80 90 99 110 120 130 140 150
10,000
50,000 5,000 50,000
1,000 5,000
20,000 2,000 20,000
500 2,000
~
1,000 ~
1o.ooo ..: 1,000 10,000
200 ~
5.000 - 500 b
- 400 ··500 ·v;
100 0
: 300 300
()
VI
2,000 200 5
50 - 200
40 250
e
1,000 100 30 . 100 '0Z"'
700 70
20 70
,.,
J:l
Q)
500 ·· -so (/)
100 40 50
300 - ~ 10
~ ~
~ 200 ~
25
e...
~
~
~
200
~ 150 "'zd ~
d 'C
Q) ~ 150
z 0 Ci
c: iii
0
w
.·•
'C
0 100 ~ UJ ~ y
0 Q)
""' ~ 90 al ·c:> 100

'C a:
Q)
a:
80 -
70 c z
0
90
80 .. ...
60
,.,
J:l
Q)
70
(/)
60
50 ··· 55
. 1.7
45 50
Viscosity of the heavy
1.5
40 -· 45 the burner needs to be ""'v
this line.
1.4
'Maximum lim ill
40 H-t-t-t-i-t-t-H-t-H-t-+-1rt+-HH-+-t+HH-H- in the fuel stora9.e_t(lnk . ·-MH-H-t-t··· t- t-H-+-+--++ t··H
I
35
How to use this chartD

fb find out the required temperature of the
weight of viscosity in the burner nozzle at 50"C
rniiiTH-tiiH-tlttl-tt-H-t+lt-t+H+H+-H+-H-1-+-l--W++++l+W.W~--L.ll.W
122 0 35
(1. First,
. F) ;find the point of viscosity of the used
oil and level it horizontally to 50"C (122.F).O
2. Next, draw a parallel line besides the
viscosity temperature line to Redwood No.1 60 .0 33 Ct:l;:!=i::t:j:jlJ=I:=I:±j:±:f=~~=±=±:t±:±::oi±::!=Ll=:t:±:±f:dbJ:±ij~d::U~~~:l.J..l~lJ_~j__~~~
3. The vertical line drawn from the intersecting 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230240 250 260270 280 290300
point indicates the required heating Temperature "F
temperature .O
0
'
' "'
•
NIIURA
•
MARINE AUXILIAR'GBOlLER
7-12 Pressure Switch (Atomize fluid, Fuel Oil)

Pressure switch for atomize fluid
pressure switch for atomize fluid is installed for low pressure alarm of atomize fluid . When atomize fluid
pressure is lower than set pressure, a point of contact is cut off and combustion is stopped with alarm .
Pressure switch for fuel oil
The pressure switch for fuel oil is used for oil pressu re drop alarm . It cuts off the contact, raises an alarm and
stop combustion when the pressure drops the preset level.
(1) SNS Type 1. Range Adjustment

Connection pressure goes up as scale shows
Spring regulator for Spring regulator
pressure difference for pressure when pressure adjustment screw is turned left-
handed (Pressure adjustment spring is pressed.)
When connection pressure goes up , section
pressure goes up logically. Pressure adjustme t •
screw can adjust connection pressure and open-
close pressure difference cannot be adjusted.
2. Differential Pressure Adjustment
The difference between connection pressure and
section pressure can be widened when pressure
difference adjustment screw is turned right-handed
(Pressure difference adjustment spring is pulled).
Pressure adjustment screw can adjust connection
pressure and pressure difference adjustment
screw can adjust section pressure. Pressu re
difference pointer shows connection pressure on
(2) RT Type
scale plate and pressure difference pointer shows
open-close pressure difference.
Section pressure = connection pressure - open-
close pressure ; because scale reading of above
adjustment procedure is based on A point, B
point is opposite.
(RT Type)
1) Setting knob 1. Range Adjustment
2) Setting scale plate Rotate setting knob to adjust to specific figures
3) Differential setting disk on setting scale plate.
2. Differential Pressure Setting
1 2 3 4 5 6 7 8 9 10
Adjust differential using setting disk. Refer to the
RT 5
l.t 1, 6 ro,
I I
2. ,4 ~ . 8 3. 2
, I
3} 4!" 0 ba r
left table to see the appropriate value.
0. 3 0. 5 0. 7 p.9. i.I 1 I 1.' 3

RT 116 I I I .I 1 ba r
I I. I I I I I
RT 117
I I I I
1 . 0 t1. 5I 2. 0 I2. 5I 3. 0 I3. 5 4.,0
bar ~ Caution
MIN. MAX .
1, 2, 3, • 4, 5, 6, 7 8 9, 10 Do not touch because it is already adjusted .
, , ,
1
Relation between differential disk scale and differential pressure
35
M EMO
36
M EM 0
37
•
Nil IURA
•
• DOMESTIC SERVICE STATION

*HEAD OFFICE:
MIURA CO.,LTD.
SHIP MACHINERY DEPT. 7,Horie, Matsuyama, Ehime, TEL: (+81)89 979 7066
Japan, 799-2696 FAX: (+81)89 979 7067
*BRANCH:
TOKYO MAINTENANCE DIV. 2-15-35 Takanawa, Minato-Ku , TEL: (+81)3 5793 1047
Tokyo , Japan 108-0074 FAX : (+81)3 5793 1045
SHIMANAMI MAINTENANCE DIV. 5-1-9 lmazu-Cho, Fukuyama, TEL: (+81)84 930 0740
Hiroshima, Japan 729-0111 FAX: (+81)84 930 0741
Fukuoka, Japan 812-0893 FAX: (+81 )92 432 3278
N.Y.CO.,LTD. 1-4-26, Takanawa Minato-Ku , TEL : (+81)3 3449 3821
Tokyo, Japan, 108-0074 FAX: (+81)3 3440 0944
CHUOKIKI CO.,LTD. 4-28-2, Abraya-Cho , Minato-Ku, TEL: (+81)52 383 3166
Nagoya, Aichi , Japan, 455-0824 FAX : (+81)52 383 3607
• OVERSEAS SERVICE STATION
MIURA SOUTH EAST ASIA PTE. LTD. 26 Boon Lay Way #01-81 Tradehub21 , TEL : (+65)6465 1147
Singapore 609970 FAX: (+65)6465 1148
• OVERSEAS NETWORK 6.TAIWAN

1.CHINA HU CHERNG (HU CHWAN) MARINE
IHI MARINE (SHANGHAI) CO., LTD. ENGINEERING CO., LTD.
Room No.706-707, Information Tower No.1403 No.18, Lane 5, Chung Chwan Rd. Keelung , Taiwan
Minsheng Rd, Pudong New Area, Shanghai, 200135, Tel : (+886) 2 24225747
P.R.China Fax: (+886) 2 24261018
Tel : (+86)21 6351 8029 MING YUNG MACHINERY.,LTD.
Fax: (+86)21 6351 8028 27.Shin Shing St. , Yan Cherng District Kaohsiung ,
Taiwan
2.GERMANY Tel : (+886)7 521 6266
TAKNAS MARINE ENGINEERING GMBH
Fax: (+886)7 521 9368
"Fruchthof" Oberhafenstr.1 20097 Hamburg, Germany
Tel : (+49)40 32 1305 7.THE NETHERLANDS
Fax: (+49)40 33 0608 NICOVERKEN HOLLAND B.V.
3.KOREA Algerastraat 20 3125 BS Schiedam, The Netherlands
DONG YANG ENGINEERING Tel: (+31)10 2380999
Fax: (+31)10 2380990
#1 0-11 ,2Ka Myeong-Ryun-Dong Dongrae-Ku Busan,
Korea FUJI TRADING (MARINE) B.V.
Tel : (+82)51 552 6503 Kortenoord 2-8 3087 AR Rotterdam , The Netherlands
Fax: (+82)51 557 4830 Tel : (+31 )1 0 429 8833
Fax: (+31 )1 0 429 5227
MSK (MIURA SERVICE KOREA)
578, Gwaebeop-Dong, Sasang-Gu, Busan, Korea 8.UAE (DUBAI)
4.PHILIPPINES Tel : (+971)4 347 4444
Fax: (+971)4 347 2771
PHIL-NIPPON KYOEI CORP.
S-705 Royal Plaza Twin Towers 684 Romedios St. , 9.USA ·
Tel : (+63)2 400 5778 5709 Old Spanish Trail Houston, TX 77023, U.S.A.
Fax: (+63)2 400 9130 Tel : (+1)713 928 5700
S.SINGAPORE Fax : (+1)713 928 5795
102, Pandan Loop, Singapore 12831 0 23132 East Echo Lake Rd ., Snohomish, WA 98296,
Tel : (+65)6777 5856 U.S.A.
Fax: (+65)6779 6711 Tel : (+1)206 624 1171
Fax: (+1)206 483 9112
FUJI HORIGUCHI ENGINEERING PTE.LTD.
24 Chia Ping Rd ., Singapore 619976 10.VIETNAM
Tel : (+65)6863 6368 SHM-VLK CO.,LTD
Fax : (+65)6863 8310 64 D2 Street, Van Thanh Bac Precinct, Ward 25,
Tel : (+84)8 3512 8379
38
1.

MARINE AUXILIARY BOILER HB-08T,10T,12T,15T,18T
Published by MIURA Co. ,Ltd. Ship machinery Dept. June 2007.
5th edition Apr. 2009. No. E990-0706-05
All rights reserved, Copyright © 2009 MIURA Co. ,Ltd.

No part of this publication may not be reproduced , transmitted , distributed or
publisher MIURA Co .,Ltd .
Visit us at www.miuraz.co.jp and get the latest information and Service News!
Printed in Japan
The Best Partner of
Energy, Water and Environment
lVI lURA
•
•
MANUAL
FOR
WATER TREATMENT
Manual No. E970-1010-02

Important Safety Information
In carrying out water treatment work for marine auxiliary boiler (hereinafter called boiler), read and fully
understand this manual and follow the instructions contained in this manual.
) Deleterious substances harmful to humans may be used in boiler water treatment. Improper handling
of such substances may cause an accident involving death or blindness.
) A boiler and incidental equipment contain hot parts that may cause burn, high-pressure parts that may
cause injury due to a pressure break, moving parts in which a part of the body may get caught, and
high-voltage parts that may cause electrical shock. Improper handling of these parts may cause
accident involving death, a fire , or other disasters.
To ensure the safety of work involved in boiler water treatment, it is essential to know possible causes
of disasters in advance. We cannot predict all potential dangers, but present dangers involved in boiler
water treatment in this manual to the best of our knowledge. Following the warnings or instructions
contained in this manual better ensures the safety of work.
In this m~nual , harm and damage are categorized into the following three levels:
1/1\ DANGER I "'Indicates any condition or practice that, if not observed , will cause
imminent danger of death or serious injury to the user.
1/1\ WARNING I Indicates any condition or practice that, if not observed, may cause
death or serious injury to the user.
1/1\ CAUTION I Indicates any condition or practice that, if not observed , may cause
minor injury to the user or property damage.
Introduction
This manual describes the procedures for handling our chemicals for proper water treatment for
marine auxiliary boiler. The instructions and safety precautions contained in this instruction manual
assume that these chemicals are used for their intended purpose. Do not use them in ways other than
those specified in this instruction manual. We are not responsible for damage caused by using these
chemicals in ways other than those specified in this instruction manual.
Before water treatment, those who carry out water treatment work for the first time as well as those
familiar with handling of our chemicals must read this manual thoroughly and understand the proper
method of handling them .
Keep this manual in a safe place so that it can be consulted whenever there is any uncertainty about
water treatment. ·
11
[Graphical symbols]
Graphical symbols used in this manual have following meanings:
Indicates certain behavior is prohibited.
PROHIBITION
Indicates touching certain area may cause personal injury.
Provides instruction to be followed (action to be taken).
Provides caution to be remembered.
Indicates potential danger of injury from heat under certain

conditions.
Provides caution to prevent boiler failure, point essential to

INOTEI effective operation, or other useful information.
Indicates related page(s).
lll
Term Definitions
Terms used in this manual are defined as follows.
These terms are marked with an asterisk (*) in the manual.
A chloride ion is monovalent anion expressed as cr. Chloride ions, that do

not react with water treatment agent nor precipitate in boiler water, provide
indicator of concentration level of boiler water.
Phenomenon that substances dissolved or suspended in boiler water are
dissolved or suspended in steam generated in boiler and transferred out of
boiler.
Amount of calcium ions and magnesium ions in water. Hardness of water is

expressed in equivalent number of milligrams of calcium carbonate per 1 L
of specimen . These are major scale components.
Acid consumption required to neutralize hydrogen carbonate, carbonate,

hydroxide, and other alkaline substances dissolved in water to pH 4.8. The
acid consumption of water is expressed in equivalent number of milligrams
of calcium carbonate per 1 L of specimen.
is component soil or sand and main ingredient glass. , that
forms film in surface of water tubes in boiler, serves as anticorrosive
component. On the other hand, if concentration of silica, that has relatively
low solubility, is high, hard scales are formed when hardness components
are present. For this reason , it is important to maintain water softener in
ood condition and to use chemicals nrtln<=•rlv
Oxides or other various insoluble substances formed in metal surface that
comes in contact with water.
Boiler compound is used to adjust pH of boiler water, form film, and disperse
scales with aims of preventing scale adhesion to boiler and protecting it from
corrosion .
The term of iron , when used in relation to water analyses, means total iron
including all compounds containing iron. Iron rust, if present in boiler, makes
it susceptible to corrosion or may turn into scales.
Electricity conduction rate is indicator of aqueous solution's ability to conduct

electricity, from which concentration of ions dissolved in aqueous solution
(amount of impurities) can be estimated .
While tap water or other water that contains certain level of impurities
conducts electricity, pure water conducts electricity poorly.
Condensed water remaining after generated steam is used. Condensate is

used in as feed water in boiler c-uc'T"''""
lV
Phenomenon of foaming in surface of boiler water. Causes of foaming
include increase in concentration of soluble salts in boiler water and formation
of soap by effect of fats and oils and alkaline substances. Foaming causes
carry-over.
Multifunctional products that combine boiler compound and oxygen
scavenger in single liquid chemical.
on of metal caused mainly by electrochemical action due to
surround environment.
Indicator of whether solution is acid or alkaline. A pH value of less than 7
indicates that the solution is acid, and pH value of 7 or greater indicates that
solution is alkaline.
Salts soluble in water. Soluble salts turn into cations and anions when
dissolved in water.
Oxygen dissolved in water. Dissolved oxygen is expressed in number of
milligrams per 1 L of a specimen .
A sulfate ion is divalent anion expressed as 8042-. Sulfate ions, if present at
high concentration, damage a protective film in steel surface, promoting
corrosion .
v
CONTENTS
Important Safety Information .................................................................... i

Introduction ................... ............................................ ... ... .. .. .... ..... .... ....... ii
Term Definitions ...................................................................................... iv
CHAPTER 1: SAFETY ......................................................................... 1
1. Safety Regulations ................ ..................................................................... 1
2. Knowledge and Skills Required for Safe Handling .............................. ..... ... 1
3. Protective Equipment ............................................. ... ................ .... .. ........... 1
4. Precautions for Safe Handling .................................................................... 2

4.1 Basic Safety Precautions ........................................ ........... ...... ............... ......... 2
4.2 Safety Precautions in Water Treatment. .......................................................... 2
CHAPTER 2: OVERVIEW ........................................................ ~ .......... 4
1. Purpose of Water Treatment ....................................................................... 4
2. Damages and Countermeasure resulted from Water Quality ...................... 4

2.1 Damages due to Scales ... .. .. ... ........................................................................ 4
2.2 Preventive Countermeasures against Scale Adhesion ....... .. ..... .. ................... 5
2.2.1 Removal of Hardness Components (Boiler External Treatment) .................... 5
2.2.2 Removal of Hardness Components (Boiler Internal Treatment) ...... .... ......... .. 5
2.2.3 Preventing Scale of Silica Component. ... .......... ........................ ....... .... ....... ... 5
2.3 Damages due to Corrosion (*) ................................ .. .................................... ... 6
2.4 Preventive Countermeasures against Corrosion(*) ....... .. ............................... 7
2.4.1 Removal of Dissolved Oxygen .... ..... ..................... .. ....... .... .. .......... ....... ......... 7
Vl
2.4.2 Control of pH .. .... ....................................................... .............. ......... ........ .. .... 7
2.4.3 Restraint of Chloride Ions ....... .. ..... .. .. ... ......... .. ....... ...... ..... ....... ... .......... .... ..... 7
2.4.4 Corrosion Restraint Component Silica Addition .... ... ....... ... ................ .... ..... :.. 7
2.5 Countermeasures against Corrosion (*) in Condensate (*) System ........ ..... ... 7
2.6 Damages due to Carry-over (*) .. ...... ................... ........... ................. ................. 8
2. 7 Preventive Countermeasures against Carry-over ............... .......... ...... ..... ....... 8
2.7.1 Electricity Conduction Control .... ... .... .... ... ........ ... .... .. ...... ..... .... .. ....... .. ........ ... 8
2.7.2 Preventing Fats and Oils from Getting into Boiler Water ........ ...... .................. 8
3. Marine Boiler Compounds for Z Boiler (*) ... ......... ......... ....... ....... ... ..... ...... ... . 9
4. Other Chemicals for Z Boiler ...................... ... ... ... .. ... .... ... .... ...... .. .. ......... .. .. 10
4.1 Alkali Auxiliary Chemical, Z-LIFE IE-11M ...... ........ .. .................................... 10
4.2 Condensate Controller, NEUTRAL Z IR-122N ..................... ....... .. ........ ..... . 11
4.3 Boiler Cleaning Agent (Deleterious Substance) .............. ... ........................... 11
4.4 Descaling Agent, SCALE DESTROYER SE-M ................ .......... ................... 12
4.5 Hot-Water Boiler Rust Preventive, MINESTAR F ......... .... ...... .... ... ................ 12
4.6 Attached Figures .. ... .... ... .. .... ........ ... .... .... .... ........ ......... .............. ...... ..... ......... 13
Chapter 3: WATER TREAT_M ENT ......... ..... ....................................... . 14
1. Maintenance Standard for Boiler Water ........ .... .... ... ........ ...................... .... 14
1.1 Maintenance Standard ... ....... ........... ... ..... ... .. ............ ............ .. .... .... ... .... ... ..... 14
1.2 Sampling Locations .............. .. .... .... ... ........ ... .......... ........... ...... ... ... ................ 15
1.2.1 Boiler Water .... ....... ...... ..... ......... .... ... .... ....... .............................. .... .... .. ... ... ... 15
1.2.2 Makeup Water, Condensate (*), and Feed Water. ..... .. ......... ..... ..... ............. . 16
1.3 Standard of Feed Water and Boiler Water .................................. ................... 17
1.4 Damage when standard values are not satisfied and how to adjust
nonstandard values .... .. ... .... .... .. ... .. .. .. .. .......................................... ........... ..... 18
Vll
2. Handling of Simple Water Quality Tester and Silica Analysis Kit ............... 20
2.1 Handling of Simple Water Quality Tester (MT-3) ........................................... 20
2.1.1 Acid Consumption (pH 4.8) (*) (CaC03) [Feed Water] ................................. 21
2.1.2 pH [Boiler Water] .. ... .. .... ..... ..... .. ........ ..... ........... ........... ......... ... .. ... ..... ....... .. . 21
2.1.3 Chloride lon (*) (CI-) [Boiler Water] ...... .. ...... ................................................. 22
2.1.4 Hardness (*) [Soft Water] ............................................................................. 23
2.2 Handling of Silica Analysis Kit ....................................................................... 24
2.2.1 Judgment of Water Quality Based on Concentration of Silica(*) ................. 25
3. Chemical Injection Procedure ................... ........ .. ...................................... 26

.
4. Blow of Boiler Water .................................................. ..... ..... ..................... 27
4.1 Surface Blow .............................................................................................. .. .. 27
4.2 Bottom Blow ........... .. ................................................................... ................... 28
CHAPTER 4: INSPECTION ............................................................... 29
1. Regular Maintenance and Inspection Standard of Boiler Inside ................ 29
1.1 Periodical Maintenance and Checking Procedures ....................................... 29
1.2 Inside Inspection Points ................................................................................. 30
1.2.1 Scale Adhesion (*) ..... ... ..... .... ... ... .......... ......... ..... ..... ...... ........... .. ........ ........ . 30
1.2.2 Sludge Accumulation .................................................................................... 30
1.2.3 Corrosion in Various Positions ... ......... ... ............ .. ... ... .... .... .. .......... ........ ...... 30
1.3 Removal of Scales(*) .................................................................................... 31
1. 3.1 Removal of Scales by Using Scale Dispersing or Descaling Agent.. ............ 31
1.3.2 Removal of Scales by Chemical Cleaning .................. ..... ...... .... ................... 31
1.4 Water Analysis Service ............................................................................... ... 32
Vlll
2. Maintenance of Boiler During Shutdown .............................·...................... 33
2.1 Maintenance During Normal Operation ......................................................... 33
2.2 Full-water Maintenance (For Long-term Shutdown) ...................................... 33

2.2.1 Preparation ..... .... ....... ....... ....... .. ......... ..... .. ..... ..... ........ ... ............................. 33
2.2.2 Maintenance Work .... .. .. .. ....... ...... ................. .... ... .... ..... ......... .... ........... ....... 33
CHAPTER 5: DISPOSAL . ~ ............ .................................................... 34

1. Disposal Procedure ..... ........... ........................................................ ........... 34
CHAPTER 6: GUARANTEE .............................................................. 35
1. Contact Information for Inquiries About Products
and Instruction Manual ...................... ................................................. ... ... . 35
2. Sale of Instruction Manual. ........................................................................ 35
3. Sale of Reagents and Instruments ...................................... .. .............. ...... 35
CHAPTER 7: APPENDIX .................................................................. 36

Specification Table ........................... ." ............................................. ....... ....... . 36
lX
CHAPTER 1: SAFETY
1. Safety Regulations
In sailing on the high seas, observe the Rules and Regulations for the Classification of Ships, the
SOLAS Convention , the MARPOL Convention , and other international conventions. Also observe
regulations in way ports or the country where the vessel was registered and other applicable
regulations.
2. Knowledge and Skills Required for Safe Handling

Water treatment work for this equipment includes checking water quality, pouring chemicals, and
operating boiler valves. Before carrying out work, fully understand this manual.
Those who satisfy the following requirements are qualified to carry out water treatment work for boiler.
They are called operators:
[Requirements to be satisfied by operators]

Those who have received explanation of handling from MIURA service engineer during trial
operation or those who have received explanation of handling directly from them
Those who have thoroughly read the MANUAL FOR WATER TREATMENT as well as the
instruction manual for this equipment and have full understanding of the contents
Those who have been permitted to carry out water treatment work and to handle this equipment by
chief engineer
Appoint a chief operator from among operators.
3. Protective Equipment
Be sure to wear helmet, goggles, safety shoes, safety belts, leather gloves, rubber gloves, protective
masks, or other appropriate protective equipment for work. Particularly when dealing with chemicals,
always put on goggles, rubber gloves, and protective masks to prevent severe accidents by spattering
of chemicals.
4. Precautions for Safe Handling
4.1 Basic Safety Precautions
In handling chemicals, observe following safety precautions:
&CAUTION
If chemical comes in contact with skin, immediately wash affected area with clean water.
If chemical gets into eyes, immediately wash eyes with clean water and seek medical
0
INSTRUCTION
advice. Do not rub eyes.
For detailed information about hazards, toxicity and measures for emergency or fire,
refer to material safety data sheet (MSDS) of product.
Store chemicals under appropriate conditions according to material safety data sheets.
4.2 Safety .Precautions in Water Treatment (Excerpt from Page 4 and Subsequent
Pages)
In carrying out water treatment work, observe following safety precautions:
& DANGER
Boiler cleaning agent is non-medicament deleterious substance. When disposing of
0
INSTRUCTION
boiler cleaning agent, be sure to consult with one of MIURA offices. Refer to material
safety data sheet (MSDS) about other cautions.
IB-053CL Indicator (3) applicable to non-medicament deleterious substance. When
disposing of boiler cleaning agent, be sure to consult with one of Miura offices. Refer to
material safety data sheet (MSDS) about other cautions.
2
&WARNING
0
INSTRUCTION
Never do operations except as they are described in manual. Failure to observe
direction may cause serious bodily injury to operator.
The salinity valve is hot and may cause burn if touched .

Be careful not to touch salinity valve directly.
Water to be sampled is hot and· high-temperature water containing steam may come
• .
CAUTION:
HOT
out of outlet of salinity valve. Sample water carefully as it may cause burn if touched .
Condensate (*) and feed water are hot. Sample water carefully as it may cause burn if
touched.
The bottom valve is hot and may cause burn if touched .
Be careful not to touch bottom valve directly.
& CAUTION
When scale(*) adhesion is too serious, adhered area is overheated locally, and strength
of materials decreases remarkably to cause such damage as swelling and bursting .
Operator must always pay attention to water quality.
0
INSTRUCTION
Open and close salinity valve slowly.
Opening valve quickly may cause failure.
Flash piping of salinity valve outlet before carry out sampling.

Impurities in piping may prevent accurate analysis of water quality.
Open and close the bottom valve slowly.

When solids in boiler water transfer to steam system because of carry-over(*), steam
purity decreases, and heat exchanging trouble, swelling or bursting of heater, may be
&CAUTION
caused.
Foaming may cause heat transfer surface of air layer in piping to be overheated locally,
resulting in deformation or blowout. Take extra care to prevent fats and oils from getting
into boiler water.
3
CHAPTER 2: OVERVIEW
1. Purpose of Water Treatment

Boiler failures attributable to water quality include corrosion(*), scales(*), and carry-over(*). These
failures damage boiler and lower its efficiency. They may also damage piping and equipment
peripheral to boiler.
The purpose of water treatment is to avoid these fai lures as much as possible and operate the boiler
efficiently. We propose to determine and manage anticorrosive capacity of boiler based on balance
between corrosive ions, such as chloride ions(*) and sulfate ions(*), and anticorrosive ions, such as
silica (*), and the pH (*).
2. Damages and Countermeasure resulted from Water Quality

2.1 Damages due to Scales
& CAUTION
0
INSTRUCTION
When scale adhesion is too serious, adhered area is overheated locally, and strength
of materials decreases remarkably to cause such damage as swelling and bursting.
Operator must always pay attention to water quality.
Table 2-1 Thermal Conductivity of Scales and Mild Steel

The largest damage factor that Thermal conductivity
Material
obstructs economical operation of boiler (Scales composed mainly of) [w/(m ·K)]
silicate 0.2- 0.5
is scale adhesion to inside walls of
carbonate 0.5-0.7
water tubes. Except distilled water, any
sulfate 0.7-2.3
other feed water (natural, industrial, or
mild steel 46.5-58.1
city water supplied from the land)
soot 0.07-0.1
contains hardness (*) components and
oils and fats 0.06-0.1
silica components, and they are
concentrated on water tube surfaces to become insoluble solids and adhere on surfaces. These
solids are called scales (boiler stones). Though depending on their compositions, physical properties,
adhering conditions, the thermal conductivities of scales are extremely lower than that of steel (i.e,
approximately 1120 to 1/1 00), as shown in Table 2-1; therefore, they decreases boiler efficiency.
Scale-forming compounds in feed water are as follows:

(1) Hardness (*) components: Ca (HC0 3)2 and Mg (HC0 3)2
Calcium [Ca (HC0 3)2] is decomposed thermally in boiler.
Ca (HC03)2 ~ CaC03 + C02 + H20
It changes to calcium carbonate [CaC0 3] and deposits or adheres water tubes to become scales.
4
(2) Silica (*): Si02
Silica [Si02] combines with hardness (*) components, zinc, or other components to form hard
scales(*).
(3) Iron oxide
This is corrosion (*) product in feed water and deposits to boiler bottom to become sludge or is
adhered to water tubes to become scales.
(Classification of scale-forming materials)
.:~~~~:::,~: ::,::~~:.:7:;:~~::h:~:i~c~:~~:;~o:~;~:;:l~:~:::i~i:
Iron oxide: When corrosion products in condensate (*) or feed water system flow
-
materials
into boiler, this is ready to be sludge or scale.
Aluminum sulfate and so on .
."••u•••••• •••••••••·••• ••••·••• •• •n•••••••• ••• ••• •• ••• •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• .
•• ••••••• ••••• •• •••••••••• •••••••••••••• ••••• •••• •••••••••••••••••••••oU•••••••••••••o•oooooouoooooo oooo oouooouoooooooooooooooooooooooooooooo l
2.2 Preventive Countermeasures against Scale Adhesion

The detailed methods to prevent scales are as follows:
2.2.1 Removal of Hardness Components (Boiler External Treatment)

Hardness components are removed from raw water with water-softener.
NOTE
Water softener needs periodical inspections. When its capacity to remove hardness
components is reduced , it must be regenerated with sea water.
2.2.2 Removal of Hardness Components (Boiler Internal Treatment)

By adding boiler compound (*) to cascade tank (to feed water with chemical injection device, if
fitted} , scales can be prevented .
MIURA provides BOILER MATE (IS-301 MR}, complex boiler compound (*), as chemical that
prevents hardness components from turning into scales. This chemical causes chemical
reaction to enclose hardness components, preventing formation of scales.
There are two methods as above, it is the most desirable treatment method fundamentally to
carry out boiler external treatment first and boiler internal treatment, next.
2.2.3 Preventing Scale of Silica Component

Silica can be removed by mechanical methods, but they require expensive equipment. For
marine auxiliary boilers, the formation of scales from silica components can be reduced by
following methods:
By keeping boiler water high alkalinity, its silica solubility is kept high to prevent silica scales
5
from adhering.
MIURA alkali aid Z-LIFE (IE-11M}, and genuine compound(*) BOILER MATE (IS-301MR},
are effective for controlling pH (*) and adjusting alkalinity.
Silica concentration is kept low by blow-down (*).
2.3 Damages due to Corrosion (*)

20
Corrosion depends on water qualities, such as pH , c
0
-~ N 15
dissolved gases, kinds and concentrations of salts(*}, ,_ E
8~ 10 I
and environments, such as temperature, and flow
speed. For boilers dissolved oxygen (*) and pH are the
-o
~~
_.
Q)
E
Ol
5
v
/
most affecting factors to corrosion .
Kinds of corrosion are as follows :
0I
0.1
--------
Relationship with dissolved oxygen
concentrations (mg/L)
(1) Corrosion due to dissolved oxygen in feed water Figure 2-1 Relationship between
When dissolved oxygen exists in boiler water, level of steel corrosion and dissolved
oxygen concentrations
protective films are destroyed and iron (*) begins to
14
elute. In addition , under these conditions, if I
corrosion products become deposits and are kept I
up on steel surfaces, oxygen concentration cells
vj
~y
are composed and iron elutes there concentratively. <_y9) /
~~-" hi"' -
J
This causes pitting in which corrosion proceeds

/~v t'-
deeply into steel surface. Besides, if corrosion
~
products in condensate/ feed water system are 9co 'a:J. ro 4o- Zl o
Feed water temperature ( 0 C)
conveyed into boiler and deposited there, oxygen
Figure 2-2 Relationship between
concentration cells are composed with dissolved dissolved oxygen concentrations
and feed water temperature under
oxygen , and similar corrosion is proceeded .
atmospheric pressure
(2) Corrosion due to an improper pH value
250
Keeping boiler water approximately pH 11-12
makes steel corrosion amount minimum. When pH 200
I
is not adjusted, especially lower, corrosion amount IDe
li-~ 150
I
becomes high.
~
~
Qi
g
8 100
I
(3) Corrosion due to dissoluble salt a::
5C'!
/ -,,.........
Chloride ion (*) and sulfuric acid ion (*) are called .-/
harmful ion, and it destroys protective film of steel 0'

123?1213 M
pH
and causes pin corrosion . This harmful ion
Fig. 2-3 Relationship between
especially, dissolved oxygen in boiler water steel corrosion rate and pH
accelerate corrosion remarkably.
Major Causes of Corrosion
r-~~~--{--~~~;~~~;~~---~-1
I water qualities Concentrations of harmful ions, especially cr. is high. I
:......... ~ ........................................................................................................................................................................................................................................................:
6
2.4 Preventive Countermeasures against Corrosion (*)
In order to prevent corrosion it is necessary to remove dissolved oxygen(*), to control pH(*) to its
proper value, and to restrain chloride(*) concentration . In addition , silica(*) fortification is effective to
control corrosion.
2.4.1 Removal of Dissolved Oxygen

Dissolved oxygen is the most harmful cause of corrosion (pitting), and any water in contact with air
dissolves oxygen .
There are two methods to remove dissolved oxygen; mechanically and chemically. Marine
auxiliary boilers in general adopt chemically.
NOTE
MIURA genuine compound BOILER MATE (IS-301 MR) react with dissolved oxygen in feed water,
that affects corrosion reaction most, and remove dissolved oxygen effectively.
2.4.2 Control of pH
Corrosion of steel due to boiler water or other hot water is minimized around pH of 12. The level of
corrosion is increased at pH much higher or lower than this value (See Figure 2-3). In an actual
boiler, however, boiler water is concentrated locally in internal wall of steam tubes significantly.
When average pH of boiler water is controlled to 12.2, pH of concentrated boiler water is higher
than 12.2, and alkali corrosion may be caused .
Thus, to prevent pH of local concentrated boiler water from becoming excessively high, the upper
limit of average boiler water pH should be restricted lower than 12.2.
NOTE
MIURA alkali aid Z-LIFE (IE-11M), and genuine compound BOILER MATE (IS-301 MR), are
effective for controlling pH and adjusting alkalinity.
2.4.3. Restraint of Chloride Ions

Boiler water includes chloride ions invariably, and these destroy corrosion-preventive films forme1...
on metal surfaces and accelerate corrosion. The concentration of chloride ions should be kept low.
Because no material that deposits chloride ions exists in boiler water, chloride ion concentration in
boiler water can be considered as scale of concentration level of boiler water.
It is also effective for checking for sea water leaks in drain cooler.
Carry out water quality inspection and if chloride ion concentration is excessively high, restrain it
by blow-down .
2.4.4 Corrosion Restraint Component Silica Addition

According to our investigation, silica that is contained in water is efficacious in corrosion prevention.
The amount of necessary silica for corrosion prevention depends on water quality.
NOTE
MIURA genuine compound BOILER MATE (IS-301 MR) have effect on proper silica adjustment of
boiler water, in case soft water or distilled water is used.
7
2.5 Countermeasures against Corrosion (*) in Condensate (*) System
Condensat~ is pure water that contains almost no dissolved solids, and has no buffering capacity for
pH(*). Therefore, if condensate includes even srnall amount of C0 2 , carried in together with steam,
pH value will easiJy decrease and corrosion will grow on steel surfaces in condensate system .
In order to prevent above pH decrease of condensate, genuine compound and condensate
treatment compound are used. This chemical constituent evaporates together with steam and
resolve when steam is condenses to increase pH .
* MIURA genuine compound BOILER MATE (IS-201 MR, 202MR) and condensate treatment
compound Neutral M are excellent corrosion controller.
2.6 Damages due to Carry-over (*)
& CAUTION
Lh
CAUTION
When solids in boiler water transfer to steam
caused .
sy~tem because of carry-over, steam
purity decreases, and heat exchanging trouble, swelling or bursting of heater, may be
2. 7 Preventive Countermeasures against Carry-over

To prevent carry-over, it is necessary to control electricity conduction rate (*) and to prevent fats from
mixing it.
2.7.1 Electricity Conduction Control

Electricity conduction is barometer of electric current condition and it shows impure concentration
in aqueous solution .
Because too much impure concentration in aqueous solution causes carry-over, adjust blow
amount not to make electricity conduction too high.
2.7.2 Preventing Fats and Oils from Getting into Boiler Water
& CAUTION
A1
CAUTION
Foaming may cause heat transfer surface of air layer in piping to be overheated locally,
resulting in deformation or blowout. Take extra care to prevent fats and oils from getting
into boiler water.
Oils and fats getting into boiler may cause foaming or carry-ave~. They may also become
carbonized in heat transfer surface or promote adhesion of scales(*).
8
3. Marine Boiler Compounds for Z Boiler(*)
To prevent boiler failures due to water, water must be treated with proper chemicals.
We provide following chemicals, that can be used with soft water and pure water (distilled water and
desalinated water).
Genuine Compound Boiler Mate IS-301 MR (Item code 9309-0)

(1) Main ingredients: Alkaline agent
Natural film component (silica-based antirust) ,
vitamin C, high polymer, volatile amine
(2) Content and form : 10 kg bag in a box, liquid
(3) Effects · The natural film component adjusts ion balance
of feed water properly to make it suitable for use
in boiler.
· The compound disperses hardness (*)
components to prevent them from turning into
scales(*).
· Boiler Water pH (*) is maintained properly.
· Corrosion (*) of condensate system is prevented
by neutralization effect of condensate (*)
treatment compound .
(4) Remarks This compound adjusts balance between
chloride ions (*) and silica as well as pH to
control quality of boiler water.
Measure concentrations of these components
by using water quality tester and silica analysis
kit.
Dosage
Dosage
Basic use and full blow-down After first use (normal operation)
3 3
2,000 ml per 1 m of boiler water 200 to 1000 ml per 1 m of makeup water
Method
Either dosage of original solution or diluted solution is available. If diluted solution is used, dilute it
with pure water (distilled water or desalinated water) .
If it is directly poured into cascade tank, about 400 to 500 L should be used per day. Check pH of
boiler water and adjust dosage.
If chemical feed tank is used, dilute chemical at ratio of 1 to 5 with water (e.g. : dilute 2 L of
chemical with 8 L of soft water), and set consumption rate of chemical in tank at about 1.5 to 2 L
per day. Check pH and silica concentration of boiler water and adjust consumption rate.
9
.
When it is mixed with any other chemical , each chemical should be diluted with pure water or soft
water over 10 times and mix it completely.
NOTE
There is usage concentration standard that is set by FDA (Food and Drug Administration) when
composite boiler compound is used for food processing.
For more information, consult with one of Miura offices.
When acid consumption(*) of water (soft water) is high (40 mg/L or higher), drain(*) recovery rate
is low, or pH of drain (*) is reduced to 7 or below because of steam or drain piping construction and
corrosion of drain piping results in high levels of iron, com !;lined use of this complex boiler
compound and a condensate (*) treatment compound may be needed.
Values in previous page are theoretical values. Especially, necessary dosage of chemical during
normal operation may be significantly increased or decreased, depending on intended purpose of
steam , drain recovery rate, and water quality. In practice, modify these dosages to keep standard
values of boiler water, measuring it with tester.
4. Other Chemicals for Z Boiler

4.1 Alkali Auxiliary Chemical, Z-LIFE IE-11M (Item code: AS1-9121-0)
(1) Main ingredient: Alkaline agent
(2) Content and form: 20 kg bag in a box, liquid
(3) Effects: It can be used with IS-MR, genuine
compound (*) , to help increase pH of
boiler water.
(4) Direction for use: Measure pH of boiler water and adjust
dosage.
Dosage
Dosage
Basic use and full blow-down After first use (normal operation)
1,000 ml per 1 m 3 of boiler water 100 to 500 ml per 1 m 3 of makeup water
NOTE
Above dosage is number when pH is adjusted by Z-LIFE IE-11M only. When Boiler compound IS-
MR is used together, adjust dosage to be kept boiler water standard , measuring pH with water
quality tester.
10
4.2 Condensate Controller, NEUTRAL Z IR-122N (Item code: 9134-0)
Condensate is in itself pure water and barely has cushioning ability against pH (*). Therefore, if
condensate includes even small amount of C0 2 and S0 2 , carried in together with steam, pH value
will easily decrease and corrosion(*) will grow on steel surfaces in condensate(*) system . To
prevent such corrosion, condensate controller is used.
(1) Main ingredient: Volatile amine

(3) Effects: By neutralizing carbonic acid in
condensate, this increases pH value,
and prevents corrosion of steel. This
gasifies in evaporation of water, goes
back to feed water line, and thus
circulates in system during boiler
operation.
(4) Direction for use: Add this into chemical feed tank that
contain boiler compound (*) and oxygen scavenger.
1.0 to 2.5 x M ml x F (m3)
M: acid consumption amount (pH4.8) (*) (mg/L)
F: amount of makeup water (m3/dal)
<Example> M: acid consumption amount (pH4.8) of pure water: 40 mg/L
3
Makeup water: 2 m /day
Dosage =(1.0 .........2.5) x40x2 =80 ......... 200 mUday
4.3 Boiler Cleaning Agent (Deleterious Substance)
~DANGER
0
INSTRUCTION
Boiler cleaning agent is non-medicament deleterious substance. When disposing of
boiler cleaning agent, be sure to consult with one of Miura offices. Refer to material
safety data sheet (MSDS) about handling precautions and other cautions.
I
(1) Main ingredient: Hydrochloric acid
(2) Content and form : 20 kg plastic container, liquid
(3) Effects: Cleaning agent to remove scales
adhering to boiler, exhaust gas
economizer, and Fresh Water
generator.
(4) Direction for use: After pouring corrosion controller (0.5%} ,
leave it with Boiler Cleaning Agent
2 to 5% or clean boiler with circulation .
During cleaning , it is bubbled , so removing bubble chemical (50ml) is
needed to boiler cleaning agent just before cleaning . After cleaning ,
neutralization is required .
II
4.4 Descaling Agent, SCALE DESTROYER SE-M (Item code: AS1-9070-0}
(1) Main ingredients: Chelate, high polymer, sodium
hydroxide
(3) Effects: This has features to remove scale
having adhered because of non-
installation, malfunction or so on of
water-softener, with boiler operating .
However, in such cases, it takes a long
term (2 weeks to 2 months) to remove
scale.
(4) Direction for use: Add this into chemical feed tank which
contains boiler compound (*) and
oxygen scavenger, to obtain 30 to 200 When used as a dispersing agent 30 mg/L.
mg/L. It is unnecessary to change When used as a descaling agent 200 mg/L.
dosages of boiler compound and
oxygen scavenger.
4.5 Hot-Water Boiler Rust Preventive, MINESTAR F (Item code: 9415-0}

(1) Main ingredient: Sodium polyphosphate
(2) Content and form: 1 kg solid netted
(3) Effects: Prevention of red water of hot-water
supply boiler. Available for foods.
(4) Direction for use: Put netted MINESTAR F (1 kg)
together with its container into cistern
tank. If no cistern tank is provided, fit
feeder in feed water line and put
MINISTER F in it. This is effective for 1
to 2 months with 1 kg of dosage and 1
t/h of flow rate. Use an antirust
injection kit for feed water to inject the
antirust continuously (ISP-AD-1 from
lchida-Kagaku Co ., Ltd .). Adjust
concentration by opening or closing
valves on main and bypass pipes
appropriately.
NOTE
These chemicals cannot be preserved in contact with air for a lor
Never add distilled solution to original compound. It may cause
degradation, crystallization of compound.
* The Ministry of Health, Labor and Welfare has established concentration standards for
these chemicals. For more information, consult with one of MIURA offices.
12
4.6 Attached Figures
Attached Figure 1 Relationship between concentrations of BOILER MATE IS-301 MR and pH (*)
11 8
l_L_l _ l. ; :; • ! : ·! · l • '
11.6
i "i_T_ 1_! I • ! --r-t ! l
114
---!·--t-+-i-- --+-+---f---+-l·-·L:l:;;)--+..-
! 1_! il ~ l''''
11.2
'----1"1
I ....-r i ! I ; I ! '
p
H11 .0
-- --l:7k::f-~- ··-+---~·-··t·-··-~-+--+····+-· ·1·····1·····
10.8
we++- --+-·--i-+-+-+-··t-·++-~-+-·
r-~-L
! I
t--f----·
f
-+--L+-+-4--~----TL+---l---
~ I j ~ ~ l f ~
10 6
HXXJ
Chemical concentration (mg/L)
Attached Figure 2 Concentrations of BOILER MATE IS-301 MR and electricity conduction rate(*)
120
E'
en 100
.s 00
60
40
20
Attached Figure 3 Z-LIFE IE-11M Chemical concentration and pH value relationship

1tar-------·---··· ·····-·-----~
~
p
:::~::: :-~-~
--~
-----
H
ltQ;____________ ··--········--- - - -·----··-····· ·
500 2500
NOTE
For standard dosages and addition procedures/water treatment, their theoretical values and
essential points are described. For more information, please contact one of Miura offices and ask
for instructions.
13
CHAPTER 3: WATER TREATMENT
1. Maintenance Standard for Boiler Water

1.1 Maintenance Standard
In maintenance of boiler water, measure following items at prescribed frequency (*1) . Increase or
decrease dosages of chemicals or blow down boiler with reference to standard values for feed water
and boiler water listed in Table 3-2 .
[J=' Page 17 "1.3 Standard Values for Feed Water and Boiler Water" in Chapter 3
Table 3-1 Water sampling standard
~
Feed water
Makeup water Condensate (*)
(makeup water+ Boiler water
(raw water) (drain (*)water)
condensate)
Sampling Outlet of water Outlet of
Oil check valve Salinity valve
location softener cascade tank
Everytime water is
pH(*) loaded to raw water Once a week Once a week Once a day
tank
Makeup water:
Hardness (*) Once a week
Everyday
Row water: Every
Hardness (*) supply time of water
to tank
Acid consumption
Once a week
(*)(pH 4.8)
Everytime water is
Chloride ion (*) loaded to raw water Twice a week Once a week Twice a week
tank
Silica(*) Twice a week
*1 Inspect these items at frequency that we recommend .
14
1.2 Sampling Locations
1.2.1 Boiler Water
& WARNING
Salinity valve is hot and may cause burn if touched.
Be careful not to touch salinity valve directly.
Water to be sampled is hot and high-temperature water containing steam may come
CAUTION:
HoT out of outlet of salinity valve. Sample water carefully as it may cause bum if
touched.
& CAUTION
Open and close salinity valve slowly.
0
INSTRUCTION
Flash outlet piping of salinity v.alve before sampling water.

Impurities in piping may prevent accurate analysis of water quality.
Take sample of boiler water from salinity valve on boiler.

Check location of salinity valve in final drawing submitted.
NOTE
lake sample of boiler water and analyze it at least twice a week as long as conditions of vessel
permit. Take sample of boiler water and analyze it before blowing down boiler. Decide amount
of water to be discharged by blowing down boiler and dosages of chemicals based on analysis
results.
15
1.2.2 Makeup Water, Condensate (*), and Feed Water
& WARNING
ACAUTION:
HOT
Condensate and feed water are hot. Sample water carefully as it may cause burn if
touched.
Take samples of makeup water, condensate, and feed water in locations as shown in Figure 3-1.
[1] Sampling location for makeup water

[2] Sampling location for condensate
[3] Sampling location for feed water
Needle valve
Chemical feed tank
Condensate
_j Water
Softene
Cascade tank
Figure 3-1 Sampling Locations
16
Table 3-2 Standard of Feed Water and Boiler Water
Boiler water (*)
Soft water Feed water Condensate (*) Chloride ion Chloride ion
<2 2~
Silica
Silica
pH(*) At 25°C - 7-9 7-9 11.2-12.2 11.7- 12.2(* 2)
Electricity
Conduction rate (*)
mS/fTI - - - ~400 ~00
Hardness (*) CaC03: mg/L ~1 .0 ~1.0 - - -

Chloride ion (*) Cl": mg/L 100(*3) ~50(*3) <10(*3) ~100(*4) ~ 100(*4)
Acid consumption
CaC03: mg/L ~40(*5) - - - -
(pH4.8) (*)
Iron(*) Fe: mg/L ~0.3 ~0.3 ~0.3 ~3.0 ~3.0
Silica(*) Si02: mg/L - - - 50- 400(*6) 50- 400(*6)

Fats mg/L Preferably 0 Preferably 0 Preferably 0 Preferably 0 Preferably 0
* 1 When chloride ion is 80 mg/L and silica is 50 mg/L, 80/50 =1.6 ~ standard values for value below 2 should be followed .
*2 If pH is below 11.7, treat boiler water as described in page 19.
*3 The concentration of chloride ions provides an indicator of whether or not sea water has gotten into water.
*4 If concentration of cr exceeds 100 mg/L, blow down boiler.
*5 If concentration of CaC0 3exceeds 40 mg/L, condensate treatment compound should also be used.
*6 In case of usage of IS-MR
Table 3-3 Damage when standard values are not satisfied and how to adjust nonstandard values
Type of
Item Description Damage caused Adjustment (*1, 2, and 3)
water
Boiler Scale of acidity and alkalinity. Pour BOILER MATE (IS-301 MR) and Z-LIFE
<11.2
water pH(*) Rough estimate of effect of Corrosion on boiler steel and drain piping. IE-11M.
boiler compound (*). 12.2< Blow-down.
Electricity Concentration of impurities of Carry-over (*)
400< Blow-down.
Conduction rate (*) water. Factor of all damages that originate in water.
Salinity concentration
Forming of pitting
Chloride ion (*) Rough estimate of 100< Blow-down.
Acceleration of corrosion
concentration of boiler water.
Rough estimate of iron
Adhesion of scale Pour BOILER MATE (IS-301 MR) and
Iron (*) elution in boiler and its 3.0<
Acceleration of corrosion NEUTRAL Z IR-122N
systems.
<50 Corrosion of boiler steel Pour BOILER MATE (IS-301 MR).
Anticorrosive component (*)
Silica(*) Adhesion of silica scale
Component of hard scales (*) 400< Blow-down.
Carry-over
Soft water Hardness (*) Scale component. 1.0< Adhesion of scale Check of water-softener.
Acid consumption Rough estimate of corrosion
40< The pH of condensate is lowered. Pour NEUTRAL Z IR-122N.
(pH 4.8) (*) of drain piping.
00 Salinity concentration
Forming of pitting
Chloride ion Rough estimate of 100< Check of water softener for sea water leaks.
Acceleration of corrosion .
Feed Scale of acidity and alkalinity. <7 Pour BOILER MATE (IS-301MR).
water pH Rough estimate of effect of Corrosion on boiler steel and drain piping . Reduce dosage of BOILER MATE
9<
boiler compound. (IS-301 MR).
Hardness Scale component. 1.0< Adhesion of scale Check of water-softener.
Blow-down.
Salinity concentration
Forming of pitting If concentration is too high, check condensate
Chloride ion Rough estimate of 50<
Acceleration of corrosion and makeup water systems for sea water
leaks.
Con dens Pour BOILER MATE (IS-301 MR) and
Scale of acidity and alkalinity. <7
ate (*) NEUTRAL Z IR-122N.
pH Rough estimate of effect of Corrosion on boiler steel and drain piping.
Reduce dosages of BOILER MATE
boiler compound. 9<
(IS-301 MR) and NEUTRAL Z IR122N.
Salinity concentration Blow-down.
Forming of pitting
Chloride ion Rough estimate of 10s Check condensate system for sea water
Acceleration of corrosion
concentration of boiler water. leaks and check for carry-over.
*1 General methods for adjusting nonstandard values are described.
*2 "Pour" in this column means pouring chemicals into chemical feed tank.
*3 "Blow-down" in this column means brow down of boiler water through bottom valve.
When concentration of chloride ions (*) divided by that of silica (*) is 2 or greater and pH is below
11 .7
0 When concentration of chloride ions (*) divided by that of silica (*) falls within the range of 2 to 2.8
a) Check that concentration of chloride ions does not exceed 100 mg/L. If it exceeds 100 mg/L, blow
down boiler from the bottom or the surface more frequently to reduced concentration level.
b) Increase dosage of IS-301 MR. This increases concentration of silica in boiler. Adjust dosage so
that concentration of chloride ions divided by that of silica drops below 2.
NOTE
If adding more than 1000 mU1 m3 of makeup water does not allow value to drop below 2, alkali
aid (Z-LIFE IE-11M) must be added.
0 When concentration of chloride ions(*) divided by that of silica(*) exceeds 2.8

It does not seem likely that increasing dosage of BOILER MATE IS-301 MR will allow concentration
of chloride ions divided by that of silica to drop below 2 or pH to exceed 11 .7. Thus, an alkali aid
(Z-LIFE IE-11M) should also be used.
To use alkali aid , add BOILER MATE IS-301 MR at ratio of 200 to 800 ml per 1 m3 of makeup water,
and add alkali aid to adjust pH.
NOTE .
To use BOILER MATE IS-301 MR in combination with Z-LIFE IE-11M , ensure that the amount of
BOILER MATE IS-301 MR divided by that of Z-LIFE IE-11M exceeds 3, and dilute mixture of
chemicals with 3 or more times as much pure water or soft water.
(Example) When 10 L of solution is to be prepared in chemical feed tank

Soft water: 7.5 L, BOILER MATE IS-301MR: 2L, Z-LIFE IE-11M: 0.5 L
The ratio between amount of BOILER MATE IS-301 MR and that of Z-LIFE IE-11M is accepted as
2 L divided by 0.5 L is 4, which is greater than 3.
The ratio between amount of mixture of chemicals and that of soft water is accepted as 7.5 L
divided by 2.5 Lis 3, which means mixture is diluted with 3 times as much soft water.
19
2. Handling of Simple Water Quality Tester and Silica Analysis Kit
2.1 Handling of Simple Water Quality Tester (MT-3)
& DANGER
0
INSTRUCTION
IB-053CL Indicator (3) applicable to non-medicament deleterious substance. When
disposing of boiler cleaning agent, be sure to consult with one of MIURA offices. Refer to
material safety data sheet (MSDS) about other cautions.
Water quality analysis is important work in comprehending water treatment condition .

Water quality should be in proper values. MIURA's MT-3 is easy-to-use water quality tester
developed with motto of "Simpler handling procedures".
[Items to be measured]
· Acid consumption (pH 4.8) (*)
. pH(*)
· Chloride ion (*)
· Hardness(*)
Table 3-3 Specifications of reagents and instruments contained in the simple water quality tester (MT-3)
Product Name Quantit Product Code Remarks
1 Treatment Manual 1 S600-002-3505-0
2 pH Tester Paper 1 0000-000-9408-0
3 M-2 Reagent OOOO-OOO-HL48-0 30ml
4 M-1 Indicator OOOO-OOO-HL47-0 35ml
5 IB-054CL Rea ent (4) 0000-000-9527-0 30ml
Contains
non-medicament
IB-053CL 2% of
6 deleterious 1 0000-000-9526-0 30 ml
Indicator (3) potassium
substance
chromate.
7 IB052CL Regulator (2) 0000-000-9525-0 30 ml
8 IB-051CL Regulator (1) 0000-000-9524-0 30ml
9 Filter Paper 1 0000-000-9406-0
10 Beaker 3 0000-000-9412-0 100 ml
11 Mess-Cylinder 0000-000-9417-0 50 ml
12 Funnel 0000-000-1205-0 604>
13 Conical Beaker 0000-000-1203-0 100 ml
14 Syringe S199-017-9010-0 5ml
15 IB-023 HL (Hardness Indicator) 0000-000-9228-0 30 ml
20
NOTE
Boiler water is not always colorless and clear. Since
judgment by color is requ ired in measuring following items,
use colorless and clear boiler water that has been filtered .
2.1.1 Acid Consumption (pH 4.8) (*) (CaC0 3 ) [Feed Water]

Acid consumption amount (pH4.8) stands for basic
components in feed water indirectly. Acid consumption
amount (pH4.8) components in feed water decomposes and Filtration
raises pH of boiler water. pH of boiler water rise slowly if

acid consumption amount (pH4.8) in feed water is low.
Reagents: M-1 indicator (indicator containing methyl red)

M-2 reagent (diluted sulfuric acid solution)
Procedure
a) Make cool sample water to room temperature and filter it
Add 5 to 6 drops of M1 indicator
if turbid .
b) Take 50 ml of sample water into beaker and add 5 to 6
drops of M-1 indicator. (It turns blue) .
c) Drop M-2 reagent with use of syringe while stirring and
count the number of drops required to make sample no
longer blue. Twice number of drops indicates acid
consumption amount (pH4.8) of feed water.
M-2 reagent (for titration)
Acid consumption amount (pH4.8) of feed water (CaCo 3 mg/L) =2 x number of drops
NOTE
When dropping reagent, ensure that beaker and syringe are placed upright.
2.1.2 pH [Boiler Water]

pH value of boiler water should be kept between 11.2 and 12.2 in order to prevent corrosion of
boiler inside, to remove hardness of boiler water and to avoid silica scale.
Reagent: pH test paper

Procedure
a) Make cool sample water to room temperature and
filter it if turbid.
b) Immerse tip of test paper into sample water.
Compare color
21
c) Pull it up immediately and compare changed color with
color examples on box.
NOTE
Be sure that temperature of test water is less than 25°C.
2.1.3 Chloride lon (*) (Cr) [Boiler Water]

Chloride ions are impurities that should be controlled to prevent
corrosion and to estimate concentration of total solids in boiler
water. By measuring amount of chloride ion, concentration ratio
and blow-down ratio can be calculated.
Concentration rate (times) = Cl- concentration in boiler water I IB-051CL regulator (1)
Cl- concentration in feed water
Blow-down rate of boiler water(%)= 100 I concentration rate
(times)
Reagents: IB-051CL regulator (1) (diluted nitric acid solution)

IB-052CL regulator (2) (regulator for chloride ions)
IB-053CL indicator (3) (potassium chromate solution)
IB-054CL reagent (4) (silver nitrate solution) Add 2 drops of IB-052CL
Procedure
a) Make cool sample water to room temperature
and filter it if turbid .
b) Bottle up sample water 10ml to beaker.
c) Add single drop of regulator (1 ). When
water is pink after dropping regulator(1} , add
regulator(1 )until water color becomes no color.
When water color is clear, go next d). Add 4 drops of IB-053CL
d) Add another drop of regulator (1 ).
e) Add 2 drops of regulator (2) and mix solution well. If
solution turns pink again, return to step a) .
f) Add 4 drops of indicator (3) and mix solution well.
Sample water is yellow.
g) Drop Regulator (4) with syringe and count drops until
sample water color becomes red brown from yellow.
Calculate concentration of chloride ions by following IB-054CL reagent (4) (for titration)
expression:
Chloride ion concentration (mgll } = (Number of drops -2) x 10
22
NOTE
1. When dropping reagent, ensure that beaker and syringe are placed upright.
2. If adding 12 drops of reagent (4) does not change color of sample water, repeat steps again with
2 ml rather than 10 ml of sample water. In this case, calculate concentration of chloride ions(*)
by following expression:
Chloride ion concentration (mg/L) =(Number of drops -2) x 50
If adding 12 drops of reagent (4) does not change color of 2 ml of sample water, water is
considered to contain chloride ions at concentration higher than 500 mg/L. It is likely that sea
water has gotten into water. Check systems for sea water leaks.
2.1.4 Hardness (*) [Soft Water]

Hardness is cause of scaling(*) in boiler. To prevent scale, it is necessary to keep hardness in
boiler feed water below 1 mgCaCO:v'L.
Reagent: Hardness indicator

Procedure
a) Before measurements, about 2L of soft water is discharged from outlet of water softener.
b) Wash measuring beaker with soft water.
c) Add 4 drops of indicator to beaker. (Refer to Note 1).
d) Add small amount (about 20 ml) of test water to beaker, and stir it thoroughly.
e) After stirring , add test water to beaker so that total volume becomes 50 ml. (Refer to Note 2) .
f) Check color change. Judge hardness with reference to Table 3-5 (Refer to Note 3).
NOTE
1. For accurate analysis, be sure to add 4 drops of indicator.
Use indicator container vertically, and drop indicator solution slowly.
2. For an accurate analysis, be sure to add 4 drops of indicator.
3. Check the color change soon after stirring . It may be impossible to conduct accurate analysis
after 10 minutes, as color may change again.
Table 3-4 Color judgment

Color Judgment Condition
Light blue- Blue Soft water check: OK Soft water
Blue purple - Red Soft water check: Not good Hardness Leakage
NOTE
If sample water turns dark green, it cannot be analyzed correctly since reagent components have
been deteriorated.
Replace it with new reagent.
23
2.2 Handling of Silica Analysis Kit
Miura uses silica (*), chloride ion (*) and pH (*) as treatment item of boiler water treatment.
Silica analysis kit (Pack Test) _makes it easy to measure silica concentration in water and we
recommend using kit for daily water treatment.
Measure concentration of chloride ions and pH with MT-3 simple water quality tester.
[Item to be measured]
· Silica
Toa bl e 3-5 s;peel"fj caf1ons of reagen t s an d .mst rumen t s con t.

amed In I . k"tI
" th e SlTICa analySIS
N2 Name Quantity Remarks
1 K-1 Reagent 1 Content : 7 ml
2 K-2 Reagent 1 Content : 4 ml
3 Diluted Water 1 Content : 70 ml
Aluminum laminate wrapped with each
4 Tube (K-3 Reagent) 40
five tubes
5 . Special Cup 1 Cup for measurement
6 Poly Syringe (big) . 1 For diluted water
7 Poly Syringe (small) 1 For test water
For concentration measurement
8 Standard Color 1
(5,10,20,50,100,200mg/L)
9 Pack Test Procedure 1 Instruction manual
Product information
Product Name Product Code
Silica Analysis Kit (one set) 0000-000-9529-0
Safety precautions
For more information about reagents , refer to material safety data sheets (MSDS) .
Quality requirements to be met by sample water

Coexisting substances, if present at low concentration , do not affect result of an analysis by this kit.
For more information, refer to instruction manual that comes with silica analysis kit.
24
2.2.1 Judgment of Water Quality Based on Concentration of Silica (*)
Product name: Pack Test WAK-Si0 2
Method of judgment: Judge with reference with color chart.
Color chart: Color samples are provided for silica concentrations of 5, 10, 20, 50 , 100, and 200
mg/1. *See the picture: :t
Procedure: Refer to following instruction manual, which comes with kit:
M(}lybdenum blue Method

fA3in l'll!agenc Ammonium Motybda*
Rang.e : 5-200 mg SiOjl(ppm)
How to use
( ) Ad<! tS m of (3) AMI 2 ~ o! j4) Sh.l.ke 2- 3 (.5) Wa1. for 3

dls1i~ K-1 noag~mt tmes mllltl!es - ~t.
l~Wlh the la~SE Pui!Mcap_ ' th8 cap
p.'Jle~. bad\.
<=A FUii<:<ltl!lE tr.e. I

I;@
//
{S) Watt for Xl <P} R~ 1M liM to (lOi ?fess ~e sides of !hu;be {i 1j ~the wt>e in t~ sample. (12) After l mmvtes. put the
~~as. claM the aperoJrE tt) ~xpel appraxtma:~ty R~a<se lilt> s:a~.s ro fia 1M ~ on ~ cd:of mart as
-
'
i'om ~ lll9 of ~e halt of \IOlume_ Ma1ntam ltlb;; up ro ~ natt Sha e lh" ·showr!Jnd~w~
tune. pr5sea ~ ~~ 5- e mes.. tne-s~colors
* .,;i f;,- ,to fi~J(tf "tll• )t,ei$t.'

After the reaction time,camper~ the color of the tube with the standard colorn. The nearest color tnd~eates the measured
value of lhe sampte. A rolor between two s!arnfard colors iruiicates a value bet\1,-een the two standard values.
Disposal of tested sample water

Tested sample water is low pH (pH 1 to 2) and cannot be discharged directly.
Before discharging it, mix it with about 100 ml of untested sample water (boiler water).
25
~N_o_T_E________________________________________________~I
If concentration of silica in sample water is judged as higher than 200 mg/1, and you want to check
accurate concentration, test sample water again according to following procedure:
[Procedure for diluting sample water (with 3 times as much water)]
a) Put 1.5 ml of sample water in another container with larger syringe.
b) Put 3.0 ml of diluent in container in a) with larger syringe (1 .5 ml x 2) and mix diluted sample
water well.
[Procedure for testing diluted sample water]
c) Test sample water diluted in b) according to procedure in previous page.
d) Thrice concentration found based on color chart is concentration of silica (*).
3. Chemical Injection Procedure

Pour chemicals into chemical feed tank and inject them continuously by controlling needle valve. If
chemicals are poured to excess, pH (*), alkalinity, and concentration of solids in boiler may be changed
- significantly, causing boiler water to be concentrated abnormally.
Chemical feed tank
Condensate
®
Cascade tank To boiler

} - - --=-- - :-""'
Figure 3-2 Chemical Injection Procedure

NOTE
· Always cover chemical feed tank and cascade tank to minimize their contact with air.
· The higher temperature of cascade tank is, less concentration of dissolved oxygen in it becomes.
Check specifications of cascade tank and feed water pump and keep temperature of cascade
tank as high as possible.
· Locate chemical feed tank above water level of cascade tank. (a).
·Adjust needle valve to modify dosage of chemical. (b)
· Boiler compounds should be added from tank continuously.
· Use everlasting material against alkalinity for chemical feed tank.
26
4. Blow-down of Boiler Water
& WARNING
0
INSTRUCTI ON
Never do operations except as they are described in manual. Failure to observe direction
may cause serious bodily injury to operator.
Impurities in feed water and chemicals, that is put into boiler as boiler compounds, will gradually
accumulate inside boiler. Concentration of solute salts and suspensions will increase in boiler water
gradually, and this often causes foaming and carry-over. In addition , increase of corrosive components
will invite corrosion of tubes, and accumulation of sludge will also cause various troubles such as
forming of scales, overheating resulting from it, and clogging of insufficiently-circulating positions.
Blow-down of boiler water is carried out to prevent these troubles. This is operation to discharge
concentrated boiler water out of boiler and to regulate concentrations in boiler water within standards.
4.1 Surface blow-down

<Amount of blow-down>
. Feed water (m 3)xConcentration of component in feed water(%)
Amount of blow-down (m 3) = ------------------------
Concentration of component in boiler water(%)
Note: Chloride ions (*) and electricity conduction rate (*) are used as concentration of component in
above formula .
<Procedures>
a) Blow down when concentration of component in boiler water has come close to its standard
value.
b) Blow down when boiler is under a low load.
c) Repeat blow-down and supply water 4 or 5 times alternately, with feed water pump in operation.
Stop blowing down boiler when water level of water level gauge is reduced by about 20 mm from
level when feed water pump is put into operation.
d) Blow-down 1 to 4 times a day.
This is to remove concentrated boiler water from evaporating surface. Try surface blow-down
before bottom blow-down.
NOTE
The number of times for blow-down depends on feed water quality, drain (*) retrieve ratio and
boiler operation rate.
Set frequency based on water quality analysis data. Please submit water data. MIURA will offer
advice to you .
27
4.2 Bottom Blow
& WARNING
Bottom valve is hot and may cause burn if touched.
CAUTION:
Be careful not to touch bottom valve directly.
HOT
CAUTION
Open and close bottom valve slowly.
INSTRUCTION
In order to eliminate sludge accumulation , blow down boiler water through bottom blow-down valve.
Bottom
valve
28
CHAPTER 4: INSPECTION
1. Regular Maintenance and Inspection Standard of Boiler Inside

Boiler maintenance and inside checking are very important in maintaining water quality and judging
water treatment results, and are also effective to keep highly-efficient boiler operation and to estimate
inspection works before docking.
For ship that quality of loaded water varies these are the essential periodical works. Refer to
procedures as follow.
1.1 Periodical Maintenance and Checking Procedures

Item Procedure Frequency
Hardness (*) check of Sample water at outlet" of water-softener and check its
water softener coloration change with hardness indicator.
Surface blow-down Open surface blow value and blow down boiler to
Bottom blow-down discharge part of boiler water.
Open bottom blow-down valve and blow down boiler
Everyday
to discharge part of boiler water.
Water level gauge * Carry out bottom blow down when you use scale
cylinder blow-down destroyer SE-M.
Open water level gauge cylinder drain valve to blow
down water in this cylinder.
Open bottom valve to blow down boiler water
Total blow-down Timely
completely.
Open inspection holes on upper and lower drums and
When vessel is
check scale adhering conditions on drum inside walls
docked.
and water tube insides visually or with inspection
Timely (at the
Boiler inside checking mirror.
time of total
When over 1mm thick of scale adhesion is
blow-down ,
recognized, consult MIURA service engineer
etc.)
immediately.
* For other matters, follow boiler operation manual.
29
1.2 Inside Inspection Points
Quality control of boiler water can be roughly evaluated by checking following points.
1.2.1 Scale Adhesion (*)

Because scales are most likely to adhere in inside of steam drum and water tubes, check these
parts especially. In some cases tube is completely clogged as shown in photograph and this
causes damages to tube.
Scale adhesion example
1.2.2 Sludge Accumulation

Sludge adheres and accumulates in different ways. In boiler, the lower drum is more susceptible to
sludge accumulation , and it may turn into scales or cause corrosion(*) if left for a long time. Blow
down boiler periodically to eliminate sludge.
1.2.3 Corrosion in Various Positions

The forms of corrosion found at inside inspection can be divided into two types: total corrosion that
occurs overall and local corrosion (or erosion) that is caused by pitting, a mass of pitting, or
adherent corrosive matters.
Corrosion of boilers occurs most likely on inside of water tubes, especially near water surface of
steam drum, (local corrosion caused by pitting and adherent corrosive matters). Caution should
also be taken to mounting parts of water tubes to drum, and sometimes expanded parts of tubes.
Corrosion example
30
1.3 Removal of Scales (*)
The degree of fouling of boiler in operation depends on history of corrosion (*}, effects of treatment of
feed water and boiler water, operation time, number of times boiler has been started and stopped,
the main material of feed water system, and other factors. The level of accumulation of scales or
sludge in boiler and components and hardness of scales or sludge vary from part to part. It is difficult
to specify when scales should be removed. This section describes approximately when scale
removal should be carried out and some procedures.
1.3.1 Removal of Scales by Using Scale Dispersing or Descaling Agent

Using SCALE DESTROYER SE-M, a descaling agent, is effective for removing scales found by
periodical inspections. This chemical can be used to remove scales while boiler is in operation.
NOTE
For details about dosage, consult with one of MIURA offices.
If descaling agent is used, blow down boiler on daily basis to eliminate scale flakes. Scale flakes, if
not eliminated, may cause clogging.
1.3.2 Removal of Scales by Chemical Cleaning

If any of following is observed , chemical cleaning is needed:
· When adhesion of thick scale (more than 1 mm) on heating surface or accumulation of sludge
mass in boiler bottom is observed.
·When steam evaporation has decreased, and fuel consumption has increased, or it takes more
time to raise boiler pressure at the start of operation.
· When organic matters or fats have mixed into boiler water.
· When iron concentration in boiler water is high (several dozen mg Fell or more}, and water
continues to be colored red .
NOTE
If you cannot determine whether chemical cleaning is needed or not, contact one of MIURA
offices.
There are various chemical cleaning procedures and chemicals for chemical cleaning available,
from which appropriate ones should be selected depending on damage conditions and boiler type.
Before conducting chemical cleaning, please consult with one of MIURA offices.
31
1.4 Water Analysis Service
We, MIURA Co., Ltd., are offering water analysis service for free to encourage MIURA chemical
users to practice correct quality control of water for efficient and safe use of our boilers. Plese bottle
Boiler water of 250mL or more and send us samples of feed water and boiler water at the time of port
call. Then we will be able to give user proper advice, after analyzing samples in details and
comprehending practical conditions of boiler water. Feel free to request for this service.
(Example)
Sender: MIURA Co., Ltd.

7, Horie, Matsuyama, Ehime, 799-2696
Vessel Name: MIURA MARU Phone No.: 089-979-7066
Person in charge:
Date of analysis: June 3, 2010
Report of Water Analysis Results

Boiler MFG No. JIS B8223
(1) (2) (3) (4)_ Special
Date of sampling 2010/05/24 2010/05124 2010/05/24 circulation boiler
Request form No. 0748569 0748570 0748571 Standard values
Type of sample water for boiler water
Soft water Drain water Boiler water Normal operation
Concentration rate
Boiler compound pressure
MIURA's MIURA's 1 MPa or below
(complex boiler
chemical chemical
compound)
pH (25°C} 6.8 9.0 11 .6 11 .2-12.2
Q)
> Electricity
.!!!
c::_ conduction rate 0.5 1.8 115.1 400 or below
.Q e(mS/m)
me
.!::>o Acid consumption
~ (.) {pH 4.8) 4
(.)
c:: (mgCaCO:/L)
0
t) Chloride ion
0 0 18 100 or below
(mgCr!L)
Q) Chloride ions and
iii 0 36
(.) sulfate ions (mg/L)
Ill
Hardness
"C-
c:: 0 1> 3> 16
CU.!;. (mgCaCO:/L)
c:: c:: Silica (mgSiOiL) 1 1 21
0 0
"iii (.)
Iron (mgFe/L) 0.20 0.05> 0.23
e....
0 Manganese
t)
(mgMn/L)
Phosphate ion
~0
·Ez (mgP043-/L)
(I) c::
.<::0
uo
If)
(i)"0
.<:::~
-~~~
Oc::
Ill
Message
<Address to which water samples should be sent>

Please send water samples to one of MIURA offices (in Japan) listed in the back cover.
* Put the name of vessel and owner.
32
2. Maintenance of Boiler During Shutdown
Since corrosion (*) occurs during not only operation but also shutdown, anti-corrosion measures is
important during shutdown.
2.1 Maintenance During Normal Operation

a) Close main steam valve with pressure keeping high after stopping boiler and keep it as it is for
shutdown.
b) Before start-up, repeat 2 or 3 times blow-down through bottom valve (until low water level alarm
buzzer starts) and water supply alternately. Practice water analysis and manage water to be
standard.
2.2 Full-water Maintenance (For Long-term Shutdown)

2.2.1 Preparation
a) After boiler is stopped, with pressure of less than 0.2 MPa, repeat 4 or 5 times blow-down from
bottom blow-down valve (until low water level alarm buzzer starts) and water supply alternately.
b) One hour or more after boiler is stopped, practice full blow-down.
c) Remove sludge from interior of boiler as much as possible.
2.2.2 Maintenance Work

a) Supply boiler water by manual up to water surface with boiler compounded (*) water.
The standard dosages of boiler compounds are specified below. The dosage depends on boiler
compound type.
Add boiler compounds enough to sustain pH (*) value of boiler water around 11.5 to 12.
3
Inject 5,000ml ·of boiler genuine compound (*) IS-301 MR per 1m feed water.
Inject 2,000ml of boiler compound IE-11M per 1m 3 feed water.
b) Ignite burner to heat up and boil boiler water properly. Remove dissolved ga~ out of water throug'
air vent valve completely.
c) After pressure is increased to 0.2 MPa, close main steam valve and seal up boiler.
d) Check boiler water for quality and pressure at regular interval during shutdown. If these are
improper, add chemicals and pressurize it.
33
CHAPTER 5: DISPOSAL
1. Disposal Procedure
Dispose of chemicals and reagents properly according to respective material safety data sheets
(MSDS).
34
CHAPTERS: GUARANTEE
1. Contact Information for Inquiries About Products and Instruction

Manual
If you have any question about products you purchased or about this instruction manual , contact one of
MIURA offices.
(The contact information can be found in the back cover.)
2. Sale of Instruction Manual

If you need instruction manual for water treatment, contact one of MIURA offices.
In that case, let us know the vessel name, the nationality of the vessel , the vessel number, the boiler
number, and the manual number in the cover of the instruction manual.
3. Sale of Reagents and Instruments

If you need reagents or instruments used for water treatment, contact one of MIURA offices.
In that case, let us know the vessel name, the nationality of the vessel , the vessel number, and the
boiler number.
35
CHAPTER 7: APPENDIX
Specification Table
Specification Equivalent Water Capacity (L) Level of Water
Evaporation (Kg/h)
Level Gauge
W=60°C
Model P=0.7MPa Full Normal at 1cm (L)
VWS- 200 180 181 126 2.7
400 359 384 261 3.8
600 539 453 309 4.4
800 718 565 377 5.3
1200 1,078 677 479 5.6
1600 1,437 . 866 638 6.4
2000 1,769 961 733 6.4
2500 2,242 1,002 774 6.4
1200ME 1,078 917 566 8.3
1600ME 1,437 1,285 794 11.7
2000ME 1,769 1,380 889 11.7
2500ME 2,242 1,421 930 11.7
VKC- 14XX 400/ 350 2,796 2,239 13.1
1416 7001 450 3,027 2,469 13.1
1418 6001 310 2,992 2,435 13.1
1426 550/ 450 2,886 2,329 13.1
1622 800/ 500 4,097 3,280 18.1
1625 800/ 500 4,247 3,430 18.1
2022 1,000/ 650 6,896 5,435 29.1
2428 1, 100/ 1,000 9,692 7,527 39.8
VWH- 200AE 180 208 149 2.9
300AE 270 214 155 2.9
400AE 359 278 180 3.9
400 359 450 300 4.5
.
600 538 460 310 4.5
800 718 760 470 7.6
1200 1,076 820 540 7.6
1600 1,435 1,040 710 8.9
2000 1,794 1,110 780 8.9
2500 2,243 1,190 870 8.9
1600ME 1,435 1,310 760 10.9
2000ME 1,794 1,380 830 10.9
2500ME 2,243 1,470 920 10.9
36
Specification Equivalent - Level of Water
Water Capacity (L)
Evaporation (Kg/h)
Level Gauge
W=60°C
Model P=0.7MPa Full Normal at 1cm (L)
VWN- 3000 2,690 2,845 2,115 17.4
3500 3,139 2,930 2,200 17.4
4000 3,587 3,605 2,630 21.0
4500 4,036 3,695 2,725 21 .0
5600 5,022 3,885 2,910 21.0
6700 6,009 5,400 4,000 28.6
7300 6,547 5,500 4,100 28.6
8000 7,172 5,630 4,230 28.6
9000 8,069 7,180 5,320 35.2
10000 9,055 7,360 5,510 35.2
11200 10,041 8,680 6,410 40.8
12300 11,000 9,320 6,640 40.8
13500 12,100 9,890 6,810 40.8
VWK- 1416 2,319 1,856 13.1
1618 3,205 2,535 17.8
1820 4,223 3,323 22.8
2022 5,433 4,229 28.8
2226 6,884 5,389 34.6
2428 8,599 6,692 41.8
2630 10,585 8,198 49.7
HB- 025 2,500 3,590 2,490 16.7
03 3,000 3,590 2,490 16.7
04 4,000 4,500 3,190 19.9
05 5,000 4,740 3,430 19.9
06 6,000 6,580 4,710 28.2
08 8,000 6,880 5,020 28.2
10 10,000 9,510 6,650 43.2
12 12,000 9,740 6,890 43.2
15 15,000 11 ,420 8,200 48.8
18 18,000 11 ,420 8,200 48.8
GK- 1428 2,860 2,170 12.8
1628 3,770 2,840 17.5
2028 6,560 4,530 28.8
2228 7,920 5,480 34.7
2428 9,290 6,340 41.9
2730 11,910 8,100 54.1
37
CHECK SHEET OF BOILER WATER BOILER MODEL
DATE Year~ 1 on
m-1' 7 7.1$_mJ.m=rx •:J?~- t- ~ it
BOILER EXH.ECO SOFTNESS F.W, pH D.W, pH B.W, pH ACID CHLORINE SIUCA COMPOUND BOILER WATER
CHECK fl;lj< ~IJj]
CHECK ;!{1'771< CONSUMPTION ION SUPPLY
DATE
7-r~?S
RUNNINGIH
;f{-(7
iD~ ..,
RUNNINGIH
tf.r.:::J
iD~
~
*0
7-r~ ?
***
pH fil pHiil pHfil ftti~H
mg/L
lii~;t;_,
mgll... <D
mgll... ~
<D/~
-~~
tv-..I
BL<:m
;!{1'771<
::to-
REMARK
• ~
as1:: o
~
.. BLUE
#iPURPLE !:::.. CHECK 0
w RED X
1
2 -
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
It TOTAL
MEMO
MEMO
--------------- -- ----------------------------------~------------------------ - -------

*HEAD OFFICE:
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(
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OVERSEAS NETWORK
1.CHINA 6.TAIWAN
IHI MARINE (SHANGHAI) CO., LTO. HU CHERNG (HU CHWAN) MARINE
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)
MANUAL FOR WATER TREATMENT

Published by MIURA Co.,Ltd. Ship machinery Dept. Oct. 2010.
2"d edition December 2010 No. E970-1010-02
All rights reserved, Copyright© 2010 MIURA Co.,Ltd.

No part of this publication may not be reproduced, transmitted , distributed or
publisher MIURA Co. ,Ltd.
Visit us at www.miuraz.co.jp and get t e latest information and Service News!
· Printed in Japan
INSTRUCTION ·MANUAL
FOR
MOTOR- DRIVEN GEA·R PUMPS
March. 19'8 6
Contents
Page
l. Purpose • • 0 . 0 •• •• • 0 0 •• 0 • •• • 0
.
••• 0 ••••• • 0 . 0 •• 0 • •• • • •••• • • 0
. 1
2. Scope of Application 1
3. Outline of Construction 1
4. Transport 1
5. Prevention of Vibration 1
6. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7. Piping ..... ... . ... .. ...... . .... . ........... : . . . . . . . . . . . . 2
8 . Connection . ...... . .. . .. ...... . . .. , . . . . . . . . . . . . . . . . . . . . . . 2

8-l. Alignment 2
8-2. Checking of Alignment 2
9 . Operation .............................................. 3
9-1. Preparation before Operation ........................ 3
9-2. Operation . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . ·4
9-3. Stopping ......... ............................... 4
10. Maintenance 4
10-1. Cautions during Operation 4
10-2. Cautions during Standstill 5
11. Inspection ... . ........ .. ·. . . ............... .............. 5

11-1 . Periodical Inspection . . . ............... .............. 5
11-2. Overhaul . . . . . . . . . . . . . ............... .............. 6
11-3. Checkup . . . . . . . . . . . . . ............... .............. 6
11-4. Assembly 6
12. Troubles and Remedies 7

Instruction Manual for Motor-driven Gear Pumps
1. Purpose
This manual has been prepared for the standard motor-driven gear pumps used on
commercial vessels- for the convenience of persons concerned with handling pumps who
belong to shipbuilders and shipowners.
Note: This manual covers items common to pumps in general. So for sucl;l details as the per-
missible limit of clearances of rotq.ting parts, list of particulars, outline drawings, sectional
assembly drawings,. test results; fist of spare parts and toois, etc. refer to the respective
data separately prepared by manufacturers.
2. Scope of Application
This manual is applicable to A.C. motor driven ordinary pu,mps such as lubricating
oil, fuel oil and fuel valve cooling oil pumps (hereinafter called pumps) .
Note: For special pumps such as cargo oil pumps, bilge pumps, main or auxiliary machinery driven
pumps which are different from ordinary pumps in service or construction, refer to their
respective instruction manuals.
3. Outline of Construction
This pump h11s in its casing one set of gear and shaft supported with bearings and liquid
is contained between the teeth. With the rotation of the gear, liquid is continuously dis-
charged around the casing inside. (See the reference figure)
The bearings located inside the seal section are self-lubricated with the liquid. The
lubrication liquid is supplied to oil passage through oil openings provided on the discharge
side and is returned to the suction side after lubrication of the bearings.
The safety valve protects the pump or the motor by opening the port and by-passing
the liquid to the suction side when the discharge pressure rises abnormally higher than the
set pressure . .
Reference: The procedure for controlling the set pressure is that after the adjust screw of the
safety valve is fully tightened with discharge/suction valves fully open, these valves
are gradually closed to set the discharge pressure at the set pressure and the suction
pressure at -380mmHg. Then the adjust screw is slowly untightened and locked at a
point where the discharge pressure or the suction pressure fluctuates very slowly.
When control is over, pump operation is started with discharge/suction valves open.
4. Transport
In transport it is necessary to proceed as follows.
a. When lifting, pay attention to safety in respect to the weight of the units lifted
and the method of using wires.
b. Be careful to avoid damage to accessories such as piping, valves, cocks, etc:
5. Prevention of Vibration
In order to minimise the vibration of pump and piping, pay sufficient attention to the
reinforcement of pump foundation and piping supports.
- 1 -
6. lnstall.ation
In installation, pay attention as follows:
a. Pump foundation must be as rigid and strong as practical.
b. Considering operation and overhaul, give as ample space as possible .
c. Installation face must be flat.
d. Location of installation rrii.ist be determined in consideration of pump suction
head.
7. Piping
Sufficient attention must be given to piping since it has a great effect on pump
performance .
a. Suction pipe must be as short as possible, and bends must !;>e as few as possible
· to minimize friction loss.
b. Suction pipe mUst be free from air pocket or air invasion.
c. Valves oh the suction side must be guarded against air invasion through the
gland.
d. Filter must be provided on the suction side for pump protection.
e. Flanges connecting to the suction and discharge nozzles should be placed
correctly in order to avoid disturbance of pump alignment when flange bolts are
unduly tightened.
f. Precautions must be taken so that expansion and contraction due to temperature
and weight of piping and valves may not abnormally affect the pump. And at the
same time, precautions must be taken to avoid misalignment of the flange caused
by pipe vibration .
g. Interior of the piping ,must be as clean as possible.
8. Connection
8-l. Alignment
On completing installation, the alignment must be checked and care must be
taken so that no misalignment will occur after connecting with piping . Since -align-
ment is duly carried out in the factory, unreasonable readjustment should be avoided.
Even though misalignment occurs, readjustment must be made carefully by loosening
both of the bolts on the suction and discharge flanges arid the foundation . After the
alignment is made, a knock pin shall be inserted .
a. Horizontal pump
It is desirable that adjustment be made by inserting a liner between common
bedplate and foundation, but if necessary, shims can be piaced between common
bedplate and motor base.
b. Vertical pump
Adjustment is made by placing shims between motor and motor base.
8-2. Checking of alignment

a. Untighten the bolts of the shaft coupling between pump and motor and check
~ 2-
the alignment at four points, 90° apart, on the coupling periphery.
b. For comparing the distance between the faces, fix a dial indicator on the shaft
coupling of the motor side as shown in Fig. l (a) and give the motor coupling one
complete rotation by hand . Then half of the variation in readings is taken as the
value of measurement, which must comply with the value in Table l.
Pump end Motor end
Fig. l
· Table l. Table 2.
Coupling periphery Coupling end face
No. of motor frame No. of motor frame
(mm) (mm)
M180L (ML5-180L) M132M (ML5-132M)

0.05 and less 0.10 and less
and less and less
M200M (ML5-20QM) M160M (ML5-l60M)

0.08 and less 0.18 and less
and more and more
c. For measuring the clearance between coupling faces, insert a thickness gauge at
four points of equal interval as shown in Fig. l (b). Then the value of measure-
ment, which must comply with the value in Table 2.
d. Ensure the rotating direction of the motor.
e. Ti~hten the coupling bolts.
f. Rotate the pump by hand to see whether it rotates smoothly .
Note: A thickness gauge should be adopted for alignment only at the times of repair, intermediate
inspection and periodical inspection. It is preferable to use a dial indft:ator for checkup
after initial installation or piping arrangement.
9. Operation
Operation after installation or reassembly must be carried · out in the following
· order :
9-l. Preparation before operation

a. Fully open the valves of both suction and discharge sides.
b . Open the air vent valve (or cock) on the casing top to fill the casing with liquid.
c. If the pump is locateQ. above the . suction level, pull .the plug out of the casing top
and fill the casing with oil while rotating the pump · by hand in order to fully
spread oil over the teeth and the bearings. Keep the air. vent plug (or cock) on the
discharge side open.
- 3-
d. See that the cock (or plug} of the pressure gauge and compound gauge is open.
e. Rotate the pump by hand to see whether it turns smoothly.
9-2. Operation
a. Start the motor, but at first repeat " ON" and " OFF" operations once or twice
and enter into operation on confirming that there is no abnormal condition with
·respect .to rotating direction, noise, vibration, starting current, etc.
b. Tighten the air vent plug (or cock) after speed has risen, and air is discharged
from the air vent and liquid is pumped up in some time. If liquid is not pumped
up in about 30 seconds after start-up , stop the motor and check the cause.
c. Avoid dry operation absolutely as the sliding contact surfaces of the bearings,
the teeth and the mechanical seal are of self-lubrication construction .
d. Pay a careful attention in the winter season because there . may be a fear of
excessive torque of motor and abnormal noise and vibration of pump caused
by oil viscosity increase. Some treatment such as heating is preferable.
9-3. Stopping
a. Stop the motor.
b. After stopping the pump, close the suction valve and then close the discharge
valve.
10. Maintenance
In order to maintain an efficient operation over a long period, the utmost care must
be taken.
l 0-l. Cautions during Operation

a. Try to operate the pump within the range of the design condition.
b. · Check the vibration, noise, pressure gauge ahd ammeter. If abnormal condition
is surveyed stop the pump immediately. Particularly, for the pu~p provided with
a mechanical seal, protect against vibration in view of the service life of the
mechanical seal.
c. Pay attention to bearin-g temperature rise. If the bearing hQusing can be felt by
hand safely, there is no fear, otherwise, measure the temperature with a ther-
mometer. Keep the permissible bearing temperature at " ambient temperature pluS
40°C" or "liquid temperature plus 20°C" . If low viscosity oil outside the range
of design condition, be careful as the bearings and the gear may be seized.
d. Keep a small amount of continuous leak from the gland. Too hard tightening of
the packing will cause premature wear of the shaft and the sleeve, overheating
arid overload. E5pecially pay a careful attention to a case where oil of high
temperature or low viscosity is used.
e. · Wheh a mechanical seal is used, oil leak is generally very small. If oil leaks in
drips, check the seal.
f. Never throttle the valve bh the suction arid discharge sides. Adjust the flow by
means of the by-pass valve on the discharge side .
- 4-
g. Never operate with the valve closed on the disoht~rgf!! :;;id~, otherwise ~ t~rnperature
rise of the liquid in the casing will cause seizure.
h. See whether the stand by pump is reversing due to the leakage from its non-
return valve.
i. In the case of a pump with automatic starting and :;;topping device, check the
pressure at the start and stop of pump as well as the interval of operation, and
if the interval is too short, check the system.
j. In the case of automatic operation under central control system, take Oiire of
the indication of _gauge on the control panel board.
k. Keep the strainer clean to avoid clogging.
l 0-2. Cautions during Standstill

a. Keep closed the discharge and suctionvalves. But such valves must be kept open
in a case where the pump is of auto start type with a foot valve or a check viilv~,
where the pump is under positive suction head dr where oil is accumulated jn the
pump casing in some way or other.
b. When the pump is shut down over a long _period, the pump must be rotated by
hand or motor periodically (once a week or so).
11. Inspection
ll-1. Periodical Inspection

Excepting the case of abnormal conditions, it is desirable to carry out inspec-
tion periodically in the following way, but since it varies according to the method
of mounting, place of installation, liquid handled, etc. it is preferable that the
operator should make a final plan of inspection in accordance with conditions.
Period
Item Action to be taken Every 12 Every 4
Every 3 months or years or
months 8,000 hrs 20,000 hrs
Check up inner and outer races as well as
Ball bearing balls for exfoliation, and if its trace is found, 0
renew it.
Check up sliding surfaces for conditions of
Line bearing contact and flaw. Measure inside diameter
0
and take necessary steps according to
manufacturer's recommendation.
--
Gland packing Check up condition of fitting and amount of
0
leakage. Renew it if leakage is too much.
Mechanical Check up condition of mating faces. 0
seal Renew it. 0
Check up contact points and flaw in portions .
facing packing and bearing. Measure outside
Shaft sleeve 0
diameter and take necessary steps according
to manufacturer's recommendation.
Check up conditions of contact, flaw in
Shaft sliding faces. Measure the outside diameter
0
of journal and treat it according to manu-
facturer'·s recommendation.
Check up surface flaw and condition of
0
"0" ring deterioration. Renew it if deformed.
Renew it. 0
- 5-
· Throttle the discharge valve to raise d.ischarge
Safety Valve pressure and confirm operation of the safety 0
valve.
Check up tooth surfaces and condition of its
setting to the shaft. Measure the outside
Gear 0
diameter and width and treat it according to
manufacturer's recommendation.
Shaft coup!·
Check up condition of wear and renew them
ing bolts and 0
if abnormal points are found .
rubber rings
Foundation See to it that the foundation bolts are
0
bolts tightened enough.
Note: The hours quoted refer to the operating hours.
ll-2. Overhaul
When overhauling the pump, attention m1.,1st be paid as follows :
a. Understand the construction well by referring to the assembly drawing and make
no mistake in the order of overhaul.
b. When separating fit and flange faces, use jack bolts and wooden hammers, and
never apply force with chisels or drivers.
c. When removing the. rotating element, take care to avoid flaw on sliding faces and
machined surfaces. It is preferable not to overhaul the mechanical seal unless
there is anything abnormal.
d. When removing rotating parts from the shaft, draw off each one carefully after
removing the locking device .
e. Handle the longsized-parts such as shaft carefully so that it may not bend.
f. Handle the parts carefully, by arranging them on sheets of paper or cloth in
good order.
g. At overhauling, put suitable match marks as many as possible to avoid mistakes
when reassembling.
ll-3. Checkup
Measure each sliding part and take necessary steps according to manufacturer's
recommendation.
ll-4. Assembly
Carry out assembly, by reversing the order of disassembly and paying attention
as follows :
a. Remove dust and stain from each part by washing it thoroughly with kerosene.
Repair it if flaw is found.
b. Fit the locking device perfectly in each rotating part if necessary.
c. When fitting the parts with match marks such as fittings and gear, be sure to
follow them.
d. Before assembling the sliding contact faces of the bearings, tooth faces and
mechanical seal, apply enough clean lube oil to them.
e. When fitting the bearings and side cover, take into account the position of oil
channel for bearing lube oil and return oil and the direction of pump discharge
and suction.
-6-
f. Insert each packing il) good order softly one by one from the bottom, staggering
each joint by 90° or 180° to a fixed position and support it lightly with the
packing gland.
g. Carefully fit the mechanical seal ~nd then confirm its movement by hand.
h. Tighten the bolts with an equal force.
i. Check up the alignment as mentioned in Section 8.
j. Rotate the pump by hand to see that it turns smoothly .
12. Troubles and Remedies

Should troubles occur, their causes must be traced and necessary remedies must be
carried out. The following, for instance, can be conceivable as troubles.
Troubles Causes Remedies

. Motor is in trouble. . Repair motor
. Pump seizes. . Repair pump.
. No power source. . Check up electric system.
Pump does not start. . Wiring is broken, or relay, etc. . Repair
are in trouble.
. Foreign matters exist in the . Overhaul the pump and remove
pump. them.
. Pump is not well filled with oil. . Fill it again .
. Air is not vented enough . . Open air plug (or cock)
. Valves are not open . Open valves.
. Valves will not open . Repair ·valves.
Pump starts, but does not . Pump is sucking air. . Check up suction system and gland
discharge liquid. packing.
. Suction pipe or strainer is . Clean suction pipe or strainer.
. clogged.
Motor rotating direction is . Change wiring.
wrong.
~ Pump is sucking air. . Check up suction system, and gland
packing.
. Pump speed are too low. . Cor:rect
. Safety valve is open . . Adjust itselectric source .
setting. -
. Suction pipe or strainer is . Clean it.
Pump starts, but specified
capacity or discharge . clogged.
Liquid viscosity is too low. . Check design specification.
. Gear shaft is worn. . Renew it.
pressure are not reached
. Suction pressure is too high . Check viscosity.
. Instruments are wrong.

{:. Suction Pressure shall be within
-380mmHg.
Confirm full opening of suction valve
Replace them with new ones.
; . Air pockets exist in suction line. . Correct piping.
Pump starts and discharges . Pump is sucking air. . Check up suction system.
liquid but soon ceases to . Pump is sucking air through Check up sealing pipe.
discharge liquid stuffing box.
{: ·Adjust mechanical seal.
Adjust packing.
-7-
0
Abnormal metal contact exists o. Check clearance.
in the rotating parts.
0
Connection is wrong. 0
Check up alignment.
0
Packing is too tightened. 0
Loosen gland or otherwise renew
Pump starts, but motor
packing.
gets overloaded. 0
Pump shaft is bent. 0
Renew shaft.
0
Motor is in trouble. 0
Repair it.
0
Liquid viscosity is too high. 0
Conform it to design condition.
0
Foreign matters ·exist in the 0
Remove them.
pump.
0
Discharge pressure is too high. 0
Conform it to design condition.
0
Bearings are wrong. 0
Renew them.
0
Lubricant is in shortage. 0
Check oil supply to bearings and
return oil system. -
0
Connection is wrong. 0
Check up alignment.
0
Bearings are wrong. . Renew them.
Pump starts, but bear- 0
Shaft is bent. 0
Renew it.
ings get overheated. 0
Thrust has increased. 0 Check whether excessive wear exists
on bearing side or whether pump is
in abnormal suction pressure
condition.
. Bearing assembly is wrong. 0
Readjust bearings.
0
Connecting is wrong. . Check up alignment.
0
Shaft is bent. 0
Renew shaft. .
0
Installation is wrong. . Correct installation condition.
0
Foundation is weak. 0
Reinforce foundation.
0
Other vibration is transmitted. 0
Reinforce piping.
Pump starts, but vibra- 0
Cavitation exists. 0
Conform suction pressure and
tion and accidential noise
viscosity to design condition.
takes place. 0
Bearings are worn. 0
Renew them.
0
Safety valve is chattering. 0
Repair it.
0
Foreign matters exist in the 0
Overhaul the pump to remove them.
pump.
0
Tooth contact is wrong. 0
Renew the gear.
In case troubles cannot be remedied in spite of the above countePmeasures, the causes
may be in the design conditions of the pump, so it is preferable to consult the shipyard or
manufacturer.
-8-
(Reference Fig .)
~21
Horizontal motor-driven gear pump
Nolfte Port Nome

No.
001 CASING 3110 OIL PAN
002 SID!: roYER 402 P\HP BED
003 SIDE COVEll 403 FRMl!:
0()( END CO\IEII 501 Gu.ND PACKlffi
101 DRIVE SIIAFT 504 GlAND
102 DRIVEN SHIII'T 520 1141!:CIIANICAL
103 Cit! VE GE All SEAL
104 DR! YEN G!:AJI 521 M!CIIANICAL
105 KEY SEAL COVER
106 ltEY 522 0 Rtf-(;
107 ltEY 701 SAFETY
110 GEAR SET VALVE BOX
RING 102 SAFEn
Ill SET SCREW VALVE COVER
201 llE.ARING 7()( SAFETY VALVE
202 lHRtJSr BALL 706 SAFETY
BEAJUM; VALVE SEAT
:101 C~LING 707 SAFETY
302 roUP LIM; VALVE SPRING
304 COUPLJI'G 712 SAFETY VALVE
RING SPRING CARRIER
Ja; CCU'Lli'IG 713 SAFETY VALVE
BOLT .t. NuT ADJUST SCREW
7U 0 RING
Vertical motor-driven gear pump
-9-
OPERATION ·M ANUAL
GLAND PACiaNG
Gland packing sho\lld be handled with the following no lice. Unless the gland
packing is handled correctly, not only life of the gland packing becomes short
but shaft sleeve is worn excessively, and eventually, pump e:fficiencybecomes low.
1. Preservation
In order to .keep good condition of gland packing, following attention .shall be paid.
Adverse circumstances · · · ·h eat, 02, 03, oil, moisture, sunlight
Gland·packing easily deforn1ed · · · ·Compacted packing rnade by more than 2 kind
of materials
2. Cleanness
Surface of gland packing should .be kept clean. When gland packing is taken out
from package,thepacking should be put on the clean paper such as news paper to
protect from dust. The packing is in no case put on the dirty floor.
3. Taking out gland packing from stuffing box

Old gland packing in the stuffing box should be taking out with packing tool. Even
small fragment should be taken out. It is not suitable counter measurement to insert
one or two pieces of new gland packing to stuffing box without taking out old ones
excepting that replacement of one or two pieces with new one is acceptable only for
temporary counter measurernent for short operation.
4. Investigation of contact sui'face of shaft or shaft sleeve to gland

.
packing.
If scratch mark or wearing is found on the surface of shaft or shaft sleeve contacting
gland packing, proper sealing can not be obtained even with new gland packing.
And if shaft alignment is had,proper sealing can not be obtained even with new
gland packing.
5. Cutting
In order that stuffing box is completely sealed, gland packing should be cut 1 or 2%
longer from designated dimension with sharp edge to prevent frayed end.·
6. Insert
Gland packing should be inserted to interior of stuffmg box one by one turning
Lwice or three times and be inserted so that both gland packing at interior and
opposite side have same pressed condition .Cut end should be positioned alternately
at 180 degrees.
7. Packing gland
Packing gland should be tightened with two. bolts to pay attention in order not to tilt
the packing gland.
If every gland packing have been inserted into the stuffing box tightly, packing
gland can be tightened with nuts on the bolts by hand when liquid pressure is
2
around 1 to 3 kg/cm . .
If liquid pressure is high, packing gland is once tightened strongly by spanner, and
loosened 112 to 2 rotation and pump should be operated.
If operation at early stage is Carried out in .condition where the gland packing is
strongly _pressed by the packing gland to get less leakage from the stuffing box,
seizure between gland packing and shaft sleeve happens or life of the gland packing
becomes short or shaft sleeve is damaged. And therefore, tigh.tness of gland packing·
should be adjusted for several hours in order to get liquid leakage 3 times lager than
at early stage.
8. Stable condition from start of operation

Paying attention to liquid leakage and motor current together with measuring
temperature on the packing gland, packing gland should be gradually tightened with
nuts taking a time.
If gland packing is once over-heated by excess tightening, effective seal can not be
expected even after loosing the nuts.
One tightening of nuts should be carried on with one rotation at maximum,
normally 112 to 116 rotation.
Next tightening should be canied on 10 to 30 minutes after stable condition has
been obtained.
During above adjustment, initial wearing, melting of grease by heat, uniform of
density of gland packing occurs and sealing co~dition becomes stable.
At this condition, amount of tightening is less than 10% of dimension of gland
packing.
9. Leakage
As gland packing is cool'ed by leaked liquid, if leakage is adjusted to zero or nearly
zero, gland packing is dan1aged in a short time by increasing friction factor between
gland packing and shaft sleeve.
Suitable quantity ofleakage is shown in table 1. This table shows normal quantity
in condition where liquid pressure is 3kg/cm2 converted into :fresh water and shaft
revolution is 3600rpm.
Based on this table, suitable quantity ofleakage should be adjusted taking into
account viscosity of liquid, temperature, specific heat, surface tension, pressure,
foreign matter contained, construction of packing gland, revolution and so on.
Much or less leakage makes life of gland packing shooter.
Table 1
Shaft size in Leakage quantity at early Leakage at stable

diameter stage of operation condition
(mm) (cc/ min) (cc/ min)
16 16 5
20 20 7
25 24 8
30 30 10
35 33 12
40 40 13
45 43 15
50 48 16
55 53 18
60 60 20
Note 1: Table I shows for ordinary gland packing .
8cc/rnin · · · · · ·about 2 drops faU

l6cc/m.in · · · · · ·about 4 drops fall
Note i
ln case that gland packing is bent alon g to shaft, trapezium effect .is obtained in ,
a section as shown figure 1 below. Fig. 1 shows extreme example. Although gland
packing except specially compacted has tendency of this effe~t more or less, this
effect .is poor at cut end.
Therefore, cut end is positioned alterna tely at 180 degrees in order to obtain this
effect.
Example oftrapezium effect

(Gland packing is thick andshaft is small
in diameter:B.ig effect is obtained.)
I
by gland paclilllg
Ideal distribution
Pressure dtstribution
tightening get long to shaft By this 2 pieces,
life other 4 pieces
Connection (In the case of JAW-FLEX COUPLING)
a.
-
Install a key and a hub on both axes. Do not strike the keys and the hubs at this time.
b. Tighten alI setscrews of the hubs.
c. Put ao INSERT into one of hubs.
d. Assemble the hubs ; The end of hub claw and the end of INSERT become a same plane.
e . At this t i me, ad i ust for distanceS (Table!) to become even on the circumference as shown .
in Figure 2. Refer to Table 1 for the tolerance of a: value.
f. Moreover, appropriate a straight edge on the hub outer, check the space between a straight
edge and the hubs at two places about so• away, and a·d just to become less than value that
E: and 13. indicate in Table 1. {Figure2, Figure!)
The longevity of INSERT is greatly influenced according to the accuracy of centering.
g. Moreover, there is a 11ethod of moving qne hub on the axis as showing in F i gure 4, too.
In thi-s case, the end of hub claw and the end of INSERT become , a same plane . Do the meth
of centering "e . and '' f . " . T i ghten all setscrews firm l y by the tightening torque in
Table 2 after centering.
ti . Us e t h e a d h e s i v e ( f o r me t a I ) o
f r t h e s e t sc r ew s o t h a t i t s ho u I d n o t I o o s e n .
(Recommended adhesive : LOCTITE 262)
Figure 1 Figure 2
Figure 3 Figure 4
TABlE TABLE 2
PARALLEL LEVEL
HUB SllE
( E )
TYPE S,M
.. <P 3 5
0. 3 8
1
<P 45,54
0. 3 8
1
q, 64
0. 38"
1
q, 8 4
0. 38
1
SETSCREW SIZE
M4
TORQUE
N·m{kgf ' m}
1. 86{0 .1 9}
ANGLE
(a) •
TYPE H 0. 5 0. 5 0. 5 0. 5 115 3. 63 {0 . 37}
TYPE $,11 0 . 4'1 0.47 0. 63 0. 9 4 M6 6. 66 {0. 68}

({3)mPr
TYPE H 0. 2 2 0. 2 3 0. 31 0 . 47 118 16 . 2{1.65}
STANDARD
DISTANCE t-. 7 1.7 1.7 2. 3 M1Q 29 . 4{3.0}
( S ) IDII
TOLERAN CE ± 0. 5 ± 0. 5 ± 0. 5 ± 0. 5
~- ..
.f(ip\\ ~
Wi ~~
......:... .... MGMTSYS
:~~~ :g: RvAC liB
INSTRUCTION MANUAL 3 SCREW PUMPS

MSE
TAIKO KIKAI INDUSTRIES CO., LTD.

113 SCREW PUMPS MSE
Contents
I 1.
2.
3.
4.
Outline of structure -- ------- ------------------------------------------ -----
Handling -- ----------------------------------------------------------------------- --·
Vibration-proof ----------------- -- -- ------------------------- ---- -- ---- -- -------
Installation -------------------------------------------------------------------------
2
2
2
2
5. Piping --------------------------------------------------------------------------------- 2
6. Connection -------------------------------------------------------- ---- -- -------- --· 3
7. Operation ------------------ --- --- ----- ------------------------------- --------------· 4
8. Maintenance ---------------------------------------------------------------:...... 5
9. Inspection ----------- --------------------------------------------------------------- 6
10. Troubleshooting --------- ------------------------------------------------------ 8
Foreword
This manual has been prepared for "Taiko Type-3
Screw Pump" and describes the essential items for
. handling and maintenance of the pump. The service life
of the pump depends on correct handling and
maintenance.
It is imperative, therefore. that the instructions
given in this manual should be closely followed.
If you have any questions regarding this manual,
please consult our Head Office or one of our branches.
113 SCREW PUMPS MSE
Safety Instructions
Lt. CAUTIONS FOR YOUR SAFETY (!)WARNING
Before operating the pump, read the TRANSPORTATION and INSTALLATION :
instruction manual (s) and folow the TRANSPORTATION work must be
· Waming label (s) carried by only a LICENSED or AUTHORIZED
· Instruction plate (s) PERSON(S) who has enough knowledge on
·Caution plate (s) his or her profession : special attention and
in order to use it correctly. caution are required when fitting a HANGING
WIRE in relation to its weight and gravity
Keep the instruction manual (s) at the
center.
same place for easy access. DROPPING or FALLING ...... DEATH or
Waming label (s) and sign in the instruction SERIOUS INJURY.
manual are classified into
· Waming OPERATION and MANIPULATION
·Caution NEVER ALLOW an UNAUTHORIZED
·Notice PERSON to operate the pump. DO NOT
TOUCH or contact to ROTATING parts or
I<!> WARNING I portion(s).
ROTATING--.. ROLLED IN, BIT. PINCHED and
Indicates a potentially hazardous SPILLED (contacted things).
situation which. if not avoided. could result in
death or serious injury.
lib. CAUTION I
Indicates a potentially hazardous
situation which. if not avoided. may result in
minor or moderate injury.
&CAUTION
OPERATION and MANIPULATION
16 NOTICE I DO NOT TOUCH or contact to
SEALING part or HOT parts while the pump is
Indicates a potentially hazardous IN OPERATION.
situation which. if not avoided. may result in HOT --.. BURNED and INJURED
damaging or defecting a product. It will be
only used for protecting the property, but not INSPECTION and MAINTENANCE
for personal safety. When OVERHAULING the pump,
Footnote : ANSI Z 535 carefully handle the HEAVY weighted parts ;
especially, fitting a HANGING WIRE.
The following work must be done by only DROPPING or FALLING --.. INJURY.
a licensed and authorized person (s) who has Before starting a maintenance work.
· Sing in maintenance work
enough knowledge on health and safety · Cut electric supply
regulation. Electric shock --.. death
Transportation. installation. Unintended Rotation --.. Rolled in. bit. and
piping, wiring, operation. inspection. and Pinched.
maintenance
In any respect. we will not guarantee any

death. injures. damages and losses result in
tollowing reason.
· Modification without our written permission.
· Using and assembling unauthorized parts. 6, NOTICE
When disposing a pump, any accessories.
used parts and oil should be treated as General Operation and manipulation
industrial waste. Do not manipulate the valves and
cocks for the pump without any specific
purpose.
Wrong manipulation --.. Damaging or
Defecting the pump.
1
113 SCREW PUMPS MSE
1. Outline of structure 3. Vibration-proof

This pump is composed of two(2) idler Care should be taken to the
rotors meshed with a power rotor, which are reinforcement of pump seat. pipe bands, etc.
cased in a sleeve. When the power rotor is in order to prevent vibration.
rotated clockwise from the driven side, the
idler rotor rotates in the reverse direction.
The sealed chamber provided for each can be 4. Installation
moved to the discharge side along the screw For installing the pump, care should be
shaft. Therefore. the liquid that enters the taken as follows:
chamber from the suction port is discharged
continuously without rotary motion. At that a. The pump seat should be rigid and of the
same plane.
time. the idler rotor is driven by the liquid
pressure (self revolution power by the oil b. The pump should be installed at the place
pressure varies with the oil pressure and ratio suitable to operation and disassembling,
of top width and bottom width of the idler but for vertical space. should be in
rotor ; So giving variety to that ratio makes it accordance with the dimension indicated in
possible to -set ideal self revolution power the drawing.
corresponding to friction which varies with c. The pump should be installed so as to
the oil pressure. viscosity, etc.) so that only make the loss of pump suction pipe to a
sealing action is made without any pumping minimum.
action. Thus, gearing pressure between
screw shafts. contact pressure with the
sleeve, etc. are held low to keep wear and 5. Piping
loss of force to a minimum. The pump should be installed as near
_The pump is so constructed that the to the liquid source as possible with the
axial thrust caused by the discharge pressure suction lift. bend and suction pipe length to a
to the rotor is balanced automatically with
minimum. Care should be taken with the
the discharge pressure by applying the following items.
discharge pressure to the balancing piston.
a. Mount a filter at the pump suction side to
protect the pump. The three-(3) screw
2. Handling shaft pump has small clearance between
screw shaft and sleeve to prevent surely
For handling, care should be taken as solid particles from entering. After laying
follows: new piping, use a filter of 80-1 00 mesh for
a. When lifting the pump, care should be a while and then replace it with a filter of
taken to safety such as lifting weight, 32-40 mesh after eliminating foreign
hooking, etc. matters completely. In the case of using
low grade heavy oil, mount a filter of 60-80
b. Care should be taken not to damage the
mesh.
piping, valve. cock and other attachments
such as the pressure gauge. b. Mount the suction pipe so as to prevent air
from accumulating and/ or entering.
c. Mount the valve at the suction side so as
to prevent air from entering its gland.
d. Correctly set the flanges connecting to the
suction and discharge ports so as to
prevent the pump from getting out of
center by tightening the flange bolts
excessively.
e. Care should be taken not to apply the
influence of elongation or shrinkage due to
temperature and the weight of piping or
valve to the pump abnormally.
f. Clean the piping inside fully.
2
113 SCREW PUMPS MSE
6. Connection 6.2 Checking the centering

between pump and electric
6. 1 Adjustment of the centering motor.
between pump and electric
motor. a. Check the centering at four (4) places
spaced equally by 90" after removing the
After installing the pump and electric coupling bolts.
motor, check the centering between them, b. Measure the coupling side as shown in Fig.
also taking care not to misalign with piping 1 (a) by fixing a dial gauge on the coupling
.after piping. side at the electric motor side and turning
When the centering is not correct. the shaft fixing the dial gauge one time.
readjust the centering surely by loosening the Then measure the difference between the
flange bolts at the suction and discharge maximum and minimum valves to check the
sides and the foundation bolts. Adjust the centering in accordance with Table 1.
centering by inserting liners between the
c. Measure the coupling and as shown in Fig.
electric motor and its seat.
1 (b) to check the centering in accordance
with Table 1.
d. Check the direction of the rotation of the
electric motor.
e. Attach the coupling bolts.
f. Check the centering by turning manually.
g. Insert the knock pin after adjusting the
centering.
h. Take care not to rust and damage the side
and end of coupling.
(a)
Pump Motor
side side
(Hatf swing of dial gauge:Cl)

(b)
Fig. 1 Fig. 2 Fig. 3
Table 1
No. of motor frame C1 side face No. of motor frame C3-C2 Coupling end face
(mm) (mm)
M l 80L(ML5- l SOL) and less 0.05 and less M 132M(ML5- 132M) and less 0. 10 and less
M200M(ML5-200M)and more 0.08 and less M 160M(ML5- 160M)and more 0. l 8 and more
Note 1.. It is preferable to use a filler gauge only for repair. intermediate survey
and periodical survey, and to use a dial gauge for initial installation or
for checking the centering after piping.
3
113 SCREW PUMPS MSE
7. Operation 7.2 Operation

7. 1 Preparation prior to operation a. Start the electric motor after checking the
motor for direction of rotation. sound.
a. Recheck to see if there is looseness in the vibration, starting current. etc. by making
bolts and nuts at each connection. the ON-OFF operation once or twice.
b. Check the filter for cleanliness and b. After checking the increase of motor speed
clogging. and the appearance of oil from the air vent
port. close the air vent port and then
I
c. Open the valves at the suction and
discharge sides fully. operate the pump.
d. Check that the cock or valve of the c. The screw shafts. bearings and sliding
instrument is opened fully. surfaces of mechanical seal inside the
e. Recheck the direction of rotation of motor pump are self-lubricated, so avoid the pump
and pump. (Proper direction of rotation is operation with no load.
clockwise from shaft end.) d. When starting the pump in colder places.
f. Start the pump after venting air at the care should be taken to the overload to
discharge side. Oil will appear from the vent motor. abnomal sound and vibration which
port. When the oil fails to appear about are caused by the increase of oil viscosity.
thirty (30) seconds later. it may be
considered that air is sucked at the
suction side or larger suction resistance
prevents the pump from sucking the oil.
In this case. stop the pump and then
inspect the suction line.
g. Supply oil to the casing fully at the time of
initial operation after installation. When the
pump is operated initially or a long period
has passed to the next operation, the
screw shafts and bearings inside the pump
and the sliding surface of the mechanical
seal may be dried. so in this case turn the
coupling by hand for a while to distribute oil
well to each part.
h. Care should be taken to the point that
when there is a difference of about 20'C or
more between the temperatures of working
oil and pump casing and the working oil of
higher temperature is discharged suddenly
into the pump, the pump may get out of the
centering with heat strain and may be
seized. Especially when starting the pump
with high temperature (70'C or more).
make warm-up operation, (make the casing
temperature even by operating the pump at
low speed and no load using the tank head
or the hydraulic oil of warming pump.)
Operate the pump after preheating the
pump casing to the temperature near the
working oil temperature.
i. Do not use other fluid except spec oil and
flushing wash the line.
4
113 SCREW PUMPS MSE
8. Maintenance 8.2 Caution during pump stop

8. 1 Caution during operation a. Close the valves at the suction and
discharge sides. But for the automatic
a. Try to operate the pump with the range of pump, mount a foot valve or check valves
design specification. at the suction side or opens fully both
b. Take care of vibration, sound, pressure suction and discharge valves when oil is
gauge, ammeter, etc. during operation. If accumulated by forced head or other
any abnormality is found during operation, means.
stop the pump immediately. Especially, the b. When stopping use of the pump for long
pump is provided with the mechanical seal, periods. rotate the pump by hand or with an
take care of vibration by taking account of electric motor at suitable intervals (every
the life of the mechanical seal. week).
c. Take care of the temperature rise of t he
mechanical seal. If you can touch the cover
with your hand, the temperature is f ine.
But if you cannot touch it with your hand,
measure the temperature with the use of a
thermometer. Allowable temperature is
room temperature plus 40t: or less and
liquid temperature plus 20t: or less.
d. Since the pump is provided with the
mechanical seal and oil is handled, a small
amount of oil dispersion may be allowed.
But inspect the pump if continuous oil leak
is found.
e. Operate the pump with the valves at the
suction and discharge sides opened fully.
Adjust the flow rate by the bypass circuit
at the discharge side.
f. Never operate the pump with the valve
closed at the discharge side. Continuous
operation of the relief valve or return type
relief valve inside the pump for long hours
may cause the oil temperature inside the
pump to be raised and the valve to be
seized.
g. Check the stand-by unit if it rotates
reversely on account of oil leak from the
check valve .
. For the automatic pump, take care of the
pressure at start and stop, and times of
start and stop. If it works. frequently, adjust
the level.
i. When the automatic operation is done by
central control, take care of the
instruments on the panel.
Check the filter for cleanliness and
clogging.
5
113.SCREW PUMPS MSE
9. Inspection 9.3 Inspection

9. 1 Periodical inspection Inspection should be done at each
sliding surface.
It is preferable to inspect the pump
periodically unless any abnomality is found.
but an inspection list should be prepared by 9.4 Reassembling
the operator according to actual conditions
Reassembling should be done in the
because the pump condition may vary
I
reverse order of disassembling taking care of
according to the method of installation.
the following items.
location. applied liquid etc.
a. Clean each part'fully with washing oil to
eliminate dust. dirt. etc. If any scratch is
9.2 Disassembling found. repair it.
b. Mount the stopper securely to the rotating
Disassembling should be done carefully part.
as follows:
c. Reassemble the faucet joint or matching
a. Be familiar with the structure by referring surface in accordance with the matching
to the drawing and disassemble the pump mark.
in the proper order.
d. Apply fresh lubricant fully to the bearings,
b. Use push bolt or wood hammer for screw shafts and mechanical seal. and
removing the faucet joint or matching then reassemble them.
surface. Never use tools such as a chisel.
screwdriver. etc. for removing them e. Reassemble the casing cover and
forcedly. mechanical seal cover with taking care of
the oil port position of return oil.
c. Take care not to damage the sliding or
machined surface when removing a f. Reassemble the mechanical seal carefully
rotating body. and then turn the shaft with hand to check
Never damage the sliding surface of the rotation after reassembling it.
mechanical seal. It is preferable not to g.Tighten the bolts evenly.
disassemble the mechanical seal unless h. Check the centering in accordance with
some abnormality is found. item 6 "Connection".
d. When removing a rotaing part. remove it i. Check that manual rotation can be done
smoothly after taking out the stopper. etc. smoothly.
completely.
e. When handling a slender part such as
screw shaft. handle it carefully so as not to
bend it.
f. Place the disassembled parts on a paper or
cloth in order and handle them carefully.
g. When disassembling the pump, make
matching marks on each part to facilitate
correct reassembly.
6
11J3 SCREW PUMPS MSE
Period
Parts Inspection Every year or Every 4 years
8,000 hours or 20,000 hours
Inspect orbit face or ball surface for
Ball bearing 0
separation. If such trace is found, replace it.
Sliding bearing Inspect the sliding surface for damage. 0
I
Inspect the sliding surface. 0
Mechanical seal
Replace it with a new one. 0
Inspect it for damage and hardness.
If deformed, replace it. 0
0-ring
Replace it with a new one. 0
Oil seal Inspect it for damage. If deformed, replace it. 0
Check the valve's action with the higher
Safety valve discharge pressure by throttling the valve 0
at the discharge side.
Inspect the part accommodating screw
Sleeve shaft for contact. damage, etc.
0
Inspect the screw face. 0.0. and sliding
Screw shaft 0
surface for contact. damage, bend, etc.
Coupling bolts Inspect them for wear. If abnomal, replace
and rubber ring it with a new one.
0
Foundation bolts Inspect them for looseness. 0
7
113 SCREW PUMPS MSE
10. Troubleshooting
If any trouble is found. fine the cause immediately and take
precaution against it. The following troubles can be considered.
Trouble Cause Precaution

Pump fails to start O Eiectric motor is in failure. O Repair the motor.
O Pump is seized. O Repair the pump.
O Eiectricity is not fed. O Check the electric circuit.
O Eiectric wire is broken. or relay O Repair.
is in failure.
O Foreign matter is entered. O Disassemble and then repair
by removing the foreign .matter.
Pump is able Liquid is not O Oil is not supplied sufficiently O Replenish.
to start, but transferred. to the pump.
O Venting air is not sufficient. Q Open the air plug (or cock).
O Valve is not opened. Q Open the valve.
O Valve fails to open. O Repair the valve.
O Air is being sucked. O Check the suction line.
O Suction pipe or filter is O Ciean.
clogged.
O Eiectric motor rotates in O Change the wiring.
reverse direction.
Required capacity O Air is being sucked. O Check the suction line and
and pressure are gland.
not met. O Speed is lower. O Check the electric source.
O Safety valve is opened. O Adjust the pressure 1 *
setting of the safety valve.
O Suction pipe or filter is O Ciean.
clogged.
O Fiuid viscosity is lower. O Check the design specification.
O Screw shaft and shaft are O Replace it with new one.
abraded.
O Suction pressure is too high. O Check the design specification.
(within -0.05MPa as standard)
O lnstrument is poor. O Replace it with new one.
Liquid is not O Air is accumulated in suction O Repair the suction line.
transferred initially, line.
but not O Air is being sucked. O Check the suction line.
immediately. O Air is sucked by stuffing box. O Check the mechanical seal.
Electric mater is O Abnormal contact is inside O Repair.
overloaded. motor.
O Centering is poor. O Adjust the centering.
O Shaft is bent. O Replace it with new one.
O Eiectric motor is broken. O Repair.
O Fiuid viscosity is too high. OTo be accorded with the
design specifications.
O Discharge pressure is too OTo be accorded with the
high. design specifications.
O Bearing is poor. O Replace it with a new one.
Gland is over- O Pressure inside stuffing box is O Check the release line.
heated. too high.
O Mechanical seal assembly is O Adjust the mechanical seal.
poor.
The pump vibrates O Centering is poor. O Check the centering.
and makes a O Shaft is bent. O Replace it with a new one.
strange noise. O lnstallation is poor. O Correct the installation.
O Other vibration is transmitted. O Reinforce the piping.
O Cavitation is produced. O Check for air buffles in fluid.
Set the suction pressure and
viscosity in accordance with
the design specifications.
O Safety valve is chattering. O Repair the safety valve.
O Foreign matter is entered. O Disassemble and repair by
removing the foreign matter.
O Bearing,screw shaft or shaft O Replace it with new one.
sleeve is abraded.
8
113 SCREW PUMPS MSE
When trouble cannot be repai red even *1 Adjustment of the working pressure of
though the above precaution is taken. please safety valve.
inform the shipyard or this company of the The pressure setting of the safety
following items. because the design condition valve can be adjusted by tightening the
of pump may be caused. discharge valve gradually until the discharge
a. Type, manufacturing number. application. pressure is reached after opening the
etc. of pump. discharge and suction valves fully and
b. Properties of handling liquid (kind, tightening fully the adjust screw of the safety
I
viscosity, temperature. etc.) valve (in the case of shop test. the suction
valve is closed gradually and set in the state
c. Features of piping (suction pressure.
of the suction loss as shown in the design
location and mesh of filter. number of
specifications but the suction pressure within
bends. etc.)
-0.05MPa is standard. In the case of many air
bubbles in fluid, it is necessary to reduce the
suction pressure.) and by tightening the
adjust screw gradually and setting the
pressure with the lock nut at the slightly
swinging point of the discharge or suction
pressure at no load side.
After adjusting the working pressure
of the safety valve. operate the pump with the
discharge and suction valves fully opened.
9
TAIKO KIKAI INDUSTRIES CO., LTD. URL http:/ /www.taiko-kk.com
•Head Office & 209-1 Shimotabuse, Tabuse-cho, Kumage-gun, Yamaguchi pref. 742-1598 Japan /l
~ VA<U.IIPIAF
Factory TEL: 81-820-52-3113-4 FAX: 81-820-53-1 001 E-mail: business@taiko-kk.com £-~~Q
•Tokyo Branch 4th floor, Suidobashi MS Building, 3-4-9 Misaki-cho, Chiyoda-ku, Tokyo 101-0061 Japan
TEL: 81-3-3221-8551 FAX: 81-3-3221-8555 E-mail : tokyo-br@taiko-kk.com
L/
/) /1
vTrJR
• Osaka Branch 8th floor. KC Building, 3-4-7 Kawara-machi, Chuo-ku, Osaka 541-0048 Japan C7 '('!!!/,_,
TEL: 81-6-6231-6241 FAX: 81-6-6222-3295 E-mail: osaka-br@taiko-kk.com z::;;:y~
Beijing Office· Shanghai Office · Taiko Ko ea C.7~
. ISO 900 1 certified 2007/ 12 MUTSUMI

Operafing Instructions MMO
MMO
High Pressure Centrifugal Pumps
P47121.8/ 2E
Contents
Page
0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
0.1 Before starting initial operation . . . . . . . . . . . . .
0.2 Quality control plan ... .. ... . . . . . . . . . . . .
0.3 Name plate ........ . . . . . . . . . . . . . . . . . .
0.4 Handling .... . ........ ... ....... . ... .
Installation ....... : . .... . ..... . .... . .
1.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Alignment of pump and driver . . . . . . . . . . . . . 2
1.3 Connecting the piping . . . . . . . . . . . . . . . . . . . 3
2 Start·up and shut-down . . . . . . . . . . . . . . . . . . 3
2.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Dismantling and reassembl ing .... ... ...... . 4
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . '
3.2 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Bearing arrangement . . . . . . . . . . . . . . . . . . . . 6
3.5 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Exploded view and list of components . . . . . . . . 7
4 Mechanical seals . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Trouble shooting . . . . . . . . . . . . . . . . . . . . . 10
0 General 0.4 Handling
When handling the pump directly coupled with the drive r,
hook a lifting rope on the pump and its driver as illustrated
below.
0.1 Before starting initial operation (Absolutely avoid to hook a lifting rope on the eye bolt of
If installed properly and operated correctly, the pump can
the driver.)
perform its specific performance in satisfactory condition
throughout a long term. Before putting the pump · into
initial operation, carefully read this Instruction Manual to
handle, operate, and maintain the pump properly .
Keep this Manual all the t imes where operator or main-
tenance personnel can have access to it easily for study any
ti me when required.
All the pump parts and components .are so manufactured
under severe quality control that they can fulfill their
functions to entire satisfaction. But any fault or trouble
attributed to one of the causes described below shall be out
of our guaranty. Fig. 1
(1 ) The ordered pump is used to handle the liquid of a

{ .
·~ different nature, density, temperature, or others than
those clearly specified in the order specification, or
operates outside the operating range specified therein .
(2) Pump damage is caused as a result improper handling
and operation, faulty installation, the use of unsuitable .
material, faulty or unskilled piping, etc.
(3) Pump damage is caused by natural disaster.
When repair is required, it is recommended to repair the
pump by our skilled serviceman as far as possible or to
return it to our factory.
0.2 Quality control plan

All inspection and test for material, dimension, perform- •'
ance, etc. are performed in the manufacturing process in
accordance with quality control plan (QCP) submitted to
\jJ th e purchaser when the pump was ordered. Only pumps
th at have fully satisfied the specified performance values
u pon inspection and test are allowed for shipment.
1 Installation
0.3 Name plate

Any pump is provided with a nameplate. Please inform us 1.1 Mounting
of the followings when ordering spare parts and rep lace- Installation and leveling of the pump should be performed
ment parts. by skilled workers. Improper installation and leveling/
e1) Pump type, Mfg. No. (Indicated in KH or KP). date of centering would cause various troubles during the pum p
producti on, etc. (identified on the name plate) runn ing.
12) Parts name, material, quanti ty, etc. described in In the case of the pump directly coupled. to the driver on
Sectional Drawing and Spare Parts List. the common baseplate, the pump set is shipped after com-
pletely levelled and centered at our fabrication shop .
However, follow the sequence given below for local installa-
tion of the common baseplate and recheck the level and
centering of pump and driver.
1
( 1) Prepare packers and leveling shims or taper Iiners neces- 1.2 Alignment of pump and driver
sary for the common baseplate installation. The pump shaft and the driver shaft (motor shaft) must be
(2) After complete cure-up of the foundation concrete, centered in line.
place and position packers along the both sides of each Follow the sequence given below for the leveling and
anchor bolt seat (if the shims are apart more than 800 centering work.
mm, additional one more shim or extra shims at equi- ( 1) Centering and leveling can be performed easily by hold-
distance between them as shown in Fig. 2) so that the ing a straightedge on the flange top of the coupling set
common baseplate locates thereon in specific position. and inserting a wedge gauge between two coupling
After each packer and shim (or taper liner) is posi- halves, as illustrated in Fig. 3.
tioned precisely, fix it by mortar application. In this case, a=a1, and b=b1, must be satisfied for the
complete leveling and centering. Accordingly, equal
Shim (Taper line r) Shim (Taper liner) clearance between two coupling halves along its entire
periphery will show that the both shafts are complete-
ly centered and levelled . .
As alternative method, a clearance gauge can be used
for the checking.
:
'
1 - - - - - - - >800 -----~ Straight edge
Fig. 2 Fitting the shims
(3) In this case, adjust and keep each packer horizontally

using a level gauge. The height of each packer is fine-
adjusted by means of shims when the common base-
plate is installed. Therefore, in this stage it would be
sufficient only to keep each packer right horizontal.
. (4) After complete cure-up of the mortar with packer on,
temporarily install the common baseplate (with the
pump and driver installed thereon) onto the packers /
Straight edge
and check the center height of the pump. Furthermore,
hold a level gauge on the discharge flange to make fine- Fig. 3
adjustment of the pump horizontality in both axial and
corsswise directions by inserting previously prepared (2) Furthermore, a dial gauge is used for easier and more
leveling shims (taper liners). precise centering and leveling. In this case, the clear-
For the pump that was shipped without the motor, ance is measured at four points spaced with 90° while
adjust its horizontality in both axial and crosswise turning the coupling set, and the alignment is perfect
directions by a level gauge being held in contact with provided that the measured deviation in clearance is
the discharge flange surface and the motor mount seat. within 5/100 mm in both axial and radial directions.
(5) After the pump was positioned and levelled as speci- (3) Be sure to check the motor rotational direction before
fied, make pre-center alignment between the pump and connecting the coupling halves. The correct rotational
the driver using a centering leveling jig (refer to Para. direction of the pump is arrow-marked on the both
1.2 for the detail.). suction and delivery casings. Namely, it is clockwise
(6) After the pre-centering work, grout mortar in each viewing from the motor side.
anchor hole . (4) After the above check, connect the coupling halves.
(7) After complete cure-up of the mortar around each
anchor bolt, tighten alternately the anchor (founda-
tion) bolts with uniform tightening torque.
(8) Grout mortar under the common baseplate until it
reaches completely each corner so that any cavity does
not exist in the grouted mortar.
After complete cure-up of the grouted mortar, recheck
the horizontality of the common baseplate.
(9) After completion of the above works, connect both the
suction and the discharge pipes to the pump.
2
1.3 Connecting the piping 1) Are the pump and the suction pipe filled up with
After completion of the direct coupling work, the suction pumping liquid?
and discharge pipes must be connected to the respective 2) Is the driver's rotating direction correct? (Pump
flanges of the pump. Perform the piping connection with rotates clockwise viewing from the driver's side)
good care for the following items. 3) No abnormal in the direct coupling?
( 1) When connecting the suction and discharge pipes, 4) No abnormal load to the pump by piping?
take proper measure to prevent piping load from
5) Is the flushing pipe connected properly and the
directly . acting on the pump. Direct load to the pump
water flow rate proper?
by piping would cause trouble.
6) Are the suction valve fully opened and the discharge
(2) The suction line must be installed in upward slope
valve fully closed?
(about 1/50) toward the pump to prevent air pocket in
the case of suction lift. And it must be installed in 7) Isn't the gland packing tightened irregularly or too
downward slope reversely in the case of forced suction. excessively? Also, isn't there any abnormal leakage
from the gland packing?
(3) Take care to minimize various losses of the suction
pipe and avoid sudden changes of cross-section and use 8) Can the pump be turned lightly by hand? Isn't there
of abrupt bends in the suction piping. Select the any touch of contact in the pump?
suction pipe such that the size is same or bigger than (2) If nothing abnormal is found upon checking the above
the pump suction nozzle size.
(
·.i,J
. .
(4) When the suction pipe size is different from the pump
items, turns on the driver's start switch and off it .
immediately to check that the pump rotates smoothly
suction nozzle size, use an eccentric tapered pipe to and shuts down quietly.
connect the suction pipe and pump suction nozzle and (3) If normal rotation of the pump is confirmed, gradually
to prevent air pocket. open the discharge valve up to the specific duty point,
(5) After completion of the piping work, recheck a'lign- after the pump reached its specified running speed.
ment as described in 1.2. When leakage from the gland is much, re-tighten the
gland packing with equal torque for adjustment.
(4) If the pump continues running with the discharge valve
fully closed, the liquid temperature in the pump will
rise, causing trouble of the pump. In such case, shut
down the pump immediately without fail.
(5) When starting the pump after long term shut-down,
recheck the above check items ( 1). and (5} thru (8) to
verify that the pump is abnormal-free.
"'v·.... 2.2 Shutdown

Follow the procedure given below for shutting down the
pump.
(1) Gradually close the discharge sluice valve up to full
close position. However, it may be left as opened
providing that a check valve is included in the discharge
pipe and the back pressure is sufficient.
(2) Turn off the driver's stop switch. At the same time,
check that the pump rotational speed decelerates
2 Start-up and shut-down smoothly and stops quietly.
(3) Stop external flushing, if any.
(4) Fully close the suction valve when the pump is kept as
2.1 Start-up shutdown for long time.
( 1) Before starting the initial operation after installation, (5) When there is a possibility of freezing in the pump,
observe the following check items and, if anything completely drain out the pumping liquid inside pump.
abnormal is found, take necessary corrective action in (Complete drain of the liquid in the line is more
accordance with this Manual. safety.)
3
2.3 Maintenance Dimensions (in mm)
Stuffing box compartment
Pump sizes
d D
32 34 50 45
2.3.1 General 40 34 50 45
The pump must run quietly and without abnormal vibra- 50 39 55 45
tion all the times. Therefore, carefully observe the follow- 65 45 65 55
ing check items while the pump is in running and, if
anything abnormal is found , shut down the pump im-
mediately and search the cause.
Packing Lantern
1) Does the suction pressure fully satisfy the pump re- Mode of Con- Pump ring 1 l ring
operation struction sizes
quired NPSH (NPSH req.)? Qty . Db Oty .
. . . . Read the suction line pressure gauge to check it. Suction lift or 32 8 8 suction
positive suction 40 8 8 end 1
2) Is the specified discharge pressure satisfied? N/a
pressure 50 8 8 discharge
3) Isn't the driver in overload running? ~ 1 bar 65 8 10 end-
[>(
32 10 8
4) Are the both suction pipe and pump filled up with Positive suction
40 10 8
pumping liquid or the discharge valve fully opened in the pressure N/b
50 10 8
pump running? > 1 bar
65 10 10
5) Is the bearing temperature normal? (no abnormal 32 6 8 suction
Vacuum
40 6 8 end 1
temperature rise?) (with con - N/c
densate feed) 50 6 8 discharge
6) Is leakage from the gland proper? 65 6 10 end 1
1) for both shaft seals
7) Is the pump running with no abnormal noise and no
vibration?
2.3.2 Shaft seal

The shaft seal is available in two different types of gland
packing and mechanical seal. The descriptions hereunder
covers the gland packing seal type. Ref11r to Chapter IV for
the detailed instructions of the mechanical seal.
The gland packing insertion space in the casing cover is
. designed to be equivalent to either five packing rings
(461 0) or three packing rings plus one lantern ring (4580).
2.3.3 Dimensions of stuffing box compartment

· and no. of packing rings 3 Dismantling and reassembling
N / a Discharge end
N/d Bot h ends
3.1 General
Before overhauling, be sure to check that the pump is in
absolutely unstartable condition.
In addition, check without fail that the both suction and
discharge line sluice valves keep full-close position, the
pump casing is normal in its temperature and no pressure is
loaded to the pump casing (that is, the casing is empty) .
When overhauling, maximum possible effort must be made
to avoid accidental trouble. Also, good care must be
exercised to protect the pump components/parts from
Fig. 4 Stuffing box compartment impact and flaw in handling of them .
4
3.2 Dismantling (16) When the part is hard to be removed after long terrn
For dismantling the pump, follow the disassembling operation of the pump, apply the penetrant to the part
sequence given below with reference to 3.6 "Exploded or use a special jig for removal. In any case, do not hit
View" and parts names listed therein. it.
Also, keep all the overhauled parts in order of overhaul so

as to smooth the reassembling work without any error.
(l) Remove any small pipings if any. 3.3 Reassembling
Reassemble the overhauled components and parts in the
(2) Remove the coupling guard.
reverse sequence of the overhauling with reference to
(3) Remove the coupling bolts and then remove the prime "Exploded View". For normal running of the pump,
mover from the common baseplate. specially follow the precautions given below.
(4) Pull out the pump side coupling half from the pump (1) Clean adequately each pump component/parts. Prevent
shaft. adhesion of dust on the connections and joint portions.
(5) Chock up the stage casings before proceeding with dis- (2) When replacing the ball bearings, use the designated
mantling to prevent them from falling down when the bearing No. without fail (See 3 .4).
bearing housing is removed. (Refer to Fig. 5)
'(7)
(3) Take good care not to damage each 0-ring and the
(6) Begin the overhauling from the discharge side. sealed contact surface of each parts.
Remove the end cover and then take off the circlip and (4) When replacing the rotating assembly (shaft, impeller,
the spacer ring. sleeve). determine the dimension (Y-X) of the casing
side spacer ring in the discharge side bearing housing in
accordance with the procedure shown in Fig. 6. In this
case, move reciprocally the rotating assembly from the
~~~~~~~~~;W'Axial discharge side to the suction side and vice-versally and
al ignment
determine the dimension of spacer ring based on the
lmpeiler
1st stage center position of the rotating assembly.
5040.1 9320.1 5040.2
Diffuser in
1st stage casing
Fig. 5
f" (8) After unscrewing off the bolts fixing the discharge side
v bearing housing to the baseplate and the casing nuts
from the casing, pull out the bearing housing together
with the ball bearing from the pump shaft.
(9) Dismantle the spacer ring, circlip, delivery side shaft
protecting sleeve and gland in sequence.
Fig. 6 Correctly sized spacer ring
(10) Unscrew off each tie bolt nut from the discharge side,
and dismantle the discharge casing and the last stage (5) Follow the table below for the tie bolts tigh tening
· impeller. torque.
( 11) Dismantle the stage casings and impellers in sequence (Unit: kgf)
of every stage. Pump size 32 40 50 65
( 12) Dismar:~tle the suction casing and the gland. Tie bolt 7 8 10 10
tightening torque
(13) Draw out the pump shaft from the bearing housing.
Table 2. Torque tightening tie bolts
(14) When the ball bearing is replaced, take it out from the
bearing housing using a pipe or the like. (6) After the reassembling work, check the condition of
(15) Inspect each part carefully and repair or replace it the coupling set in the procedure given in Para. 1.2 and
when deemed as necessary. start the pump pursuant to Para. 2.1.
5
3.4 Bearing
(1) Bearing specification - Single row deep groove ball
bearing
Pump size 32 I 40 50 65
Bearing No. 6305C3 6306C3 6307C3
Table 3. Bearing No.
Further, the bearings used are of contact rubber sealed

type.
Example: Makers NSK DDUC3
NTN LLUC3/2A
KOYO 2RS
(2) Bearing ·replacement interval
Replace the bearings with new ones either every about
5000 running hours or every two years' running.
3.5 Spare parts
3.5.1 Order for spare parts

When ordering spare parts, let us have the following in-
formation without fail.
• Pump type No. and size
• Manufacturing No.
(These numbers are identified on the name plate attached
to the pump).
• Part name
• Part No.
(Refer to attached List of Components)
• Required quantity
• Material code
3.5.2 Recommended List of Spare parts for 2 Years' Operation

No. of pumps (including standby pumps)
Part No. Part designation 1 and 2 I 3 I 4 I 5 I I
6 and 7 8 and 9 I 10 and over
No. of sets
2100 Shaft with keys 1 1 2 2 2 3 30%
2300 Impeller 1 1 1 2 2 3 30%
3210 Deep groove ball bearing 1 1 2 2 3 4 50%
4120.1 0-ring 1 1 2 2 3 4 50%
4120.2 0-ring 1 1 2 2 3 4 50%
4610 Gland packing (set of rings) 2 2 3 3 3 4 50%
5240 Shaft protecting sleeve 1 1 2 2 3 4 50%
On pumps With mechanical seals
4000 Gasket Part nos. 2 3 6 8 8 10 50%
5241 Seal sleeve 4610 5240 + 2 2 2 3 3 4 40%
4330 Mechanical seal are not fitted 2 2 4 5 6 7 50%
Couplmg
I
Elastic transmission elements 2 2 3 3 3 4 50%
6
3.6 Exploded View and List of Components
4120.2 2300 1080 4120.2 2300 1711
- ~
)
I
9050
·- - /
(
\
--- ___.524~
0 1~
4120 l
1
9200.2
1070
~.I
0
Part No. Part Designation Part No. Part Designation Part No . Part Designation
1060 Suction casing 4120.2 0-ring 9021 Gland bolt
1070 Discharge casing 4520 Stuffing box gland 9050 Tie bolt
1080 Stage casing 4580 Lantern ring 9200.1 Hex . nut
1711 F inal stage diff user 4610 Stuffi ng box packi ng 9200.2 Hex. nut
2100 Shaft - 5040.1 Spacer ring 9201 Threaded plug
2300 Impe ller 5040.2 Spacer ring 9320.1 Circl ip
3210 Deep groove ball bearing 5070 Thrower 9320.2 Circl ip
3500 Bearing housing 5240 Shaft protecting sleeve 9400.1 Key
3600 Bearing cover 5251 .1 Spacer sleeve 9400.2 Key
3610 Bearing end cover 9010 Hex. head bolt 9400.3 Key
4120.1 0 -ri ng 9020 Stud 9400.4 Key
7
4 Mechanical seals
~ s
dmm Amm .
MM032 38 11
4.1 General Cautions MM040 38 11
(1) The mechanical seal service life is significantly shortened MM050 43 15
by impurities if included therein . Therefore, clean the
MM065 50 22
mechanical seal and the pump internals when reas-
sembling and prevent invasion of such impurities into
the mechanical seal from the flushing line during pump
running.
(2) Absolutely avoid dry-running (including the running
at seal chamber pressure less than the atmospheric
pressure) . Dry-running would cause seizure and damage
4.3 Dismantling
of the mechanical seal and occasional damage of the
pump.
(3) The slid ing end face of the mechanical sea l is finished
very accurately by lapping. So, it must be handled with 4.3.1 Dismantling procedure
good aare neither to flaw nor break the sliding end Refer to para. 3.2 for the pump d ismantling procedu re. The
face. mechanical seal shall be dismatled from one side and then
to other side. The dismantling sequence hereunder is
(4) Once overhauled, replace the sliding end face of the
subject to completion of d ismantling the bearing housing
mechanical seal with new one or repair it by lapping
unit.
as a rule.
(1) Unscrew off hexagon socket head bolts and then
remove seal cover (4710) from the casing.
4.2 Construction
Fig. 7 illustrates the mechanical seal construction. (2) Seat (4 750) is inserted in the seal cover through 0 -ring
(4120.3). Therefore, it can be taken out only by push -
ing it strongly by hand.
(3) Pull out the rotating parts of mechan ical seal from seal
sleeve (5240). At this time, the spacer sleeve (5251.2)
may be pulled out in advance to prevent washer (4720)
from contacting the spacer sleeve (5251 ).
4.3.2 Inspection and adjustment of dismantled

parts
(1) Inspect the wear state of the sl iding surface of the seal.
(2) As a rule, the mechanical seal once used, must be
I mo replaced with new one irrespective of the runn ing
I
4770 47AO
9140 4120. 1 hours . However, stopper (4740) , back-up ring (4724)
Fig. 7 Construction of mechanical seal and spring (4 770) are available for further re-use unl ess
they are flawed. In addition, if the wear degree of seat
Part No. Part Designation Materials Pes.
(4750) and washer (4720) is small , these parts also are
4000 Flat gasket Valqua # 1500 2
4120.3 o-r irig V. iton 2 available for further re-use by lapping-repair .
4120.4 0-ring Viton 2
(3) Inspect the presence or non-presence of f law on the
4710 Seal cover FC20 2
4720 Washer Carbon 2 portion of seal sleeve (5240) to insert the 0-ring
4724 Back up ring SUS304 2 (4120.4) .
4740 Stopper SUS304 2
4750 Seat SiC 2 (4) Check the presence or non-presence of flaw on the
4770 Spring SUS304 2 contact surface of seal cover (4710) and the seat
5241 Sea l sleeve FC20+HCr plated 2 (4750) .
5251 .2 Spacer sleeve FC20 2
5600 Pin SUS316 4 (5) After the above inspection, clean adequate ly each part
9140 He x. bol t SUS420J2 8 in washing oil.
8
4.4 Reassembling (4) After applying oil coating to the seal sleeve, insert t he
( 1) Insert 0 -ring (4120.3) in Fig. 8 in the seal cover after rotating portion of the mechanical seal on the seal
thin oil coating (turbine oil or machine oil) was applied sleeve in alignment of the spring rear projection with
thereto. Then, apply same oil coating to the periphera l the notched hole of the seal sleeve. And push t he
surface of the seat and insert it in the seal cover, with sliding surface of the washer in the spring compression
its lapped surface upside. At this time, pay special direction two or three times to check the 0-ring follow-
attention to the positions of the notch for seat locking ability.
and lock pin (5600). After insertion, check for inclina- (5) Insert the spacer sleeve (5251.2) in the shaft.
tion of the seat.
(6) Wipe off the sealing end faces of the seat and t he
washer in fingers for complete removal of dust. After
4750 that, joint the seal cover with gasket (4000) to the
casing by tightening hexagon socket head bolts (9140)
with uniform tightening torque.
This completes the mechanical seal reassembling.
4710
Fig. 8
(2) After inserting back-up ring (4 724). 0-ring (4120.4)

and stopper (4 740) in washer (4 720). insert the pro-
jected portion of the spring (4 770) into the notched
hole of the washer. In this case, pay special care to the
following.
(a) Apply oil coating in small quantity to 0 -ring
(4120.4) .
(b) Pay attention to the coiling direction of spring
(4770). Viewing from the suction side, the right-
hand coiled . spring .is for the suction side use and
the lefthand coiled one for the discharge side use.
(Refer to Fig. 9) Reverse fitting of these springs
would cause them to break during the pump
I running. Therefore, fit them at the specified side
without fa il.
Righ t-hand coiled spring Left-hand coiled spring
Fig. 9
(3) Insert seal sleeve (5240) in the shaft and then insert
0 -ring (4120.1) in the seal sleeve after thin oil coating
applied thereto .
9
5 Trouble shooting
When repair is required to eliminate fault or defect, the portion to be repaired must be checked using a proper instrument.
Accordingly, inspect and calibrate the instrument before the use.
5.1 Discharge capacity down

Possible cause Remedy/corrective action
1. Too high back pressure The actual required head is too high as compared with the initial
design head.
Accordingly, consider of the increase in no. of revolutions, the use of
larger impeller, or the increase in no. of stages.
2. Insufficient exhaust from pump or piping Exhaust carefully once more. Repair the piping when deemed as
necessary and add an exhaust valve and an exhaust pipe.
3. Blocked suction pipe .or blocked impeller Clean the pipe and take out the impeller for inspection and cleaning
when deemed as necessary .
4. Too low suction head (Cavitation) Check the water level in feed water tank. Also, be sure to check that
all the suction line valves are kept fully opened. In addition, inspect
the suction pipe to check for poor fluid flow or great flow resistance.
Clean well the strainer if provided.
5. Reverse rotational direction Interchange the wiring connection to the motor terminal. Should the
pump rotate reversely, check the packing sleeve and retighten it as
necessary.
6. No. of revolutions (rotational speed slower Check voltage and frequency.

than the specified.)
7. Wear of pump component Overhaul the pump to check the wear degree of parts and replace
worn parts with new one(s) if necessary.
5.2 Overload of driver (electric motor)

1. Pump back pressure Iower than the Close the discharge sluice valve up to the specified pressure point.
specified
2. Handling of fluid with greater specific Where it is not possible to keep specific gravity and temperature
gravity or at lower temperature than that indicated in the specification, but the discharge capacity may be
specified in specification reduced , reduce the discharge capacity to the allowable rate of the
driver. When good effect cannot be obtained even after that, be in
touch with our Technical Department.
5.3 Excessive discharge pressure

1. Excessive rotational speed Check the rotational speed (no. of revolutions) carefully. In the event
of failure in speed down, be in touch with our Technical Department
for further instruction. In such case, it will be necessary to either
reduce the number of stages or to cut the impeller diameter.
2. Too low discharge temperature or too When the pump running in such conditions is required, be in touch
large specific gravity with ou r Technical Department for further instruction.
3 . Too high force head Investigate carefully the force head. If the change of this pipeline is
impossible, be in touch with our Technical Department.
10
5.4 Leak from pump (leak from others than the gland)
1. Insufficient tightening torque of mounting Retighten them with uniform tightening torque after complete
bolts shut-down internal pressure drop and complete cool-down of the
pump.
2. 0-ring Ritighten the bolts. If fluid still leaks even after retightened, replace
0-ring with new one.
3. Rapid change of fluid temperature Rapid temperature down would cause eventual leak from the pump.
Accordingly, check whether or not fluid leaks from the pump even
after the temperature rises up to normal degree. If still leaked, it will
show fault of 0-ring. When fluid still leaks even after the bolts re-
tightened, take corrective action in the above ltem-2.
5.5 Leak from gland packing

1. Wear or imperfection or improper Re-insert the packing rings.
insertion of packing rings
2. Damage of packing sleeve caused by Re-polish or replace the sleeve. After replacement of the packing,
over-clamped or irregularly clamped gland tighten carefully the gland nut.
3. Unsmooth rotation of pump, so called, Unsmooth rotation of the shaft causes leak from the gland.
swing of the shaft In such event, check carefully gap in the bearing and replace it with
new one if necessary. If fluid still leak even after replacement, over-
haul the pump to find out faulty part.
5.6 Overheat of bearing

1. Imperfect centering of pump and driver Check the centering and leveling state.
(motor)
2. Abnormal piping load acts on the pump. Modify properly the piping to remove abnormal load on the pump,
and make re-centering.
3. Inaccurate clearance between coupling Adjust it to the value shown in the drawing.
halves
•
-
4. Damage of bearing or deterioration of
grease
Replace the bearing or grease with new one.
11
ELECTRIC PRESSURE TRANSMITTER
TYPE: MBS5100
I OPERATION MANUAL I
1. Installation
(1) Install pressure transmitter at where it is easy for maintenance and service.
(2) Install pressure transmitter on strong board or installation board as the
pressure lead inlet faces downward directly.
(3) Lock spanner on the two side of pressure lead inlet not to receive power like
twist at the inlet during piping.
(4) Avoid the place that corrosion gas exists.
(5) Avoid the place that is over 85 oc, surrounding temperature changes
suddenly, and that is under 0°C in case of water pressure.
(6) Pressure transmitter for low pressure (standard below 0.6MPa (6kgf/cm 2 })
should be installed at the same height with pressure incidence place as
possible as it can be, or adjust head gap after installation; because the
Influence of _head gap appears-.on output.
(7) Use preventing swinging rubber together when press,ure transmitter is
installed at the place that swinging exceeds 100 Hz.
(8) Install damper when measured pressure has pulsation or water hammer.
(when pulsation is over 2% of regular pressure transmitter and the cycle
exceeds 20mSec, or size of water hammer exceeds 150%.)
(9) Install pipe siphon (to infuse water) when the being measured fluid
temperature is high because of over heated steam and so on.
(1 0) Install tank siphon when measured fluid needs to be replaced at around
100°C.
Fig.1 Installation procedure ·~· ..
Flange
Pipng screw J
2. Connection
Electric pressure transmitter type: MBS51 00 is 2 (two) conductor type, so that

connect as below.
Fig.2 Connection procedure
., l. ·'
" .
·· 4-20 mA
1:+ !Supply
~-
2:- r Supply
3: · Test
~ . f ~~nect case
4 - 2DmA
} -- - - - . .---o +
24V d.c.
Vmo~. • 3DV d.c.
40-2DDmV
.•
1 ,j ·I • .,, ' ••>'
• • r • ~ •
3. Adjustment
Adjustment on the ground is not necessary; however, error some times occurs
against body side gauge because of head gap and so on . In that case, re-adjust
after installing on the ground .
The adjustment procedure is as follows.
3-1 Primary Adjustment

Adjust pressure transmitter when it pasts over 20 minute~ after it is electrified.
(1) Open pressure lead inlet of pressure transmitter to make it non-pressure

state.
(2) Confirm that output electric current is 4mA (within +0.5% F.S) .
(3) When the non-pressure electric current exceeds above number (+0.5% F.S),
take the lid off and adjust it with ZERO adjuster.
3-2 Adjustment during operation
Adjust pressure transmitter after provided output electric current is confirmed at
non-pressure state.
(1) Confirm that output electric current is within 20mA (0.5%F.S) after
. measurement maximum pressure is added to pressure transmitter.
(2) When the output electric current at measurement maximum pressure
exceed above number ( +0.5% F.S), adjust it with SPAN adjuster.
(3) Repeating "3-1 Primary Adjustment" and "3-2 Adjustment during operation"
a few times can adjust pressure transmitter correctly.
3-3 Adjustment of head gap

Pressure transmitter for low pressure (Standard below 0.6Mpa (6kgf/cm 2 ))
should be installed at the same height with pressure incidence place as possible
as it can be; however, when they are installed at different height, head gap
needs to be adjusted . When the being measured material is vapor, it does not
need to be adjusted . ·
(1) When the density ·(Specific gravity) of the being measured material is
unknown, adjust pressure transmitter with ZERO adjuster to make the
number same (same electric current output) with body side pressure gauge.
F ig.3 Adjustment procedure
. \.' '
·----- .. ' ·' '
[mA]1
I
20
4-f-I
I
#
Po Po p p· p
[mA] i
20T
I
...41!
/
'
Po p· p p
Technical data
(1) Performance
Non-linearity :<+0.2%FS
Hysteresis and repeatability :<+0.2%FS
Zero point adjustment :<+0.02%Fsrc
Span adjustment :<+0.2%rc
Overload pressure:2 x FS :2xFS
Burst pressure:4 x FS :4XFS
(2} Electrical specifications

Output ·:4-20mA
Supply voltage :10-30 Vd.c
Supply voltage dependency :< +0.1 %FS/1 OV
Current limitation :28mA
Load
: [V supply -10VJ_ 1O[Q]
0.02A
Response time :<4ms

(with dampener) :about 10ms
(3) Mechanical characteristics

Material Wetted part :AISI 316L/W. No.1.4404
Enclosure part :Anodized AIMgSi 1
Weight :0.4kg
(4) Environmental conditions

EMC-Emission :EN 50081-1
EMC Immunity
.Static discharge 8kV :EN 50082-1 (IEC 801-2)
HF, static 1OV/m 26MHz-1 GHz :EN 50082-t(IEC 801-3)

HF, induction 3Vrms 150kHz-1 OOMHz :EN 50082-1 (IEC 801-6)
HF, induction 1Vrms 10kHz-50MHz
LF, induction 3Vrms SOH.z-1 OKHz
Transitional burst 4kV clamp :EN 50082-1 (IEC 801-4)

Transitional surge 1kV RS=42 :EN 50082-1 (IEC 801-5)
Insulation resistance :>100MQ at 100V d. c.
Main frequency SOOV 50Hz :SEN 361503
Temparature Operation :-40-85°C
Transport :...;so-85°C
Enclosure :IP65
Vibration stability 20g/20Hz-2kHz . :IEC 68-2-6
Shock resistance Shock SOOg/1 ms, 100g/6m :IEC 68-2-27
Free fall :IEC 68-2-32
5. Measurement
r..
0
~mL\TL\KE
ST3000 Ace
Smart Transmitter
Electronic Differential Pressure I
Pressure transmitter
Model: JTD, JTG, JTA, JTC,

JTE,JTH,JTS
User's Manual
\\
\
Yamatake Corporation
CM2-DST800-2001
First issue: Mar. 1999, Rev. 2: June 2006
Copyright, Notices and Trademarks
Printed in Japan - © 2006 by Yamatake Corporation All Rights Reserved

While this information is presented in good faith and believed to be
accurate, 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 its written agreement
with and for its customer.
In no event shall Yamatake Corporation be liable to anyone for any
indirect, special or consequential damages. This information and
specifications in this document are subject to change without notice.
Introduction
Thank you for your purchasmg of out ST3000 Ace senes Smart Transmitter.
The ST3000 senes IS a high-accuracy, high-performance product that has been
mstalled m over 500,000 locatiOns smce It was mtroduced to the market m 1983 The
ST3000 was the world's first smart transmitter and contmues to be used by
manufacturers worldwide.
Users can easily perform most operatiOns, from start of measurement, to reading
measured data, to disp]aymg and changmg mternal settmgs, values and states. A hand-
held Smart Field COmmumcator (SFC) IS also available that connects quickly to all
Ace transmitters, for a faster solutiOn to any problem at hand.
Applicability
The ST3000 Ace senes IS available, m the followmg configuratiOns.
ST3000 Ace series

'" Differential pressure transmitter JTD91 OA, JTD920A, JTD930A,
JTD921 A, JTD931 A, JTD960A,
JTD961A
Gauge pressure transmitter JTG940A, JTG960A, JTG980A
Absolute pressure transmitter JTA922A, JTA940A
Flange differential pressure/ pressure JTC929A, ITC940A
transmitter
Remote-seal differential pressure JTE929A, JTE930A
transmitter
Remote-seal pressure transmitter JTH920A, JTH940A, JTH960A
Remote-seal absolute pressure transmitter JTS922A, JTS940A
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter

Safety Yamatake Corporation
Safety precautions
I ntrod uctlon
Correct mstallatwn and operation and penodic mamtenance are essential to safe
operation of your differential pressure transmitter. Read the safety mstruchons
contamed m this manual before operatmg, mamtammg or startmg the transmitter.
These mstructwns provide a comprehensive gmde to safe operatiOn.
Inspection
Check that the eqmpment specificatiOns match your ordenng mformatwn. If any
damage IS found upon receipt of the transmitter, Immediately contact with your
Yamatake representative. Keep the model name and senal number which are marked
on the eqmpments nameplate, at hand. The nameplate IS mounted on the top of the
eqmpment enclosure.
This equipment has been tested under stnct quality controls, before sh1ppmg.
Precautions
In this manual, the followmg symbol marks are used to safely operate this product.
&wARNING
I
Wammgs are mdicated when mishandling this product might result m death or
senous InJUry to the user.
&cAUTION
CautiOns are mdicated when mishandling this product mtght result m mmor
InJury to the user, or only physical damage to this product.
Always observe safety mstructwns. Read the next page. Yamatake CorporatiOn or any
of Its affiliates or representatives shall assume no responsibility, or offer any guarantee
with respect to any failure resultmg from viOlatiOn of these mstructwns.
ii ST3000 A ce - Smart Transmitter Electromc Differential Pressu re Transm itter

Yamatake Corporation Safety
Safety rules
Installation
&wARNING
• When mstalling the transmitter, ensure that the transmitters gaskets do not
protrude from the process connectiOn parts, such as flanges contactmg the
process pipes.
• Never use the transmitter m applicatiOns that are outside the rated pressure or
temperature range. Always observe connectiOn specifications. Damage to the
transmitter, or leakage, may endanger plant, eqmpment or human safety
• In areas designated as explosiOn-proof, apply to any cabling work the methods
specified m the explosiOn-proofing gmdelines.
& CAUTION
• After mstallatwn, do not step on the transmitter as this may damage It, or cause
physical InJury
• The glass mdicator may break If hit with a tool or other obJect, and cause
physical InJUry
• Install the transmitter correctly Incorrect mstallatwn may lead to output errors
or viOlate applicable regulatiOns.
• This transmitter IS heavy Durmg mstallatwn, please ensure that your footmg 1s
safe, and always wear safety shoes.
Electrical w1ring
& WARNING
• To avOid electnc shocks, dry hands completely before performmg wmng work
and turnmg the power OFF Wear gloves over 'dry hands.
&cAUTION
• Before startup, study the specifications carefully and ensure that the wmng IS
correct. Winng errors may cause hardware damage or other malfunctions.
• Provide a power supply that matches the specificatiOns of the transmitter.
Incorrect power supply may cause hardware damage.
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter iii

Mamtenance
&wARNING
• Before disconnectmg the transmitter from the process for any reason mcluding
mamtenance, wait for safe levels m restdual pressure, flmd or gas. Extreme
cautiOn should be taken to avotd flmd eruptiOn.
• Prevent bums. Check ventmg or drammg directiOn, and keep plant personnel out
of the way of vented gas or dramed fluid .
• When operational, never open the cover m an explosiOn-proof area. A vOid
explosiOns or other combustiOn accidents.
&cAUTION
• Stnct product controls were exerctsed dunng the manufacture ofthts transmitter.
Never modify the transmitter many way In-plant modificatiOns may result m
damage to the transmitter or to property and human safety
Communication equipment
&cAUTION
• Avmd use of commumcatJOn eqmpment near thts transmitter. Interference from
such eqmpment as a transceiver, a cellular phone, a PHS, a beeper may result m
malfunctiOn (at some transmtsswn frequencies). In any case, observe the
followmg precautiOns:
Check m advance of usmg any such eqmpment, the clearance reqmred to ensure
safe operation of the transmitter. When usmg commumcatwns eqmpment,
always mamtam a distance at least equal to thts distance, between the
commumcation eqmpment and the transmitter.
Close transmitter cover before usmg commumcatwn eqmpment.
IV ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter

(/)
-1
,
w
0
0
0
/ Z~606t09 OJ DST J3000 New Ace TRANSMITTER ~
>
n
)>
(I)
A "'C
+ ..,
"'C
0
<
QJ
POWER
SUPPLY
r:>l ASSO• lA TED
~APPARA TUS
n
0 INTE I RAL MLLIAMM!;TI;R 0
B :::::l
..,
r+
NON-HAZARDOUS LOCA liON HAZARDOUS ICLASSIFIEDl LOCA liON CLASS l ll ill DIVISION 1 GROUPS
A B C D E F AND G HAZARDOUS
-..,c
0
ICLASSIF IEDl LOCATION QJ

~
THE TRANSMITTER MAY BE MOUNTED WITHIN A CLASS l DIVISION 2 HAZ:t>.RDOUS
ICLASSIFIEDl LOCA liON WITHOUT THE FMRC APP, OVED ASSOCIATED APPARATUS IF
THE POWER SUPPLY RA TII~GS DO NOT EXCEED THE ~1AXIMUM VOLT AGE CURRENT
-·
AND POWER RATINGS OF THE TRANSMITTER THE CLASS l DIVISION 2 INSTALLATION
AND WIRING PRACTICES SHOULD BE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL @] INSTALLATION OF ALL FMRC APPROVED DEVICES SHALL BE IN ACCORDANCE TO
CODE IANSI/NFPA 70! THE MANUFACTURERS INST ALLA liON DRAWINGS WHEN INSTALLING THE EQUIPMENT
[Ij THE FMRC APPROVED MILLIAMMETER SHALL CONTAIN THE FOLLOWING INTERNAL INTRINISIC SAFE INSTALLATION SHOULD BE IN ACCORDANCE WITH ANSI/ISA RP12 6
PARAMETERS 'RESISTANCE • 360 Li·6011H AND Ci· OF THE MILLIAMMETER MUST HAVE INSTALLATION OF INTRINSICALLY SAFE SYSTEMS FOR HAZARDOUS !CLASSIFIED!
A SUIT ABLE FMRC APPROVAL FOR THE HAZARDOUS AREA LOCATIONS AND THE NATIONAL ELECTRICAL CODE IANSI/NFPA70l
INTERCONNECTION MAY ONLY OCCUR BETWEEN THE INTRINSICALLY SAFE APPARATUS DUST- TIGHT CONDUIT SEAL SHOULD BE USED WHEN INST AI LED IN CLASS ll
lOST J3000 New Ace TRANSMITTER! AND FACTORY MUTUAL ENTITY APPROVED AND CLAS ill ENVIRONMENTS
ASSOCIATED APPARATUS INSTALLATION OF THE ASSOCIATED APPARATUS SHALL
COMPLY WITH THE MANUFACTURERS INSTRUCTION OF THE AS SOCIA TED APPARATUS TO DETERMINE PROPER MATCHING OF I S EQUIPMENT AND THE MAXIMUM
D THE FACTORY MUTUAL APPROVED ASSOCIATED APPARATUS INCLUDES ANY FACTORY WIRING LENGTH USE THE FOLLOWING ENTITY PARAMETER MATCHING FORMULAS '
MUTUAL ENTITY APPROVED SINGLE OR DUAL BARRIER Voc OR VI :ii VMAX
lsc OR II :ii I MAX
THE FMRC APPROVED SMART FIELD COMMUNICATOR ISFCl MAY BE CONNECTED AT ANY [a l: E Ci + C wiWIRINGl
POINT IN THE LOOP BETWEEN THE FMRC ENTITY APPROVED AS SOCIA TED APPARATUS La l: ELi + L wiWIRINGI
AND THE TRANSMITTER
ENTITY PARAMETERS , V MAX ·~2 ~V I MAx·225mA INTEGRAL MILLIAMMETER NOTE
Voc-7 SV lsc-221mA Po·414mW WITH INTERNAL PARAMETERS • THIS DRAWING MUST NOT BE CHANGED
WITHOUT PRIOR AUTHORIZATION FROM
Ci·O Li·O INDUCT ANCE·10 !' HMAX FACTORY MUTUAL
BECAUSE THE SFC HAS THE MAXIMUM OUTPUT PARAMETERS OF Voc• 7 SV lsc•22 1mA CAPACITANCE•1nFMAx
AND Po · ~1 ~mW IF THE SFC IS APPLIED IN THE INTRINSICALLY SAFE LOOP THE MAX- RESISTANCE·30MAX
IMUM ALLOWABLE .CONNECTED INDUCTANCE ILal AND CAPAC ITANCE !Cal OF THE LOOP
E MUST BE CONSIDERED I SEE SHEET 21 WHEN SELECTING AN APPROPRIATE BARRIER AS
THE AS SOCIA TED APPARATUS AND A SUITABLE WIRING CABLE TO CONNECT THE BARRIER
TO THE TRANSMITTER
NOTES OJ MAX IMUM ENTITY PARAMETERS OF DST 13000 New Ace TRANSMITTER:
V MAX· ~2 4V IMAX • 225mA (i •0 032!'F Li ·0 308mH P MAX • 1ZW
<
, • 7
' ::. ::
~~J
..~...., n~TF ~
/ Z~606t:09 lsum • lse !ASSOCIATED APPARATUS! • lseiSMART C01111UNICATORI
VsLIII • Voe IASSOCIA TED APPARATUS) • Voe !SMART COmJNICA TORI
& THIS SHEET IS AOOEO .
99-1-5
it* •n-
CONSIDERATION OF AN INTRINSICALLY SAFE LOOP Isum La IMILLI HENRYS! Ca IMICROFARAOSI
Vsum
BASED ON ENTITY PARAMETERS 111l.LI
c
A
A/8
HPERES c 0 !VOLTS A/8 D
20 90.00 330.00 700.00 5 H97 275.91 735.77
THE ENTITY CONCEPT ALLOWS INTERCONNECTION OF INTRINSICALLY SAFE APPARATUS TO
ASSOCIATED APPARATUS NOT SPECIFICALLY EXAMINED IN SUCH COMBINA TIDN 21 82.00 300.00 635.30 10 3.21 9.64 25.69
23 68.00 250.00 530.10 15 078 2 35 6.26
BASICALLY THE MAXIMUM UNPROTECTED CAPACITANCE ICil AND INDUCTANCE llil OF THE
25 58.00 210.00 449.00 20 0.34 1.01 2.7
INTRINSICALLY SAFE APPARATUS INCLUDING INTERCONNEC TING WIRING PARAMETERS ILw Cwl
MUST BE EQUAL OR LESS THAN THE CAPACITANCE !Cal AND INDUCTANCE ILal WHICH CAN 28 46.00 170.00 358.40 22 0.26 0.78 2.09
BE SAFELY CONNECTED TO THE ASSOCIATED APPARATUS ALSO THE MAXIMUM OUTPUT 30 40.00 150.00 312 40 24 021 063 1.67
PARAMETERS IVae lse Pol OF THE ASSOCIATED APPARATUS MUST BE EQUAL OR LESS 017 0.51 1.37
32 36.00 135.00 27L.80 26
THAN THE MAXIMUM ENTITY PARAMETERS IVHAx IHAX PHAXI OF THE INTRINSICALLY SAFE
35 31.00 110.00 229.90 28 0.14 043 1.14
APPARATUS
B 40 23.00 87 .00 176.30 30 0.12 0.36 0.97 ~
en IF THE SFC IS CONNECTED TO THE INTRINSICALLY SAFE LOOP FURTHER CONSIDERATION
45 19.00 70.00 139.40 32 0.11 032 0.84
-1 MUST BE TAKEN AS SHOWN BY THE FOLLOWING EXAMPLES
(,.,) 50 15.00 56.00 113.10 34 0.09 0.28 0.73
0
0 EXAMPLE 1. La 55 12.00 48.00 93.50 36 0.08 0.24 0.65
0
57 11.00 43.00 87 .10 38 008 0.22 0.58
)> MAXIMUM OUTPUT CURRENT llsuml TO THE LOOP IN THE WORST SITUATION IS THE SUM
0 OF THE DELIVERED CURRENT llsel BY THE BARRIER AND THAT llse l BY THE SFC 60 10.00 40.00 78.70 40 006 0.19 0.52
(!)
IF lse OF THE BARRIER IS 93mA 62 9.50 37.00 73.70 42 0.06 0.18 0.47
en lsum • 93mA • 22 1mA • 115 1mA 65 8.80 34.00 67.10
3 THEN BY APPLYING 120mA IT HE NEXT HIGHER VALUE OF THE RESULTING lsuml TO THE 70 7.50 28.00 57.90
Ill
~ RIGHT TABLE Lo FOR GROUP AlB IS DETERMINED La• 2 50mH 75 6.70 25.00 50.50
c
-1 THE ABOVE OBTAINE La VALUE MUST SATISFY THE BELOW RELATIONSHIP 80 6.00 22.00 44.40
iil La ~ Li !TRANSMITTER! • Lw IWIRINGI • Li ISFCI 85 550 2000 39 30
::J LA BEL
Ill
ACCORDINGL Y THE WIRING INDUCTANCE NEVER EXCEEDS THE VALUE 90 5.00 18.00 35.10
3 La - Li ITRANSMITTERI - Li ISFCI i e
"
100 4.00 15.00 2850
.,~ L w ~ 2 SOmH - 0 308mH - 0 = 2 192mH
1r~
110 3.00 12.00 2360
~,f
NOTE lr THE ABOVE Lw VALUE IS SMALLEr THAN THE INDUCTANCE OF A CABLE
m
=::.l~f~~~~~'""
120 2.50 10.00 19.80
ANOTHER BARRIER WITH A SMALLER lse VALUE SHOULD BE SELECTED
10 130 2.00 9.00 16.90 RANGE -...
0
tt EXAMPLE 2. Co 140 1.60 8.00 14.60 _W.P
0
::J D
150 130 7.00 12.70 p
0 MAXIMI M OUTPUT VOLT AGE IVsuml Tl THE LOOP IN THE WORST SITUA TION IS THE SUM OF
160 1.00 6.20 11.20 '"'"""'
;~ fNnn P""flfl<5
~'"""" ..
1 ~=~~~- .~.. -~·-··

THE DELIVERED VOLT AGE IV eel BY THE BARRIER AND TAA T IV eel BY THE SFC
0 170 0.80 5.50 9.90
~
IF Vee OF THE BARRIER IS 28V
180 0.60 5.00 8.80
Vsum • 28V + 7 SV • 35 SV
iil
-.,
200 0.50 4.00 7.20
::J THEN BY APPLYING 36V !THE NEXT HIGHER VALUE OF THE RESULTING Vsuml TO THE
RIGHT TABLE Co FOR GROUP AlB IS DETERMINED Ca·O 081' F 220 0.40 3.20 5.90
~
-o THE ABOVE OBTAINED Co VALUE MUST SATISFY THE BELOW RELATIONSHIP ~
(!)
Co ~ Ci ITRANSMITTERI • Cw IWIRINGI • Ci ISFCI ~
Ill
ACCORDINGLY THE WIRING CAPACITANCE NEVER EXCEEDS THE VALUE I ~6 iL----:-
---
'-! YAMATAKE PROPRIETARY '
v
Ill
c: Co - Ci ITRANSMITTERI - C1 ISFCI i e
f..---- 1 111~ r,lfl TITLE ~
E nOR i£* 99- 1- 7
----------
------
iil Cw ~ 008).1F- 0032).1F- 0 • 0048).1F EXTERNAL WIRING DIAGRAM
.,-1 ~ ~- DST J3000 TRANSMITTER
Ill
::J
NOTE IF THE ABOVE Cw VALUE IS SMALLER THAN THE CAPACITANCE OF A CABLE
ANOTHER BARRIER WITH A SMALLER Vee VALUE SHOULD BE SELECTED
~
------- -· ~- INTRINSICALLY SAFE LOOP
I"'01 '¥}'
0
17
• • OWG..O
Ill
3 l21111AT.AKE 80 3909 12 REV ""'
I»
e.
• --,-
.,~
··~
l j 0
CAI: 0
:I
Yamatake Corporation Safety
Unpacking the transmitter

This transmitter 1s prectston eqmpment. Handle It carefully to prevent an acctdent and
damage.
Checking accessones
In the package you recetve from Yamatake or our representative, IS mcluded the mam
umt of a transmitter and the followmg accessones:
• One 3-mch L-shaped wrench
Checking specifications
The spectficatwns are marked on the transmitter nameplate. The spectficatwns on th1s
nameplate should agree exactly w1th your order. Especially, check the followmg:
• Tag No. (TAG No.)
• Model No. (MODEL)
• ProductiOn No. (PROD No.)
• Low and high limtts of set range (RANGE)
• Supply voltage (SUPPLY)
• Explosion-proofing conformance (mark IS applicable only to explosiOn-proof model)
lnqu1ry
Dtrect any mqumes about thts transmitter to our nearest branch office or
representative (listed at the end of thts manual).
When markmg an mqmry, have handy a copy of the details marked on the nameplate:
• Model No. (MODEL)
• ProductiOn No. (PROD No.)
Storage
Storage over long penods requues spectal procedures, to avoid damage to this
mstrument. Always store the transmitter
• Indoors and at normal temperature and humidity
• In a locatiOn subject to mmimum vibratiOns and shocks
• Before unpackmg, not after
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transm.itter vii

Structure and Contents of the User's Manual

Structure and contents
-
This user's manual explams the structure of this transmitter and provides operatmg
mstructions, m the followmg order
Chapter 1: Functions, Configurations, and Structure of ST3000

Ace and SFC
This section covers the basic functiOns, structures, and configurations of a ST3000
Ace senes Smart Transmitter anda Smart Commumcator (SFC). First-time users of
this transmitter are asked to read this section m advance of operatiOn.
Chapter 2: Installation
InstructiOns for mstalling, pipmg, and cabling this transmitter. Important Items related
to mstallatwn (grouped by type of measurement data).
People m charge of mstallat10n, pipmg, and cabling are reqmred to read this sectiOn.
Chapter 3: Operation
Provides mstructwns for connectmg an SFC to this transmitter, and basic mstructions
for key operatiOns.
Includes procedures for settmg a tag number and checkmg transmitter specificatiOns.
Except for basic mstructions for operatmg an SFC, mstructions are grouped by the
type of measurement data.
Read th1s before actually startmg measurement.
Chapter 4: Usmg SFC

Explams operatiOns that can be executed usmg an SFC. Refer to this sectiOn for basic
operatmg mstructwns and procedures for startmg operatiOn, displaymg measured data
dunng oper_atlon, pnntmg transmitter data, and changmg transmitter settmgs.
Chapter 5: Maintenance and Troubleshootings

Provides mamtenance and trouble shootmg mstructwns.
viii ST3000 Ace- Smart Transmitter Electronrc Differential Pressure Transmitter

Table of Contents
Chapter 1: Functions, Configurations, and Structures of ST3000

Ace and SFC
1-1 Function and configuration ofthetransmitter .. ........... ..... .. .. .. ....... ..... ... ....... ................... 1-2
1-1-1 Function and configuration of the transmitter ........ ... ... ..... ... ... .......... .... .... .. .... ....... .. 1-2
1-1-2: Parts names of the transmitter .... .. ....... .... ........ .......... ... ......... ..... .. .. ..... ........... ........ 1-4
1-1-3: Indicator (Option) ... ..... ........... ...... .. .. ......... .. ..... .. ... ...... .... .. .. .. .... ........ .. ............ ... .. .. . 1-6
1-2: Function and configuration of SFC .... ........ .............. ............. ... ........ ................... .. ... .. ..... 1-10
1-2-1 Function of SFC ........... ......... .... .. .... .. ... ... .. ... ... ...... ... ........... .. .. ..... ...... ... ... ......... ...... 1-10
1-2-2: Configuration of SFC ... ..... ....... .. ........ ......... ........ ... .. ......... .. ...... ...... .. ............. .......... 1-12.
Chapter 2: Installation
2-1 Installation environment. ...... ...... .... ........ ...... ......... ....... ..... ..... ..... ...... .......... ..... .... .......... . 2-2
2-1-1 General environmental conditions ............ .............. .. ......... ..... ........................ .. ... .... 2-2
2-1-2: Environmental conditions for explos1on-proof transmitter ..... ..:................. ...... ... ..... 2-3
2-1-3: Environmental conditions for mtnns1cally-safe transmitter .. .. .. ........ .. .._........... .. ... .. :. 2-5
2-2: Installation ...... ..... ........... ..... .. ... ...... ... .... ... ..... ............ .... ....... .. ...... .. ...... ...... ................... . 2-6
2-2-1 Installation dimens1ons ............. .... .... ... .... .... .... .. ........ .... .... ...... ... .. ...... ... ... ...... ... .... .. 2-6
2-2-2: Installation environment ....... ... ....... ........... .......... ... ...... ..... ....... ....... ........ ... .... ..... .... 2-6
2-2-3: Installing the transmitter ... .. ......... .... .... .... ........ ..... .... .. .. ........... .............. .......... ....... . 2-7
2-2-3-1 :[Remarks] Remarks related to mstallation ........ ..... .. ........ ....... ...... .......... ......... 2-8
2-2-3-2:1nstallation position of remote sealing type transmitter on closed tank .. ..... .... . 2-8
2-2-4 · Transmitter mam unit Installation position .. ..... ....... ....... ..... ..... ... ...................... ...... . 2-10
2-2-5. Installation of process (Models JTC/JTE/JTH/JTS) ........ .... .... ... ... .. ...... ... ..... .. ... .. ... 2-13
2-2-6. Mounting FEP protection film .. .... ..... ........ ... .... .... ... .. ... .... ...... .. ........ .... ........ .. .. ....... . 2-17
2-2-7 Direct mount type mstallation (patent pending) ......... ......... ..... .. ...... .... .. ... ... .......... .. 2-19
2-2-8: 1/2 1nch remote Installation (model JTE/JTH) ... .. .............. ... ... ...... ................. .. ... ... . 2-27
2-3: Piping ........... ... ..... ......... ... ... ........ ...... ... ... ....... .. ... ........... .... ............ ........... .... .. ..... .. .. ....... 2-28
2-3-1 Flow rate measurement- Pipmg (model JTD) ....... ...... .......... ...... .... ........... ....... ..... 2-28
2-3-1-1 :Pip1ng considerations ...... ... ......... ...... .... ... .... ... .... ..... ... ........ .... ....... ...... ... .. ... .... 2-28
2-3-1-2:Pipmg for liqu1d or gas flow rate measurement ..... ..... ..... ... .. ... .. .... .... ...... .. ... .... 2-29
2-3-1-3:Pipmg for steam flow rate measurement ...... ...... ......... ..... ..... ....... .... .. ............. 2-31
2-3-2: Pressure measurement - p1p1ng (model JTD/JTG/JTA) ...... ......... ... ...... .. ..... ..... ...... 2-33
2-3-2-1 :Pipmg .... ........... ... ........ .... ... ...... .. .... ... ...... ...... ...... ..... ....... ......... ... ... ... .. .. ....... .... 2-33
2-3-2-2:Pressure measurement - Pipmg ............ ......... ... ... ...... ..... ...... .... ... .. .. .... .. ....... .. 2-34
2-3-3: L1qu1d level measurement - Pipmg (model JTD/JTG) ...................... .................. ..... 2-36
2-3-3-1 :Pip1ng ..... .... ... ..... ...... ......... .... ......... .... .... ... ............. .... ... ........... .. ...... ... ... ......... . 2-36
2-3-3-2:0pen tank - Pipmg ...... ... ....... .... ..... ...... ... ... ..... ..... .... ..... .......... .. .... ... ...... ... ....... 2-37
2-4 Electncal w1nng .. .... .............. ...... ...... ... .......... ... ................. ...... ..... ... ........ .... ................... . 2-40
2-4-1 Winng for transmitter - Regular model ................ .. ..... .. ......... .......... .......... .. .. .... .... .. 2-40
2-4-2: Winng for transmitter - flameproof spec1al explos1onproof ........ .. ...... ...................... 2-42
2-4-3: Winng transmitter- lntnns1cally safe .. .. ... ....... ... .. ...... ... ......... .. .... ..... ... ....... ...... ..... .. 2-43
2-5. Process connection port - Change port position .. ..... .. ... ............. .... ... ... .... .. .. ... .. ............. 2-44
2-5-1 Bottom port to top port (model JTD/JTG/JTA/JTC) .... ..................... .. ... ...... .. .... ... .... 2-44
Chapter 3: Operate and stop the transmitter

Table of Contents
3-1 Preparation ......... ....... ...... ... .. .... ... ..... ....... .. ....... .. ...... ...... .. .... ...... ...... ... .. ........... .............. 3-2
3-1-1 Connecting SFC .... ... ..... .... .. .... ...... ... .... ..... ...... ..... ... ........ .............................. ... ....... 3-2
3-2: Setting tag no. and check1ng specifications .. .. ..... ......... ........ ... .......... .. ..... ...... .... .. .. .. ...... 3-3
3-2-1 Starting commumcations ..... ...... ... .... ......... ....... .. .. ..................... ...... ..... ... ....... ... .. ... . 3-3
3-2-2: Setting tag no .. ..... .. ...... .. ...... .... .... ...... .. ........ ... ..... ...... ... .... ................ ...................... 3-4
3-2-3: Checkmg output format .. .. .... ... ....... .. ... ..... ...... .. .. ............ ... .. .. .. ......... ...... ... ... .... ..... .. 3-6
3-2-4 Check1ng display setting ....... ..... .. .... .. ............ .... .. ...... ...... ... ..... ... .............. ..... .... .. ... 3-7
3-2-5. Checkmg eng1neenng unit of measured pressure ........ ..... ......... .. ...... ........ .... ..... .. .. 3-8
3-2-6. Check1ng low and h1gh limits of setting range ... .... ... .. ... ... ... .. ... ........... ..... ....... ... ..... 3-8
3-2-7 Check1ng dampmg time constant ..... .... ... ....... ........ .. .. ...... ....... ... ... .... .. .... ..... ... ... ... .. 3-9
3-2-8: Checkmg sealed liqu1d temperature correction function setting ..... ................. .... .... 3-10
3-3: Measurement by model JTD ........ ... .... .... .... .. ..... ... .... .... ........ ....... ... ..... .... .. .. ...... ..... .... ... 3-12
3-3-1 Flow rate measurement ... .... ... ... .... .... .. .. .... ... .......... ....... ...... ...... ... .... ....... ......... ..... . 3-12
3-3-1-1 :Preparation for measurement ... .. ............. ..... .... ......... .... ................. .. ...... ......... 3-12
3-3-1-2:Starting measurement. ..... ..... ...... .......... .. ...... ... .. .. ....... ...... ...... .......... ... ..... ...... . 3-15
3-3-1-3:Stoppmg measurement.. ... ... ... ... ............... ... .... ... ... .... ... ..... .. ........ ..... .. ......... .. .. 3-17
3-3-2: Gas pressure measurement.. .. ......... ..... ... .. .. ..... .... ... ........... ...... ... ..... .... .... .... ... .. ..... 3-18
3-3-2-1 :Preparation for measurement ................... .. .. .. ..... ..... ........... .. ...... .... .. .. ..... .... .. . 3-18
3-3-2-2:Starting measurement.. ..... .......... ......................... .. ........ ..... .. .... .... ............... .. .. 3-19
3-3-2-3:Stopplng measurement ...... ... .... ... .... ... ....... ...... ...... ..... .. .... ............. ... .... ... ... ..... 3-21
3-3-3: L1qu1d level measurement of open tank and closed tank (dry leg) ··· ······ ··.··············· 3-22
3-3-3-1 :Preparation for measurement ... ... ...... ... ....... ... ......................... .. .... .... ........ ...... 3-22
3-3-3-2:Starting measurement. .. ..... ........... .. ....... ......... ..... .... ........ ....... ..... ................ .. .. 3-23
3-3-3-3:Stoppmg measurement .. ... .......... .. .. ............... .. ............... .. ... ......... ... ............. ... 3-25
3-3-4· L1qu1d level measurement of closed tank (wet leg) .................... .. .. .............. ..... ..... . 3-26
3-3-4-1 :Preparation for measurement .. ... ... ..... ... ........... .. ... ... .. ... .... .... ..... ...... ..... .... ... ... 3-26
3-3-4-2:Starting measurement.. ... .... ...... ... .............. ..... ......... ... .... ...... ........ ... ....... ...... ... 3-27
3-3-4-3:Stoppmg measurement .... .... ... ... .... ... .. ..... .... .. ... .... ... ....... .... ... ... ... .. .. ...... ... ..... .. 3-29
3-4: Measurement with model JTG/JTA ................. .. ....... .... ... ... ................... ... .. .. ... .... .... .... ... 3-30
3-4-1 Pressure measurement ... ...... ... .. ...... ...... .. .... ..... ...... .. ... ...... .. .. ........ .... ... .... .. .... ... .... . 3-30
3-4-1-1: Before stating ....... .... ... ... .... ... .. ....... .. ... ....... .. ... ............ .. ...... .................... .. ... ... . 3-30
3-4-1-2:Starting operation .......... .. .. ... .... .... ... .... .... .. ... ..... .. ..... .. ....... ........ ..... ....... ... ..... ... 3-31
3-4-1-3:Stoppmg operation ......... ...... ...... ..... ........................ ................... ................. ..... 3-32
3-4-2: L1qu1d level measurement ... ..... ..... .... ...... ... .. .... ...... .. ...... .... .... ... ..... ... ....... .... .... ... .... 3-34
3-4-2-1 :Before you start ... ............ ... ..... .. .. .......... ...... ............ .. ...... ................. ....... ... .... .. 3-34
3-4-2-2:Starting operation ....... ... .... ..... ..... ... .. .. ... ..... ......... .. ... ... ... ........... .. .. .... ... ........ .. .. 3-35
3-4-2-3:Shopplng operation ..... ... .. .......... ........... .. ..... .. .......................... ... .... .. ..... .... .... .. 3-36
3-5. Measurement with model JTC ....... .. ... ... ... .... .... ...... ...... .. ..... .... ........ .. .. ... ... ... ... ...... ..... .... 3-37
3-5-1 Pressure measurement ........... ...... ... ...... .... ..... ... .... ........ ..... ...................... ...... .. ..... . 3-37
3-5-1-1 :Before you start ..... ...... ..... .. .. ..... ....... ... ..... .. .. .. .. .. ..... ... ... ....... .. .. ........ ........... ..... 3-37
3-5-1 -2:Starting operation ... ........... .. ....... ..... .... ............. ..... ... ....... ........ ......................... 3-38
3-5-1-3:Stoppmg operation ....... .... ... .... ... .. ... ... ... ... .... ..... ....... ...... ..... .. ... .. .... ..... ... .. ........ 3-39
3-6. Measurement with model JTE ... ................. .... ..... .. .......... .......... ... ............... ... .......... .. .. .. 3-40
3-6-1 Pressure measurement ...... .. ... .. ...... .. .... .. .. ... .... ... ...... .. ...... ............. ................. .. ... ... 3-40
3-6-1-1 :Before you start ....... .... ... ...... .... .. ... ............ ..................... .. ........... ......... .. .. ...... .. 3-40
3-6-1-2:Starting operation ... ... ........ ... .. ...... .. .. ........ ... ... ........ .... .. .... ........ .... .. .. .... ... .. .. ..... 3-42
3-6-1-3:Stoppmg operation .... ... .... .. ... ................ ... .... ....... ... ... .. ..... ... ..... ......... ....... .... .... 3-43
3-6-2 : Cautions related to flow rate measurement .... .................... ....... .. .... .. ... .. ..... .. ...... ... 3-44
Table of Contents
3-6-3: Mounting the flange for Flow rate measurement (Model : JTE) ............... .... .. .... .. .... 3-45
3-7 Measurement with model JTH/JTS ....... ... ....... .... ...... ......... ..... ... .. ... .. ..... .. .. .... ... .. .... .. ..... 3-46
3-7-1 Pressure measurement .... ... ....... ... .... .... ....... .... ... ..... ... ..... .... .......... ....... ... .......-... ... .. 3-46
3-7-1-1 :Before you start ... .. .... .... .. .... ....... ...... ...... .. .. ... ........ ... ........... ..... ...... ..... .. ...... ..... 3-46
3-7-1-2:Starting operation ..... .... ... ... .. ... ..... ...... .. ... .... .... ... ... .... ...... .... ....... ... .... .. .. ........... 3-48
3-7-1-3:Stoppmg operation .. ..... ......... .... .......... ......... ........ ....... ..... .. .. ... ....... ....... ..... .. ..... 3-49
3-8: Zero-po1nt adjustment --- Based on actual liqu1d level ..... .. ....... .. .... .......... ... ......... ... ...... 3-50
3-9: Zero-span adjustment with 1nput pressure equivalent to range ..... ..... ...... .. ... ................. 3-52
3-10 : External zero adjustment (option) ..... .. .. .. ... ...... .. ... ........ ......... .... ..... ... ... ... .. .. ....... ..... ..... 3-54
3-10-1 External zero adjustment ......... ......... ... ........ .... .. ... ...... .... ..... ... ... ..... ......... ........ ..... 3-54
3-11 Set range calculation for liqu1d level measurement ... .. .... ....... :.............. ...... ....... .......... 3-56
3-11-1 Open tank or closed tank (dry leg) or remote seal set range calculation ...... ........ 3-56
3-11-2: Closed tank (wet leg or remote seal)--- set range ............... ........ .............. ........ ... 3-61
Chapter 4: Operation using SFC

4-1 Bas1c mformation ········ ·· ······· ' ·· ······· ···· ··········· ··· ·· ·· ·· ······ ··· ···· ·· ······ ··· ······· ·· ·· ··· ··· ·· ······ ··· ··· ·· 4-2
4-1-1 SFC functions ...... .... .... ............. .... .. ... ..... ... .. ... ..... .. .. ...... ... ..... ...-: .... .. .......... ..... ... .. .... 4-2
4-1-2: Key operation and display mteraction ····· ···· ·· ····· ·· ··· ··· ···· ··· ·· ···:· ·· ··· ····· ··· ············ ······ 4-4
4-1-3: SFC keyboard .. ........ ... ..... ..... ...... ... ..... ..... .......... .... ..... ...... ... .. ... ..... ..... ....... .... ... .. .. ... 4-5
4-1-4 Bas1c key 1nput operations ............ ..... .... .... . __............ ... .. .. ....... ........... .... ... .. .... .... .. .. 4-6
4-1-5. Functions of SFC keys .... ........ ... .... .... .. .... ..... .... ..... ......... ..... ... .. ... .......... .... ... .. ..... ... 4-7
4-1.-6. Dedicated functions ... .. .. .... .... .. .... ... ... ... ...... ..... ... .. .. .. .. ... ...... .. .. ....... ..... ....... .... ..... .... . 4-15
4-1-7 Chargmg SFC .................. .................. ... ........ .. ... ................ ..... .. ... ....... ....... .... ... ... .. . 4-17
4-2: Start measurement .. .. ... .... ... .......... .... .... ... .. .. .... ... ... .. ..... ..... ..... .... .... ... ... .. .. .. .. .. .. ....... .. .. .. 4-18
4-3: Display measured data ...... .... .. .. .. .. .......... ............... ... .. ............... .. ...... .. ... .. ............... .. ... . 4-19
4-3-1 Display 1nput differential pressure .................. ........ .. .... .... .... ... ........ ... .. ... .. .. ......... ... 4-19
4-3-2: Display transmitter output (%) ........ .. .. .. ..... .. ............ ... ...... ..... ......... .... .... ...... .... ....... 4-19
4-4 Pnnting --- SFC with pnnter .. ... ...... ... .......... .. ... .... ... ... ..... ... .. .. ...... ..... ...... ...... ...... .. ... .. .. ... 4-20
4-4-1 How to prmt .... .......... .... ... ....... .. ......... .. .. .. ......·....... : .... ...... ..... ....... ......... ... ..... ...... .. ... 4-20
4-4-2 : Pnnting mternal data --- Mamtenance pnnting .. ... ... .. .... .... ..... ..... ... .... ......... .... ........ 4-21
4-4-3: Pnnt data responses - Action pnnting .... ... ... ... ...... .. .. .... ..... ... ........ ... ... .. ... .... ... .... .. .. 4-23
4-5. Display and change transmitter settings ..... .......... .. ... .... ..... ....... .. .. ...... .... .............. ... .. .... 4-25
4-5-1 Displaymg and chang1ng transmitter settings - overv1ew .. .... .. ...... .. .... ...... ...... .. ...... 4-25
4-5-2: Display1ng or chang1ng tag number ........ ... .. .. .... .... ... ....... ... ..... ...... .. ...... .................. 4-27
4-5-3: Displ~y or change output format .... .. .... ... .... .. .. ... .. .. .... .. ·...... ... ... .. ........ ........ .... .. ..... .. 4-29
4-5-4. Display or change mdicator·display format (!Flow rate I Lmear I Display flow rate) 4-31
4-5-5. Display or change mdicator display format (Eng1neenng unit I%) ... ........ : ..... .. ..... .. 4-34
4-5-6. Display or change h1gh and low limits of eng1neenng quantity .. .. ... ....... .... .. .. ..... ..... 4-36
4-5-7 Display 9r change low flow cutoff value ................................... ..... ....... ... ....... ..... ... . 4-39
4-5-8: Display or change low/h1gh limits and span of set range ............... ...... ................ ... 4-44
4-5-9: Display or change eng1neenng unit for measured pressure ...... .... .... .. .. .... ....... ....... 4-46
- 4-5-10: Display or change damp1ng time constant ... ............ ......... .... ....... ......... .... .. ...... ... . 4-47
4-5-11 Display burnout direction .. .. .... ........... ......... .... ... .... ..... ... ... ..... ........... ... ...... .......... .. 4-49
4-5-12: Displaymg PROM No ...... ... .... .. ... .. ........... .. ... .. ......... ....... .... .... ... ... ....... ..... ... ......... 4-50
4-5-13: Display sensor temperature .. ....... ... ..... .. ......... ..... ... ........... .............................. .. ... 4-51
4-5-14: Display software vers1on .... ... ... ... .... ........ ........ ............ ..... ...... ..... .... .. ... .... ...... .... .. . 4-52
4-5-15. Displaymg an changmg sealed liqu1d temperature correction function ..... ..... .. ... ..4-53
Table of Contents
4-6: Constant current source mode ......... ................. ...... ....... ............... ..... ... .................. ... ... . 4-55
4-6-1 Set constant current source mode ................. ...... .... ...... ...... .. ... ........ ... ........... ........ 4-55
4-6-2: Release constant current source mode ... ....... .. ..... .. ...... .... ............... .... .. ......... .... .. . 4-56
4-7 Winng a memo ..... .................... .. ...... ... .... ... .. .. ....... ... .. ... ... : .. .. ...... ....... .... ..... .......... ......... 4-57
4-7-1 Recording m scratch pad 1 ············· ·· ···· ······.··········· ······ ···· ······ ······· ··········· ···· ···· ······· 4-57
4-7-2: Recording m scratch pad 2 ....... ............. ... ............. ... .................. .. ... ... ..... ... ....... ... .. 4-60
Chapter 5: Maintenance and trabouleshooting

5-1 Zero adjustment. ... ...... ... ... ...... ............... ...... ......... .......... .... .. ....... .................. ................. 5-2
5-1-1 Overv1ew ... .... .. .... .................. ............ ........... ..... ... .... ... ............. .. .... .... ........ ... .... .. .... 5-2
5-1 -2: Zero adjustment under uniform mput pressure (with SFC) ..... .. .............................. 5-3
5-1-3: Zero adjustment based on 1nput pressure corresponding to LRV (with SFC) .... ..... 5-4
5-1-4 Zero adjustment based on actual level (with SFC) .. ... ........ ......... ... .. ....... ..... ...... .. .. 5-5
5-1-5. Zero adjustment us1ng external zero adjustment mechan1sm (option) ....... ...... ....... 5-7
5-2: Sav1ng and restonng data ..... ...... ............. ... ... ......... ........................... .. .. ... .... ....... .. ....... .. 5-8
5-2-1 Savmg data ..... .... ....... ........... .... .............. ..... .......... ...... .... ... ..... ........... ....... ... ..... .... . 5-8
5-2-2: Restonng data ....... ..... .... ....... .. .... .............. ..... ..... ....... ... ......... ... .. .... ....... ........ ...... ... 5-10
5-3: Recovery of calibration data/ Status Record .(New functions) ················ ·············· ···· ··· ·'· 5-11
5-3-1 Return to Factory Preset ... ... ...... ... ............... .............. ...... ....... ........ ...... ....... ....... .... 5-12
5-3-2: Status Record .... .. ........... ....... ........ .... .... ..... ...... ... ..... ............ ...... .... .......... ... .. ... ...... 5-13
5-3-3: Load Zero Calibration Record ...... .. ..... ...... ..... .... .... ................ ....... ............ .. ....... .. ... 5-18
5-3-4 Zero Calibration Data m Dev1ce ............ ...... ....... .... ..... ..... .... ........ ...... ..... .. ... ... ........ 5-22
5-4: Disassembly and assembly .. ........ .................... ..... ...... .... .... .... ......... .... ...... ........ ....... .... 5-25
5-4- 1 Before you start ................... .... .. ........... .. ......... .................. .. ..... ..... .. .. .. .. ....... .. ..... .... 5-25
5-4-2: Dismount/Mount Center body cover (Model JTD/JTG/JTA/JTC) ...... ................... ... 5J26
5-4-3: Washmg the sensor ....... ... .. .. .... ............... ... ..... ........... ...... ........... ............... ..... ....... 5-28
5-4-4. Remodelling for High-load res1stance external meter .. .. ..... ........ ......... ................ ... 5-29
5-5. Calibrating set range and output s1gnals ... ..... ..... ....... .... ...... .. ...... .. .... ....... ... ................. . 5-34
5-5-1 Qverv1ew ... ..... ..... .. ....................... .... ...... .... ..... .. ,..... ................... ....... ... ... ... ... ...... .... 5-34
5-5-2: Calibrating set range based on reference 1nput ........ .. ........... ................... .. ............ 5-34
5-5-2-1 :Preparation .............. .. .... ... ... ..... .... ..... ...... ... ... .. __ .... ...... ........ ... .... ... ... ... .. .......... 5-34
5-5-2-2:Calibrate low limit ....... .... ................. ..... ..... ... .. ..... .... ..... .. ....... ...... ..................... 5-35
5-5-2-3:Calibrate h1gh limit ......... .. ..... ........................... ................ ...... .. .. ... ... .. ... ... ........ 5-37
5-5-3: Calibrate output s1gnals ...... ....... ........... ... ..... ....... .... .......... .... ....... ... ............. ........... 5-39
5-5-3-1:Before you start .. .... .......... ............... .... ... ...... .... .... ..... .... ........ ...... .... .... .. .. ......... 5-39
5-5-3-2:Calibrating output s1gnal 0% .... ........... ......... ....... .......... ....... .... .. ..... .... .... ...... .. . 5-40
5-5-3-3:Calibrating output s1gnal 100% .......... ........ .. .. ................ ............. .. .. ...... .... .... ... 5-42
5-5-3-4:Savmg calibrated values and releas1ng constant current source mode ...... ... .. 5-45
5-6. Erasmg calibrated data .... ........... .. .......................................... ........ ... ..... ....... ....... .... ...... 5-46
5-6-1 Erasmg calibrated data .... .. .. ...... .. ...... .. ... ...... ... ... ........ ... .. .... ...... ........ ............ ......... 5-46
5-6-2 : Erasmg #mark ........... ................ .... ....... ... ...... ..... .... .. .... .... ... ...... ... ..... .... ... .......... .... 5-47
5-7 Troubleshooting ..................... .. ... .. ... ............ ...... ........ .. ... ... ............... .. ................ ...... .. .... 5-50
5-7-1 Checkmg operation and actions ......... .... .... ....... ............... ...... ............ ..................... 5-50
5-7-2: Error dunng commumcations ... .... ............. .... ... ..... .. .. ... .................. ........... ... ........ ... 5-51
5-7-3: Self-Diagnostic message ........... .......... .................... .... ............ ..... ...... .................... 5-52
5-7-4 Self-diagnosis by mdicator (option) ..... ............ ....... ... ... ......... .... .... .. .. .. .. .. ... ... ...... .. .. 5-56
5-8: Insulation res1stance test and withstand voltage test ......... ... ........ .. ..... .... ..... ... .............. 5-58
Table of Contents
Appedix A
Operating pnnc1ple .. .. .. .... ... .......... .... ...... ..... ... ... .. ... .... ....... ...... ...... ..... ................ ......... .. .. .... .. A-2
•
List of Figures & Tables
Figure 1-1 Block diagram of the transmitter ................................................................... ........ ... . 1-2
Figure 1-2 Structure ofthe transmitter (model JTD) .... ................. .. ....... ...... ....... .... ... ...... .......... 1-4
Figure 1-3 Structure of the transmitter (model JTC) ........ .. .... ..... .... .... .. .... .... .... .. ... ... ... .. .... ... ...... 1-4
Figure 1-4 Structure ofthe transmitter (model JTE) ........ .... .. ............... .. ... ... .... ..... .......... ........ ... 1-5
Figure 1-5 Display umt of mdicator ............... ......... .. ............. ............ .. .... ... ... .... .... ... ....... ...... .. ... 1-6
Figure 1-6 Failure display on mdicator .. .......................... .................... .. ..... ... .. ... ..... ......... ... ....... 1-7
Figure 1-7 Self-diagnosis result display on mdicator. ... .. ...... ............ .. .. .... .... ........ ......... ......... ... . 1-8
Figure 1-8 .... ....... ................... .... .... ....... ....... .......... ............ ... ... .. .... ..... ...... ... .. .... .... ... .. .......... ...... 1-9
Figure 1-9 Parts names of an SFC ..... ................... .......................... .... ....... ....... .......... .... ......... .... 1-12
Figure 2-1 Name plate and conformance mark ....... .... .. ... .. .. ..... ... ... ... .. ....... .... .. ....... ... ......... ....... 2-4
Figure 2-2 Installing the transmitter ... ........... ........ ... ......... ......... ..... .... .. ....... ..... .. ..... .. .. ..... ... ....... 2-7
Figure 2-3 Equipment for line mountmg ................ ............ ........ ........... ... .... .... ........... ........... ..... 2-7
Figure 2-4 Example ofliqmd level measurement m a closed tank .. .... ..... .. .. ...... ... ........ ... ... ...... . 2-8
Figure 2-5 .. ..... .... .. .... ........... ............ ................................ ..... .... ....... .... ....... ... ...... ........ .. ........ ..... 2-8
Figure 2-6 ConnectiOn to a tank ... ........... .. ............ .... ... .... .. .. .. ... .. .... .... .. .... ........... ..... ......... ... .... .. 2-13
Figure 2-7 ..... ....................... ....... .................. ...... ... ........ ... ........... .. .... .. ..... ....... .. .. .... ...... ............. 2-13
Figure 2-8 ....._... ........ ................................... ........ .. ... ... .... ....... ..... ... .. ............... .... ............ ....... .... . 2-13
Figure 2-9 Extenor VIew of pressure receivmg part ......... ...... ... ... ... .:...... .. .. ... ..... .... .... ............. .. 2-15
Figure 2-10 Extenor VIew of gasket.. .......... .. .............. ............ .......... .... .. ...... .... .. .... .... ... ......... .. .. .. 2-15
Figure 2-11 Mountmg on an enclosed tank ...... ..................... .... ... .... ... ... ..... .... ... ....... ....... ...... ... .. .. 2-16
Figure 2-12Mountmg on an open tank ................ ..... ...... .. .. .......... ..... ..... ............. ........ ............ .... . 2-16
Figure 2-13 ..... ........................................... .. ............... ... ................. .... ........ .... ....... .. ......... ..... ...... _. 2-17
Figure 2- 14 ................... .... .... ................... .. ... .. .......... ... .. .. .... ... ............................. .. ... ...... .......... .. .. 2-17
Figure 2-15 ........ ......... ................................................. .......................................... ......... .............. 2-17
Figure 2-16 ... .. ................................ .. ................................ ..... ... ... .. .... .... .. ....... .. ... ..... ................ .... 2-18
Figure 2-17 .............................................................. ............. ..... ....... .. .......................... ........... ..... 2-18
Figure 2-18 .......... ... ................. ................... ........ .......... .. .... .. ...... ...... ..... ........ ... ............................ 2-18
Figure 2-19 Example of direct mount type mstallat10n ...... .......... ........................ .......... ... ....... .. .. . 2-19
Figure 2-20 Remote sealing type transmitter and direct mount type mstallat10n ktt. .... .. .......... ... 2-1 9
Figure 2-21 Adaptor assembly drawmg (model JTE) .................. ....... ... .... ...... ................... ..... ..... 2-20
Figure 2-22 Extenor VIew of adaptor ...... .. ,.. .. .. ........... .......................... ................................ ...... .. 2-21
Figure 2-23 Adaptor length ........................ .. ............. ........................................ .... ..... ... ......... .... ... 2-21
Figure 2-24 Mountmg adaptor on transmitter ................. ........... ... .............. .......... .... ....... .... ...... ... 2-21
Figure 2-25 Mountmg the process side flange No .1 .................................. .... ............................... 2-22
Figure 2-26 Mountmg transmitter flange ................. ...... .................. .... .... ... ................ .. ........... ..... 2-23
Figure 2-27 Mountmg the process s1de flange No.2 ......................................... ... .................... .. ... 2-23
Figure 2-28 Mountmg tube clamp ....................................... .. ......... ... .. .... .... .... .... ............ .............. 2-24
Figure 2-29Example ofmstallat10n by conditiOn .............. .. ..... ... ..... .. .......................................... 2-26
Figure 2-30 InstallatiOn for tank level measurement (Example) ... .. ........... ...... ... ... ...... ............... .. 2-27
Figure 2-31 3-way manifold valve ............................... ........................................ .... .. .. .. .... ..... ...... 2-28
Figure 2-32 Extension p1pe ......... ... .................. ..................... ...... ....... .................... ...................... . 2-28
Figure 2-33 High pressure markmg on center body .......... ...... .... ..... .... ... ................... .. ...... .... ....... 2-29
Figure 2-34 Pipmg for liqmd or gas flow rate measurement (Example- I) ... ......................... .. ..... 2-30
Figure 2-35 Pipmg for liquid or gas flow rate measurement (Example-2) ...... ....... ...... ........ ... .. ... 2-3 1
Figure 2-36 Pipmg for steam flow rate measurement (Example) ..................... ..... .................... ... 2-32
Figure 2-37 High-pressure mark on center body ... ..... .... .. ...... ............. ..... ..... .... ... ...... ... ..... ...... .. .. 2-33
Figure 2-38 Gas pressure measurement- Pipmg ..... ... ............. .................. .......... .. ...... ........... ...... 2-34
Figure 2-39Example ofpipmg .... ...... ........ ... .... ... .. ... ........ ........................... ...... ... ....... ......... .... .. .. 2-35
Figure 2-40 High pressure mark on center body ..... .... ................................................... ... .... ... ..... 2-36
Figure 2-41 Open tank- Pipmg example ..... ...... ..... ... .... ... ..... ...... .. ..... .......... ... ..... ........ .... ..... ....... 2-37
Figure 2-42 Enclosed tank- Pipmg (dry-leg sealing example) .... .. ............ ....... .... .. ..... .. ........ ... .... 2-38
Figure 2-43 Enclosed tank- Pipmg (wet-leg sealing example ..... ......... ... ......... .. .. ................. ... .... 2-39
Figure 2-44 Winng ... ....... ... ... ........ ........... ... ... ........... ........ .. .... .. ..... ..... ...... ... ....... .. ...... ... ...... .... ..... 2-40
Figure 2-45 Supply voltage and external load resistance - relatiOnship ....... ... ........... .. ... ... .......... 2-41
Figure 2-46 Unlock transmitter case .... ... .... .. ......... ... ........ ...................... .... ..... .. ............... .. .... .... .. 2-42
Figure 2-4 7 Pressure resistant packmg cable adapter ...... ..... ....... ..... ... ... .... .. ............ .. ....... ....... .... 2-42
Figure 2-48 System configuratiOn of mtnnsically safe transmitter. ... ;... ...... ... ......................... ... .. 2-43
-.;-igure 2-49 Change process connection port positiOn ....... ........ ... ...... .......... ... ...... .... .............. .. .. . 2-44
1:igure 3-1 Connecting SFC .................................. ..... .... .. .... .. ......... ...... ......... .... ... ........ ... ... ... ...... 3-2
Figure 3-2 ................. .. ..... .... .. ........... ......... .. .................. ..... ...... .... ............ .... ...... .. .... ........... .. .... . 3-1 -1
Figure 3-3 Mimmum liqmd level charactenstic .... .......... .. ... ......... ...................................... ........ 3-37
Figure 3-4 Determmmg the zero position ...................... .......... ...... ...... ... ...... ... ....... ... ................. 3-37
Figure 3-5 Mimmum liqmd level charactenstlc .... ................. ................. ... ............... ... ... ....... .... . 3-40
Figure 3-6 Deterrnirung the zero position .......... ... .................... .. .. ................. ... .... ... ....... .. .......... 3-41
Figure 3-7 Installation for flow rate measurement with onfice plate ... ....... .... .. ... ....... ... ........ .... 3-45
Figure 3-8 Mimmum liqmd level charactenstic ............. ... .... .... ... .... ... ... .... ... ... ... .... ... ......... ... .. .. . 3-46
Figure 3-9 Determmmg the zero position ... .................... ...... ............ ............. ...... ..... ... ....... .. .. .:.. 3-47
Figure 3-10 Zero adjustment dunng liqmd level measurement .... ..... ... .. ....... .... ..... ..... .. ............... 3-50
Figure 3-11 .... ..... ........ .. ... ....... .......... ..... .......... ......... ...... ... ........ ...... .... ............. .. ........ ..... .... ......... 3-5 2
Figure 3-12 External zero adjustment ....................... .... ..... ...... ... .. .... .......... ... .... .... .... ....... ........ .... 3-54
Figure 3-13 Output adjustment value and duration oftnmmer operatiOn ...... ... .. .............. ...... ..... 3-55
Figure 3-14 Open tank .. .... .. .. .:...... ..... ... .... ..... ............ ...... ... ..... ........... .. .. ..... .... ...... .. .. .. .... ......... .... . 3-56
Figure 3-15 Closed tank .............. ...................... ..... .. .............. ......... ..... .......... .... ....... ... ... ... .... ..... .. 3-56
Figure 3-16 ............. .... .. .... .... .......................... ... .... ..... .. ..... ............ .... .. .... .... ... ... ... ... .. ......... .. .. .. ... . 3-57
'igure 3-17 Open tank .... .. .. .. .. ....... ...... ...... ......... ..................... ..... ..... .... .... ... ....... ... ..... ..... ...... ....... 3-58
Figure 3-18 Closed tank ... ... ................ ............. .... ...... .... ... ............ .. ..... .... .... ..... .... ............... ... ...... 3-58
Figure 3-19 Open tank ................ ... .... ..................... .... .. .. ..... .. ...... .. ... ..... ........ .... ........ .. ... ... .. ... .... ... 3-59
Figure 3-20 Open tank ... ... ... .... ................................. ..... ... .... ..... ..... ... ...... .... .............. .. ... .. ....... ... .. . 3-60
Figure 3-21 Closed tank (wet leg) .................................. ... .. ...... ... .... ... .. .. ... .... .... .. .... ... ..... ....... ...... 3-61
Figure 3-22 Closed tank (wet leg) ... ... ... .... ... ... .. .... .... .... ....... .... ............. .. .. .... ..:.... .. .......... ... ... ....... 3-62
Figure 3-23 Closed tank (wet leg) .. ...... ............ ........................ .. .. .. .... ... ..... ..... ........... ... ..... ... ... .... . 3-63
Figure 4-1 SFC key-board ... .... .... ... ............ ......... ....... ... .... .... ..... .... ... .............. ..... ... ....... ... ... .. ..... 4-5
Figure 4-2 Mamtenance prmtmg- example ....... ....... .. ..... ....... ...... ............................... ........... .... 4-22
Figure 4-3 ActiOn pnntmg- Example ... ......... ... ......... .. ...... .... ......... .... ....... .................. ..... ... .. ... .. 4-24
Figure 4-4 Relat1onsh1p between 1nput and output(%) determmed by low flow cutoff value settmg ... 4-39
Figure 5-l Locking case cover ...... ..... ..... ................ ........... ..... .. ... ...................... ... .. ....... ... ..... ..... 5-25
Figure 5-2 Center body cover fixmg bolts .... ..... ......... .. ..... ... .... .. .. .......... .... .... .................... .... .... 5-26
Figure 5-3 Cabling and pipmg eqmpment ..... ... ... ........... ... ........ .... ..... .......... .... .... ................. .. .... 5-35
Figure 5-4 ConnectiOn for calibratiOn ..... ...... .. ..... .................. ... ... .. ... ....... ... ..... ........ .... ..... ..... .. ... 5-40
Table 1-1 Lmear I Square root display status ..... ........ ... .. ...... .... .......... ....... .... ............... ....... ..... 1-7
Table 1-2 External zero adjustment display status ............... .. ... ..... .... .. .... ...... ........ .... .... ........... 1-8
Table 1-3 Standard parts names and functions ...... ...... .... .. ...... ... ..... ... ..... .... .... .. ...... ..... ... ..... ..... 1-13
Table 1-4 OptiOnal parts names and functions ...... ...... .. .... ....... ... ......... ... ................... ........... .... 1-13
Table 2-1 Adaptor flange tightemng torque ... ..... ......... .......... .. .......... ......... .... .. ....... .. ..... .... .... .. . 2-1 3
Table 2-2 ···· ·········· ····························· ···· ················ ···· ··· ···· ················· ··· ··· ···· ···· ··· ·· ··· ··· ·· ····· ········ 2-18
Table 5-1 status message and mearung .... ......... .. ... ....... .... ... ............ .. ... ... .. ... .. ... .... ........... ..... ... . 5-1 3
Overv1ew
Basic functions, structures, and configurations of a Smart Transmitter and Smart
Commumcator (SFC). First-time user of a ST3000 Ace transmitter are asked to first
gam basic understanding of the functiOns and structures of the transmitter. They
should read this sectiOn before performmg any advanced configuratiOn functiOns.
ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter 1-1

Functions, Configurations, and Structures of ST3000 Ace and SFC Yamatake Corporation
1-1: Function and configuration of the

transmitter
~ • .:[. ·: .jl i . . ; '-. . . . .' . '. ~ .
1-1-1: Function and configuration of the transmitter

l al!ID
Introduction
Th1s transmitter offers a range of functwns that ass 1st m the measurement of
differential pressure. A differential pressure sensor IS mounted on a composite,
semiconductor sensor for the transmiSSIOn of flow rate, pressure, and liqmd level data.
A composite semiconductor sensor mcludes a static pressure sensor and a temperature
sensor for the measurement of changes m static pressure and ambient-temperature.
These changes can affect accurate differential pressure measurement. By measunng
static pressure and ambient temperature data, the transmitter compares the measured
differential pressure agamst a true differential pressure, stored m memory The sensors
are mstalled m the meter body along w1th a multiplexer, an AID converter, a
microprocessor m the transmitter umt, canous storage devices, and a 0 / A converter.
Function and configuration

The followmg illustratiOn shows the basic functwns and configuratiOn of th1s
transmitter·
Dig1tal s1gnal
Meter body
Figure 1-1 Block diagram of the transmztter
Flow rate, pressure, and liqmd level of the process tlmd are transmitted to the
differential pressure sensor on the composite semiconductor ch1p, m the meter body
The sensor output IS converted from analog to digital signals simultaneously w1th the
temperature and static pressure that are sensed With the temperature sensor.
1-2 ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter

Yamatake Corporation Functions, Configurations, and Structures of ST3000 Ace and SFC
The A ID converted signals are processed m the microprocessor, and output (after
conversiOn to 4-20 rnA DC analogue signals corresponding to the set range.)
PROM The data stored m this memory mcludes the mput/output, temperature,
and static pressure charactenstlcs of the meter body, the model , and the
valid range of range settmgs.
EEPROM This IS a nonvolatile memory that retams vanous settmg data of the
transmitter even dunng the power-off state.
AID This converter converts analog signals to digital signals.
DIA This converter converts digital signals to analog signals.

1-1-2: Parts names of the transmitter

IntroductiOn
Th1s transmitter consists mamly of a term mal board, an electromcs module, a
transmitter umt case, an mdicator, and a center body
Structure and parts names
The followmg illustratiOn shows the structure and parts names of this transmitter
cover
Transmitter unit case
Termtnal board with tte rated tndicator
Figure 1-2 Structure ofthe transmztter (model JTD)
Termmal board wtth tte rated tndicator
Figure 1-3 Structure of the transmztter (model JTC)
1-4 ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter

Sensor
Electromcs module
Case cover
Flexible cable
Termmal board with ite rated Indicator
Figure 1-4 Slruclure of I he lransmzller (model JTE)
Parts name Description
Center body Consists of a composite semiconductor sensor, a pressure

diaphragm, an excessive pressure protectiOn mechaiusm,
etc.
Center body cover Two center body covers sandwich the center body Connect
a connectmg pipe to this part.
Bolts and nuts Fixmg the center body between covers, are a senes of bolts
and nuts.
Sensor It consists of a composite semiconductor sensor, a pressure
receivmg diaphragm, a flange , a capillary tube, etc.
Electronics module COnsists of electronic circUits havmg functiOns for
processmg differential pressure and other signals, and
transmittmg them.
Transmitter umt case Housmg the electronics module and the termmal board.
Case cover Encloses the transmitter umt case.
Termmal board with Denves electnc signals from withm the mstrument.
mtegrated mdicator Connect an SFC to this termmal board. Integrated w1th the
termmal board IS an optional digital mdicator that displays
an analogue output.

1-1-3: Indicator (Option)

..;s,~ ~MRI E & LEZW I I 11*111
Display unit of mdicator

The display umt of an mdicator consists of the followmg:
Digital display Bar graph display
·---------· /
~L888BDISP FLOW .A.UP ZERO DOWN ...
~ ------~'
~ ~
' --~~'
7 '\
L1near/Square External zero pomt
root display adjustment display
Figure 1-5 D1splay umt of zndicator
Digital display
The mdicator displays the output value of a transmitter m% or any engmeenng umt m
the digital mode. The display umt IS a 4.5-digit 7-segment LCD
·---------·
Indicates a value outside the display range by flashmg as shown below.
-1.8888
DISP FLOW .a.UP ZERO DOWN•
• When the display value IS withm either of the followmg ranges, the limit value
flashes .
Range of display value Display
Display value < -19999 -1999

/ I '
Display value > 19999 19199

/ I '
• In some cases, a transmitter failure IS mdicated by the followmg display

The response action IS outlined m " 5-7 -4 Self-diagnosis by mdicator ( optwn)" on

page 5-56.
.____I ~ .__I_____.
.____I ~ 1'-------'
Figure 1-6 Failure display on zndicator
Analog bar graph display

The output value of a transmitter IS displayed m a 11-segment analog bar graph. The
relatiOnship between the output value and the segment display status (on and blinkmg)
IS as show, below.
Output (OUT) Segment status
0%
5% ~
OUT < 0%
~ OUT < 5%
OUT < 15%
Blink
On •
D
DO
15% ~ OUT < 25% DOD
25% ~ OUT < 35% DODD
35% ~ OUT < 45% DDDDD
45% ~ OUT < 55% DO DODD
55% ~ OUT < 65% DDDDDDD
65% ~ OUT < 75% DDDDDDDD
75% ~ OUT < 85% DDDDDDDDD
85% ~ OUT < 95% DDDDDDDDDD
95% ~ OUT < 100% DDDDDDDDDDD
100% < OUT Only the nght most DDDDDDDDDD.
segment bl ink.
In the constant current mode, the enttre bar graph blinks.

In thts case, the bar graph and digttal display blink alternately
Lmear I Square root display

Read the display to Judge whether the transmitter output and the mdicator display are
linear (differential pressure) or the result of extractmg square root (flow rate).
The JUdgement cntena based on the display are shown below·
Table 1-1 Lmear I Square root display status
Display Output Display status Category
Lmear Lmear None Lmear

(DIfferential pressure) (Differential pressure)
Square root Lmear DISP FLOW Display flow rate
(Flow rate) (Differential pressure) (Display square root)
Square root Square root FLOW Flow rate
(Flow rate) (Flow rate) (Square root)

External zero adjustment display

The operation status of the external zero adjustment functiOn (optwn) IS displayed.
The Judgement cntena based on the display are shown below·
ZERO stays on for a transmitter With the external zero adjustment functiOn.
Table 1-2 External zero adjustment display status
Adjustment status Dasplay
Runnmg ZERO
Output IS mcreasmg A UP ZERO
Output IS decreasmg ZERO DOWN ...
Error I /
'/
ZERO
I '
In the event of an error, take the necessary action, referrmg to " 5-7 -4 Self-diagnosis
by mdicator (option)" on page 5-56.
For the adjustment procedure, refer to "3-10· External zero adjustment (option)" on
page 3-54.
Self-diagnosis display on mdicator

Turn on the power and check that the indicator IS m the normal status.
If the cable has an abnormality, the mdicator does not light up.
If the mdicator has an error, Error No. corresponding to the error type IS displayed.
Err2 Error detected by self-diagnosis

(ROM error)
Figure 1- 7 Self-diagnoszs result display on zndicator
• When the transmitter Itself IS not functwnmg properly, the mdicator display will be
as shown m " Digital display" on page 1-6.
In the event of an error, take the necessary action, refernng to " 5-7-4 Self-diagnosis
by mdicator (option)" on page 5-56.
Engmeenng unit label

Use the engmeenng umt label sheet (included) to mdicate the display area on the
engmeenng umt.
* If you specify an engmeenng umt at the time of ordenng, the eqUipment will be
shipped w1th the specified label already attached. Change the engmeenng umt
label by the followmg procedure when necessary

* Pomter labels for analog bar graphs are provided on the engmeenng umt label
sheet. Use them for momtonng m the field.
Select a umt label or a pomter label and remove It from the sheet.
2. Attach the label to the designated positiOn as illustrated below.
.. ... 0 .. 100
Pa
loFaG
...
P1 ab&
•••
hPa abc
lol'a
kP1 .ate
kPaG
MPa ebc
....... o
atm
tnHg
.....
-Aq
kgtJcmtO
...
WhO
mbarG
...
Q(Jc;MI
...., Q.J
kgt tcmtllb& IM'IHQ abc tnHg ... kt ..0
Q.J Jill SkJ / h ro
..0
mJ/ h
m~ , h km:tlh
kJ/ h
NM 1 1h kN mJth ''"
J IIMI ,_
ro kit"*' m' r"'*- Nral- NJ ,m Nm:t1..W. Q.J
......
-~
c ...
kilt) fftl / 0 t1D
kgtm2
Nrn 1 t0
QJCftll
• Ill
'lo
kg
c
0
Q.J
::> X10 X10' X10' I
- a..
..0
ro
....
Q.J
......
c
0
a..
Figure 1-8

1-2: Function and configuration of SFC
1-2-1: Function of SFC
Introduction
An SFC 1s provided for commumcations with this transmitter via signal cables. The
SFC has functiOns for reading measured data, displaymg and changmg data, and
displaymg the details of self-diagnostics. The display screen data can be pnnted If an
optiOnal pnnter IS mcluded.
InformatiOn on the SFC provided m this manual IS appl icable to software version 7 1
or later. SFC IS available m English and Japanese.
The English version has English notations on the keyboard and displays and pnnts
data m English. Both versiOns are operated with one set of procedures.
Instructions on a Japanese SFC are provided m "Chapter 4 OperatiOn usmg SFC" of
this manual.
Details on operatiOn of the English versiOn are mcluded m a separate manual ;
.&_WARNING
• Always switch to manual control the process loop, before startmg commumcat10ns
between this transmitter and the SFC.
• Commumcat10ns m the automatic process control state may be affected by sudden
changes m output, and result m hazardous operatiOn.
Note that above warmng does not apply to the combmatiOn of a transmitter and an
S FC of the analog overlay type.
• Choose a general-type SFC or an mtnns1cally-safe type, depending on the
operatiOn environment.
ExplosiOn-proof atmospheres reqmre the use of an SFC that has an explosiOn-
proof conformance ~ark. NEVER use a non-conformant SFC m explosive
atmospheres.
• Never replace mtemal parts or change cabling. This may compromise the
mtnns1cally safe performance.
• Rechargmg of the SFC must never be performed m explosive atmospheres .
.&_CAUTION
• Colon ( ) displayed m the data display wmdow means low voltage. Recharge the
SFC.
• Recharge according to the mstruct10ns m "4- 1-7 Chargmg SFC" on page 4-17 In
some cases, over-discharge may shorten battery life.

Function of SFC
An SFC IS used mamly m the followmg situatiOns:
Read measured data, display ·

• Transmitter mput (differential pressure, sensor temperature)
• Transmitter output (%)
Display or change settmgs:

• Tag number
• Output format (linear or flow r.ate)
• High- and low-limit of the settmg range
• Dampmg time constant
• Engmeenng umt of differential pressure
• Low flow cutoff value
• Software versiOn of SFC and transmitter
Mamtam or replace the transmitter (refer to Chapter 5)

• Save and resend data to the transmitter
Display a transmitter I SFC error

• Display a self-diagnostic message
Pnnt data (applicable to an SFC with a pnnter)

• Pnnt stored data stored or status data m a batch format. This function IS called
mamtenance prmtmg.
• Pnntmg this transmitter's response to an mstructwn from an SFC (This functiOn IS
called action pnntmg.)
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter 1-11

1-2-2: Configuration of SFC
Parts names
The followmg illustratiOn shows the structure and parts names of an SFC
Power sw1tch
Commumcat1on cable Battery charger
Figure 1-9 Paris names of an SFC

Parts names and functions

The followmg table shows the functions and structures of SFC parts:
Table 1-3 Standard parts names and functions
Power switch • The SFC automatically s_tarts self-diagnostic checks when

th1s switch Is turned ON. -
• Turn OFF switch to end an operation of changmg a
settmg.
Key board • Use 32 touch keys.
• Key are color-coded for ease of use. Detailed mstructwns
m Chapter 4.
Screen • Commumcatwn data IS displayed m 16 characters x 2
lines.
Commumcat10n • Use cable for connectmg an SFC to a transmitter.
cable
Commumcatwn • Connect the plug of the commumcatwn cable to this
cable connector connector.
Battery charger • Use this charger for rechargmg an SFC.
• Charge the SFC 1f colon ( ) displayed on the screen.
Battery charger • Connect the plug of the battery charger to this connector.
connector
Table 1-4 Optional parts names and functions
Pnnter • Th1s pnnter pnnts settmg data and measured data.

Rolled paper case • Rolled prmtmg paper 1s housed m th1s case.


Overv1ew
Instruct10ns for the mstallat10n of p1pes and cables associated with this transmitter.
Also covers mstallatlon of the transmitter. For users that are responsible for
mstallat10n work .

2-1: Installation environment
2-1-1: General environmental conditions

~~· ~BD------------------------------------------------------------------
Introduction
Install under environmental conditiOns specified here, to fully explOit transmitter
performance over long penods.
Always mstall an explosiOn-proof transmitter where regulations demand such
precautiOns.
Environmental conditions
Select a locatiOn to meet the followmg conditiOns:
• Temperature fluctuatiOns should be as small as possible.
• Avmd mstalling m locatiOns that are exposed to radiated heat from other plant
eqmpment.
• Insulate agamst freezmg m the measured flmd or sealing liquid.
• Avmd mstalling m corrosive atmospheres.
• External zero-adjustment functiOn IS an optiOn that may be subject to output
fluctuations If mstalled near to sources of strong magnetic mterference. Install such
models at least 1 m remote from plant eqmpment producmg strong magnetic
mterference as over 10 gauss measured where a motor or a pump IS mstalled.
2-2 ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transm itter
2-1-2: Environmental conditions for explosion-proof

transmitter
Explosion-proof transmitter mstallation precautions

Exploswn-prooftransrrutters have passed mspect10ns at a public orgamzat10n m
compliance with Japanese Labor Safety and Hyg1ene Laws. As spec1fied, use
exploswn-prooftransm1tters m hazardous locatiOns. Smart Transmitters are available
m two types of explosiOn-proof specifications: flameproof, spec1al explosion-proof
spec1ficat1ons and mtnnsically-safe specificatiOns.
Exploswn-prooftransimtters have a conformance mark that provides requ1red
mformat10n for explosion-proof performance. Install explosiOn-proof transmitters
correctly, and follow the mformatlon on the name plate.
Environmental conditions for explosion-proof transmitter

Install a explosion-proof transmitter m locations that meet the followmg explosiOn
class, Igmtton temperature, and hazardous envuonment class conditions:
• ExplosiOn class and Igmtwn temperature of gas:
IICT4 (IIC All types of gas and steam; T4 Gas and stem whose IgnitiOn
temperature IS 135°C or higher.)
• Hazardous environment class
Class 1 locatiOn or Class 2 location
InstallatiOn m a Class 0 locatiOn prohibited.
• Temperature
Select a locatiOn where the temperature always stays under high limits specified by
the conformance mark. AMBIENT TEMP refers to the ambient temperature of the
transmitter and METER BODY TEMP refers to the temperature of the meter body
that 1s m contact with the liqmd. The low lim1t IS -20oC for both ambient temperature
and meter body temperature

Temperature precautions
The transmitters explosiOn-proof performance cannot be guaranteed outside these
temperature limits. If temperature should exceed the high limits, mstall msulat10n and
ventilatiOn, to mamtam the effective operatmg temperature.
TAG NO.
L-----------------------~
MODEL.
~PRODNO. -----------------------------
0 ~RANGE
01-
~ i MAXW.P
-, UJ SUPPLY 24V DC OUTPUT 4-20mA DC DATE Q
t;z
0 ~· AMBIENT TEMP "C
1- METER BODY TEMP "C
Conformance mark
Figure 2-1 Name plate and conformance mark
Preference document
Industnal Safety Institute ofthe Japanese Mimstry of Labor, New Explosion-Proof
Gmdelines for Plant Electrical Facilities (Gas ExplosiOn-Proof 1985)

2-1-3: Environmental conditions for intrinsically-safe

transmitter
Environmental conditions for mtrms1cally-safe transmitter

Install and mtnnsically-safe transmitter at a locat10n meetmg the followmg explos10n
class, Igmtion temperature, and hazardous envuonment class condit10ns:
• Explos10n class and Igmtlon temperature of gas:
3aG4 (3a: Gases and steam of explos10n class 2 mcluding hydrogen; G4 Gas and
steam whose IgmtlOn temperature IS 135°C or higher.)
• Hazardous environment class
Class 0 locat10n, Class 1 locat10n, Class 2 locat10n
• Temperature
Select a locat10n where the temperature always remams mside the high limits
specified by the conformance mark. AMBIENT TEMP refers to the ambient
temperature of the transmitter and METER BODY TEMP refers to the temperature
of the meter body that ISm contact With the liqmd. The low limit IS -l0°C for both
ambient temperature and meter body temperature. (For mformat10n on the
conformance mark, refer to Figure 2-1 )
Reference document
lndustnal Institute of the Japanese Mimstry of Labor, New Explos10n-Proof
Gmdelines for Plant Electncal Facilities (Gas Explos10n-Proof 1985)
Remarks
The followmg mstruct10ns are especmlly Important for use of mtnnsically-safe
transmitters.
• Cabling and mstallat10n
For cabling work, fo]Jow the Explos10n-proof Gmdelines. For detailed mformat10n,
refer to "2-4-3 Winng transmitter- lntnnsically safe"
• Mamtenance
Changmg parts or mternal cabling may result .m the loss of explos10n-proof
performance. Repatr a transmitter by replacmg Its complete pnnted cucmt board.
ST3000 Ace - Smart Transmitter Electronic Differential Pressure Transmitter 2-5

2-2: Installation
2-2-1: Installation dimensions

Refer to the external dimensiOns m specificatiOn sheets.
2-2-2: Installation environment

Refer to "2-1-l General environmental conditiOns" on page 2-2.

2-2-3: Installing the transmitter

JQiii!Wi Ji • - L LEUL~"'-1
--nD
U - - l l l l i P...F;111
1 - - - - - -- - - - - - -......---IIII"B..,!If......-~~~ii1"T I!WM!1i:'miif
Before mstalling the transmitter
Prepare the followmg Items

• 2-mch pipe
• Mountmg bracket (U-bolt, nu, mountmg bolt) (Optwn)
The transmitter can be mstalled by the followmg two methods:

• InstallatiOn with pipe stanchiOn (Refer to Figure 2-2).
• InstallatiOn with by line mountmg (Refer to Figure 2-3).
In the both cases, fix the transmitter to a vertical or honzontal 50 mm pipe with a U-
bolt usmg a mountmg bracket. Mount the transmitter on a bracket usmg the four bolt
holes on the reverse side of the pressure receivmg part. Fix the pipe firmly to the
foundation and make sure that It IS stable. When you choose the line mountmg
method, provide eqmpment to be used for connectmg a 2-mch pipe to the line pipe.
-Note As.for the procedure for mountmg atransmztter on the 2-znch pzpe, note
that the sequence of assembling the transmztter, the bracket, and the 2-
znch pzpe depends on the znstallatzon directzon.
Nut for U-bolt
2-1nch p1pe
Figure 2-2 Installing the transmztter
Figure 2-3 Equzpmentfor line mountmg

2-2-3-1: [Remarks] Remarks related to installation
High lim1t liqu1d level
Low limit liqu1d level
A > 10cm
- __ J_ __ -- -- -- -- -- -- -- --
Figure 2-4 Example ofliqUld level measurement zn a closed tank
- Note I Mount the transmlfter at least I 0 em below the tank nozzle posllwn. f[lt
cannot be mounted below thzs level, refer to "InstallatiOn posztzon of
remote sealing type transmztter on closed tank "
2. If the liqUld to be measured contazns hydrogen, consult wah us con-
cermng the handling method.
3 In case of the hzgh temperature and hrgh vacuum model, the response
speed ofthe transmllfer wzll be low ifthe measurement temperature and
the ambzent temperature are I OoC or lower. Make sure that the ambzenl
temperature of the capillary tube and the center body rs always hzgher
than JO oC.
2-2-3-2: Installation position of remote sealing type transmitter on closed

tank
In mstalling the transmitter mam unit above the lose flange of a closed tank, the
followmg conditions must be satisfied. The mstallatJOn positiOn of a remote sealing type
transmitter IS studied on an assumptiOn that the tank iS empty
HP PO· Pressure m the tank (Absolute

pressure: kPa abs.)
p' Specific gravity of liquid sealed m
p' the capi llary
PO h: Height from the lower flange of
the tank to the transmitter
Figure 2-5
When a transmitter IS mstalled as ill ustrated above, negative pressure attributed to the
head pressure of the sealed liqmd m the capillary iS applied to the diaphragm of the
transmitter mam unit (lower flange Side) besides the mner pressure of the tank.

The pressure applied to the diaphragm surface should be equal to or htgher than the
low limit allowable pressure value P (kPa abs.) of the transmitter mam umt. The
conditiOns for meetmg this requtrement are specified below.
An applicatiOn m whtch the pressure m the tank IS vacuum reqmres spectal care
because greater negative pressure 1s applied to the diaphragm of the transmitter mam
umt of the lower flange side.
PO+ (-p'h/102)?::: P1 kPa = 102 mmH 20
h .s (PO-P) X 1021p '
Low lim1tof Range of liqUid
Specific gravity
allowable contact
of sealed liquid
pressure temperature
p' P (kPa abs.) oc

Regular type 0.935 2 -40 to 40
High temperature service 1.07 2 -5 to 90
High temperature I vacuum service 1.07 0.133 -5 to 100
High temperature I high vacuum servtce 1.09 0.133 10to250
Oxygen use, chlonne servtce 1.87 53 -10 to 40
Remarks: The lo limit of allowable press~re changes tf the liqmd contactmg
temperature exceeds the above range. In such a case, refer to the
specificatiOns.
2. The range of ambient temperature IS the range of liqmd contactmg
temperature m the above table or the normal operation range of
ambient temperature whichever IS narrower.
Example:
Use a general use remote sealing type transmitter model JTE to a vacuum application.
Liqmd contactmg temperature: Normal temperature
Low limit of allowable pressure (P): 2 kPa abs. (15 mmHg abs.)
Specific gravity of sealed liqmd (p '): 0.935
Therefore, the followmg conditiOn must be met to satisfy the transmitter spectficatJOns:
PO+ (-p'h/102) > P1 kPa = 102 mmH 2 0
If the mternal pressure (PO) of the tank falls to 3 kPa abs., the allowable range of "h" IS
expressed with the followmg formula:
h < (PO - P) X 1021p'
m whtch P = 3, P = 2, p' = 0.935
h < (3- 2) x 10210.935 = 109 mm
Therefore, the transmitter position must not be higher than 109 mm above the lower
flange of the tank.
Remarks: If the above conditiOn IS not met, the diaphragm surface will be pulled by
negative pressure exceeding the allowable range. As a result, the sealed
liqmd will be gasified due to pressure exceeding the standard vapour
pressure. If the negative pressure further mcreases, the diaphragm can be
destroyed due to buckling. We recommend to mount a transmitter mam
umt at least 10 em above the lower flange because these conditiOns are
not always clearly determmed by customers.

2-2-4: Transmitter main unit installation position

I!JiiBi!l¥
--
No special restnchon IS Imposed on the mstallatwn position, It IS the best to mstall the
transmitter mam umt m such a way as to set the pressure recetvmg diaphragm
vertically After mstallation, calibrate the zero pomt by the followmg procedure.
Perform zero pomt calibratiOn by the followmg procedure:

Fix the high pressure and low pressure side diaphragms at the same height and make
sure that the mput pressure to the transmitter IS umform.
Tum ·offthe sealed liqmd temperature correctiOn functiOn for the calibratiOn work.
Refer to "4-5-15 Displaymg an changmg sealed liqmd temperature correctiOn
functwn" for changmg the temperature correctiOn function.
Zero pomt calibration usmg SFC

Check that the mput and the output are 0 kPa and 0%, responsively
Step Key · Descnption SFC screen
Turn ON the power switch of the

SFC. After makmg sure that the LOOP IN MANUAL?
process IS m the manual control
mode, press the key
PRESSID
2 DE READ
Press the 0 DE READ
key DSTJ TAG NO
G LIN DP FIT-1234
3 INPUT
Press the ( ...~ ] and keys m SHIFT-

that order.
INPUT
INPUT FIT-1234
WORKING...
INPUT FIT-1234
0.0000 kPa

Step Key Descnption SFC screen
4 INPUT
Press the key OUTPUT FIT-1234
WORKING. ..
OUTPUT FIT-1234
0 00%
If the SFC screen display IS not 0 kPa and 0% m steps 3 and 4, respectively, perform
zero calibratiOn by steps 5 to 9
If 0.005 kPa IS displayed m step 3, perform calibratiOn by the followmg procedure:
5 INPUT
B INPUT
Press the [ ""'~) and
m that order
keys, SHIFT-
INPUT FIT-1234
WORKING. ..
J,
INPUT FIT-1234
0 005 kPa
6 RESET
RES ET
Press the key INPUT FIT-1234

ZERO INPUT?
7 NON-VOL
INPUT
ARE YOU SURE!?
8 NON-VOL
NON-VOL
INPUT FIT-1234
WORKING.
INPUT FIT-1234
INPUT ZEROED

9 Repeat <step 3> and <step 4>

and make sure that 0.00 1s
displayed.
Zero pomt calibratiOn IS
completed.
If the SFC screen display differs from the above, refer to "Chapter 5 Mamtenance and
trabouleshootmg" and take the necessary action.
2-12 ST3000 Ace - Smart Transmitter Electrontc Differential Pressure Transmjtter

2-2-5: Installation of process (Models JTCtJTEtJTHtJTS)

~e:zre=m o au.,.'J~~~~Ja."'
&cAUTION :
'
Before mstalling the transmitter, remove the "Protective cover"
Protective cover
Example: Remote seal type
Installation method
Referrmg to Figure 2-6, mount the
flange on the process.
Flash diaphragm Extended diaphragm
Figure 2-6 ConnectiOn to a lank

For the adaptor flange tlghtemng torque, refer to Table 2-1
Table 2-1 Ad~ptor flange tightemng torque
Material Tightening torque (N•m)
SNB7 20 ±1
SUS304 10 ±1
Pipmg
Liqmd level measurement man open tank (models JTC929/940)
Connect the pipe as shown m Figure 2-7
Liqutd level measurement m closed tank connectmg pipe gas sealing (dry leg) (models
JTC929/940)
Connect the pipe as shown m Figure 2-8.
100%
p
---.--- - - - -- \ liqu1d level
Volume contamer
Ia% Tank 2
Tank
liqu1d level
l- - -'--- -=-==--
h
p p
Figure 2- 7 Figure 2-8

Installation mehod
Step procedure
Mount the flange on the process stde flange usmg bolts and a gasket(*).
Tighten the bolts evenly and firmly to prevent leakage.
Bundle the capillary tubes of the htgh pressure and low pressure stdes
together to decrease the mfluence of ambtent temperature difference . Fix
the capillary tubes so that they may not be moved by wmd or vibratiOn.
(You are advtsed to loosely wmd surplus tubes and fix them.)
*· The process user zs asked to provzde aflange gasket. ffyou use a semz-
metal or rubber gasket, select a gasket ofan approprzate shape so that
ll may not contact the transmztter diaphragm.
2 In case of liqmd level measurement of an open contamer, fix the flange
firmly where ts not exposed to great temperature fluctuatiOns or any
vibratiOn. Protect the seal diaphragm to prevent damage. Make sure that
netther dram, nor dust ts accumulated on It.
Remarks:
1 Don 't twtst the capillary tubes.
2. In unwmding a capillary tube, hold the flange part and unwmd the
large loop ofthe tube.
3 You are advised to mount the capillary tubes below the honzontal
plane.
4. Don ' t turn the capillary tubes m such a way that tt twtsts the root of the
flange.
5 You are advtsed to fix the capillary tubes to prevent vibratiOn.
3 Gasket selectiOn for the flange (3 mches flush mount type)
The mstruct10ns for selectmg a gasket for the flange are provided below.
Since the diaphragm diagram ts 95 mm¢, a commerctally available 3
mches gasket will contact the diagram to cause a measurement error.
Select an appropnate matenal according to the liqmd, operatmg pressure
and temperature and select a gasket of an appropnate mner diameter. (Its
diameter must be appropnate so that the gasket never contaCts the
diaphragm even If It ts misaligned or crushed.)
Remarks:
1 Select a gasket of an appropnate mner diameter. (The diaphragm
diameter IS 95 mm¢.)
The diameter of a commerctally available 3 mches gasket 1s
mappropnate for th1s purpose. (80 to 90 mm¢)
2. A gasket should never contact the diaphragm even tf It ts crushed or
deformed.
• A gasket made of a soft matenal can be deformed by bemg tightened.
• Vertlcal gasket mountmg can cause problems such as falling and
tmsalignment.
Align the gasket accurately
3 In case of a flange With a FEP protectiOn film , observe the followmg
mstruct10n bestdes 1 and 2.
• Excesstve ttghtemng can destroy the protectiOn film.
• Mount the protectiOn film according to "FEP protection film mountmg
procedure"
• Excesstve grease or gasket misalignment ts suspected tf the zero pomt
sJ:uft greatly after mountmg the pressure recetvmg umt.

Figure 2-9 Extenor vzew ofpressure rece1vzng part
Example of selection
Matenal: Asbestos (Non-asbesl
Flmd: Sea water Ecxternal dimens1on: 134 mm
Temperature: Normal temperature Inner diameter· 98 +2/-0
Pressure: 300 kPa max. Thickness: 2 mm
FEP protectiOn film
Flange: . 3BJIS 1OK
Figure 2-10 Extenor vzew of gasket

Mounting the flange for liqu1d level measurement (model JTE)

Remarks: Take enough care because the positiOnal reqmrement of the htgh pressure
stde flange of the transmitter depends on the tank type (open tank or
enclosed tank). In case of an open tank, mount the .htgh pressure stde
flange on the lower flange of the tank. In case of an enclosed tank, mount
the h1gh pressure stde flange on the upper flange of the tank.
High pressure s1de flange

~
Tank
Transmitter ma1n unit

Low pressure s1de flange
Pipe stanch1on
Figure 2-11 Mountzng on an enclosed tank
Mounting the flange for liqu1d level measurement (model JTH/JTS)

An example of transmitter mstallat10n for measurmg the liquid level man open tank IS
shown below.
Tank
Flange
Mounting bracket
Pipe stanch1on
Figure 2-12 Mountmg on an open tank

2-2-6: Mounting FEP protection film

________. a__________. _________________________________________ a.a
~--.
3 mches flange
Perform the followmg work Immediately before mountmg the flange of the pressure
receivmg part:
1 Hold the transmitter m such a way that the diaphragm of the pressure receivmg
flange faces upward.
2. Apply about 15 g of diaphram grease to the diaphragm surface and spread It thmly
on the whole surface With a finger.
(The average grease thickness on the diaphragm IS about 2 mm.) (Refer to Figure
2-13)
3 Engage the FEP protectiOn film mto the rased face surface of the diaphragm. (refer
to Figure 2-14 )
4 Push the center of the diaphragm so that grease comes out to the outside.
Push slowly so that no air IS left between the diaphragm and the FEP protectiOn
film.
Squeeze out grease so that almost no grease remams on the raised face part.
If you squeeze out about 5 to 7 g, the average grease thickness on the diaphragm
surface will be about 0.5 mm. Work carefully enough so that the diaphragm may
not be deformed by excessive force. (Refer to Figure 2-15 )
5 _ Lay asbestos (non-asbestos) on the flange of the pressure rece1vmg part and mount
It on the process flan~e. Tighten the bolts and nuts at about 20 N.m.
6. If zero pomt fluctuatiOns disable normal operatiOn, collect mput data usmg the SFC
before and after tlghtenmg the flange. Make sure that the fluctuatiOn IS about 0 1
kPa. Repeat the work If the fluctuatiOn IS greater because great fluctuatiOns can
cause zero pomt shiftmg.
-Note A conszderable skillzs reqwredfor grease applicatzon to suppress zero

rr
pomt jluctuatzons to a low level. you find lf difficult, ask our servzceman.
EP protection film (0.4t)
Figure 2-13 Figure 2-14
Figure 2-15
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter 2-17 .

1%, 2 mches flange

Perform the followmg work Immediately before mountmg the pressure receivmg
flange of the mstrument on the process flange:
Hold the transmitter m such a way that the diaphragm of the pressure rece1vmg
flange faces upward.
2. Apply about 10 g (about 1/4 of one tube) of diaphram grease (No. DG-203 , Daikm
Kogyo) to the diaphragm surface and the gasket contact surface of the flange and
spread It thml y on the whole surface With a finger so that the average grease
thickness on the gasket may be about 0.5 mm.) (Refer to Figure 2-16.)
-Note J.Don Y deform the diaphragm by applymg excesszveforce to lf dur-
mg grease applicatwn.
2. Don 't leave any azr (foam) m the grease.
3 Engage the FEP protectiOn film mto the diaphragm of the flange . Lift one side and
engage It qmetly from the opposite direction without leavmg air. (Refer to Figure
2-17)
-Note ! .Make sure that the FEP protectwn.film flghtly contacts the metallic
diaphragm.
2. The wavy part of the FEP protectwnfilm should not be convex.
4 After mountmg the FEP protection film, be sure that no air IS left between the
diaphragm and the FEP protection film. Remammg air lowers the measurement
accuracy m some cases. lfremammg air IS fo und, push out air from the center
toward the outside by pressmg with a finger. (Refer to Figure 2- 18.)
5 Lay a FEP covered gasket or an asbestos gasket on the pressure receivmg flange
and mount It on the process flange .
The recommended tightemng torque for bolts and nuts IS shown m Table 2-2 (for
reference).
-Note 1 Tighten the bolts wzth even torque.
Table 2-2
Flange rating Tightemng torque (N.cm)
JIS lOK- 50 mm 30
JIS 10K- 40 mm 20
ANSIIJPI 150# - 2 mches 28
ANSI /JPI 150# - 1.5 mches 20
~.,,~o.s
Figure 2-1 6 Figure 2-1 7 Figure 2- 18
2-18 ST3000 Ace -Smart Transmitter Electronic Differential Pressure Transmitter

2-2-7: Direct mount type installation (patent pending)

(model JTE )
Outline
The direct mount type IS an mstallatwn kit (adaptor, tube clamp) for a remote sealing
type transmitter that was developed to enable easy mstrumentatwn for tank level
measurements. The direct mount type elimmates the need for a stanchion for mstalling
the transmitter mam umt. Combmed with the Yamatake 's umque temperature
correctmg functiOn for sealed liqmd and capillary tube bundling, 1t achieves
outstanding temperature charactens1Ic.
Figure 2-19 Example ofdirect Figure 2-20 Remote sealing lype transmu/er and
mount type mstallatwn direct mount type mstallatwn k1t
Features
Simple and easy mstrumentatwn
• A transmitter can be mounted directly on a tank usmg an adaptor. There IS no more
need for a stanchion. It saves the space around the tank.
• The capillary tubes are bundled and fixed man orderly manner usmg the tube clamp.
A product of the most smtable capillary length can be obtamed as long as the
distance between tank flanges IS known.
Outstanding ambient temperature charactenstic

• Yamatake's remote sealing type transmitter has a temperature correctiOn functiOn for
sealed liqmd (patent announcement completed) which mmimJzes the mfluence of
amb1ent temperature changes on sealed liqmd pressure applied as head pressure. It
greatly decreases zero pomt shiftmg. (Influence of seasonal temperature change: 115
to 1110 compared with the conventiOnal model.)
• Zero sh1ftmg due to the capillary temperature difference IS decreased to 2 compared
With the conventiOnal model by bundling the capillary tubes w1th a spectal tube
clamp.

Specifications
The specificatiOns of the direct mount type mstallatwn kit that comes with a remote
sealing type transmitter are presented here. For the spectficatwns of a remote sealing
type transmitter to be combmed with this kit, refer to Specification sheets.
<Specifications of direct mount type mstallahon kit>
Matenal:
Adaptor SCS13 (eqmvalent to SUS304)
Adaptor fixmg bolt: SUS304 (M8)
Tube clamp Brass+ Nickel platmg
Adaptor mountmg:
Instrument side Mount with 4 adaptor fixmg bolts
Flange side Mount With 4 adaptor fixmg bolts
Tube clamp Bundle the both sides of a folded capillary tube and clamp
them.
Wetght: Approx. 600 g
Combmable transmitters
Models: JTE9290
• The direct mount type mstallatwn kit can be combmed only With general use remote
sealing type differential pressure transmitters of the above models. It cannot be
combmed wtth htgh temperature I high temperature vacuum I high temperature, high
vacuum use transmitters.
Installation method
(1) Installation dimenstons
Figure 2-21 , Figure 2-22, and Figure 2-23 show an adaptor assembly mounted on a
process, an extenor vtew of an adaptor, and the adaptor length of the mstallatwn kit,
respectively For the other dimensiOns, refer to the external dimensiOns m " 1
Overview"
t'IUl ~l:liUfl J.liJ.l~
Transmitter srde flan e Process srd e flan 1
Figure 2-21 Adaptor assembly drawmg (model JTE)

L 64 ~I
--:- -:::::-:-::-::~- :+:

Figure 2-22 Exterwr vzew of adaptor
Figure 2-23 Adaptor length
(2) Installation environment

Refer to the remarks m "2-2-1 InstallatiOn dimensiOns" on page 2-6.
(3) Installation procedure
Step Procedure
Fix the adaptor on the transmitter mam umt.
Make sure that the adaptor IS firmly fixed to the transmitter mam umt w1th
four bolts. If It IS not firmly fixed, fix It firmly (Refer to Figure 2-24)
Remote sealing type

differential ressure transmitter Adaptor fix1ng bolt
Figure 2-24 Mountmg adaptor on transmzlter
2 Mountmg the transmitter flange (transmitter fixmg side) on the process

side flange.
Mount the transmitter flange (*1) (transmitter fixmg side) on the process
side flange before fixmg It to the other end of the adaptor fixed to the
transmitter. (Refer to Figure 2-25 )
* 1 A transmitter can be fixed to the high pressure and the low pressure
side flange.
&cAUTION
• In measure the liqmd level m an enclosed tank usmg a transmitter
other than model JTE929 0 , be sure to mount the high pressure
side flange (HP) m the upper part ofthe process.

Step Procedure
Figure 2-25 Mountzng the process stde flange No. 1
CD Mountmg on the process flange

Mount the transnutter flange on the process flange usmg bolts and a
gasket.
&cAUTION
• In measure the liqmd level m an enclosed tank usmg a transmitter
other than model JTE929 0 , be sure to mount the high pressure
side flange (HP) m the upper part of the process.
@ Gasket selection for the flange

The process user IS asked to provide a gasket for the flange.
Select a gasket of an appropnate shape so that It may not contact the
diaphragm.
Select an appropnate matenal according to the liqmd, operatmg
pressure and temperature and select a gasket of an appropnate mner
diameter.
&cAUTION
• The flange of the 3 mches flush mount type has a diaphragm
diameter of 95 mm~. Therefore, don ' t use a commercially
available 3 mches gasket (inner diameter 80 to 90 mm~) for It. A
3 mches commercially available gasket may contact the
diaphragm to cause a measurement error because Its mner
diameter IS small.
• Select a gasket of an appropnate Inner diameter so that It never
contacts the diaphragm even If It ts misaligned or crushed. A
gasket made of a soft matenal can be deformed by bemg
tightened.
• Align the gasket accurately Vertical gasket mountmg can cause
problems such as falling and misalignment.
• In case of a flange wit~ a FEP protectiOn film , out It according to
the mstruct10ns m "FEP protectiOn film mountmg procedure"
Never tighten It excessively to prevent destructiOn of the
protectiOn film.
2-22 ST3000 Ace- Smart Transmitter Electromc Differential Pressure Transmitter

Step Procedure
• The mner pressure of a tank must be the atmosphenc pressure or
higher to mount a transmitter mam umt on the upper flange of the
process. If the mner pressure IS lower than the atmosphenc
pressure, be sure to mount It on the lower flange of the process.
3 Mount a set of transmitter mam umt and adaptor on the transmitter side
flange .
Firmly fix the set of transmitter mam umt and adaptor checked m " 1" on
the transmitter Side flange mounted m "2" with four bolts. (Refer to Figure
2-26)
Protection pope
Process sode flan e
Figure 2-26 Mountzng transmztter flange
4 Mountmg the other transmitter side flange on the process flange.

Mountmg the transmitter side flange that has not been mounted on the
process on the process flange. (Refer to and m Figure 2-27)
Figure 2-27 A1ountzng the process s zde flange No.2
5 Bundling capillary tubes with a tube clamp

Bundle the capillary tubes usmg the tube clamp. Fix the tube clamp firml y,
but not forcefully enough to smash the capillary tubes. (Refer to Figure 2-
28.)
ST3000 Ace - Smart Transmitter Electronic Differential Pressure Transmitter 2-23

Step Procedure
Transmitter Side flange --+
Tank
Tube clamp
Protection p1pe
Transmitter s1de flange
Figure 2-28 Mountzng tube clamp
Remarks related to capillary tube handling

• Don ' t twist the capillary tubes.
• In unwmding a capillary tubes, hold the flange part and unwmd the
large loop of the tube.
• In folding a capillary tube, don ' t apply unnecessarily great force .
The mimmum bending radius (diameter) IS about 5 em. Don 't repeat
bending and unbending.
• Don ' t tum the capillary tubes m such a way that It twists the root of
the flange.
• You are advised to fix the capillary tubes m the middle positiOn to
prevent vibratiOn.
Lh CAUTION
• The mner pressure of a tank must be the atmosphenc pressure or
higher to mount the folded part of the capillary tube above the
upper flange ofthe process as shown m Figure 2-25 If the mner
pressure IS lower than the atmosphenc pressure, be sure to mount
It below the lower flange of the process.
• In takmg up a capillary m the upward direction, be sure to spectfy
olefimc covenng for the capillary tubes.
• If a capillary tube has no olefimc covenng, make sure that the
capillary take-out direction IS below the honzontal plane.
Otherwtse, ramwater can be accumulated m the protectiOn pipe at
the capillary take-out port.

Step Procedure
6 Zero adjustment
After mstaHing a transmitter on the tank, adjust the zero pomt.
For the zero pomt adjustment procedure, refer to "3-5 Measurement with
model JTC", "3-6. Measurement With model JTE" or "3-9· Zero-span
adjustment With mput pressure eqUivalent to range"
7 Settmg the sealed liqUid temperature correctiOn functiOn
Set the height between flanges usmg the SFC.
For the settmg procedure and the functiOn, refer to "4-5-15 Displaymg an
changmg sealed liqUid temperature correction functwn"
Thts functiOn mtmmizes the mfluence of ambient temperature changes to
greatly Improve the zero shift performance.
8 Others
CD Remarks related to an open tank
6 CAUTION -
• The low pressure side flange of the transmitter that IS not
connected to the process should be fixed firmly where It not
exposed to vibration or great temperature changes. Damage on
the seal diaphragm or dram or dust accumulatiOn can cause an
error.
@ InstallatiOn by condition
Refer to Figure 2-29

Inner pressure of tank: Atmosphenc pressure Inner pressure of tank: Atmosphenc press ure
Mounted at the bottom of the tank Mounted at the top of the tank
Capi llary tube w1th o lefimc covenng Capillary tube w1th olefinic covenng
Inner pressure of tank: Atmosphenc pressure Inner pressure of tank : Atmosphenc pressure
Mounted at the bottom of the tank Mounted at the top of that tank
Capillary tube w1thout olefimc covermg Capillary tube without olefin1c coverm g
Inner pressure of tank= Vacuum (be low atmosphenc pressure)
Figure 2-29 Example ofznstallatwn by conditwn

Yamatake Corporation Functions, Config.urations, and Structures of ST3000 Ace and SFC
2-2-8: 1/2 inch remote installation (model JTE/JTH)
Installation procedure
Step Procedure
InstallatiOn dimensiOns
Refer to the external dimensiOns m specificatiOn sheets.
2 Installation
CD Fixmg the adapter to the transmitter
Make sure that the adapter IS fixed to the end of the capillary tube
securely with 4 sets of bolts and nuts. If It IS not fixed, fix It
securely
At this time, apply grease to the lock bolts.
0 Mountmg on the process
Figure 2-30 shows an example of mstallatwn on a tank.
For detailed mformatwn, refer to "2-2-5 InstallatiOn of process
(Models JTC/JTE/JTH/JTS)" on page 2-13
Transmitter mam unit
Pipe stanchion
Figure 2-30 Installatzonfor tank level measurement (Example)
&_CAUTION
• In bending the capillary tube, do not twist It.

• The mm1mum bending radius (diameter) ofthe capillary tube IS about 5 em. Do
not bend It forcefully to a smaller radius.
• A flmd of some properties becomes solidified ms1de the adapter to disable smooth
measurement. In such a case, suffi ciently warm the outside of the adapter to
prevent solidificatiOn of the flmd.

2-3: Piping
2-3-1: Flow rate measurement - Piping (model JTD)
2-3-1-1 Pipmg considerations
Introduction
Pipmg method depends on such conditiOns as transmitter position and pipe-line
mstallatwn. It IS generally sufficient to use a 3-way mamfold valve and connect an
extension pipe.
Since the model JTD has separate connector ports for high and low pressure,
distmgmsh them correctly for mstallatwn work. A 3-way mamfold valve IS optional.
3-way manifold valve (option)

A regular, 3-way marufold valve IS shown m the followmg illustration:
Figure 2-31 3-way manifold valve
Extens1on p1pe (option)

Both strmght extension pipe and umon extensiOn ptpe shown below, are available.
Straight pipe
Figure 2-32 Extenszon plpe

·Yamatake Corporation Functions, Configurations, and Structures of ST3000 Ace and SFC
High-pressure markmg
H mdicates high pressure on the centerbody Check the mark to ensure correct
mstallation, dunng pipmg work. The low pressure s1de has no mark.
Figure 2-33 High pressure markzng on center body
Pipe selection
Select a schedule number and nommal thickness for the connectmg pipe leading from
a process, based on such conditiOns as process pressure.
For example, use a 112 mch, steel p1pe with a schedule number 80.
Matenals and requ1rements

Prepare m advance the followmg parts and always refer to the illustratiOn.
• 3-way mamfold valve
• P1pe
• Mam valve
• Umon or flange
• Tee
• Dram valve
• Dram plug
• Vent plug
• Seal pot (for steam flow rate measurement only)
2-3-1-2: Pipmg for liquid or gas flow rate measurement
Recommended p1pmg - Example 1

The illustratiOn shows a typical example of p1pmg. This transmitter IS located below
the differential pressure output port of the process p1pe.
The fo llowmg apply·
Grade the p1pe at the differential pressure output part.
InclinatiOn symbol m illustratiOn: Low level High level

After p1pmg work, ensme that the connectmg p1pe, the 3-way mamfold valve, and the
transmitter have no pressure leak.
Low
pressure s1de
Figure 2-34 Pipzngfor liquzd or gasflow rate measurement (Example-f)
Th1s transmitter IS located underneath the differential pressure output port of the
process p1pe.
Recommended p1pmg - Example 2

The illustratiOn shows a typical example of pipmg. Th1s transmitter 1s located above
the differential pressure output port of the process pipe.
The followmg apply·
Grade the pipe at the differential pressure output part.
InclinatiOn symbol m illustration: Low level High level ·

After pipmg work, ensure that the connectmg pipe, check for pressure leaks around the
3-way mamfold valve, and the transmitter.
Differential pressure
Orifice output port
High
pressure s1de
Low
pressure s1de
Figure 2-35 Pipmgfor liquzd or gasflow rate measurement (Example -2)
This transmitter ts located above t~e differenttal pressure output port of the process
pipe.
2-3-1-3: Pipmg for steam flow rate measurement
Recommended ptpmg - Example

The illustratwn shows a typical example of ptpmg. Recommended for a transmitter
located below the differential pressure output port of the process p1pe.
The followmg apply·
Grade the ptpe at the differential pressure output part.
InclinatiOn symbol m illustratiOn: Low level High level
After pipmg work, ensure that the connectmg pipe, the 3-way mamfold valve, and the
If the process pipe IS vertically mounted, mount seal ports at different levels to prevent
zero dnft. But m thts case, you cannot apply the prevwusly-used zero adjustment

procedure (usmg a 3-way mamfold valve). For zero shift occurnng at different levels,
use an SFC.
Low
pressure Side
Dra1n
valve
Figure 2-36 Pipzngfor steam flow rate measurement (Example)
This transmitter IS located under the differential pressure output port of the process
p1pe.

2-3-2: Pressure measurement- piping (model JTD/JTG/JTA)

~- I rtJ i..,..._tiliUllf&:&''M£ RF -£ £& Ciftt __. 'PYITI F li~'MI:~
2-3-2-1: Pipmg
In trod ucti on
Connect the high-pressure side of this transmitter to the process pipe. Open the low-
pressure side to the air.
High-pressure mark
H mdicatmg high pressure IS marked on the center body of this transmitter.
Check the mark dunng pipmg work. The low-pressure side has no mark.
Figure 2-3 7 High-pressure mark on center body
Before Installing the transmitter

Prepare the followmg parts. Refer to the illustratiOn for pipmg example.
• Pipe
• Mam valve
• Umon or flange
• Tee
• Dram valve
• Dram plug
• Gas vent plug

2-3-2-2: Pressure measurement- Pipmg
Recommended piing - Example

For gas pressure measurement, ptpmg should be performed followmg the typical
example shown here. Always observe these pomts:
At the differential pressure output, make pipe vertical.
After completmg pipmg work, check for pressure leaks around connectmg pipe and
transmitter
....- Gas vent plug
Process p1pe
Figure 2-38 Gas pressure measurement - Pzpmg
Pipmg method
The pipmg method for the flutd to be measured depends on the meter mstallatiOn
position and the pipe line state. Typical examples of ptpmg are shown m Figure 2-6.
Connect ptpes by the followmg procedure:
(1) Use aT-shaped JOint for the connectmg pipeline.
(2) Install a mam valve between the entrance of the connectmg ptpe and the T-shaped
JOint.
(3) If the process IS a honzontalline, tilt the ptpe to allow dratmng from the pressure
line.
-Note In case ofa hzgh pressure process. select a JOtnl of appropnate specl-
ficatwns and shape and a pzpe of appropnate shape and matenal
wllh care.

(4) Determme the connectmg pipe schedule number and the nommal thickness of the
connectmg pipe from the process based on conditiOns such as the process pressure.
Dra1n valve
Siphon
Process
Figure 2-39 Example ofpzpzng
Auxiliary equ1pment
(1) Oil sealing and air purgmg
If the pressure medium (such as suspensiOn, high viscosity, and corrosive fluid)
should not be led directly to the element, avmd tt by means of sealing or purgmg.
Vanous sealing and purgmg methods are available. Consult with us for each case.
(2) Preventmg pulsatiOns
If the process has senous pulsatiOns or great pressure fluctuatiOns, provide a
throttle valve m the middle of the connectmg pipe to prevent pulsatiOns.

2-3-3: Liquid level measurement-. Piping (model JTD/JTG)

~·~·~nmo.m.-_. ___.._._. . _.~---------------.-.~-.--.--.ma-.m..-~MDwm--
2-3-3-1: Pipmg
Introduction
For measurement by model JTD of liqmd level m a tank, pipmg method depends on
whether the tank IS open or enclosed. For enclosed tanks, pipmg IS modified according
to whether you use the gas sealing method (dry leg) or the liqmd sealing method (wet
leg).
For measurement by model JTD of liqmd level m a tank, pipmg method usually
depends on the tank IS open.
High-pressure mark (model JTD)

H mdicatmg high pressure IS marked on the center body of this transmitter.
Check the mark dunng pipmg work. The low-pressure side has no mark.
Figure 2-40 High pressure mark on center body
Before starting
The followmg parts are reqmrements for pipmg work. Refer to illustration.
• 3-way mamfold valve
• Pipe
• Mam valve
• Umon or flange
• Tee
• Dram valve
• Dram plug
• Seal pot (for enclosed tank and wet-leg only)

2-3-3-2: Open tank- Piping
Recommended p1pmg - Example

For open tanks, connect the high pressure side of this transmitter to the lower part of
the tank. Open the low pressure side to the mr.
After completmg pipmg work, check for pressure leaks around the connectmg pipe,
the transmitter, and the 3-way mamfold valve. The illustratiOn shows a typical
mstallatwn.
Connect the h1gh pressure s1de of th1s transmitter to the lower part of the tank.
Install th1s transmitter below the lowest liqmd level to be measured.
Open tank
Open tank
L1quJd level
Mam valve
3-way
manifold valve
Dram plug Dra1n plug
Figure 2-41 Open tank- Pipzng example

Recommended p1pmg for dry leg - Example

When usmg the dry-leg method, connect the high pressure stde of this transmitter to
the lower part of the tank. Connect the low pressure Side to the gas-sealing pipe of the
tank.
After completmg pipmg work, check for pressure leaks around the connectmg pipe,
the transmitter, and the 3-way marufold valve. The followmg shows a typical
mstallation.
Always connect the high pressure Side of this transmitter to the lower part of the tank.
Install thts transmitter below the lowest liquid level to be measured.
Tee
Low
pressure
srde
Tee
Drarn
valve Drarn plug
Figure 2-42 Enclosed tank- Pipmg (dry-leg sealing example)

Recommended p1pmg for wet leg - Example

When usmg the wet-leg method, connect the high pressure side of this transmitter to
the sealing p1pe of the tank. Connect the low pressure s1de to the lower part of the tank.
After completmg p1pmg work, check for pressure leaks around the connectmg p1pe,
the transmitter, and the 3-way mamfold valve. The illustratiOn shows a typical
mstallatwn.
Be sure to connect the low pressure side of this transmitter to the lower part of the
tank.
Install this transmitter below the lowest liqmd level to be measured.
Low
pressure
s1de
Dram Dra1nplug
valve
Figure 2-43 Enclost;d tank- Pipzng (wet-leg sealing example
:ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter 2-39

2-4: Electrical wiring
2-4-1: Wiring for transmitter - Regular model

'A¥ r a n'I!Mtl'l.'i!IM J& ZIIIMiHl
Introduction
Followmg wmng mstructwns when no exploswnproof standards apply
As well as the followmg, durmg wmng and cabling of an exploswnprooftransmitter,
refer to the mstructwns for flameproof special exploswnproof and mtnnsically safe
transmitter (provided later).
Wirmg
Wire and cable this transmitter as shown m the illustratiOns.
SUPPLY CHK-/S- term1nal)
Connect the ground line

Jumper plate either 1ns1de or outs1de
the transmitter.
External
+ meter
METER (CHK-/M- term1nal)

METER + (C HK-/ M+ term1nal)
Connect t he ground line
either 1ns1de or outs1de
the transmitter.
Figure 2--14 Wirzng

-Note l .Externalload reszstan.ce of at least 250 requzredfor commumca-

tzons wllh an SFC. {[total load reszstance of the recezvmg mstrumenl
zs less than 250, znsert the necessary reszstance to the loop.
2./n uszng Yamatakes field type mdicator (model NWSJOO, NWS35) ,

check that the model number of the lransmltler has B7 for afield
meter (hzgh load reszstance) mdicates the optwnal speqficatwn. If
not B7, remake thzs transmltfer according to 5-3-4
For detazled znstructwns, refer to the meters documentatiOn.
Conduit p1pe for cables

Lead cables mto the transmitter case, as follows:
Mount a condmt pipe m the condmt hole (G 112 female thread) provided on the side of
a transmitter, and lead cables through the pipe.
Seal the part that contacts with the condmt p1pe. Use a sealing agent or a seal plug to
positively prevent entry of water.
Install transmitter so that the cables lead mto It, from the bottom.
If reqmred, use a special elbow to change cabling directiOn (G I, G2, or G3 m the
appendix).)
Grounding
Two ground termmals are provided. One termmal IS on the termmal board, and the
other IS outside the transmitter. Ground either one.
Connect a ground termmal to a type-D ground (Ground resistance not higher than 100
Q) or better ground.
Grounding IS essential when mstalling exploswnproof transmitters.
Welding m close proximity to transmitter.
Duectly ground welding machme and transformer, for Its power supply
Never connect such eqmpment by the ground termmal to the stanchion p1pe that holds
a transmitter. Welding current may Influence measurements.
Supply power and external load res1stance

Confirm the relatiOnship between the 1560
external load resistance and the supply
voltage. As shown m the illustratiOn, the g
Q)
(,)
relationship should be ms1de the shaded c:
area. t!
·~
External resistance: The total resistance
'0
connected to the output termmals of a co
.2
transmitter (includes resistances of all i6
c:
cables m the loop plus the mternal $>< 250
resistance of the mstruments ). w
Honzontal axis represents supply voltage
0 10.8 16.3 45
of a transmitter, and vertical axis Supply voltage (V DC)
represent external load resistance.
Figure 2-45 Supply voltage and
external load res1stance - refa-
twnshzp

2-4-2: Wiring for transmitter -flameproof special explo-

sion proof
~=m--~,~--~a..-ma~-.a.------------------~----HM~~URMU~.UUft~MmmM~
Guidelines
Flameproof special exploswnproof construction reqmres special precautions and
mstallatwn methods. Refer also to "2-4-1 Winng for transm1tter - Regular model" on
page 2-40.
Detailed mformatwn IS contamed m New Exploswnproof Guidelines for Plant
Electrtcal Facilities (Gas Exploswnproof 1985) published by Industnal Safety
Institute ofthe Japanese Mimstry of Labor.
&wARNING
• Conformance IS proven for the pressure resistant packmg cable adapter

(accessory) for connectmg external cables. Conformance testmg treats the adapter
as an mtegral part of the transmitter. If any other cable adapter IS used.
exploswnproof performance cannot be guaranteed.
• Tighten the case cover fully, to the end, and lock.
• Clearly delineate safety responsibilities m operatmg procedures. Especially, for an
exploswnproof transmitter, specify lockmg of the cover of the transmitter case.
Lockmg
Before cabling can be performed. USE a 3 mm hexagonal wrench to open the lockmg
structure.
Figure 2-46 Unlock transmztter case
Leading-In external cables

Use a pressure resistant packmg cable adapter (accessory) or a condmt pipe fittmg, to
complete lead-m of cables to a transmitter.
Pressure res1stant
pack1ng cable adapter
Figure 2-4 7 Pressure reszstant packzng cable adapter

2-4-3: Wiring transm_

itter - Intrinsically safe
_,. .. iSM! as !?jljill em :rr· n2 z ·-=..... .. rm
Guidelines
Intnnsically safe constructwn reqmres special wmng precautwns and mstallatwn
methods. Also refer to "2-4-1 Wirmg for transmitter- Regular model" on page 2-40.
Detailed mformatwn IS contamed m New Exploswnproof Gmdelines for Plant
Electncal Facilities (Gas/Steam Exploswnproof 1979) published by the Japanese
Industnal Safety Institute of the Mimstry of Labor.
&wARNING
• Protect transmitter from electncal or magnetic mfluence (such as mixmg and
mductwn) from other electncal Circmts.
• Install a Zener barner (8907/51-24/45) at a non-hazardous locatwn and ground
mdependently by type A grounding work.
Wirmg
Intnnsically safe mstallatwn IS ach1eved according to these mstructwns.
Inductance of external cables of the mtnnsically safe Circmt should not exceed 0.31
mH, and capacitance should not exceed 21 nF
Ordinary eqmpment connected to the Zener barner should not exceed 500V AC and 35 A.
lntrms1cafly safe system - Configuration

System configuratiOn
The system configuratiOn IS shown~ below. The diagram also shows the layout of an
mtnnsically safe system consistmg of a transmitter, a portable settmg display, a field
type current mdicator, and a Zener barner. The system components must be designate
eqmpment havmg conformance that IS proved by relevant public orgamzatwns.
Nonhazardous location
Ordinary
equ1pment
Figure 2-48 System configuratwn of mtrznstcally safe transmtfler
System configuratwn
*I A non-field-use current mdicator may also be configured mto the system.
*2. Connect non-field-use current mdicator to either of the two posittons. Some
systems have no portable settmg display
--
Functions, Configurations, and Structures of STJOOO Ace and SFC Yamatake Corporation
2-5: Process connection port - Change port

position
2-5-1: Bottom port to top port (model JTD/JTG/JTAJJTC)

lifT X
Introduction
The process connectiOn port IS built on the transnutters (model JTD/JTG/JTA/JTC)
center cover. The port positiOn IS mcluded among the user specificatiOns, but It may be
changed at any time to SUit your needs. InstruCtiOnS for changmg the process
connectwn port from top to bottom are here.
Figure 2-49 Change process connectwn port posllwn
Procedure
Steps Procedure
Remove four bolts fixmg left and nght adapter flanges.
2 Remove both (left and nght) vent dram plugs.
3 Fix with bolts, both adapter flanges to the top of the transmitter.
Tighten bolts to the specified torque.
Specified torque:SNB 7, SUS630· 20 ± 1 N .m
SUS304 10 ±5 N.m
4 Apply sealing tape around the screws of the vent dram plugs.
Spray with lubncant.
5 Screw vent plugs mto the bottom part of the transmitter.
Tighten plugs to the specified torque.
Specified torque: 5 ±0.3 N.m
Use the Identical procedure to change the port positiOn from top to bottom .

Overv1ew
Instructions for connectmg an SFC to th1s transmitter.
Basic mstructwns for key pad operatiOn.
Procedures for settmg a tag number and checkmg the transmitters specificatiOns.
Preparations and procedures for startmg and stoppmg vanous measurements with the
transmitter.
Instructions for stoppmg a transmitter for mamtenance or replacement.

Operate and stop the transmitter Yamatake Corporation
3-1 : Preparation
3-1-1: Connecting SFC
SFC connection
The illustratiOn shows how to connect an SFC to the transmitter.
Remarks: Connect the SFC commumcatwn cables to the transmitter termmals, as
follows.
Red cable: Supply + termmal
Black cable: Supply - termmal
-Note External load res1stance must be at least 250 for commumcatzons wllh an
SFC. If total load reszstance of the recezvmg instrument 1s below 250 add the
difference to the loops reszstance.
Power
supply
24VDC
+ /
.--------,
Rece1v1ng -
~--.L~~R~e~d~c~a~bl~e--~~----4=~~~~~~~~~~~
Instrument + 1--JIIW'---------------'------+---t--ttr"
250D.
Figure 3-1 Connectmg SFC
General key pad operations

Operate SFC keys With these pomts m mmd:
• Press keys firmly and slowly No response on the screen mdicates mput failure. In
such a case, press the key agam, slowly
• If a key press makes no change on the screen, It may mean that the ky ts not
supported by the connected transmitter. You should find the correct key usmg the
manual.
• Refer to Chapter 5 to start from the Initial state.

Yamatake Corporation Operate and stop the transmitter
3-2: Setting tag no. and checking

specifications
3-2-1: Starting communications

Mm.--.------------------------------------------------~-----..w~---~~~
Important
&wARNING :
• In some cases, commumcatlons between th1s transm1tter and the SFC m the
automatic mode cause sudden change m the output. Although th1s change IS only
temporary, 1t may result m a hazardous s1tuat10n. Sw1tch to manual the process
control loop before startmg commumcatwns between the transmitter and the SFC.
Procedure
Th1s procedure starts commumcatwns between th1s transm1tter and the SFC.
Step Key DescnptJOn SFC screen
Place m manual mode, the No display

process.
2 Refer to Figure 3-1 and connect

the SFC to the transm1tter
3 Tum ON the SFC power sw1tch.

LOOP IN MANUAL?
. NON-VOL
Press the key I PRESS 10
4 DE REA D
DE READ
Press the~ key DSTJ TAG NO
GD The default tag number

xxxxxxxx.
IS
LIN DP FIT-

3-2-2: Setting tag no.

~--~-~----_.._.__._.. ._..__._..__..m. .- .. .._. .._BW•aa.mu.aam---.
Procedure
Start commumcattons With the transmitter. Use this procedure, to set a tag no ..
The tag no. IS displayed on the name plate of this transmitter.
The procedure for settmg FIT-1234 for the tag no. IS mcluded, below.
1 DE CONF.
Press the [ ALPHA J, (~:; ), [=.•' ), DSTJ TAG NO

LIN DP FIT-
and ~ keys m that order.
DECONF
~
GJ
2 TIM E
B TIME
Press the (ALPHA] and ( 'l__- ) keys m
that order.
DSTJ TAG NO
LIN DP FIT-
[!]
3
B ' 0 ' (2j and
SW VER
GJ Press the
~ keys m that order.

DSTJ TAG NO
LIN DP FIT-1234
0 SW VER
G
[Gj
4 NON-VOL
NON-VOL
Press the [~J
"L~J~.
key DSTJ TAG NO
WORKING..
Tag No. FIT-1234 IS set. DSTJ TAG NO

LIN DP FIT-1234

Correct an mput
Correct keymg errors, usmg this procedure:
Press the EJ key to release alphabet mode. Press the EJ key to shift the cursor
A+-+ DE
back by one column and press the [ALPHA] key agam. mput correct character.
Correct keymg errors usmg th1s procedure:
Press the EJ key to shift the cursor back by one column. Input a correct number.
A+-+ DE

3-2-3: Checking output format
Procedure
Check the output format (linear I square root) of the transmitter, usmg th1s procedure.
To change the output format, refer to Chapter 4
Press the ( c~~ ) key
B DSTJ CONFIG
CONFORM?
2 NON-VOL
NON-VOL
Square root output
Press the . key
CONFORM
SQUARE ROOT
Lmear output
I CONFORM
LINEAR
3 Press the ( ,c~:, ] key twice.

~ )
DSTJ FIT-1234
READY. .
(Twice)

3-2-4: Checking display setting
Procedure
Check the display settmg (flow rate I linear I display flow rate) of the transmitter,
usmg this procedure.
To change the settmg, refer to Chapter 4
Step Key Descnphon SFC screen
Press the ( ~J key

DSTJ CONFIG
CONFORM?
2 Press the key

DSTJ FIT-1234
DISPLAY?
Square root output

NON-VOL
Press the key
IFLOW
DISPLAY CONF
Lmear output and linear display.
DISPLAY CONF
LINEAR
Lmear output and flow rate display.
DISPLAY CONF
DISPLAY FLOW
4 Press the ( ,c.~•, ) key twice

r::::=1 DSTJ FIT-1234
~ READY. ..
(Twice)

3-2-5: Checking engineering unit of measured pressure

.. . -
Procedure
Check the engmeenng umt of measured pressure, usmg this procedure.
Here, It IS assumed that [kPa] IS selected.
To change the engmeenng umt, refer to Chapter 4
1 Press the ( ...J' J key
EJ UNIT FIT-1234
kPa
3-2-6: Checking low and high limits of setting range

t l!l
Procedure
Check the low and high limits of the settmg range, usmg this procedure.
It IS assumed that the followmg values are set:
• Low lirrut (LRV): 0.0000 kPa
• High limit (URV):50 kPa
To change the settmg, refer to Chapter 4
1 Press the [ L~· ] key
~
LRV FIT-1234
~
Q 0000 kPa
2 Press the [ ~:.; ) key

I~
URV FIT-1234
100%
50 kPa

3-2-7: Checking damping time constant

~--
6UwmwmMfiSU _ _.W___________________ _ E•------------------a.---.u·aUMHI~i~~~~~~
Procedure
Check the dampmg time constant usmg the followmg procedure.
Here, 1t JS assumed that [1.0 second] set for the dampmg time constant.
To change the dampmg time constant, refer to Chapter 4
Step Key DescriptiOn SFC screen
I Press the (. ~) key
B DAMP FIT-1234
10 s

Operate and stop the t ransmitter Yamatake Corporation
3-2-8: Checking sealed liquid temperature correction

~DUE_ function setting
_ .______a g_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ZD___.U._.._._.U_.mma.MM.WP~Ra&-
Procedure
Check that the sealed liqmd temperature correctiOn functiOn IS set by the followmg
procedure.
This function IS not set when the height display on the SFC screen IS "0 m"
For the procedure for changmg the settmg, refer to Chapter 4
Step Key Description SFC screen
Press the ( ~) key
B DSTJ C ON Fl G
CONFORM
2 Press the ~ ~~~ key three times.

DS TJ CON F IG
Or else, press the [~~ key four HE IGHT?
times.
3
lllr1J key
NON-VOl
Press the
I~~GHT
4 Press the ( ,c;:, ) key twice.
r::l DST J FIT- 1234
~ R EADY. ..
(Twice)
Sealed liquid temperature correction functiOn

When the liqmd level of a tank IS measured usmg a remote sealing type differential
pressure transmitter, the density of the sealed liquid m the capillary tube changes as
the ambient temperature changes. Th1s ordinarily causes about 4-5 % zero shiftmg.
The model JTE has a composite semiconductor sensor with a functiOn for correctmg
sealed liqmd temperature by means of temperature measurement and anthmetic
3-1 0 ST3000 Ace - Smart Transmitter Electromc Differential Pressure T ransmitter

operation with a microprocessor. This assures accurate level measurements. (The zero
sluft IS reduced to 1/5 from the previous level.)
Example of zero shift

L (Difference between flanges): 2500 mm (2.5 m)
R (Measurement span): 2500 mm (2.5 m)
A (Temperature coefficient of sealed liqmd): O.OOl JCC
T (Ambient temperature change): 55oC
A x Tx L
Zero shift= R x 100 ........ .. .(1)
-fl J--------- ~ -----1---r--- From (1)
Zero shift of a model Without temperature
L (mm) correction:
0.001 X 55 X 2500 X = _ o/o
-n -------------- 2500
100
(Conventional transmitter)
55
Zero shtft of a model With temperature correction

Figure 3-2 functiOn ST3000· 1%

3-3: Measurement by model .JTD
3-3-1: Flow rate measurement
3-3-1-1: Preparation for measurement
&wARNING
• Make sure that the process IS m the manual control mode.
If the automatic control mode obtams, switch to manual control before startmg the
followmg procedures.
• Dram poisonous flmds takmg care, and makmg provisiOns to protect personnel.
• Always close the differential pressure output valve (mam valve), the dram valve,
the gas vent plug (refer to Figure 2-32 and Figure 2-33
Procedure 1
Lead process pressure mto the pressure receivmg part of the transmitter, usmg this
procedure:
Steps Procedure
1 Gradually open the mam valves of both the high pressure side and the low
pressure side (Refer to Figure 2-32 and Figure 2-33). Lead process flmd
mto the connectmg pipe.
2 Fill with process flmd, the pressure receivmg part of the transmitter.
• Gradually open the high pressure side stop valve. Close after the pressure
receivmg part has completely filled with process flmd.
• Gradually open the low pressure side stop valve. Close after the pressure
receivmg part has completely filled With process flmd.
Low pressure stde&'l~~!:f~~~

stop valve
Dram plug
3 Decrease to zero, the differential pressure applied to the transmitter.

• Gradually open the high pressure Side stop valve to lead process pressure
mto the pressure receivmg part of the transmitter.
• In this state, equal pressure IS applied to the high pressure s1de and the
low pressure side of the transmitter (equal pressure state).
4 Check for pressure leaks m the connectmg pipe, the 3-way mamfold valve,
and the transmitter.

Procedure 2
Perform zero pomt calibratiOn, usmg this procedure.
Zero pomt calibratiOn by SFC operatiOn.
Check that the transmitters mput IS 0 kPa and Its output IS 0%.
NON-VOL
Turn ON the power switch of the
SFC. After makmg sure that the LOOP IN MANUAL?
process IS m the manual control
mode, press the key
PRESSID
2 DE READ
DE READ
Press the~ key DSTJ TAG NO
0 LIN DP FIT-1234
"
.)
Press the [ SHII'~) and
B INPUT
that order.
keysm SHIFT-
INPUT FIT-1234
WORKING. ..
J,
INPUT FIT-1234
0 0000 kPa
4 INPUT
WORKING. ..
OUTPUT FIT-1234
0 00%
If the screen display IS not 0 kPa m <step 3> or 0% m <step 4>, proceed to <step 5> to
perform zero pomt calibratiOn.

Assummg that 0.005 kPa was displayed m <step 3>, perform zero pomt calibration,
B INPUT
Press the ( .",.f ) and
m that order
keys, SHIFT-
INPUT FIT-1234
WORKING. ..
J,
INPUT FIT-1234
0.005 kPa
6 RESET
Press the key INPUT FlT-1234
ZERO INPUT?
7 NON-VOL
Press the key INPUT
ARE YOU SURE!?
8 NON-VOL
NON.VOl
INPUT FIT-1234
WORKING. ..
INPUT FIT-1234
INPUT ZEROED
9 Repeat <step 3> and <step 4>

and make sure that 0.00 IS
displayed.
Zero pomt calibratiOn IS
completed.
If the SFC displays a screen other than those shown above, refer to the relevant
mstructiOns m Chapter 5

3-3-1-2: Startmg measurement
Procedure
Apply the differential pressure of the process by operatmg valves, usmg this
procedure. Display the measured value usmg the SFC.
How to apply process pressure.
Steps Procedure
Ensure that the 3-way mamfold valve ISm the followmg state:
• High pressure side stop valve: Fully open
• Low pressure side stop_valve: Fully closed
• Equalizer valve: Fully open
2 • Close the equalizer valve.
• Open the low pressure side stop valve gradually
Low pressure Sid~~~~~~~

stop valve
How to display measured value

The followmg conditions are assumed:
Low limit of settmg range: 0 kPa
High limit of settmg range: 50 kPa
Input differential pressure of transmitter· 25 kPa

In this case, the output IS 50%. (Lmear output)

.,.) INPUT
B INPUT
Press the ( ."'.f J and
m that order
keys, SHIFT-
INPUT FIT-1 234

WORKING...
INPUT FIT-1234
25.00 kPa
4 INPUT
50.00%
5 At the completiOn of measurement, remove the clip from the

commumcatwn cable. Switch the process to normal operatiOn.
&cAUTION
Securely close the cover of the transmitter case. Imperfect
closure allows entry of water, and may damage mternal
termmals as well as the electromc module. Such damage
may reqmre parts replacement, possibly of the entire
module.
• If mput and output values do not match, check the range and recalibrate. If after
recalibrat10n, they remam mcons1stent, troubleshoot the transmitter as described m
Chapter 5
• If the displayed data value IS unstable, adjust the dampmg time constant. Refer to
Chapter 4

3-3-1-3: Stopping measurement
Procedure
Stop the transmitter, usmg this procedure:
Steps Procedure
Tum off the transmitter
2 Operate the 3-way mamfold valve by the fo llowmg procedure :

Close the low pressure Slde stop valve.
Open the equalizer valve.
Close the h1gh pressure side stop valve.
High
pressure s1de
3 .Close the mam valves on the high and low pressure sides.
Refer to Figure 2-34 and Figure 2-35
&cAUTION
• If you plant to leave the transmitter OFF for a long penod oft1me, always dram
process flmd from the connectmg p1pe and the pressure rece1vmg part.
• Leave the equalizer valve open.

3-3-2: Gas pressure measurement

."' :aP"ft'P* 4¥ fiE •JIIIO!.& ZU
ihWARNING
• Ensure that the process IS m the manual control mode.

If the process IS m automatic control mode, switch to manual before startmg the
procedure.
• Dram pOisonous flmds takmg care, and makmg proviSions to protect personnel.
• Close the differential pressure output valve (mam valve), the local valve, the dram
valve, the gas vent plug. Refer to Figure 2-38 .
How to measure gas pressure

Perform zero pomt adjustment and mtroduce process pressure mto the transmitter,
• Zero pomt adjustment
Steps Procedure
Open both the high pressure side and lo pressure side vent plugs and open
the pressure receivmg part to the atr.
2 Refer to "Procedure 2" on page 3-13 (3-3-1-1 Preparation for
measurement). Perform zero pomt calibration.
3 After completmg zero pomt calibratiOn, close the high pressure side vent
plug.
Introducmg process pressure and ventmg au
Steps Procedure
• Open the mam valve (refer to Figure 2-38) to mtroduce process pressure
• Open the local valve gradually, to mtroduce process pressure mto the
pressure receivmg part of the transmitter.

Steps Procedure
2 • Open the high pressure side vent plug gradually, to vent air from the
center body
• After ventmg air, close the vent plug and the local valve.
3 Check for pressure leaks m the connectmg pipe and the transmitter.
3-3-2-2: Starting measurement
Procedure
Operate the valves usmg this procedure, to apply process pressure to the transmitter
and display the measured value by operatmg the SFC.
How to apply process pressure
Steps Procedure
Open the local valve gradually

These conditiOns are assumed here:
• Low limit of settmg range:O kPa
• High limit of settmg range:50 kPa
• Input differential pressure of transmitter· 25 kPa

In this case, the output IS 50%
2 INPUT
Press the [ ... ~ J and

B INPUT
m that order
keys, SH IFT-
INPUT FIT-1234
WORKING. ..
INPUT FIT-1 234

25.00 kPa
3 INPUT
INPUT
Press the t;tr~a key INPUT FIT-1234
~.
50.00%
4 At the end of measurement, remove the clip of the

commumcat10n cable and switch the process to ordinary
operatiOn.
&cAUTION
Close securely the cover of the transmitter case. Failure to
do so will result m entry of water, and cause damage to
mternal terrnmals and the electromcs module .
• If mput and output values fail to match, check the range and recalibrate. If after
recalibrat10n, they remam m consistent, troubleshoot the transmitter as described m
Chapter 5
• If the displayed data value IS unstable, adjust the dampmg time constant by refernng
to Chapter 4

3-3-2-3: Stoppmg measurement
Procedure
How to stop the transmitter
Steps Procedure
Tum off the transmitter.
2 Close the local valve
.., Close the mam valve. (Refer to Figure 2-38.)

.)
&cAUTION :
• If you plant to leave the transmitter OFF for a long penod oft1me, completely
dram process flmd from the connectmg pipe, and from the pressure rece1vmg part.

3-3-3: LiqLtid level measurement of open tank and closed

tank (dry leg)
wme~~~~-W--BEMW~--------~----~--~--~----~=m--••·~ME~M~rft--NWF~mAmNE•~-mD~~~~
3-3-3-1. Preparation for measurement

&wARNING
• Place the process m the manual control mode.
If the process IS m the automatic control mode, switch to manual before
performmg work.
• Dram pOisonous flmds carefully, takmg provisiOns to protect workers.
• Check that the differential pressure output valve (mam valve), the dram valve, the
gas vent plug (refer to Figure 2-41 and Figure 2-42).
Calculating setting range

Calculate the settmg range. Refer to "3 -11 Set range calculatiOn for liqmd level
measurement" on page 3-56.
Procedure
Perform zero pomt adjustment and mtroduce process pressure mto the transmitter by
th1s procedure:
Zero pomt calibration

Steps Procedure
Open the dram plugs and the stop valves of both the high pressure side and
the low pressure side. Open the pressure receivmg part to the air.
If flmd remams m the pressure rece1vmg part, blow 1t to dram.
2 Refer to "Procedure 2" on page 3-13 (3-3-1-1 PreparatiOn for
measurement), and perform zero pomt calibratiOn.
3 After.completmg zero pomt calibratiOn, close the high pressure side dram
plug and the h1gh pressure side stop valve.
lntroducmg process pressure
Steps Procedure
• Open the mam valve (refer to Figure 2-41) to mtroduce process pressure
• Open the high pressure s1de stop valve gradually to mtroduce process
pressure. After mtroducmg process pressure mto the pressure rece1 vmg
part of the transmitter, close the h1gh pressure stde stop valve. ·
2 Check for pressure leaks m the connectmg pipe, the 3-way mamfold va lve,
and the transmitter.

3-3-3-2: Startmg measurement
Procedure
Operate the valves With this procedure, to apply the differential pressure of the process
to the transmitter. Display the measured value usmg operatmg the SFC.
Steps Procedure
Check that the 3-way mamfold valve ISm the followmg state:
• High pressure side stop valve: Fully closed
• Low pressure side stop valve: Fully open
• Equalizer valve: Fully d osed
Low High
pressure s1de pressure s1de
2 Open the high pressure side stop valve gradually
Zero pomt adjustment durmg measurement

Refer to "3-8. Zero-pomt adjustment --- Based on actual liqUid level" on page 3-50 to
adjust the zero pomt dunng measurement.
These conditiOns are assumed here:
• Low limit of settmg range:O kPa
High limit of settmg range:50 kPa
• Input differential pressure oftransm1tter 25 kPa

In th1s case, the output 1s 50%. (Lmear output)
3
Press the [ SHI~) and l mkeys,
INPUT
SHIFT-
rn that order
INPUT
INPUT FIT-1234
WORKING. ..
INPUT FIT-1234
25 .00 kPa
4 INPUT
INPUT
Press the ~ key INPUT FIT-1234
50.00%
5 At the end of measurement, remove the clip of the

commumcatwn cable and sw1tch the process to regular
operatiOn mode.
&cAUTION
Close securely the cover of the transmitter case. Failure to
do so will enable entry of water, and cause damage to
mtemal termmals and the electromcs module.
• If the mput and output values do not match, check the range and recalibrate.
If they remam mcons1stent, troubleshoot the transmitter as described m Chapter 5
• If the displayed data value 1s unstable, adjust the dampmg time constant. Refer to
Chapter 4

3-3-3-3: Stoppmg measurement
Procedure
How to stop the transmitter.
Steps Procedure
1 Turn off the transmitter.
2 Operate the 3-way mamfold valve usmg this procedure:

Close the low pressure stde stop valve.
Open the equalizer valve.
Close the high pressure Side stop valve
3 Close the mam valve. Refer to Figure 2-42
_&CAUTION
• If you plan to leave the transmitter OFF for a long penod, dram process tlmd from
the connectmg ptpe and the pressure receivmg part.

3-3-4: Liquid level measurement of closed tank (wet leg)
Important!
&wARNING
• Place the process m the manual control mode.
If the process ISm the automatic control mode, change 1t to the manual control
mode oefore performmg this work.
• Dram pOisonous flmds with enough care, makmg provisions for protectmg
workers.
• Make sure that the differential pressure output valve (mam valve), the dram valve,
the gas vent plug (refer to Figure 2-41) and the h1gh pressure side and low
pressure Side stop valves of the 3-way mamfold valve are closed. Also, make sure
that the equalizer valve of the 3-way mamfold valve IS open.
Calculating setting range

For the procedure for obtammg the settmg range by calculatiOn, refer to " 3-11 Set
range calculatiOn for liqmd level measurement" on page 3-56.
Procedure
Perform zero pomt adjustment and mtroduce process pressure mto the transmitter
usmg this procedure:
Zero pomt calibratiOn
Steps Procedure
Feed sealing liqmd from the seal pot to fill the connectmg p1pe With
sealing liqmd.
2 Gradually open the stop valves of both the h1gh pressure s1de and the low
pressure side, and the dram plugs, to fill the pressure recei vmg part of the
transmitter with sealing liqmd.
3 When sealing liquid flows out from the dram plugs, close the stop valves
of both the high pressure side and the low pressure side and the dram
plugs.
In this state, the same pressure IS applied to the high pressure s1d_e and the
low pressure side of the transmitter (equal pressure state).
4 Refernng to "Procedure 2" on page 3-13 (3-3 -1- 1 PreparatiOn for

measurement), perform zero pomt calibratiOn.
5 After completmg zero pomt calibratwn, close the equalizer valve. Open
the stop valve and the dram plug of the low pressure stde to dram seal ing
liqmd. Close the stop valve and the dram plug of the low pressure side.

Introducmg process pressure
Steps Procedure
Open the mam valve (refer to Figure 2-43) to mtroduce process thud mto
the connectmg p1pe.
2 Gradually open the low pressure s1de stop valve to mtroduce process tlmd.
After mtroducmg process flmd mto the pressure rece1vmg part of the
transmitter, close the low pressure Side stop valve.
3 Make sure that the connectmg p1pe, the 3-way mamfold valve, and the
3-3-4 . . 2: Starting measur~ment
Procedure
Operate the valves by the followmg procedure to apply the differential pressure of the
process to the transmitter and display the measured value by operatmg the SFC.
Steps Procedure
Make sure that the 3-way manifold valve ISm this state:
• High pressure s1de stop valve: Fully closed
• Low pressure s1de stop valve: Fully closed
• Equalizer valve: Fully closed
2 Fill the liqmd sealing p1pe w1th sealing liqmd.
3 • Gradually open the h1gh pressure s1de stop valve.

• Gradually open the low pressure s1de stop valve.
Low High
pressure s1de
Low pressure Sldeb'l~~!:j~~~

stop valve


Refer to "3-8 . Zero-pomt adjustment--- Based on actualliqmd level" to adjust the
zero pomt dunng measurement.
The followmg conditions are assumed here:
• Low limit of settmg range: 50 kPa
High limit of settmg range: 0 kPa
• Input differential pressure of transmitter: 25 kPa
4
Press the [ .",.:] and keys, SHIFT-
m that order
INPUT
INPUT FIT-1234
WORKING. ..
INPUT FIT-1234
25.00 kPa
5 INPUT
INPUT
Press the ~M~, . key.
~fi~ INPUT FIT-1234
50.00%
6 ~ After completmg measurement, remove the clip from the

commumcatiOn cable and switch the process to regular
operation.
,& CAUTION
Close the cover of the transmitter case securely Imperfect
closmg allows entry of water such as ram, damagmg
mtemal termmals and the electromcs module.
• If the Input and output values are mcons1stent, check the range and perform
calibratiOn agam. If they are still mcons1stent, use the troubleshootmg procedure
explamed m Chapter 5
• If the displayed data value IS unstable, adjust the dampmg time constant by refernng
to Chapter 4.

3-3-4-3. Stopping measurement
Procedure
How to stop the transmttter
Steps Procedure
Turn off the transmttter.
2 Operate the 3-way mamfold valve by the followmg procedure.

Close the low pressure stde stop valve.
Open the equalizer vale.
Close the htgh pressure stde stop valve.
Low
Low pressure Slde!?li::::c.!!S'L-j

stop valve
3 Close the mam valve. (Refer to Figure 2-43 )
_&CAUTION ·.
• To leave the transmttter off for a long penod, dram process flmd from the
connectmg ptpe and the pressure recetvmg part.

3-4: Measurement with model JTG/JTA
3-4-1: Pressure measurement

3-4-1-1 Before statmg
&wARNING
• Make sure that the process IS m the manual control mode. If the process IS m the
automatic control mode, make sure that It has been changed to the manual mode.
• For hazardous tlmds (pmsons etc.) take any necessary actiOns to prevent physical
hazard and ensure that work proceeds With adequate care.
• Before startmg a measurement procedure, ensure closure of the pressure valve
(mam valve), the local valve, the dram valve, and the gas vent plug. (Refer to
Figure 2-38)
Gas pressure measurement

Perform zero-pomt calibratiOn and mtroduce process pressure, with this procedure:
~Zero pomt cal ibrat10n(Only for Model. JTG. In case of Model JTA, don ' t perfonn th1s procedure)
Steps Procedure '

\ ---.)
Open the vent plug to release the pressure rece1vmg part to the open air.
2 Referrmg to "2-2-4 Transmitter mam umt mstallat10n pos1t10n", perform
zero-pomt calibratiOn.
3 When ca~ibrat10n IS complete, close the vent plug.
~ Introducmg process pressure and ventmg air
Steps Procedure
• Introduce the process pressure mto the connectmg pipe by opemng the
mam valve (Refer to Figure 2-38). If the process temperature Is high,
allow cooling time so that the connectmg pipe IS stable at a safe
temperature, before startmg work.
• Open the local valve gradually t9 mtroduce the process pressure mto the
pressure rece1vmg part of transmitter.
2 • Vent air from the center body by gradually openmg the vent plug.
• After ventmg air completely, close the plug and the local valve.
Gas vent plug

Steps Procedure
3 Ensure zero leakage exists at the connectmg p1pe and transmitter.
3-4-1-2: Starting operation
Procedure
Operate the valve )Nith the followmg procedure and <uJply the process pressure to
transmitter. Display the measured value by operatmg the SFC keys.
Process pressure applymg operatiOn
Steps Procedure
Open gradually the local valve.
Measured value displaymg operatwn

The followmg case IS explamed here:
High limit: 50 kPa
• Input pressure to the transmitter· 25 kPa
2 INPUT
EJINPUT
Press the ('"'~ ) and
m that order
keys, SHIFT-
INPUT FIT-1234
WORKING. ..
INPUT FIT-1234
25.00 kPa


INPUT
3 INPUT
Press the ~ key INPUT FIT-1234
50.00%
4 After completmg·measurement, remove the clip of the

commumcat10n cable and then switch the process to normal
operatiOn.
&cAUTION
Close securely the case cover of the transmitter.

Take precautiOns agamst moisture mgress mto the
transmitter body Ramwater entermg the transmitter will
damage the mtemal termmals and the electromcs module.
• If the output value does not correctly reflect the mput value, check agam the range
and calibrate the transmitter. If mappropnate output value persists for the mput
value, apply troubleshootmg procedures (Chapter 5).
• If the displayed data value IS unstable, adjust the dampmg time constant (Chapter 4).
3-4-1-3: Stoppmg operation
Procedure
Stop the operatiOn of the transmitter by th1s procedure :
Steps Procedure
Turn OFF the transmitter.
2 Close the local valve.
3 Close the mam valve. (Refer to Figure 2-38).

&cAUTION
• When a long term shutdown IS planned, completely dram all process flmd from
the connectmg ptpe and from th~ pressure rece1vmg part of transmitter.

3-4-2: Liquid level measurement

- = Ht. . . . .
3-4-2-1: Before you start
&wARNING
• Make sure that the process ISm the manual control mode. If the process ISm the
automatic control mode, make sure that 1t has been changed to the manual mode.
• For hazardous flmds (poisons etc.) take any necessary actiOns to prevent physical
hazard and ensure that work proceeds w1th adequate care.
• Ensure closure of the mam valve, the dram valve, and the gas bent plug on the
p1pe (Refer to Figure 2-41)
Setting range calculation

In deterrnmmg the settmg range by calculatiOn, refer to " 3- 11 Set range calculation
for liqmd level measurement" on page 3-56.
L1qu1d level measurement

Perform ·zero pomt calibratiOn and mtroduce process press ure, by th1s procedure:
• Zero pomt calibration
Steps Procedure
Open the dram plug to release the pressure rece1vmg part to the open a1r.
If flmd remams m the pressure rece1vmg part, blow out flmd.
2 Refernng to " 2-2-4 Transrrutter mam umt mstallatwn positiOn" on page 2-
10, perform zero pomt calibratiOn.
3 When calibratiOn IS complete, close the vent plug.
• lntroducmg process pressure and ventmg mr
Steps Procedure
• Open gradually the mam valve (Refer to Figure 2-4 1) to mtroduce the
process pressure mto the connectmg p1pe.
• After mtroducmg the process pressure mto the pressure receivmg part of
the transmitter, close the mam valve.
2 Ensure zero leakage exists at the connectmg p1pe and transmitter

Procedure
Operate the valve With the followmg procedure and apply the process pressure to
transmitter. Display the measured value by operatmg the SFC keys.
• Process pressure applymg operation
Steps Procedure
Open gradually the mam valve (Refer to Figure 2-41 ).

When adjustmg the zero pomt dunng measurement, refer to "3-8. Zero-pomt
adjustment--- Based on actual liquid level" on page 3-50.
Measured value displaym~ operation
The followmg case IS explamed here :
High limit: 50 kPa .
• Input pressure to the transmitter 25 kPa
B INPUT
Press the [ •"' ~ J and
m that order
keys, SHIFT-
INPUT FIT-1234
WORKING. ..
INPUT FIT-1234
25.00 kPa
3 INPUT
50.00%
4 After completmg measurement, remove the clip of the

comrnumcat10n cable and then switch the process to normal
operation.
&cAUTION
Close securely the case cover of the transmitter.
Take precautiOns agamst mOisture mgress mto the
transmitter body Ramwater entenng the transmitter will
damage the mternal termmals and the electromcs module.

• If the output value does not correctly reflect the mput value, check agam the range
and calibrate the transmitter. If mappropnate output value persists for the mput
value, apply trouble shootmg procedure (Chapter 5).
• If the displayed data value IS unstable, adjust the dampmg time constant (Chapter 4) .
3-4-2-3: Shopping operation
Procedure
Stop the operation of the transmitter by this procedure:
Steps Procedure
Tum OFF the transmitter
2 Close the mam valve. (Refer to Figure 2-41)
&cAUTION
• When a long term shutdown IS planned, completely dram all process flmd from
the connectmg pipe and from the pressure receivmg part of transmitter

3-5: Measurement with model JTC
Checkmg m1mmum liqu1d level position (zero position) and zero pomt at
equal pressure mput
Set the zero pomt of the measured Iiqwd level at the center of the seal diaphragm on
the process connectiOn flange surface of the transmitter. (Refer to Figure 3-3 )
Measurement range H IS from the flange center of the transmitter to the height of the
specificatiOn range. Lower the liqwd level m the measured tank to be below the lower
end of the diaphragm on the process flange surface.
Always check the zero pomt after equalizmg the pressure on the high and low pressure
side diaphragms. For full checkmg procedure, refer to "2-2-4 Transmitter mam umt
mstallatwn pos1t10n" on page 2-10.
100%
Remarks:
The output for li qu1d level
changes IS NOT
proportional to the actual
liqu1d level m the range
up to 25 mm from the
mm1mum liqu1d level (0% H
level) because they have
the nght s1de.
90</lmm -Output
Figure 3-3 Minzmum liqutd level characterzstzc
100% level
0% leveL __ !_ __
Zero po1nt check level -=
Figure 3-.:f. Determmmg the zero poslfzon

Zero adjustment
The zero pomt of the transmitter can be adjusted either by commumcatmg with the
SFC or usmg the external zero adjustment functiOn (optiOn).
Procedure
Steps Procedure
When the liquid level m the tank can be lowered to the low limit value
(0%) of the measurement range:
• Procedure the SFC
Refer to the procedure of 3-8. Zero-pomt adjustment --- Based on actual
liquid level and the procedure of "3-9· Zero-span adj ustment with mput
pressure eqUivalent to range"
• Procedure usmg the external zero adjustment functiOn (optiOn)
Refer to "3-1 0: External zero adjustment (option)"
2 When the liqUid level m the tank cannot be lowered to the low limit value
(0%) ofthe measurement range:
• Procedure usmg the SFC
Refer to the procedure of " 3-8. Zero-pomt adjustment--- Based on
actual liqUid level"
• Procedure usmg the external zero-adjustment functiOn (optiOn).
Refer to "3-1 O· External zero adjustment (option)"

The transmitter IS ready for operation when zero-pomt adjustment IS completed. Thi s
procedure IS described m the previOus Item. Before yo u start, always check these
Items:
( 1) Check the 'correspondence between mput and output values.

• If the output does not correctly reflect the mput, check the range, check the
flange position on the process, and calibrate the transmitter agam . If an
mappropnate output value persists for the mput value, apply troubleshootmg
procedure (Chapter 5).
(2) Check the displayed data.

• If unstable value IS displayed, adjust the dampmg time constant.
(3) Perform the followmg Items carefully·

• Disconnect the SFC from the transmitter termmal. Ensure that the tern1mal IS
sufficiently tight, and not loose.
• Close the case cover. Screw m the cover firml y until It can no longer be turned.
• This transmitter has a lockmg structure. After closmg the cover, tighten the lock
usmg a hexagon wrench.

3-5-1-3: Stopping operat1on
Procedure
Turn off the transmitter
&cAUTION
• When a long-term shutdown 1s planned, completely dram all process flmd from
the connectmg p1pe and from the pressure rece1vmg part of transmitter.
ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter

3-6: Measurement with model JTE

When startmg operation, adjust the transmitter m 1ts actual process state. The specific
gravity of the sealed-m liquid IS stated m the specifications m AppendiX A. Specific
graVIty changes With temperature at the rate of 0.QQ08rC.
Use the temperature of the capillary tube for 1tems related to specific gravity
Checkmg mm1mum liqu1d level position (zero position) and zero pomt at
equal pressure mput
Set the zero pomt of the measured liquid level at the center of the seal diaphragm on
the process connectiOn flange surface of the transmitter. (refer to Figure 3-5)
Measurement range HIS from the flange center of the transmitter to the height of the
specificatiOn range. Lower the liqmd level m the measured tank to be below the lower
It IS assumed that the low-pressure side diaphragm IS mounted at a hetght tdenttcal to
that of the htgh-pressure side diaphragm. Never allow any liqmd to exert a head
pressure on these elements, and always equalize the pressure on the lower- and high-
side diaphragm when checkmg the zero pomt. For the checkmg procedure, refer to "2-
2-4 Transmitter mam umt mstallat10n positiOn" on page 2-1 0.
100% ··-----·-------------·------------------
Remarks:
The output for liquid level
changes Is NOT
liquid level m the range
mm1mum liquid level (0% H
the nght s1de.
90</>mm ...... Output
Figure 3-5 Mimmum liquzd level characterzstzc

100% level
0% level
zero paine---------------
check level
Figure 3-6 Determznzng the zero posllzon
Zero adjustment
The zero pomt of the transmitter can be adjusted either by commumcatmg with the
SFC or usmg the external zero adjustment function (optwn).
ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter 3-41 .

Procedure
Steps Procedure
When the liqmd level m the tank can be lowered to the low limit value
CO%) of the measurement range:
Refer to the procedure of zero adjustment based on the actualliqmd level
m "3-8 . Zero-pomt adjustment--- Based on actualliqmd level" on
page 3-50 and the procedure of zero span adjustment based on the range
eqmvalent mput pressure m "3-9· Zero-span adjustment with mput
pressure eqmvalent to range" on page 3-52.
• Procedure usmg the external zero adjustment functiOn (optiOn)
Refer to "3-1 O· External zero adjustment (optiOn)" on page 3-54
2 When the liqmd level m the tank cannot be lowered to the low limit value
CO%) of the measurement range:
m "3-8. Zero-pomt adjustment--- Based on actualliqmd level" on
page 3-50.
• Procedure usmg the external zero-adjustment functiOn (optiOn).
Refer to "3-1 0: External zero adjustment (optiOn)" on page 3-54

The transmitter IS ready for operatiOn when zero-pomt adjustment IS completed. This
procedure IS described m the previOus Item. Before startmg, always check these Items:
(I) Check the correspondence between mput and output values.

flange position on the process, and calibrate the transmitter agam. If an

• If unstable value IS displayed, adjust the·dampmg time constant.
(3) Perform the followmg Items carefully·

• Disconnect the SFC from the transmitter termmal. Ensure that the termmal IS
• Close the case cover. Screw m the cover firmly until tt can no longer be turned.

3-6-1-3: Stoppmg operation
Proc·e dure
&cAUTION
• When a long-term shutdown IS planned, always dismount the transmitter flange
from the tank, clean diaphragms With a soft brush, wash usmg a solvent, and store.
Take care not to deform or damage the diaphragms.
ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter _ 3-43

3-6-2: Cautions related to flow rate measurement

Refer to the mstructwns on flange mountmg for flow-rate measurement, to operate the
transmitter for flowrate measurement.
Always complete zero-pomt checkmg before mtroducmg flmd to the ptpe.
Thts precautiOn ts warranted smce the model JTE has a structural charactenst1c that
prevents mountmg of an equalizmg valve or stop valve.
For vertical ptpes wtth differential pressure take-out flange port, the htgh pressure stde
flange and the low pressure stde flange exhibit a level difference. In th1s case,
determme the zero pomt by settmg LRV

3-6-3: Mounting the flange for Flow rate measurement

(Model: JTE)
_ ._ .________. a__________________~----------------------------DME&.aMOO.-~~·~~
Mount the flanges on the process refernng to Figure 3-7
(0: Pipe Diameter) Orifice plate
Pipe diameter: larger than 3 tnches

D. P· htgher than 1OkPa
Diam. Ratio: 0.30 to 0 .70
Figure 3- 7 lnstallatwnfor flow rate measurement wah or~fice plate
&cAUTION
• Don't twist the capillary tubes.
• In unwmding capillary tubes, hold the flange part and unwmd the large loop of the
tube.
• Don't turn the capillary tubes m such a way that It twists the root of the flange.

3-7: Measurement with model JTH/JTS

When startmg operation, adjust the transmitter m Its actual process state. The specific
gravity of the sealed-m liquid IS stated m the specificatiOns m Appendix A. Specific
gravity changes With temperature at the rate of 0.0008/°C. Use the temperature of the
capillary tube for Items related to specific gravity, m this section.
3-7-1-1 Before you start
Mimmum liqu1d level position for liquid level measurement (zero position)
Set the zero pomt ofthe measured liqmd level at the center of the seal diaphragm on
the process connectiOn flange surface of the transmitter. (Refer to Figure 3-8.)
Measurement range H IS from the flange center of the transmitter to the height of the
specificatiOn range. Lower the liquid level m the measured tank to be below the lower
100% ----------------------------------------
Remarks:
The output for liqu1d leve l
changes IS NOT
liqu1d level m the range
m1mmum liqu1d level (0% H
the nght s1de.
90</>mm - Output 100%
Figure 3-8 Minzmum liqurd level charactenstzc

100% level
0% level
Zero poiiif _______________ _
check level
Figure 3-9 Determmmg the zero posztzon
Zero adjustment
The zero pomt of the transnutter can be adjusted either by commumcatmg with the
SFC or usmg the external zero adjustment function (optwn).

Procedure
Steps Procedure
When the liqmd level m the tank can be lowered to the low limit value
CO%) ·of the measurement range:
m " 3-8. Zero-pomt adjustment--- Based on actualliqmd level" on
page 3-50 and the procedure of zero span adjustment based on the range
eqmvalent mput pressure m "3-9 · Zero-span adjustment With mput
• Procedure usmg the external zero adjustment functwn (optwn)
Refer to " 3-10· External zero adjustment (optwn)" on page 3-54
2 When the liqmd level m the tank cannot be lowered to the low limit value
(0%) of the measurement range:
m "3-8. Zero-pomt adjustment--- Based on actualliqmd level" on
page 3-50.
• Procedure usmg the external zero-adjustment functwn (option).
Refer to"3-l O· External zero adjustment (optwn)" on page 3-54

The transmitter IS ready for operation when zero-pomt adjustment IS completed. This
procedure IS described m the previous Item. Before startmg, always check these Items:
(1) Check the correspondence between mput and output values.

flange position on the process, and calibrate the transmitter agam. If an

• If unstable value IS disp'layed, adjust the dampmg time constant. (Chapter 4)
(3) Perform the followmg Items carefully ·

• Dtsconnect the SFC from the transmttter termmal. Ensure that the termmalts
• Close the case cover. Screw m the cover firmly until It can no longer be turned.

3-7-1-3: Stopping operation
Procedure
_&CAUTION -
• When a long-term shutdown 1s planned, always dismount the transmitter flange

from the tank, clean diaphragms With a soft brush, wash usmg a solvent, and store.
Take care not to deform or damage the diaphragms:
ST3000 Ace -Smart Transmitter Electromc Different ial Pressure Transmitter 3-49
3-8: Zero-point adjustment --- Based on

actual liquid level
Introduction
Zero pomt can be adjusted durmg liqmd level measurement Without actually lowenng
to zero the liqmd level. The transmitter output can be adjusted to the actual level,
based on the actual liqu1d level measured w1th a level gauge.
An example of liqmd level measurement m a closed tank (by the wet leg method) 1s
show, below.

~
Tank
Transmitter mam un1t

Low pressure s1de flange
Figure 3-10 Zero adjustment durmg liqUld level measurement
Procedure
Use these procedures to adjust the transmitter output value to the actual level dunng
liqmd level measurement, based on the actual liqu1d level.
It IS assumed that the zero pomt IS adjusted under the followmg conditiOns:
Low limit 1000 mm (0%)
High lim1t 0 mm (100%)
LiqUid level measured With level gauge: 500 mm (50%)
Display on SFC 45%

Step Key Procedure SFC screen
INPUT
WORKING. ..
• The current output of the J,
transmitter will be displayed.
OUTPUT FIT-1234
• Change the displayed value 45.00%
to 50% by the followmg
steps.
2
Pre~s the 0 G
A CT PR
0ACT PR
key and
keys m that order.
OUTPUT FIT-1234
50.00%
G
3 Press the key
OUTPUT FIT-1234
• The SFC asks whether or not SET LRV?
to execute zero adjustment
for 50% output.
4 NON-VOL
• Zero adjustment has been 50.00%
completed.

3-9: Zero-span adjustment with input

pressure equivalent to range
Introduction
The LRV (input pressure for 0% output) and the URV (input pressure for 100%
output) van be set based on the actual pressure by applymg the pressure eqmvalent to
the desired range. The LRV and URV are set automatically based on the desired liqmd
level or mput pressure. Zero span adjustment IS completed by th1s opera~IOn.
Procedure
Zero span adjustment procedure under the followmg conditiOns IS explamed below.
Desired LRV value 1050 mm (0%)
Desired URV value 50 mm (100%)

~
50 mm 100% ligu1d level
1000 mm
Tank
0% liqu1d level
Pipe stanch1on Closed tank
Figure 3-11
Procedure for settmg LRV (input differential pressure at 0% output)
Step K ey Procedure SFC screen
r:::=;l Press the[~·) key

LRV FIT-1234
~ • The current set value for LRV 1050 mmH 2 0
will be displayed.
2
Press the ~!a key
LRV FIT-1234
to set the LRV based on the
current pressure.

Step Key Procedure SFC screen
3 NON-VOL
Press the key LRV FIT-1234
WORKING. .
• The data will be loaded to the
memory of the transmitter
LRV FIT-1234
and the SFC and the new
1050 mmH 20
LRV value will be displayed.
Procedure for settmg URV (input differential pressure at I 00% output)
Step Key SFC screen
Press the[~::) key

URVF URV FIT-1234
100% II
• The current set value for LRV 50 mmH 20
will be displayed.
2 Press the key

URV FIT-1234
to set the URV based on the
current pressure.
3 NON-VOL
Press the key URV FIT-1234
WORKING. ..
• The data will be loaded to the J,
memory of the transmitter
URV FIT-1234
and the SFC and the new
50 mmH20
URV value will be displayed.

3-10:External zero adjustment (option)
3-10-1 :External zero adjustment

. J: s
Introduction
A transmitter With external zero-adjustment functiOn enables on-site zero pomt
adjustment work Without usmg an SFC.
A transmitter With both a digital meter and external zero-adjustment function displays
ZERO m the display umt.
Adjustment range
Set to any value an output corresponding to the current mput. Set w1thm the range of-
1.25% (3.8 rnA) and +105% (20.8 rnA).
Procedure
Figure 3-12 External zero adjustment
How to adjust zero pomt.
Steps P rocedure
Make sure that the differential pressure to be set IS applied to the

transmitter.

Steps Procedure
2 Usmg a flat-blade screwdnver, turn the zero-adjustment tnmmer to the

desired directiOn (+ or -) until It stops while pushmg It down. Adjustmg
operation will begm. Adjust It so that the output becomes the set value.
• Procedure for mcreasmg output: Turn the tnmmer fully m the positive
(+) direction while pushmg It down. 6 UP IS displayed on the digital
meter.
• Procedure for decreasmg output: Turn the tnmmer fully m the negative(-
)directiOn while pushmg It down. vDOWN IS displayed on the digital
meter.
_&CAUTION
• Turmng the adjustment tnmmer too far will break It.

• Do not remove the cross-recessed screw. Adjustmg umt may break
and cause personal InJury
• Zero pomt adjustment IS mterrupted by commumcatwns from the SFC.
• Dunng zero~pomt adjustment, only the set value and the settmg status
can be read by commumcatwns from the SFC.
Output adjustment value

The output adjustment value changes according to the penod dunng which the
adjustment tnmmer IS kept m the fully-turned state, as shown.
100 ·-··-·---·----·---····-·········-··-····-·--·--·---.-------~
15 .
10 -
5 --
0 ~~-------------~
10 15 20 22 26 30 40 47
Figure 3-13 Output adjustment value and duratwn o.ftnmmer operatzon
• The longer the duratiOn, the larger the output adjustment value. (See illustratiOn,
above.)
• The longer the duratiOn, the more qmckly the adjustment value mcreases or
decreases. (See illustratiOn, above .)
Error diagnostics
Adjustment functiOn, ZERO blinks on the mdicator.
An error will result If the adjustmg operation contmues for about 50 seconds.
And, the set value IS restored to Its ongmal value.

3-11 :Set range calculation for liquid level

measurement
3-11-1 :Open tank or closed tank (dry leg) or remote seal

set range calculation
'iliA Ailll;b
_Set range calculation (Ex. model JTD)

Calculate the set range usmg these procedures:
The followmg symbols are used to express density and distance.

It IS assumed that the density 1s fixed, dunng liqmd level measurement.
p Specific gravity of liqmd m tank
Po Specific gravity of liqmd m high pressure side connectmg pipe
I Distance between 100% liqmd level and 0% liqmd level (measurement range)
h Distance between 0% liqmd and high pressure outlet port
d Distance between high pressure outlet port and transmitter.
100% liqwd level

rr=======l 100% liqu1d level
High pressure I High pressure
outlet port outlet port
Open tank
Low
pressure JTD pressure
s1de s1de
Figure 3-14 Open tank Figure 3-15 Closed tank
Differential pressure at 0% liqmd level (Pressure on high pressure side - Pressure on

low pressure side)= hp + dp 0 = LRV
Differential pressure at 100% liqmd level (Pressure on high pressure side - pressure on
low pressure side)= lp + hp + dp 0 =(I+ h)p + dp 0 = URV
Therefore, set the range as follows:

Low lim1t (LRV): hp + dp 0 , High limit (URV): (I + h)p + dp 0
Example of calculatiOn:
I = 1500 mm, h = 250 mm, d = 500 mm
p = o.9, Po = 1.0

If the above conditiOns are assumed, the followmg results are obtamed:
Differential pressure at 0% liqmd level= (250 x 0.9) + (500 x 1.0) = 725 mmH 2 0 =
7 110 kPa
Differential pressure at 100% liqmd level = {(1500 + 250) x 0.9}+ (500 x 1.0) = 2075
mmH 2 0 = 20.35 kPa

Low limit (LRV): 7 110 kPa {725 mmH 20}, High limit (URV): 20.35 kPa {2075
mmH 20}
Set range calculation (Example model JTG)

It IS assumed that the density IS fixed, dunng liqmd level measurement.
p Specific gravity of liquid m tank
Po Specific gravity of liqmd m connectmg pipe
100% liqu1d level
High pressure
outlet port I
0% liqu1d level
h po
d Open tank
JTG
Figure 3-16
Pressure at 0% liqmd level = hp + dp 0 = LRV

Pressure at 100% liqmd level = lp + hp + dp 0 = (I + h)p + dp 0 = URV

Low limit (LRV): hp + dp 0 , High limit (URV): (I + h)p + dp 0
I = 1500 mm, h = 250 mm, d = 500 mm
p = 0.9, Po= 1.0
STJOOO Ace -Smart Transmitter Electronic Differential Pressure Transmitter 3-57

Differential pressure at 0% liquid level = (250 x 0.9) + (500 x 1.0) = 725 mmH20 =
7 110 kPa
Differential pressure at 100% liqmd level = {(1500 + 250) x 0.9} + (500 x 1 0) = 2075
mmH 20 = 20.35 kPa

Low limit (LRV): 7 110 kPa {725 mmH 20 } , High lim1t (URL): 20.35kPa {2075
mmH 20 }
Set range calculation (Example model JTC)

Calculate the set range usmg these procedure:
It IS assumed that the density IS fixed , dunng liquid level measurement.
I Distance between 100% liquid level and 0% liqmd level (measurement range)
d Distance between high pressure outlet port and transmitter.t
Blow valve
p
100% liqu1d level
Volume container
2 Tank
2 Tank
Open to a1r 0% liqu1d level
- -
h
p p
Figure 3-1 7 Open tank

Figure 3-18 Closed tank
Dtfferential pressure at 0% liqmd level (Pressure on h1gh pressure side - Pressure on

low pressure side)= hp = LRV
Differential pressure at 100% liqmd level (Pressure on htgh pressure side - pressure on
low pressure stde) = lp + hp =(I + h)p = URV
Therefore, set the range as fo llows:

Low limlt (LRV): hp ; High limit (URV) : (I + h)p
I = 1500 mm, h = 250 mm,
p = 0.9
Differential pressure at 0% liquid level = 250 x 0.9 = 225 mmH 20 =2.206 kPa
Differential pressure at 100% Iiqmd level = (1500 + 250) x 0.9= 1575 mmH 20 = 15 45
kPa


Low limit (LRV): 2.206 kPa {225 mmH 20}, High limit (URV): 15 45kPa {1575
mmH 2 0}
Set range calculation (Example model JTE)

It IS assumed that the density IS fixed , dunng liqmd level measure.ment.
Po Specific gravity of sealed liqmd
I Distance between 100% liqmd level and 0% liquid level (measurement range)
I UU'1o liqUid level
Open tank
0% liqu1d level
p
Low
pressure
s1de
Figure 3-19 Open tank
Differential pressure at 0% liqmd level (Pressure on h1gh pressure side - Pressure on

low pressure side) = hp = LRV
Differential pressure at 100% liqmd level (Pressure on high pressure s1de - Pressure on
low pressure s1de) = lp + hp = (I + h)p = URV

Low limit (LRV): hp ; High limit (URV): (I + h)p
I = 1500 mm, h = 250 mm, d = 500 mm
p = 0.9, Po= 0.935
lfthe above conditiOns are assumed, the followmg results are obtamed:
Differential pressure at 0% liqmd level= (250 x 0.9) = 225 mmH 2 0 = 2.206 k.Pa
Differential pressure at 100% liqmd level= (1500 + 250) x 0.9 = 1575 mmH 2 0 =
15 45 kPa

Low limit (LRV): 2.206 kPa, High limit (URL): 15 45 kPa

Set range calculation (example model JTH)

It IS assumed that the density JS fixed, dunng liqmd level measurement.
I Distance between 100% liqmd level and 0% liquid level (measurement range)
h Distance between 0% liquid and high pressure outlet port
100% liqu1d Ieve
Open tank
0% liquid level
p
connect1on
Figure 3-20 Open tank
Differential pressure at 0% liqmd level= hp + dp 0 = LRV

Differential pressure at 100% liqmd level = lp + hp + dp 0 = (I + h)p + dp 0 = URV

Low limit (LRV): hp + dp 0 , High limit (URY): (l + h)p + dp 0
I = 1500 mm, h = 250 mm, d = 500 mm
p=0.9, p 0 = 1.0
If the above conditions are assumed, the followmg results are obtamed:
Differential pressure at 0% liquid level= (250 x 0.9) + (500 x 1.0) = 725 mmH 2 0 =
7110kPa
Differential pressure at 100% liqmd level= {(1500 + 250) x 0.9 } + (500 x 1.0) = 2075
mmH 2 0 = 20.35 kPa
Therefore. set the range as follows:

Low limit (LRV): 7 110 kPa, High limit (URL): 20.35 kPa

3-11-2:Ciosed tank (wet leg or remote seal) ---set range

- w.cmn
Set range calculation (example model JTD)

It I_s assumed that the density IS fixed , dunng liqmd level measurement.
Po Specific gravity of sealing liqmd
I Distance between 100% liqu11d level and 0% liqmd level (measurement range)
~pressure
---;,c--------- ~ outlet port
100% li u1d level
d
0% li u1d level
__ p
~ Low pressure
'--+--outlet port
Closed tank
h
po Closed tank
(wet leg)
Low pressure High pressure

s1de s1de
Figure 3-21 Closed tank (wet leg)

low pressure side) = dp 0 - hp = LRV
low pressure Side)= dp 0 - (1 + h)p = URV

Low limit (LRV): dp 0 - hp; High limit (URV): dp 0 - (1 + h)p
Example of calculation:
I= 1500 mm, h = 250 mm, d = 2000 mm
p = 0.9, Po= 1.0
lfthe above conditiOns are assumed, the followmg results are obtamed :
Differential pressure at 0% liqmd level= (2000 x 1.0)- (250 x 0.9) = 1775 mmH 2 0 =
17 41 kPa

Drfferentuil pressure at 100% liqmd level= (2000 x 1.0)- (1500 + 250) x 0.9 = 425
mmH 2 0 = 4 168 kPa

Low limit (LRV): 17 41 kPa { 1775 mmH 20}, High limit (URL): 4 168 kPa {425
mmH 2 0}
Set range calculation (example model JTC)

It IS assumed that the density IS fixed, dunng liqmd level measurement.
Po Specific gravity of sealing liqmd
d Distance between h1gh pressure outlet port and transmitter.
Blow valve
p
-~--------------
100% liqwd level
Cll-t-----'------1
>
ro
>
Q.
d R 0 Tank
......
Vl
P 0 0% liqu1d level
Differential pressure at 0% liqmd level (Pressure on h1gh pressure s1de- Pressure on

low pressure Side) = hp - dp 0= LRV
Differential pressure at 100% liqmd level (Pressure on h1gh pressure s1de - Pressure on
low pressure Side) = (I + h)p -dp 0 = URV

Low limit (LRV): hp -dp 0 , High lim1t (URV): (I+ h)p - dp 0
l = 1500 mm, h = 250 mm, d = 2000 mm
p = 0. 9, Po = 1. o
Dtfferentml pressure at 0% liquid level =(250 x 0.9) - (2000 x 1 0) = -1775 mmH 20 =
-17 41 kPa

Dtfferentlal pressure at 100% liqwd level= (1500 + 250) x 0.9- (2000 x 1.0)= -425
mmH 2 0 = -4 168 kPa

Low limtt (LRV): -17 41 kPa { 1775 mmH 20} , High limtt (URL) : -4 168 kPa {425
mmH 2 0}
Set range calculation (example model JTE)

The followmg symbols are used to express density and dist':lnce.
It IS assumed that the denstty ts fixed , durmg liqmd level measurement.
p Spectfic gravity of liqmd m tank
1 Distance between 100% liqmd level and 0% liqmd level (measurement range)
h Distance between 0% liqmd and htgh pressure outlet port
d Dtstance between htgh pressure outlet port and transmitter.
100% liquid level
d
Closed tank
0% liquid level
Dtfferenttal pressure at 0% liqmd level (Pressure on htgh pressure stde - Pressure on

low pressure side)= dp 0 ,- hp = LRV
Dtfferenttal pressure at 100% liqmd level (Pressure on htgh pressure stde - Pressure on
low pressure stde) = dp 0 - (I + h)p = URV

Low limtt (LRV): dp 0 - hp; High limtt (URV): dp 0 - (I + h)p

I = 1500 mm, h = 250 mm, d = 2000 mm

p = 0.9, Po = 0.935
Differential pressure at 0% liqmd level = (2000 x 0.935) - (250 x 0.9) = 1645 mmH 20
= 16.13kPa
Differential pressure at 100% liqmd level= (2000 x 0.935 ) - ( 1500 + 250) x 0.9 = 295
mmH 20 = 2.893 kPa

Low limit (LRV): 16.13 kPa {1645 mmH 2 0 }, High limit (URL): 2.893 kPa {295
mmH20 }

Overv1ew
Connect the SFC to this transmitter m order to perform checks on measured data and
to change settmg data.
This section deals with basic operatmg procedures for an SFC, such as
commumcat10ns with the transmitter.
For detailed mformat10n on an SFC, refer to SFC User 's Manual (CM2-SFC100-
2001 ).

Operation usmg SFC Yamatake Corporation
4-1: Basic information
4-1-1: SFC functions

-·~~~---------------------------------------------------------------------
Introduction
Read the measured data of a transmitter and change Its settmg. Simply connect the
SFC to the transmitter and marupulate the key-pad.
Start measurement
.
Start commumcatiOns between the SFC and the transmitter.
Display measured data

An SFC displays a range of useful data:
• Display the differential pressure (engmeenng umt) applied to the transmitter
• Display the output (%) from the transmitter
Display self-diagnostic results

An SFC can display transmitter errors and SFC errors, usmg a vanety of functwns.
For detailed mformation, refer to Chapter 5
Prmting
If fitted with a pnnter, these pnntmg functiOns are available:
• Mamtenance pnntmg outputs the complete mternal data of a transmitter.
• Action pnntmg IS a uruque response to a key operation.
Display and change transmitter settings

An SFC has functions for displaymg or changmg:
• Tag number
• Output format
• Display format (flow rate I linear I display flow rate)
• Display format (engmeenng umt I % display)
• High and low limits of engmeenng quantity
• Low limit of set range
• High limit of set range
• Span of set range (display only)
• Engmeenng umt of measured pressure
• Dampmg time constant
• Low flow cutoff value
• Burnout directiOn (display only)
• Production number (display only)

Yamatake Corporation Operation usmg SFC
• Software versiOn (display only)

• Measurable maximum differential pressure (display only)
• Height between flanges
Savmg set values and settings

After changmg a set value or a settmg, always save the new value m the transmitter
usmg SFC operations.
Once mput to the transmitter, a set value and a settmg are automatically saved after a
delay of about 30 seconds. Such data are not erased by tummg off the transmitter.
Mamtenance
The constant current source mode can be selected for loop checkmg of a transmitter.
Other functions
A scratch-pad functiOn -enables convement recording of such mformat10n as a date and
a name.
ST3000 Ace - Smart Transmitter Electrontc Differential Pressure Transmitter 4-3

--
4-1-2: Key operation and display .interaction
General mstructions for key operation

Operate SFC keys according to the followmg mstruct10ns:
• Press keys securely and slowly No response on the screen mdicates a failure to mput
the key Press the key agam, slowly
• If key-pad actiOn makes no change on the screen, this key may have no functiOnality
for the currently-obtrumng operation stage. Or, the key may not be supported by the
currently-connected transmitter.
• Start from the m1t1al state, after operatmg a wrong key InstructiOns m Chapter 4
General rules for mteraction with screen

Operate an SFC m the mteractive mode.
Interact With the screen, followmg these basic rules:
f-) key to answer Yes to a questiOn on the screen.

NON·VOL
• Press the
If answer IS Yes to a question on the screen, currently-obtammg SFC functiOn
proceeds to the next hierarchical level.
If answer IS Yes to EXIT?, currently-obtammg SFC functiOn will return to the top
hierarchical level.
• Press the ( ,c;:, ) key to answer No to a question on the screen.

If answer IS No to a question when performmg a special-purpose function, currently-
obtammg SFC functwn proceeds to the prevwus hierarchical level.
If answer IS No to EXIT?, the first screen of the currently-obtammg function
appears.
• Press the (t"j3 key or the ltiJJ key to select a different functiOn m the same
hierarchical level.

4-1-3: SFC keyboard

A &P
Appearance
Both Japanese and English language key-pads are available.
The followmg illustratiOn shows an Engli sh key-pad.
Figure 4- I SFC key-board

4-1-4: Basic key input operations

- ,.. 9 vvn jl
Key mput procedure

How to mput alpha characters and end alpha-entry mput:
Step Procedure
Press the ( ALPHA ) ( whtte) key

• A • cursor will blink m the data display wmdow.
2 Press the desired character, to mput.
• The mput character will be displayed.
• Actual character for each key IS shown m the top, nght-hand corner of
the key
3 Press the (ALPHA) key agam to end mput.
How to mput numbers, symbols, or a functiOn (indicated at the center of a key):
Step Procedure
Press the (ALPHA J key tf a . cursor IS blinkmg m the data display wmdow.
• A_ cursor will be displayed.
2 Press the key to mput character or functiOn.
How to mput the functiOn mdicated Immediately above each key·
Step Procedure
1 Press the (ALPHA) key

• SHIFT _ cursor will be displayed m the data display wmdow.
2 Press the key to mput functiOn .

4-1-5: Functions of SFC keys

~-.-.mm-.~ . ._..__._.. . . . . . . . . .._. ..-. . . . . .._. . . . . . . ._._._._.. .~~~~~
Introduction
The SFC keys are grouped by maJor functiOns, mdicated by colors.
An SFC has common functions, and dedicated functions. Common functiOns are
applicable to other eqmpment besides this transmitter. Dedicated functions are
applicable only to this transmitter.
Common functiOns can be selected usmg the [ ~ •) , ('~ ) , alphanumenc keys.
(Some are selected by pressmg the ( .",,.;) key first.)
Dedicated functions have a hierarchical structure and can be selected by pressmg the
[ cON.") key first.
Groupmg by color
The 32 keys on the key-pad are classified mto five color groups. Colors and their
corresponding functiOns are shown, below.
Remarks:
Some keys are not used With a transmitter.
Key color · MaJor function
Light green • Start commumcatwns with a transmitter

• Enable selection of a dedicated function
• Set or change measurement conditions
• Dlsplaymg the set data of a transmitter
• Select a menu
Orange • Display measured data
• Select a screen
• Save data
Yellow • Input a numenc value
• Pnnt data
• Enable memo recording
Dark green • Execute diagnostics
• Check the span of the set range
White • Move the cursor m the data display wmdow
• Change the functiOn of a key of another color
• Cancel the current settmg

Key color MaJor fu nction
All colors • Input an alpha character
(Press the [ALPHA] key first.)
Functions of green keys

Different functions are executed by pressmg a green key alone, or pressmg a green key
after pressmg the ( .,..{ ) key
Green keys have the followmg maJor functions:

• Start commumcations With a transmitter
• Enable selectiOn of a dedicated functions
• Set or change measurement conditions
• Display the set data of a transmitter
• Select a menu
An alpha character can be displayed by first pressmg the [ALPHA) key and then pressmg
the corresponding alphabet key
ExplanatiOn
Key mark
Press a key Press a key after ( ""'.{) key
ID· Used when the conversiOn out-

DE READ
Press th1s key to start put IS DE. Has the same function
0 commurucatwns With the

transmitter. Displays the tag no.
of the transmitter.
as ID
Change the tag no. from this

screen by mputtmg a new
number.
CONF No function
B Press th1s key to use a dedicated

function. The dedicated
functiOns have hierarchical
structure. Refer to 5-1-6.
DAMP· No functiOn
B The current dampmg time

constant IS displayed. Change
the dampmg time constant on
this screen.
UNIT No function
EJ The current engmeenng umt IS

displayed. Change the
engmeenng umt on th1s screen.

Explanation
Key mark
Press a key Press a key after ( ...~) key
LRVO%. No functiOn
~
Displays the Lower Range Value
-
(LRV) of the current set value.
Change the LRV on this screen.
URV 100%. No function
~
The Upper Range Value (URV)
'100%
of the current set value IS
displayed. Change the URV on
this screen.
DECONF
MENU ITEM. DECONF Used to display or
Press this key to change the select vanables output m digital
~ M output format (linear I square

root).
commumcatwn.
Functions of orange keys
Different functiOns executed by pressmg an orange key only, or by pressmg the ( .""~]
key first and then pressmg an orange key
Orange keys have the followmg maJOr functiOns:
• Display measured data
• Select a screen
• Save data
Display an alpha character by first pressmg the (ALPHA ) key, and then pressmg the
corresponding alphabet.
Explanation
Key mark
Press a key Press a key after ( ...~ ) key
SET No functiOn
Press this key to set a desired
output value for the current mput
value.

Explanation
Key mark
Press a key Press a key after ( ...~) key
NEXT No functiOn
Press this key to display a screen
m the next hierarchical level of
dedicated functions.
Press this key after the ( "".:] key
to change the darnpmg time
constant.
Press this key after the ( u..tf J key
to change the engmeenng umt.
PREY· No functiOn
Press this key to go back to the
previous hierarchical level, for
dedicated functiOns.
Press this key after the ( ,_; J key
to change the dampmg hme
constant.
Press this key after the [ u..tf ) key
to change the engmeenng umt.
INPUT
OUTPUT (INPUT): INPUT
Thts key displays the output(%) Displays the differential pressure
from the transmitter. bemg mput to the transmitter.
Press this key, mput a numenc
NON -VOL
value, and press the · . key

"' l ..
The transmitter will become a
constant current source. It will
output only the current value that
corresponds to this value. This
functiOn IS used for mamtenance
purposes.
RESET
CORRECT RESET
Press th1s key to calibrate the se Initializes the transmitter to the
range. delivery settmgs.

Explanation
Key mark
Press a key Press a key after ( s ..~ ) key
NON-VOL
ENTER. NON-VOL.
Press this key to send data to the Save data m the transmitter. Data
transmitter. not erased by turmng off the
(Yes): transmitter.
Press this key to answer Yes to a
question on the data display
wmdow.
Functions of yellow keys

Different functiOn are executed by pressmg a yellow key only, or by first pressmg the
( s"'~) key and then pressmg a yellow key
The yellow keys have the followmg maJor functiOns:

• Input a numenc value
• Pnnt data
• Enable memo recording
Display an alpha character by pressmg the E) key and then pressmg the
corresponding alphabetic key
ExplanatiOn
Key mark
Press a key Press a key after [ s"'~ ) key
PRINT
9· PRINT An SFC with a pnnter
9 (number) mput. starts pnntmg.
G
IS
This IS called mamtenance
pnntmg.
FEED
8. FEED· The prmtmg paper IS fed
8 (number) mput. by 1 line each time this key IS
~
IS
pressed.
Press the [ ,c.~•, Jkey to cancel this
functiOn .
7 to 4 No function
[2J 7 to 4 (number) IS mput.
to
~
Explanation
Key mark
Press a key P ress a key afte r ( ....; ) key
SW VER
3 SW VER. When the SFC ts
3 (number) mput. connected to a transmitter, the
G
IS
software versions of both
eqmpment umts, are displayed.
When the SFC ts not connected
to a transmitter, the software
. version the SFC ts displayed .
'
2, 1 No function
0 2 or 1 (number) IS mput.
0
TIME
+/- +/- 1s mput TIME. In the case of SFC with a
pnnter, the current date and time
~
/" press the [ALPHA J key and thts
are displayed.
key m that order to mput I
SCR PAD
. A dec1mal pomt IS mput. SCR PAD· Press th1s key to
record a memo.
0 --+ press the (ALPHA J key and this

key m that order to mput a space.
ACT PR
0· 0 (number) IS Input. ACT PR. The response from the
transmitter IS pnnted each time
0 this key IS pressed. This 1s called

action pnntmg.
Press the ( ,c;:1 J key to end this
function.
Function of dark-green keys

Differential functions are executed by pressmg a dark-green key only, or by pressmg
the ( ....; ) key and then pressmg a green key
The dark-green keys have the followmg maJor functions:

• Execute diagnostics
• Check the span of the set range

An alpha character can be displayed by pressmg the ( .L..... ) key and then pressmg the
corresponding alphabetic key
Explanation
Key mark
Press a key Press a key after [ .",.T') key
F/S DIR
STAT Displays the self- F/S DIR. Displays the output
diagnostic result of the signal processmg directiOn, m
B transmitter. the error status.
URL
SPAN Display the current span. URL . Display the maxim um
value of the differential pressure
EJ '
that can be measured With the
transmitter.
Functions of white keys

The functiOns of the white keys are explamed, below.
The white keys have the fo llowmg maJor func tiOns:
• Move the cursor m the data display wmdow
• Change the functiOn of a key of another color
• Cancel the current settmg
Expla nation
Key mark
Press a key P r ess a key after ( .",.T') key
-+ The cursor moves forward by No functiOn
(3 one positiOn.
~· The cursor IS moved back by No function

A~D E
one position.
B
ALPHA. Press thts key No function ·
EJ Immediately before mputtmg an

alphabetic character (including I
). Press agam to release the
functiOn.
SHIFT Press this key to mput No function
B the functiOn that IS mdicated

above a key

Explanation
Key mark
Press a key Press a key after ( ....t) key
CLR. Press this key to clear the Use this key to end a dedicated
display Set the SFC to standby functiOn .
status (wa1tmg for mput).
(No): Press this key to answer
No to a question.
4-14 ST3000 Ace- Smart Transmitter Electromc Differential.Pressure Transmitter

4-1-6: Dedicated functions
Dedicated functions
An SFC has the followmg maJor dedicated functions:
• Display and change the output format
• Display and change the display format
• Save data
• Display and change the low-flow cutoff value
• Display sensor temperature
• Display PROM No.
• Displaymg and changmg sealed liqmd temperature correctiOn functiOn
Hierarchical structure
The dedicated SFC functiOns have a hierarchical structure. First, press the ( c"":' ] key
Then, follow the mstructwns displayed m the data display wmdow.
Operation keys are shown m parentheses ( ). The display IS shown m a rectangle 0.
The directiOn of processmg IS shown wtth an arrow ~
STJOOO Ace - Smart Transmitter Electromc Differential Pressure Transmitter 4-15

~
....
I 0
Q')
(CONF)
t
ICONFORM' I (ENTER:)--- - - •
. . _ - -- iCLR)
ISQUARE ROOT or ILINEAR I (ENTER,..._
......-{CLR)
\ LINEAR I C/)
"T1
t (NEXT) (PREV)+ (")
t (MENU) t ~~m-1 DATA LOADED
(J)
....j
w
j ILINEAR \ or \ SQUARE ROOT
(ENTER,..._
......-{CLR)
1DOWN LOAD DATAq
ISQUARE ROOT I
t (NEXT) (PREV)+
0
0
t (NEXT) (PREV) +
0
t (NEXT) (PREV) +
\ DEFAULT I IDOWN LOAD DATAi ~~~~;-I DATA LOADED
)>
(') I DISPLAV7 I (ENTER or \ f LOW I (MEN U) t
(1) '--·- - - ' - ......-{CLR)
(J)
3Ill
::l
....j
iil
:I
Ill
3
~
..,
m t (NEXT) (PREV)+
ii I I SAVE DATA' ~~~~il SAVE DATA
...0
(')
I SAVE/ RESTORE?
t (NEXT) (PREV)+
t (NEXT)
IRESTORE DATA?
(PREV) + End
~~~~il RESTORE DATA
:I
c=;
IHEIGHT? I End
(Supported by model JTE/ JTR transm itter only))
c t (NEXT) (PREV) + (ENTER,..._ MODE - EXPAND I
IMODE =EXPAND I. ......-{CLR) t,--.:...:....:.__:__-.-'
~ ISENSOR TEMP? I (ENTER,..._
......-{CLR)
I T : 27 c t (NEXT) (PREV)+
;; t (NEXT) DOWN LOAD DATA~~~~~;-~ DATA LOADED
...iii'
:I
I PROMNO ?
(PREV)+
I
(ENTER,..._
......-{CLR) L
\ 2_00:..cO. :. .O:,:.O.;____.JI
OO (Example or PROM No) End
-<
D)
t (NEXT) (PREV)+
End 3
D)
"'C
;; IXXXXXXXXXXXXX I (Original display) S'
Ill (End dedica ted function)
Ill
..,c ""'
CD
(")
(1)
....j ..,
0
iil
:I 0
Ill
3 D1
:::.., =.
(1) 0
~
4-1-7: Charging SFC
Timmg and duration

Charge the SFC when: begms blinking ui the data display wmdow.
Approximate chargmg time reqmred IS shown, below·
• Non-exploswnproof SFC 6 hours
• Intrmstcally safe SFC. 10 hours
Important item
Charge an SFC at a non-hazardous locatiOn.
Procedure
How to charge an SFC: USE the battery charger (included).
Step Procedure
I Turn off the power swttch of the SFC.
2 Disconnect the commumcatiOn cable from the transmitter.
"'
..) Disconnect the commumcatwn cable plug from the SFC.
4 COnnect the plug of the battery charger cable to the SFC.
5 Connect the plug of the battery charger body to a commercial power

receptacle.
Chargmg will begm.
6 When the reqmred chargmg time elapses, disconnect the battery charger,
end chargmg.

4-2: Start measurement
Important!
Make sure that the process 1s m manual control mode before startmg commumcatiOns
between the SFC and the transmitter.
Procedure
How to start measurement by SFC.
Connect the commumcat10n

cable of the SFC to the
transmitter.
• Connectmg procedure ts
described m "3-1 PreparatiOn"
on page 3-2.
2 NON-VOL
Tum on the power switch of the
SFC. After checkmg that the LOOP IN MAN UAL?
process IS m manual control
NON.VOl
mode, press the key
PRESSID
3 DE READ
DE READ
Press the~ key DSTJ TAG No.
0 LIN DP FIT-1234
4 Read the tag number (displayed

m the data display wmdow). DSTJ TAG No.
Check whether the SFC IS LIN DP FIT-1234
connected to the correct
transmitter.
• If not, connect the
commumcatton cable to the
correct transmitter. Repeat
from <step 2>

4-3: Display measured data
4-3-1: Display input differential pressure

--------------------------------------------------a.----we--Jmn--n~
Procedure
How to display the differential pressure bemg applied to the transmitter.
Press the (."'~)key

B SHIFT-
I
2 INPUT
INPUT
Press the key
• The nght display mdicates that INPUT FIT-1234

the differenttal pressure bemg 25 kPa
applied to the transmitter IS
2,500 kPa
4-3-2: Display transmitter output (0/o)
Procedure
Display the output bemg transmitted by the transmitter usmg this procedure:
Step Key Descnptwn SFC screen
INPUT
Press the key
• This mdicates that the OUTPUT FIT-1234

transmitter o tput IS 50%. 50 %

4-4: Printing --- SFC with printer
4-4-1: How to print

-
Introduction
An SFC w1th a pnnter can pnnt transmitter settmg mformat1on at the begmnmg, or
dunng, measurement. It can also pnnt transmitter responses.
Mamtenance prmting and action prmting

An SFC has two ways to pomt. Select either way usmg key operations.
• Mamtenance pnntmg
This function enables pnntmg of a transmitters mtemal data: tag number dampmg
time constant, output range, differential pressure, and output value.
• Action pnntmg
This functiOn enables pnntmg of a transmitter 's response to SFC key operatiOn, after
each key operation.
Overv1ew of prmter
The SFC mternal IS a thermal pnnter that pnnts 24 characters per line.
When an SFC IS turned on, the pnnt head stops after a two-way motion and becomes
ready for pnntmg. Paper feeds out to a distance of about 5 mm .
Feed recording paper

How to feed recording paper·
""'.i' ) and 0
1 FEED
EJ FEED
Press the [
this order).
• Recording paper IS
key (in
fed each
I
SHIFT-
I
~ 0 FEED
time the key IS pressed. I PRINTER FEED

I
2 Press the ( c:: key to release the

@] )
1 1
paper feeding .functwn.

)
• PRINTER FEED disappears

and the screen returns to the
ongmal display

4-4-2: Printing internal data --- Maintenance printing

'BBI::If I QjC'gl i~W:! M a P. "WSM l!l ~~~~.R!U. Ril!i~&'Ui!i!~t~R~!!:In.J3
Prmted data
This functiOn enables pnntmg of mternal data: tag number, dampmg time constant,
output range, differential pressure, output value, and self-diagnosis result.
Use this function for recording the settmgs and failures of the transmitter.
Procedure
How to execute mamtenance pnntmg: Execute this operatiOn even dunng
measurements.
1 Hold down the( ,c;:, ) key until

[EJ )
the screen shown at nght,
displayed.
IS
DSTJ
READY. ..
FIT-1234
2 Press the ( sHJ.t ) key
B I
SHIFT-
I
"'-' PRJ NT
PRINT
Press the~ key DSTJ FIT-1234
0 WORKING. ..
J,
• Pnntmg will begm. I PRINTING...

I
4 Press the ( ,c;:, ) key at the end of

[EJ )
pnntmg.
DSTJ
READY. ..
FIT-1 234

Mamtenance prmting - Example

An example of prmted data 1s shown, below. The meamngs of mdiv1duallines are
explamed.
Example pnntout Meanmg

'99-04-01 02 :22 Date, tlme
TAG NO FIT 1234 Tag number
TYPE DIFF PRESSURE Type
ANA/DE ANALOG XMTR Output mode
FORM LINEAR Output format
(or SQUARE ROOT)
PROM# 2104695800 PROM number
SWVER 8.1 Software vers10n
DAMP 0.00 s Dampmg t1me constant
SPAN 70.00 kPa Span
LRV 10 00 kPa Measured value corresponding to 0% output
URV 80.00 kPa Measured value corresponding to 100% output
URL 99.64 kPa Max1mum value of set range
F/SAFE DOWNSCALE Burnout direction
HEIGHT O.OOOOm Take flange he1ght
DISPLAY
CONF DOSP FLOW D1splay format
TYPE ENG. UNIT D1splay type
EULO -10 000 Low lim1t of engmeenng quantity
EUHI 50 .00 High lim1t of engmeenng quant1ty
INPUT 45.00 kPa Input differential pressure to transmitter

OUTPUT 50.0 % Transm1tter output(%)
sv T = 25oC (7rF) Temperature detected by temperature sensor
STATUS CHECK= OK Self-diagnos1s result of transmitter
Figure 4-2 Mazntenance przntzng - example

_._.._____________________________________________________._._~~.ru~-
4-4-3: Print data responses -Action printing
Prmted data
This function enables prmtmg of a transmitters responses to SFC key operatiOns, each
time a key IS operated.
Use this function for pnntmg responses of each key operation.
Procedure
How to pnnt data: Execute this operation even dunng measurements.
Step Key Descraphon SFC screen
Hold down the ( ,c,::, ) key until

~ DSTJ FIT-1 234
~ the screen shown at nght, IS READY. ..
displayed.
2
0
A CT PR
Press the ( ."'~ J and

B ACT PR
m that order.
keys, SHIFT-
G DSTJ FIT-1234
ACTION PRINT?
..,
.)
NON-VOL
Press the key
The followmg mformatiOn IS
I PRINTING..
pnnted:
DSTJ FIT-1234
*ACTION PRINT* START
READY. ..
TAG. NO F ~ T-1234 (Tag No.)
92.07 07 13:10 (Date and t1me)
4 Each time a key IS operated, Its

details and the response are
pnnted.
5
Press the ( •"'~ ) and G
ACT PR
BACT PR
m that order, to end pnntmg
sessiOn.
keys, SHIFT-
G DSTJ FIT-1234
ACTION PRINT?

~
Press the ( ,c,:-:, ) keys.
PRINTING..
)
*ACTION PRINT* END IS pnnted I I

DSTJ FIT-1234
READY. .
Action prmting - Example

An example of pnnted data corresponding to an operated key IS shown, below.
Exampe of pnntout
ACT PR NON-VOL
BG * ACTION PRINT * START

TAG No. FIT-1234
B URL
'97.08.01
DAMP
SPAN
13:10
0.0
70.00
SECONDS
kPa
B LRV 10.00 kPa
[£) ACT PR
BG~ * ACTION PRINT * END
Figure 4-3 Actwn prmtzng- Example
4-24 ST3000 Ace - Sm~trt Transmitter Electromc Differential Pressure Transmitter

4-5: Display and change transmitter settings

t:1~~~~j~~~~~~~~~~~~.k§.~W'i~i;~l!{~~~'~[l i?>_;!
4-5-1: Displaying and changing transmitter settings -

.
overv1ew
Applicable settings
The followmg settmgs (values and states) can be displayed or changed by operatmg
SFC keys. This operation can be executed even dunng measurements.
O · Enab led - Disabled
Item Change Dtsplay
Tag number 0 0
Output format 0 0
Display format 0 0
High and low limits of engmeenng quantity 0 0
Low limit of set range 0 0
High limit of set range 0 0
Span of set range 0 0
Engmeenng umt 0 0
Dampmg time constant 0 0
Low flow cutoff value 0 0
Burnout direction -
0
PROM No. - 0
Software ve rsiOn -
0
Sensor temperature -
0
Sealed liquid temperature correction function 0 0
Save settings
After changmg settmgs (values and states), save settmgs us mg this proced ure.
Remarks:

Settmgs (values and states) that are mput to the transmitter are automatically saved
after about 30 seconds. Not erased by switchmg OFF the transmitter.

NON -VOL
Press the ( ...~ J and fjt) keys, SHIFT-

m that order.
DSTJ FIT-1234
READY. ..
• The data has been saved m the DSTJ FIT-1234

transmitter ACTION PRINT?

4-5-2: Displaying or changing tag number

-
Procedure
Display or change the tag number usmg this procedure.
Here, the procedure to change FIT-1234 to ACV-5678 as m this example.
Turn ON the power swttch of the

SFC. ILOOP IN MANUAL?
J,
IPRESS 10
NON-VOL
NON-VOL
Press the key
2 DE READ
Press the GJ key
DE READ
I TAG No.
GJ Branch:
• If no change reqmred to the tag
WORKING. ..
DSTJ TAG No.

number press the ( 1c,::, J key LIN DP EIT-1234
DSTJ FIT-1234
READY. .
3
GJ ,(~Ofj' J,
DE READ
8DE READ
Press the ( ALPHA ) ,
and [ DAM~) keys, m that order.

DSTJ
LIN DP
TAG No.
ABC-1234
0 Remarks:
After an mput error, return the
B F cursor by pressmg the (
6
A+-+ DE
ALPHA) and
B
the keys, m that order.
Press the ( AlPHA ) key agam and

mput the correct keys.

4 TlME
'l.:) keys,
EJ
TIME
Press the [ ALPHA) and (
m that order
DSTJ
LIN DP-
TAG No.
ABC-1234
~
5
0 ' ~ ' [3 and
~
Press the DSTJ TAG No
G::J keys, m that order. LIN DP ABC-5678
FEED
[~l
0
FEED
0
6 NON-VOL
NON-VOL
Press the keys. DSTJ TAG No.

WORKING. ..
DSTJ TAG No.

LIN DP ABC-5678
7
Press the ( SHIFf J and keys, SHIFT-
m that order.
NON-VOL
DSTJ TAG No.

WORKING..
The data 1s saved m the
transmitter
DST J ABC-5678
DATA NONVOLATILE
J,
DSTJ ABC-5678
READY. ..

...,4-5-3:
__..,.,,..,-...,_Display
.....wm.-.,...,..,a,......,or
__ change output
_,.....,._....,jjj._....., format
________ ,_____ ~~.~~
Introduction
This functiOn works for flow rate measurement.
Flow rate IS proportional to the square root of the differential pressure ansmg at a
contractmg mechanism. Flow rate IS also proportional to the transmitters output
differential pressure. In the linear format, differential pressure IS converted to
electncal signals and output, without further processmg. In the square root format, the
square root of the differential pressure IS calculated m the transmitter, and the result
output.
Display or change the currently-selected format by key operatiOn.
When square root 1s selected, set low-flow cutoff value, flow rate mode, and dropout
format. Refer to 4-5-7 ..
Procedure
Display or change the output format (linear/square root) ofthe transmitter usmg th1 s
procedure:
Step Key Descnptton SFC screen
Press the ( ~] key
0 DSTJ
CONFORM
CONFIG
2 NON .VOL
NON-VOL
Press the key

I CONFORM
LINEAR
(Lmear)
or
D1splay the currently selected CONFORM

output format (linear or square SQUARE ROOT
root).
(Square root)
3 Branch:
• If no change reqmred to the
OE CONF.
format, press the (~o:·) key and

proceed to <step 4>
• If no change reqmred to the
format, press the ( ,c~, ) key
tWICe.

4 NON-VOL
NON-VOL
Press the ~ key CONFORM
ENTERED IN SFC
CONFORM
. LINEAR
I
5 Press key
I CONFORM
WORKING. ..
6 NON-VOL
NON-VOL
CONFORM
. WORKING
I
Changes the output format to CONFORM
linear or square root. DATA LOADED'
7 Press r=1 key

r:::l l=.J DSTJ FIT-1234
~ WORKING. ..
8
Press the [ .",.,.:-) and keys m SHIFT-
that order.
NON-VOL
DSTJ FIT-1234
WORKING. ..
DSTJ FIT-1234
• Saves the data m the DATA NONVOLATILE
transmitter.

4-5-4: Display or change indicator display format

(Flow rate I Linear I Display flow rate)
~ X ""i"'M"fi ge at m:. • ~ ~~~~
Introduction
This functiOn enables displaymg or changing the display format, of the mdicator.
• When the output format IS square root, the display format IS fixed to flow rate
(FLOW).
• When the output format IS LINEAR, select either LINEAR or DISP FLOW for the
display format.
-Note Dzsplay flow rate. In some cases, for processmg by hzgher level eqwpment.
the reqwred output format of a transmztter zs linear select flow rate can be
selected for the mdicator displayformal when the transn1111er outputformat
zs linear
-Note For detazled znformatwn on the mdicator, refer to 3-8.
Procedure
Display or change the display format (linear I display flow rate) of the transmitter
mdicator usmg this procedure: ·
Press the ( ~f J key

DSTJ CONFIG
CONFORM
2 Press the key

DSTJ CONFIG
DISPLAY?
3 NON-VOL
NON-VO L
Press the DISPLAY CONF

FLOW
(Output fo1111at: Square)
DISPLAY CONF
LINEAR
or (D1splay format: Lmear)
Displays the currently-selected DISPLAY CONF

display format (flow rate, linear DISP FLOW
or display flow rate).
(D1splay format: D1splay fl ow rate)
ST3000 Ace - Smart Transmitter Electromc Different ial Pressure Transmitter 4-31
4 Branch:
[EJ If no change reqmred to the

format, press the ( 1",!;,"1 ) key
DECONF
~
tWICe.
To change to the format, press
OECONF.
the (~u ' J key, and proceed to the

next step.
* 1) When the output format IS
square root, the display format
cannot be changed from flow
rate (FLOW).
5
5 1key
NON. VOL
NON-VOL
Press the DISPLAY CONF
ENTERED IN SFC
DISPLAY CONF
DISP FLOW
6 Press the (M key several DISPLAY

times, or press the ( 1c;_•, Jkey DOWN LOAD DATA?
7 NON.VOL
NON-VOL
Press the ~ key
IDISPLAY
WORKING. ..
• Changes the display format to DISPLAY

linear or display flow rate. DATA LOADED!
DSTJ CONFIG
DISPLAY?
8 Press the (~~~ )key

DSTJ FIT-1234
READY. ..

EJ
NON-VOL
Press the ( ."'~ Jand
that order.
keys m SHIFT-
DSTJ FIT-1234
WORKING..
• Saves the data m the DSTJ FIT-1234

transmitter. DATA NONVOLATILE
DSTJ FIT-1234
READY. ..
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter 4-33·

4-5-5: Display or change indicator display format

(Engineering unit I 0/o)
~~~~-----------------------------------------------..-----.m-.ma-.-
Introduction
This functiOn enables displaymg or changmg the display format (engmeenng umt or
%) ofthe mdicator.
Procedure
Display or change the display format (engmeenng umt I%) of the mdicator usmg this
procedure:

NON.VOl
Press the ( .coJ),

B · ,~)and
keys, m that order.

DISPLAY TYPE
% (0 0)
or
Displays the currently selected DISPLAY TYPE
NON-VOL
display format (engmeenng umt ENG. UNIT (4 .5 FIG)
or%)
2 Branch:
rc:l If no change reqmred to the
~ format, press the ( ,c.;,•1 ) key
(Twice) twice.
To change the format, press the
DE CONF.
[:') key, and proceed to the

next step.
3 NON-VOL
NON.VOL
PLAY TYPE
ENTERED IN SFC
DISPLAY TYPE
% (0 0)

4 Press the key several

DISPLAY
times, or press the ( ,c~•, ] key DOWN LOAD DATA?
((7.l)
~
5 NON-VOL
NON-VOL
Press the ~ key
I DISPLAY
WORKING. .
Changes the display format to %
or engmeermg umt.
DISPLAY
DATA LOADE!
DSTJ CONFIG
DISPLAY?
6 Press the (~~~)key
~
DSTJ FIT-1234
)
READY. ..
7 NON-VOL
Press the ( ...~ ) and

B
keys, SHIFT-
m that order.
NON-VOL
DSTJ FIT-1234
WORKING. ..
Saves the data m the transmitter. DSTJ FIT-1234

DATA NONVOLATILE
DSTJ FIT-1234
READY. ..

4-5-6: Display or change high and low limits of

engineering quantity
~~~E~~----------------------------------~--------aaas.ae.ammmnw--
Introduction
This functiOn IS effective only when engmeenng umt IS selected for the mdicator
display format. Enables settmg of the htgh and low limits of flow rate display, m
engmeenng quantity (engmeenng umt).
Procedure
Display or change the high and low limits of engmeenng quantity, which IS displayed
on the mdicator, usmg this procedure:

NON-VOL
Press the [ COH"f) , and DISPLAY TYPE

ENG. UNIT (4.5 FIG)
keys, m that order.
• Check that engmeenng umt IS

NON-VOL
selected.
2 Press the key

EULO (at 0%)
0 0000
• In <step 4> and <step 5>, set -
10.0 for the low limit of
engmeermg quantity

Step Key Desert phon SFC screen
3
GJ,0 ·
TIME A CT PR
TIME
Press the ( 'l.:] , EULO (at 0%)
~ O
SCR PAD
and 0
ACT PR
keys, m that
-10 0
[2]
ACT PR
order.
GJ
SCR PAD
0ACT PR
G
4 NON-VOL
Press the key EULO (at 0%)
ENTERED IN SFC
• The low limtt of engmeenng EULO (at 0%)

quantity (-10.0) has been set -10 0
5
Press the f~~· key EUHI (at 100%)
60.0
• In <step 6> and <step 7>, set
50.0 for the high limit of
engmeenng quantity
6
0 ,GJ,0 ACT PR SCR PAD
l0
ACT PR
Press the
GJ keys, m that order.

ACT PR
and EUHI (at 100%)
50.0
0SCR PAD
c:J
ACT PR

7 NON-VOL
Press the key EUHI (at 100%)
ENTERED IN SFC
• Set the high limit of EUHI (at 100%)

engmeenng quantity (50.0). 50 0
8 Press the key

DISPLAY
DOWN LOAD DATA?
NON-VOL
Press the key
I DISPLAY
WORKING. ..
• Changes the high and low DISPLAY

limits of engmeenng quantity DATA LOADED!
to the set values.
DSTJ CONFIG
DISPLAY?
9 Press the [ t~,) key
O:D )
DSTJ
READY. ..
FIT-1234
10 NON-VOL
B
NON-VOL
Press the ( .",.t Jand
that order.
keysm SHIFT-
DSTJ FIT-1234
WORKING ...
• Save the data m the transmitter. DSTJ FIT-1234

DATA NONVOLATILE
DSTJ FIT-1234
READY. ..

4-5-7: Display or change low flow cutoff value

- · - ~
Introduction
This function IS effective only when square root IS selected for the output format.
When the flow rate falls below a fixed value (valid range of low flow cutoff value: 0 to
20%), the flow rate IS processed as zero.
Also, a dropout format (linear/zero) and a flow rate mode (DEFAULT I EXPAND) can
be selected.
Linear Square root

(Cutoff value: default value)
Output Output
Input Input
Square root
(Cutoff value: Any set value)
. D_r_o_p_o-
I - ut_l_in-e-ar--.1 . -0-ro_p_o-ut_z_e-
I - ro---,
Output Output
Cutoff value Cutoff value
Input Input
Flow rate mode

DEFAULT Ordinarily, thts mode IS selected, m most cases.
EXPAND · This mode IS selected when the range IS expanded. For example. when
the range ts set near the normal flow rate, or when reverse flow rate
output must be obtamed usmg a reversible onfice.
Figure 4-4 Relatronshrp between rnput and output(%) determmed by low.flow cut-
off value settzng
-Note Flow rate mode

DEFAULT Ordinarrly, thrs mode I S selected, rn most cases.
EXPAND · Th1s mode IS selected when the range rs expanded. For
example, when the range IS set near the norma/flow rate, or
when reverse flow rate output must be obtarned usmg a
reversible orifice.

Overv1ew
This sectiOn explams the mamtenance of the ST3000 Ace and a range of mterestmg
ways to ensure that your transmitters performance goals may be contmuously met
dunng Its operatmg life.
Instructions for savmg data m this transmitter, disassembly and assembly procedures,
output checkmg and calibratiOn procedures, and troubleshootmg procedures.
At the start of operatiOn or dunng operatiOn, deal with performance problems by
followmg these procedures. If you cannot fix the problem, It IS possible that there IS a
problem with the product Itself and you should contact your Yamatake representative
Immediately

Mamtenance and trabouleshooting Yamatake Corporation
5-1: Zero adjustment
5-1-1: Overview
~-----------------------------------------------------------------n.a.-.=
Introduction
Zero adjustments can be classified as:
Calibratmg the zero pomt based on the current mput value
2. Settmg the set range (LRV /URV) based on the current mput value.
Items for adjustment

The two adjustment methods are clearly delineated, below. ExplanatiOns of these
procedures are found , on subsequent pages.
Zero adjustment for use under umform pressure (with SFC)
Balance adjustment usmg sealing liqmd (with SFC)
Zero adjustment for use as a level gauge (with SFC)
Zero adjustment usmg an external zero adjustment mechamsm (optiOn)

Yamatake Corporation Mamtenance and trabouleshooting
5-1-2: Zero adjustment under uniform input pressure

(with SFC)
EBHMDRmrrmmm·--------------------.a-..-a.--------------------------~W&M~WMU-~~·~~~
Pomt
When a transrrutter IS used, change the applied mput pressure to uruform pressure
before performmg zero adjustment. In some cases, factors such as the mountmg
posture of the transmitter prevent mdicat10n exactly at 0%. Perform zero adjustment
usmg these procedures. However, the zero pomt may also be correctly adjusted by
changmg the transmitters onentatwn.
Procedure ·
Calibrate the zero pomt based on the current mput value.
The current mput value as zero umform pressure IS the differential pressure that IS
applied to the sensor due to the mfluence of mountmg posture, etc.
Rewnte the factory set zero pomt calibratiOn data. This operatiOn does not change the
LRV or the URV If the current mput value exceeds 3 125% of the transmitters
measurement range (URL-LRL), a warnmg message(* 1) for this operatiOn IS
displayed.
Key-pad operatiOns:
INPUT RESET NON-VOL
0 10 kPa
Detailed procedures usmg an SFC as found m "3-3-1-1 PreparatiOn for measurement'·

on page 3-12.
NON-VOL
* 1 Press the key after display ofwarnmg message CalibratiOn value over OK?
Zero calibratiOn normal # IS displayed.

5-1-3: Zero adjustment based on input pressure

corresponding to LRV (with SFC)
~~~=--rrm-=m=
---..-.-.-------BUMW.--------------.----~•-.---..-~a.-.._.-~
Pomt
Even If a transmitter Itself has a correct zero pomt under umform pressure, It
sometimes does not output zero due to unbalanced sealing liqmd m the connectmg
pipe. Adjust the balance usmg these procedures.
Perform this adjustment after ensunng that the sealing liquid level IS sufficiently high
for ordinary measurement state.
Procedure
. Set the LRV (low limtt of range corresponding to 0% output) based on the current
mput value
The current mput value, whtch IS the differential pressure applied to the sensor, should
be set for the LRV Without changmg the span, this settmg automatically changes the
LRV and the URV The factory set zero pomt calibratiOn data IS not rewrttten.
(Example) Current mput value= 0.025 kPa, LRV = 0 kPa, URV = 10 kPa
The result of the key-pad operatiOn will be, as follows :
LRV = 0.025 kPa, URV = 10.025 kPa
Key-pad operatwns:
NON-VOL
0 10 kPa
Detailed procedures usmg an SFC are found m "3-9· Zero-span adjustment With mput
5-4 ST3000 Ace -Smart Transmitter Electromc Differential Pressu re Transm itter
Yamatake Corporation Maintenance and trabouleshooting
5-1-4: Zero adjustment based on actual level (with SFC)

i!Nihd. li!J W 'f!d'iiW~ smm tt'i"'" PI" M I 1 I bm:iC~5ti4XS!Hk
Po1nt
When a differential pressure transmitter IS used as a level gauge, the zero pomt can be
adj usted by either one of two methods. In both cases, adjust the zero pomt by changmg
the LRV and the URV Refer to 2 Settmg the set range (LRV /URV) based on the
current mput value m " 5-1-1 Overview" The factory set zero pomt calibratiOn data 1s
not rewntten.
Method 1
Set the LRV by settmg the current mput value for 0%.
Mamtam same liquid level for which 0% IS the output. Set the zero pomt based on this
mput value.
Example: Current mput value = 0.025 kPa, LRV = 0 kPa, URV = 10 kPa
The result of the key-pad operation will be as follows :
LRV = 0.025 kPa, URV = I 0.025 kPa
Key-pad operations:
NON·VOL
0 10 kPa
Detailed procedures usmg an SFC are found m "3-9 · Zero-span adjustment With mput
pressure eqmvalent to range" on page 3-5 2.
Method 2
Set the LRV by settmg the current mput value for the specified value
Example: When the transmitter output IS 35%, 1t can be adjusted to the
current liquid level (e.g. 40%) obtamed with a level gauge,
usmg these key-pad operatiOns.
LRV = 0 kPa, URV = I 0 kPa are changed to LRV = 0.5 kPa,
URV = 10.5 kPa
Key-pad operatiOns:

INPUT NON-VOL
0 10 kPa
Detailed procedures usmg an SFC are found m "3-8. Zero-pomt adjustment--- Based
on actual liqmd level" on page 3-50.

5-1-5: Zero adjustment using external zero adjustment

mechanism (option)
iilt!lll ~& • M fiiASW " -=z- "i~li!RIS· ii!"W~~~
Pomt
2. Settmg the set range (LRV /URV) based on the
current mput value m 5- 1-1 Overview apply to
zero adjustment usmg an external zero adjustment
mechamsm. Therefore, the LRV and the URV are
automatically wntten by this operatiOn. The
factory set zero pomt calibratiOn data IS not
rewntten.
0 10 kPa
The adjustmg procedure IS found m ''3- 10· External zero adjustment (option)" on
page 3-54
ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter 5-'7

5-2: Saving and restoring data
5-2-1: Saving data

"
Introduction
Save the set values and states and other data stored m th1s transmitter to the SFC.
Restore data to other transmitters.
This function ts useful when replacmg a transmitter. It saves mput work and prevents
key-pad errors.
An SFC has memory capacity for one transmitter only Restore all data to a
transmitter, before savmg data from another transmitter.
Note that the data saved usmg this procedure IS erased by turnmg off the SFC .
Always restore data to a target transmitter, before turnmg off the SFC.
Procedure
How to save data:
1 DE READ
Press the GJ key
DE READ
DSTJ TAG NO
0 LIN DP FIT-1234
2 Press the [ CONfj key

DSTJ CONFIG
CONFORM?
3 Press the key to display

DSTJ CONFIG
the screen shown, on the nght. SAVE/RESTORE
4 NON-VOL
Press the key SAVE/RESTORE
SAVE DATA?

5 NON-VOL
Press the key SAVE DATA
WORKING...
SAVE DATA
DATA SAVED
• Savmg has been completed. DSTJ CONFIG

• Release the save mode by step SAVE/RESTORE?
6.
6 Press the ( 1c,:-:. ] keys.

r=::=l DSTJ FIT-1234
~ The save mode IS released. READY. ..

Maintenance and trabouleshooting Yamatake Corporation
5-2-2: Restoring data
Procedure
How to restore data:
1 DE READ
DE READ
Press the ~ key DSTJ TAG NO
Q LIN DP FIT-1234
2 Press the ( ~r) key

DSTJ CONFIG
CONFORM?
3 Press the key to display

DSTJ CONFIG
the screen shown, on the nght. SAVE/RESTORE?
4 NON-VOL
NON-VOL
Press the ~) key SAVE/RESTORE
SAVE DATA?
5 Press the ~ key

SAVE/RESTORE
RESTORE DATA?
6 Press the ( 1c;:, ) keys.

@] )
• The save mode 1s released.
RESTORE DATA
WORKING. ..
J,
• Restonng has been completed. RESTORE DATA

Release the restore mode by step DATA RESTORED
7
7 Pr<;:ss the ( r::, J keys twtce.

[B )
• The restore mode has been
DSTJ
READY. ..
FIT-1234
released.

5-3: Recovery of calibration data/ Status

Record.(New functions)
Introduction
You can use the followmg functions by usmg the new commumcator "CommPad"
• These functwns are effective later than Ver.B.6 of the transmitter's software version.
• To operate these functions, please connect the CommPad.
• The followmg shows the methods of operatmg CommPad.
-Note Please connect the Commpad by the method of "3-1 -1 Connectzng SFC "
Please refer to "CM2-CFN100-2001 Smart Field Commumcator CommPad

(Common Editwn)User's A1anual" and "CM2-CFNI00-2002 Smart Field
Commumcator CommPad (Smart Transmztter Editwn) to confirm the
detailed startmg and operatwn method"
&cAUTION
• Make sure that the controller m the control loop IS m manual mode before startmg
commumcatwn. When you tap on "Start," the CommPad starts digital
commumcat10n to the connected mstrument by generatmg an alternatmg current
signal (4 mA/20 rnA).. If a control valve IS connected m the control loop, a
malfunction may result. Please be extra careful.
• Return to Factory Preset: Revert the caribrated data to the value calibrated
at the factory
Status Record: Displays status record saved m the Transmitter.
• Load Zero Calibration Record: Displays the zero calibration record ms1de the
CommPad saved when zero calibratwn of the
Transmitter IS performed on the CommPad.
• Zero Calibratwn Data m Device: Displays the zero pomt calibratwn data saved m
the Transmitter.

- --
5-3-1: Return to Factory Preset
(1) At the "Summary screen" ofthe CommPad, tap on "Return to Factory Preset"
-
Correct Input (zero)
CorrectlRV
CorrectURV
IReturn to Factory Preset I

Reset Conections
OUTPUT -0.02 %
INPUT
<Back
Home
Exit Lov Help Aux.
(2) The confirmatiOn message appears. Tap on "Yes."
ST3000 DP
ABC-001
CommPad
-
? 1 Return to Factory Preset.
····-~{ .. Are you sure?
~~No
OUTPUT %
.------;
INPUT ....
Exit Lov Help Aux.
(3) Calibrated data IS Retured to Factory Preset.

5-3-2: Status Record

You can confim1 the status message that occurved m the past. (It IS di splayed only the
message, not displayed the number of times.)
Table 5-l status message and meanmg
Status message Mean~ng
Invalid database Configuration data and/or calibration data 1s corrupt.
Chara. PROM Fault PROM Function Fault
- Input data error

Suspect Input - Problem 1n the process
- Transmitter Fault
Status
MDU/DAC Fault Electronic parts fault
NVM Fault Electronic parts fault
RAM Fault Electronic parts fault
ROM Fault Electronic parts fault
Meter Body Over

Meter body temperature 1s too h1gh.
Temperature
The Zero correction factor IS outs1de the acceptable limits

Excess Zero Correct
for accurate operation.
Non- The Span correction factor 1s outs1de the acceptable limits

Excess Span Correct
for accurate operation.
critical
status · The mput pressure exceeds two times the upper range
Meter Body Overload or
limit of the transmitter.
Meter Body Fault
- The transmitter fault
Correct Reset Calibration data 1s Initialized .
External Switch Fault External switch fault

At the " Summary screen" of the CommPad, tap on "Conf" ~ "Mamtenance" ~

"ConditiOn Record", You can see the followmg display
( 1) To display the previOus records of the status of the Transmitter, tap on the "Status
Record" button.
I Load Zero Calibration Record

IZero Calibration Data in Device I
Status Record
(2) The previOus records of the status appear on the screen.
Status History
Suspect I nput
-critical Status History
t··lete Body Over Temperature
t··leter Body Overload
O,· r·4eter Body Fau
Co ect Reset
Save
Home View
Exit Log Help Aux.
For more mformat10n on the messages, see "6. Troubleshootmg."

Some of the messages m "6 . Troubleshootmg" will not be recorded as Status
Record.

(3) If no cntlcal failure or mstrument status occurred m the past, "None" appears on
the screen as below.
. .. ·'· - ..
.... :..-'•.- .-
pT3000 DP
XXXX63
0
~it1ca lStatLs H;storv
None
Non-critical Status Histo:y
N-one
<Back
I Read I Clear
I Save
Home (summary( Conf.

l V"eew
Exit Log Help Aux.
(4) By tappmg on "Save," you can save the displayed data. The fi le to be saved IS
automatically named. Tap on "OK" without changmg anythmg.
=·~~_:(~·:-·; ~.:.:.·-~: ~"" ',
.. ~ . ! . ~ .
Name: jmJ!f!f.i!f!'!f:.m•~I•!FB~"!~ 1
Folder · ICPadDiag DstJ ,..I
T ')•pe : IVlew File (*txt) ,..I
LocatioJ : IMam memor~' ,..I
OK
II Cancel
I

The name of an automatically-named saved file 1s composed as follows :

D_(PROMID)_(tag name)_(year/monthlday/hour/mmute).txt
If either of the followmg 2 characters that cannot be used m a Windows file name
1s contamed m the tag name, the character(s) will be converted automatically as
follows:
" "(dot)~"_" (underscore)
" I " (slash)~" - " (tilde)
(5) Tap on "ok."
4
CommPad ~
-
• file name
1
- -.j D_2561426400_XX)OOU(XX_
200604271542.txt was
saved.
<Back save
Home V'aew
Exit Log Help Aux.

·(6) To clear the status record, tap on the "Clear" button. The "Save" screen appears. If
you need to save the data before cleanng It, tap on "Yes." If you do not need to
save the data, tap on "No." The confirmatiOn message will appear. Tap on "Yes."
, . ·\ Save before data dear Are

~~j -J'you sure7
I Yes II· fto
< Back
Home V'tew
Exit Log Help Aux.
(7) The data of the saved list file can be copied to your PC and viewed on the PC. You
can read the file wtth a text editor or other software.
The data will look like the example shown below.
Status Record
2006/05119 08.38
Cntical Status History·
Chara. PROM Fault
Suspect Input
ROM Fault
Invalid Database
Non-cntical Status History·
Meter Body Over Temperature
Meter Body Overload
Or Meter Body Fault
Correct Reset
ST3000 Ace --Smart Transmitter Electromc Differential Pressure Transmitter 5-17

5-3-3: Load Zero Calibration Record

·-~----------------------------------
At the "Summary screen" of the CommPad, tap on "Conf' ~ " Mamtenance" ~
"ConditiOn Record", You can see :the followmg display
(I) To display the record of the zero calibratiOn amounts saved mside the CommPad,
tap on the "Load Zero Calibration Record" button.
Load Z-ero calibration Record
IZero calibration Data in Device I

status Reccrd
<Back
Home V'tew
Exit Log Help Aux.
(2) Saved data appears on the screen. The calibrated amounts at the zero pomt agamst
the maximum value of the set range (URL) for each mstrwnent are displayed m
percentage terms.
Each value shows how much the calibrated value shifted from the value at the fac-
tory
'
.. ' -- ;
''1 • • ~ . --
~T3000 DP
!xJ:XXXX63
M) I StabJs I0
URL 99.64 lkPa ... I
1 06/04/12 16.17 1.05 %of URL
2 06/ 04/10 17:15 0.88 % ofURL
3 06/04/06 10:15 0.08 % of URL
4 06/04/ 04 12:14 0.05 %ofURL
<Bad I Graph
I I Dekt:e
Home ISummaryl Conf.

I V'eew
Exit Log Help Aux.

(3) To change the display to a graphical form , tap on the "Graph" button .
..
.&-~·~-·:(.: ~~---~ .~ ..
- ··J •
ST3000 DP
XXXXXX63
1---------------
-5~·~
-7"·o L...__ _ _ _ _ _ _ _ __~
-+t
..-,-D-at-a__,, I Scale
Home Summary! Conf. I V"tew
Exit ~ Help Aux.
(4) Tappmg on the "Scale" button will change the scale according to the maximum
value of the data .
•r
:JT3000 DP
63
~ 0 c,;
. .,
URt
:: ~c
...: ~
.. IStatuS 10
~-
---~
• r--
- 2 ~··c
-+t
I Data
I I 'Scale
Home Summary! Conf. I V"rew
Exit ~ Help Aux.

(5) You can delete data. Tap on the data you want to delete to highlight tt, and tap on
the "Delete" button.
URL 99.64 l._kP_a_ _ _....

__,l
1 06/04; 12 16:17 1.05 % ofURL

2 06/04 f 10 17:15 0.88 %of URL
3 06/()4.'06 10:15 0.08 %of URL
4 06/04/ 04 12:14 0.05 %of URL
<Back
I Graph I I Delete
Home ISummaryI Conf.
I V"tew
Exit Log Help Aux.
(6) The confirmation message appears. Tap on "Yes."
: 7 ·~, Delete'06/04/ 06 10:15

·- . ~.f ./ 0.08 q,c, of URL'.Are you
sure?
4
<Back Delete
Home V"tew
Exit Log Help Aux.

(7) The data IS deleted.
URL ~9.64 IkPt> ..-1

L . . __ _ _ _ _ _ .
1 0.;,/04/ 12 16. 17 1.05 O,i;. of URL

2 06:'04,:1CJ 17: 15 0. 88 C;·~. of LtRL
J 06/04,:04 12: 1.::. 0.05 c:,.~ of URL
Dclete
Home View
Exit Log Help Aux.

5~3-4: Zero Calibration Data in Device

~---a~.-----------------------------------------------am-.-.wa~mNmr.
At the "Summary screen" ofthe CommPad, tap on "Conf' ~ "Mamtenance" ~
"Conditwn Record" , You can see the followmg display
(1 ) To display the record of the zero calibratiOn amounts data saved m the Transmit-
ter, tap on the "Zero CalibratiOn Data m Device" button.
I Load Zero Calibration ~ord

IZero CalibratiOn Da'ta in ·DeVice I
Status Record
<Bad.
Home
Exit Lug .Help Aux.
(2) You can save up to five different data sets.
URL 99 .64 jkPa ·I

1 {latest} -0.22 % of URL
2 -0.22 %ofURL
3 -0.22 %ofURL
4 -0.22 % ofURL
5 -0.22 c,t, of URL
<Bade Save
Home View
Exit Lug Help Aux.

(3) By tappmg on "Save," yo u can save the displayed data:

The file to be saved IS automatically named. Tap on '·'OK" without changmg any-
thmg .
. '
.. :~'
. . . .
, •
...r· .. ,
f ...... _, . ~ ~ ·:
• :.,.,. - • ";. .. ~ .... 4~' ..... ' ' •
Save As
Name:
Folder · lcPadlntCorrDstJ .... 1
Type : !View File (*b..1:) .... 1
Locati01 ·: IMam memory .... l

OK II Cancel I
The name of an automatically-named saved file IS composed as follows:

IC _(PROMID)_(tag name )_(year/month/day/hour/mmute ). txt
If either of the followmg 2 characters that cannot be used m a Windows file name
IS contamed m the tag name, the character(s) will be converted automatically as
follows:
" "(dot)~"_" (underscore)
" I " (slash)~" ~ " (tilde)

· (4) Tap on "ok."
u CommPad ~
i- · 1 file name __.......

- -<.~ ,., IC_2349331500_XXXXXX63
_200604 181657.txt was
saved.
4 -0.22 % ofURL
5 -0.22 %of URL
<Bade Save
Home
Exit Log Help Aux.
The data of the saved list file can be copied to your PC and viewed on the PC. You
can read the file with a text editor or other software.
The data will look like the example shown below.
Zero CalibratiOn Data m Device

2006/05/19 08.37
1(latest) -0.21 % of URL
2 -0.21 % ofURL
3 -0.23 % ofURL
4 -0.23 % ofURL
5 -0.22 % ofURL
5-24 • ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter

5-4: Disassembly and assembly
5-4-1: Before you start

M" Wmll& 18 T C
~WARNING
• Never open the case cover while this transmitter I~ ON m a hazardous locatiOn
(specified m "2-1-2: Environmental conditiOns for explosiOn-proof transmitter"
on page 2-3).
• Handle wtth special care explosiOn-proof pressure transmitter. If may lose Its
explosiOn-proofing performance due to corrosiOn, deformatiOn, or damage of the
case or the cover or damage to a screw or a Jomed part.
• The explosiOn-proofing performance of a explosiOn-proof pressure transmitter IS
not guaranteed unless It IS LOCKED Always tighten the case cover completely,
and lock the case cover.
Dismount and mount the case cover

This transmitter has a lockmg structure. Before dismountmg the case cover, unlock the
mechamsm usmg a hexagonal wrench (included).
When remountmg, msert the case cover fully and lock It, usmg a hexagonal wrench.
~CAUTION . : ;·
' ' '
• After mountmg the case cover, ensure that no dust or ram gams mgress mto the
transmitter case.
Loc k
Figure 5-1 Lockmg case cover

5-4-2: Dismount/Mount Center body cover (Model JTD/

JTG/JTA/JTC)
.. .
~------·-.-..-.-maa.-----.•••---------..----.-..----.-.-aa•rr••m•._ ww~.-~.---~.-~-
Dismount cover
Remote the four sets of bolts and nuts, shown m the illustratiOn.
Remarks:
After dismountmg, handle the center body cover carefully AvOid damage to the
diaphragm.
Figure 5-2 Center body cover jixzng bolts
When mountmg the center body cover, tighten the bolts to the followmg torque.
Replace the seal gasket, If It IS damaged.
Mount cover
Cover bolts/nuts and tightenmg torque
Bolts/nuts tightenmg torque (N.m)

Bolts/nuts
Model No. Bolts I Nuts
- matenal W hen new W hen ex1stmg
gasket 1s used gasket IS reused
JTD910A MIO SUS304 15 ± 1 10 ± I
JTD920A M10 Carbon steel
22 ±2 17 ± I
JTD930A SUS630
SUS304 15 ±9 10 ± I
JTD960A Ml2 Carbon steel
45 ±2 30 ± 1.5
SUS630
SUS304 35 ±2 20 ± I

Bolts/nuts tightemng torque (N.m)

Bolts/nuts
Model No. Bolts I Nuts When ex1stmg
matenal When new
gasket IS used gasket IS reused
JTD921A M16 Carbon steel -

90±2
JTD931A SUS630
JTD961A
SUS304 55 ±2 -
JTG940A M10 Carbon steel

22 ±2 17 ± I
JTG960A SUS630
(Side, up/
SUS304
down 15 ± 1 I0 ± I
connectiOn)
JTG980A Ml6 Carbon steel
90±2 90 ±2
(Side, Up/ SUS630
down
SUS304 55 ±2 55 ±2
connectiOn)
JTA922A MIO Carbon steel
22 ±2 17± 1
JTA940A SUS630
SUS304 15 ±1 10 ± 1
JTC929A MlO Carbon steel
22 ±2 17 ± 1
SUS630
SUS304 15 ± 1 10 ± 1

5-4-3: Washing the sensor
Introduction
The transmitter and Its mountmg pipes must be kept clean to mamtam transmitter
accuracy and to assure satisfactory performance. Deposits accumulatmg m the
pressure chamber of the transmitter will result m measurement errors.
Rinsmg the center body (model JTD/JTG/JTA/JTC)

Rmse the center body followmg this procedure:
( 1) Remove the hexagon head bolts from the center body and remove the cover.
(2) Wash the diaphragm and the mner surface of the cover With a solvent and a soft
brush. Take sufficient care to avoid or damagmg the diaphragm.
(3) When reassembling the center body, replace the cover gasket w1th a new gasket as
necessary
(4) Tighten the cover bolts to the specified tightenmg torque. (Refer to "5-4-2: Dis-
mount/Mount Center body cover (Model JTD/JTG/JTA/JTC)")
Mamtenance m cold reg1on

If you stop the mamtenance operation after measunng a liqmd that can freeze such as
water, dram water from the center body (by loosenmg the dram plug).
Mamtenance of sensor
The sensor does not need any special routme mamtenance/inspectwn. When the flange
IS removed dunng mamtenance, wash the diaphragm usmg a soft brush and solvent.
Take sufficient care to avmd damagmg the diaphragm .

5-4-4: Remodelling for High-load resistance external

meter
Introduction
Yamatake NW35 , NWS300 IS a htgh-load resistance external meter. When connectmg
an external meter oflugh-load resistance (not below 10 Wand voltage drop not below
200 mV) to thts transmitter, select a model number wtth
-B7 (optwnal spectficatwn).
If you modelts no -B7, replace 1t wtth an mdicator/termmal board assembly of -B7
specdicatwns, or remodel the mdicator/termmal board assembly
Replacement procedure
How to remodel or r:eplace the mdicator/termmal board assembly·
&cAUTION
• Never touch electromc parts on the electromcs module directly wtth hands.
Electromc parts are easily damaged by electrostatic effect. If It IS unavmdable to
touch electromc parts directly with hands, take necessary precautiOns. The
electromc parts and the hands should have an Identical electnc potential.
• After dismountmg the electromcs module, put It m a conductive bag to prevent
electrostatic damage.
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter 5-29,

Dismount term mal board assembly
Step Descnption
Turn off the transmitter.
2 Dismount transmitter case cover.
3 Disconnect signal cables from the termmals. Disconnect the condmt

pipe from the case. Pull out the signal cables from the case.
4 Remove the ground screw. Dismount the collar at the same time .
Ground screw
5 Remove the 3 screws that fix m place the termmal board.

Set screw
Set screw
6 Pull out toward you, the mdicator/termmal board assembly
&cAUTION
'
• Hold both ends of the display umt w1th fingers. Pull out
gently and Without any Sideways movement, the assembly
The flexible cable may be destroyed tf pulled With too much
force .

Step Descnpt10n
7 Of the 3 plastic plates that fix the circmt board, dismount the one next
to the connector (SPM connector).
SPM connector
Electronics module
Plate
Plate
g Remove the SPM connect to separate the mdicator/termmal board

assembly from the body
9 Dismount the remammg 2 plastic plates.
)
External zero c1rcuit board
ElectroniCS module
10 Dismount the electromcs module from the termmal.
II Cut jumper (WI) of the mdicator/termmal board assembly Or, replace

the assembly with an mdicator/termmal board assembly of -87
specificatiOn.
Before cutt1ng Wl After cutt1ng Wl
A
Wl

Step Descnptaon
12 Assembly the transmitter by reversmg the above procedure. Finally,

mount the cover on the transmitter case. more details on the next page.
• Always lock the cover.
& CAUTION
• Tighten the cover firmly Any looseness may result m water
mgress.
Assembly
Step Descnption
Mount the electromcs module on the mdicator/termmal board

assembly
2 Mount the two plastic plates that were dismounted latest.
• Ensure that the plates are securely fitted to the mdicator/termmal
board assembly
• Ensure that the plate groove IS securely engaged with the notch of the
electromcs module.
• If an external zero adjustment c1rcmt IS connected, ensure that It IS .
ms1de the claw of the mdicator/termmal board assembly
)
External zero c1rucuit board
ElectroniCS module
3 Connect the SPM connector to the connector of the electromcs module

and fix It With a plate, as shown m the illustratiOn.
• Ensure that the plates are securely fitted to the mdicator/termmal
board assembly
• Ensure that the plate groove IS securely engaged with the notch of the
electromcs module.
• Ensure that the SPM connector IS secure, and cannot be displaced.
~~ X
Step Descnption
4 Insert the mdicator/termmal board assembly mto the case

• Insert carefully without dismountmg the plate or catchmg the flexible
pnnted cucmt board (FPC) between the two.
5 Fix With 3 screws, the mdicator/termmal board assembly

• Tightemng torque: 12 ±0.1 N•m
Set screw Set screw
6 Insert the collar mto the ground screw. Tighten the screw.
• Tightenmg torque: 12 ±0.1 N•m
Ground screw
7 Connect cables to the mdicator/termmal board assembly
8 Check the operation and mount the cover.

S-5: Calibrating set range and output

signals
5-5-1: Overview
Some calibratiOn work must be performed by Yamatake or our authonzed service
provider. Generally, th1s work reqmres a high-preciSion reference mput device and
highly accurate measunng eqmpment. Such work IS not ordinarily performed by end-
users of Yamatake eqmpment. These mstruct10ns are provided for the benefit of users
who must perform calibratiOn work themselves.
Calibration mcludes mput calibratiOn (set range) and output calibratiOn (output
signals)
5-5-2: Calibrating set range based on reference input

IS:- --
5-5-2-1: Preparation
Introduction
The low limit (LRV) and the htgh limit (URV) of the set range are calibrated by
mputtmg reference pressure.
Calibrate the LRV and the URV, m that order
Equ1pment
Prepare the followmg eqmpment m advance of calibratiOn:
Standard pressure generator:Pressure generated must be close to the measurement
range of the transmitter.
• Accuracy reqmrement: ± 0.05% F.S or ± 0.1% settmg
• Power supply · 24VDC
• Precision resistance: 250 n ± o.005%
• Voltmeter Dtg1tal voltmeter w1th accuracy (1 OV DC range) of ± 0.02%
rdg + 1 dgt
• SFC
Calibration conditions
All ofthe followmg conditwns must be met, before performmg calibratiOn:
• A wmdless laboratory Wind will apply pressure to the pressure rece1vmg umt on the
s1de open to the a1r, mfluencmg the calibratiOn accuracy

Yamatake Corporation Maintenance and trabouleshooting
• Standard temperature of23°C and humidity of65%. Normal pressure range (15°C to
35°C) and normal humidity range (45% to 75%) are allowable, If no sudden changes
occur.
• Accuracy of the measunng equipment must be at least 4 times that of the transmitter.
Assemble the transmitter

Generally, cable and pipe the equipment, as shown below.
Open
the low-pressure
s1de to the a1r
Power supply
24V DC
Voltmeter
Figure 5-3 Cabling and plpmg eqwpment
Set range
Before startmg calibration work, use the SFC to check that the set range of the
transmitter agrees wtth the specificatiOns. If no agreement, use the SFC to set correct
range. Procedures are found m "4-5-8. Display or change low/high limits and span of
set range" on page 4-44.
The set range IS calibrated assummg that the low limit 20 k.Pa and the high limit IS 100
kPa.
5-5-2-2: Calibrate low limit
Procedure
How to calibrate the low limit value:
It IS assumed that the SFC and the transmitter have JUSt started normal
commurucatwns.

Example: Low limit value of set range: 20 kPa
Step Key Descraption SFC scr een
Apply pressure so that the

manometer of the standard DSTJ TAG NO
pressure generator mdicates 20 LIN DP FIT-1234
kPa.
2 Press the[·~·) key
~
. LRV FIT- 1234
• The low-limit value cunently .f.O 00 kPa
stored m the transmitter IS
displayed. It IS assumed that
the value ts 20 kPa
3 RESET
Press the key LRV FIT-1 234
CORRECT LRV?
4 NON-VOL
Press the key LRV FIT-1 234
ARE YOU SURE!?
NON-VOL
NON-VOL
WORKING. ..
• The low-limit value has been LRV FIT-1 234

calibrated to the current mput LRV CORRECTED
pressure to the transmitter.
• The low-limit value currently LRV FIT-1234
stored m the transmitter can be 20.00 kPa
confirmed.
5 NON-VOL
Press the [ .",;- J and e"

keys, SHIFT-
m that order
NON-VOL
DSTJ FIT-1234
WORKING. ..
• The calibrated low-limit value DSTJ FIT-1234

IS saved m the transmitter. DATA NONVOLATILE

5-5-2-3: Calibrate high limit
Procedure
How to calibrate the high limit value ..
Example: High limit value of set range: 100 kPa
Apply pressure so that the

manometer of the standard DSTJ TAG NO
pressure generator mdicates 100 LIN DP EIT-1234
kPa.
2 Press the (~:;)key

URV F URV FIT-1234
100% )] kPa
100 00
• The high-limit value currently
stored m the transmitter IS
displayed. It IS assumed that
the value ts 100 kPa
'"'
.)
RESET
CORRECT URV?
4 NON-VOL
NON -VOL
URV FIT-1234
ARE YOU SURE!?
NON-VOL
WORKING. ..
• The high-linut value has been URV FIT-1234

calibrated to the current mput URV CORRECTED
pressure to the transmitter.
• The htgh-limit value currently URV FIT-1234
stored m the transmitter can be 100 00 kPa
confirmed.

5 NON-VOL
Press the ( ...~) and -~ keys, SHIFT-

m that order
NON-VOL
DSTJ FIT-1234
WORKING. ..
• The calibrated h1gh-lim1t value DSTJ FIT-1234

1s saved m the transm1tter. DATA NONVOLATILE

5-5-3: Calibrate output signals

Introduction
Output signal calibratiOn (adjustment of the D/ A conversiOn umt) IS unnecessary
under ordinary operatmg conditiOns. Normally, this work IS performed by an
authonzed service provider of Yamatake. For end-users who must performed th1s
work, prepare the followmg equipment m advance of work:
Equ1pment
• High-preciSion ammeter w1th accuracy of 0.03% F.S. or higher
• Precision resistance: 250Q ±0.005%
• SFC
Setting up
Refer to Figure5-4 Connect a SFC and an ammeter.

Refer to " 3-2-1 Startmg commumcat10ns" Check connectiOns to ensure correct

connectiOn. Check that the SFC and the transmitter are m the normal commumcat10n
status.
High pressure
ammeter
I
Output check
Power supply
Power supply cable
20V DC
....___ _ _ _ ___J Prec1s1on
res1stance
Figure 5-4 Connectzon.for calibratzon
5-5-3-2: Calibrating output signal 0°/o
Procedure
Set the output to 0% and calibrate the transmitter so that the ammeter mdicates 4 rnA .
INPUT
WORKING. ..
(The current output IS displayed.) OUTPUT FIT-1234

000 %

2 ACT PR
ACT PR
Press the~ key OUTPUT TAG NO
G 0 %
3 NON-VOL
NON.VOL
OUTPUT FIT-1234
WORKING. ..
• The transmitter has been set to
the 4 rnA (0%) constant current
OUTPUT FIT-1234
mode.
0.00 % #
• # IS displayed on the screen
dunng the constant current
mode.
4 Ensure that the ammeter mdicates

4mA. OUTPUT FIT-1234
0.00 % #
5 INPUT
INPUT
OUTPUT FIT-1234
WORKING. ..
The current output IS 0%. OUTPUT FIT-1234

0.00 % #
6 RESET
Press the (flm key
RESET
DSTJ FIT-1234
• lfthe mdicated value IS lower CORRECT DAC ZERO#
than 4 rnA, go to <step 7> If It
IS higher than 4 rnA, go to <step
8>
7 Press the ~ key

OUTPUT FIT-1234
Check the ammeter mdicatwn WORKING. ..
after each key-press.
OUTPUT FIT-1234
INCREASED 4mA #
DSTJ FIT-1234
CORRECT DAC ZERO#

8 Press the key

OUTPUT FIT-1234
• Check the ammeter mdicatwn WORKING. ..
OUTPUT FIT-1234
DECREASED 4mA
OUTPUT FIT-1234
CORRECT DAC ZERO#
9 Press the ( ,c;:, J key after

r:::l DSTJ FIT-1234
~ completmg calibratiOn work. READY. ..
10 Refer to mstructwn m Item 4

Save the calibrated value and
release the constant current source
mode.
5-5-3-3: Calibrating output signal 100°/o
Procedure
Set the output to 100% and calibrate the transmitter so that the ammeter mdicates 20
rnA.
INPUT
WORKING..
OUTPUT FIT-1234
000 %

2
Q, G G
ACT PR ACT PR
8 ACT PR
Press the
keys (numenc key), m that order.
and OUTPUT TAG NO
I100
GACT PR
G
3 NON-VOL
NON-VOL
OUTPUT FIT-1234
WORKING. ..
• The transmitter has been set to

the 20 rnA constant current
OUTPUT FIT-1234
mode
100 00 % #
4 Ensure that the ammeter mdicates

20mA. OUTPUT FIT-1234
100 00 % #
5 INPUT
WORKING. ..
• The current output IS 100%. OUTPUT FIT-1234

100 00 % #
6 RESET
Press the key DSTJ FIT-1234
• lfthe mdicated value IS lower CORRECT DAC SPAN#
than 20 rnA, go to <step 7> If It
IS higher than 4 rnA, go to <step
8>

7 Press the
OUTPUT FIT-1234
• Check the ammeter mdicatJOn WORKING. ..
OUTPUT FIT-1234
INCREASED 20mA
OUTPUT FIT-1234
CORRECT DAC SPAN
8 Press the ~j key

OUTPUT FIT-1234
• Check the ammeter mdicatJOn WORKING. ..
OUTPUT FIT-1234
DECREASED 20mA#
DSTJ FIT-1234
CORRECT DAC SPAN
9 Press the ( ,<;:, ) key after

DSTJ FIT-1234
completmg calibratiOn work. READY .. #
10 Refer to mstruct10n m Item 4

Save the calibrated value and
release the constant current source
mode. '

5-5-3-4: Saving calibrated values and releasing constant current

source mode
Procedure
Forcefully save the calibrated value to non-volatile memory of this transmitter and
release the constant current mode:
Press the ( •"'~) key

B SHIFT- #
2 NON-VOL
WORKING. ..
DSTJ FIT-1234
DATA NONVOLATILE
• Forceful data savmg IS
completed. DSTJ FIT-1234
READY. ..
3 INPUT
OUTPUT FIT-1234
WORKING..
• The current output IS 100%. OUTPUT FIT-1234

100 % #
4 Press the ( 1c~, ) key

r::=1 OUTPUT FIT-1234
~ • # disappears, mdicatmg that the WORKING. ..
constant current mode has been
released.
DSTJ FIT-1234
READY. ..

5-6: Erasing calibrated data
5-6-1: Erasing calibrated data

~za caw w 'i'WW"WIEIS! ·. '
Procedure
Reset the calibrated data to the 1mt1al values (factory set data):
Step Key Descnpt10n SFC screen

RESET
Press the [ .",.f ) and keys, m SHIFT-

that order.
RESET
DSTJ FIT-1234
RESET CORRECTS?
2 NON-VOL
NON-VOl
osrJ FIT-1234
CORRECTS RESET
J,
• The calibrated data IS Initialized. DSTJ FIT-1234

READY. ..

5-6-2: Erasing # mark
Procedure
#appears when the calibrated data IS reset to the mitial values. To erase: Actual
pressure IS reqmred for this procedure. Input actual pressure to the transmitter. Refer to
"3-9· Zero-span adjustment with mput pressure eqmvalent to range" or " 5-5-2:
Calibratmg set range based on reference mput"
How to set the low-limit value, based on actual pressure
Set the actual pressure applied to

the transmitter to 0 kPa. DSTJ FIT-1234
READY. ..
2 Press the(~'· ] key

LRV FIT-1234
0.0000 kPa #
3 Press the key

LRV FIT-1234
SET LRV?
4 NON-VOL
NON-VOL
URV FIT-1234
WORKING. ..
• The Initial value for the low LRV FIT-1234

limit IS displayed. 0.0123 kPa #
How to calibrate the low limit value, based on actual pressure
5 ACT PR
ACT PR
Press the~ key LRV FIT-1234
~ 0 kPa #
6 NON-VOl
Press the (:~~) key

NON-VOL
LRV FIT-1234
0.0000 kPa #

7 RESET
Ensure that no pressure IS applied CORRECT LRV?
to H.L.
8 NON-VOL
Press the~~ key

NON-VOL
LRV FIT-1234
ARE YOU SURE!?
5-48 STJOOO Ace - Smart Transmitter Electromc Differential Pressure Transmitter

13 FIS OtR
F/S DIR
Press the [ n~~ ) key DSTJ FIT-1234
0 WORKING. ..
,!.
The # mark disappears. DSTJ FIT-1234

STATUS CHECK= OK .
i

5-7: Troubleshooting
5-7-1: Checking operation and actions

•~• "E .,. . . -
Introduction
l8d' 2 a n: J wa I ••& WTZ
-
The operation of the transmitter cam be checked usmg the SFC. In the event of an
abnormality, take appropnate action according to the self-diagnostic message
displayed on the SFC.
If the transmitter, the process, the SFC, or the commumcat10n system has any
abnormality dunng measurement, take appropnate actiOn by followmg the self-
diagnostic message displayed on the SFC.
Abnormalities can be classified as follows :
• Any abnormality m the transmitter, the process, the SFC, or the commumcat10n
system Is suspect.
• An abnormality of the transmitter IS suspect.
• An abnormality of the transmrtter or the process IS suspect.
• An abnormality of the SFC or the commumcation system IS suspect.
Check operations
Before checkmg the operatiOn of the transmitter, connect a SFC to the transmitter.
Check for commumcatmg state. Employ these procedure.
1 FfS DfR
F/S DIR
Press the [ MA~J key DSTJ FIT-1 234
(2] WORKING. ..
DSTJ FIT-1234
STATUS CHECK =OK
IF a message other than Self- (Other message)
diagnosis Result OK IS displayed, J,
take reqmred actiOn. Refer to
DSTJ FIT-1234
mstruct10ns m the subsequent
READY. .
pages.
• If an error message IS displayed, When more th an on problem IS found

d urmg self-diagnosti CS. messages a re
refer to the messages m the
di s played. each 111 1ts turn. for abou t 5
subsequent page. seconds.

5-7-2: Error during communications
Message and requ1red action

Respond to error messages that are displayed dunng commumcatwns.
Message Required actiOn

FIS OIR
DSTJ FIT-1234 • Press the ( ..A~~ J key Take actwn according to the
READY. .. message .
.!- (3 seconds later) DE READ FIS OIR
•The~ and ( ....~") keys are effective, even

I PRESS STATUS! L:J'
m this state.
• After takmg the necessary actwn, press the [n] key

to check that Self-Diagnosis Result OK IS displayed.
Low battery Charge the SFC by followmg the
mstructwns m "4-1-7 Chargmg SFC" on page 4-17
FIS OIR
• Press the ( arA'r" J key and take necessary action

I..... # according to the message. # disappears when the
problem IS solved.
FIS CMR
• When # disappears, press the [ sTAT") key to make

sure that Self-Dmgnos1s Result OK IS displayed.
ST3000 Ace -Smart Transmitter Electrontc Differential Pressure Transmitter 5-51

5-7-3: Self-Diagnostic message

~~!
- w•• .. =
Message
The fo llowmg messages are displayed by pressmg the [n] key at the time of a failure.
The meanmgs of the messages and the necessary actiOn are summanzed, here.
An abnormality of the transmitter, the process, the SFC, or the commumcation
system IS suspect.
Message Meamng Reqmred action
• Transmitter makes no • Repeat the procedure for

NO XMTR RESPONSE response. startmg commumcat10ns.
FtS OIR
• Press the [ arAT" ) and see what

message IS displayed.
• Check the loop, the SFC
connection loop, load
resistance, and the supply
voltage.
Abnor mality of the transmitter IS suspect.

.
Message Meanmg Reqmred action
MDU/DAC fault Contact the appropnate

IMDU/DHC FAULT personnel.
I
Memory fault Contact the appropnate

I NVM FAULT personnel.
I
PAC fault Contact the appropnate

IPAC FAULT personnel.
I
RAM fault Contact the appropnate

IRAM FAULT personnel.
I
ROM fault Contact the appropnate

IROM FAU LT personnel.
I

Message Meamng Reqmred actiOn
The temperature Contact the appropnate

I NO DAC TEMP COM correction data on the personnel.
electromcs module was
I
lost.
Unknown error state Contact the appropnate
I STATUS UNKNOWN personnel.
I
An abnormality of the transmitter or the process IS suspect.
The temperature m the Install the transmitter m such a

SENSOR OVER TEMP center body IS too high. way that the temperature does
# not become too high.
• Input data error. Check the process.

I SUSPECTINPUT • Problem m the Set the transmitter to the
process constant current source mode
I FIS O+R
• Transmitter fault and press the [ sTAT" J key If no

• Differential pressure message IS displayed, report
transmitter fault the problem to the contact
pomt mdicated on the rear.
• The mput differential • Check the PV value and
I M.B. OVERLOAD OR I pressure exceeds 2 replace the transmitter With a
times the high limit model of a larger range If
ofthe valid range. necessary
METER BODY FAULT • Differential pressure • Contact the appropnate
transmitter fault personnel because the
pressure rece1vmg part of the
transmitter may be damaged.
An abnormality of the SFC or the commumcation system IS suspect.
SFC fault • Repeat the procedure for

ISFCFAULT startmg commumcatiOns.
• Ifthe same message IS
displayed agam, contact the
appropnate personnel.

Message Meanmg Req mred action
Commumcatwn fai lure • Check that the SFC IS

IFAILED COMM CHK connected correctly
FIS OIR
I
• Press the ( arAr"_] key If
COMM ERROR IS
displayed, replace the SFC.
If any other message IS
displayed, take the
corresponding actwn, shown
m this list.
Commumcatwn - Check the connectwn between
ILLEGAL RESPONSE problem. the SFC and the transmitter,
the cabling, and the power
supply
Pnnter failure Contact the appropnate
IPRINTER FAIL' # personnel.
I
Too-small loop Adjust the resistance value.
ILOW ROOP RES resistance
I
• Too-large loop Too-small Impressed voltage.

IHI RES/LOW VOLT resistance Increase the voltage Z.
I • Check the loop
resistance and adjust
It.
An operation error 1s suspect.
• Wrong key mput

Press the [ ' "'.t- J key to check
KEY NOT ALLOWED ! • Wrong key mput
the di splay and start the key
procedure
mput agam.
CalibratiOn reqmred Calibrate the low and h1gh

ICORRECT RESET# limit values of the set range.
I
Key unsupported Press correct key
INOT SUPPORT
I

Message Meamng Reqmred actiOn
Excessive span Check that the mput pressure

EXCESS SPAN CORR cali brat10n agrees With the calibrated
# value and calibrate the high
limit of the set range.
Requested output value
Press the ( ,c;:, ) key and mput
EXCESSIVE OUTPUT > Output range (-
1.25% to 105%) m data agam.
constant current source
mode
Excessive zero Check that the mput pressure
EXCESS ZERO CORR calibration agrees with the calibrated
# value and calibrate the low
limit of the set range.
The transmitter • Start the commumcat10ns
INVALID DATABASE database IS not correct agam.
when the SFC IS turned • Check the database, calibrate
ON . the transmitter agam, and m
put correct data.
Appropnate mput Check the mput value. If It IS
ICORRECT LRV? value for the settmg. wrong, correct It.
I
Set range > High limit
Press the ( ,c;:, ) key to check
ENTRY > SEN RANGE of set range x 1.5
the numenc value, and repeat
the settmg procedure.
Invalid request Check SFC operat10n

INVALID REQUEST procedure.
· ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter 5-55

5-7-4: Self-diagnosis by indicator (option)
Introduction
When the mdicator or the transmitter has an abnormality (when the mdicator IS set),
the details will be displayed m the digital display umt of the mdicator.
Self-diagnostics follow1ng power ON
Digital mdicator RAM Contact the appropnate
.- '
~ I / failure personnel.
c,-,-
/ I' "'-.
(Blink)
.-
Digital mdicator ROM Contact the appropnate
c,-,-c,
"'-. I /
failure personnel.
/ I "'-.
(Blink)
Self-diagnostics dunng regular operation
Message Meanmg Req mred action
Senous failure of Contact the appropnate

-- transmitter personnel.
--
--
I I
~ (Alternatmg display)
--
--
--
I I
External zero pomt Contact the appropnate
adjustment failure personnel.
' I /
ZERO
/ I \
(Blink)
5-56 ST3000 Ace - Smart Transmitter Electromc Differential Press ure Transmitter
Transmitter or Contact the appropnate

mdicator failure personnel.
t (Alternatmg display)

5-8: Insulation resistance test and

withstand voltage test
&cAUTION
In prmciple, do not perform an msulat10n resistance test or a withstand voltage test.

In some cases, the built-m vartstor With a function for absorbmg surge voltage may
be destroyed dunng these tests.
If a test must be performed for an unavoidable reason, carefully follow the
procedure.
Test procedure
• Disconnect the external cables from the transmitter.
• Short-circmt the+ and- SUPPLY termmals and the+ and - METER termmals.
• Perform a test between the short-circmted parts and the ground termmal.
• The reqmred Impressed voltage and the JUdgement cntena are shown bellow. Don 't
apply higher voltage to protect the mstruments from destructiOn.
Judgement criteraa
Test Judgement cnten a
Insulation resistance test 2 x 10 7nor higher at test voltage of 25V DC (Not

htgher than 25oC and 60%RH)
Withstand voltage test 50V AC, 1 mmute, set current 2 rnA.

ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter Appendix A-1
AppedixA Yamatake Corporation
Operating principle
• ' • • • • - - '. ~~·..:) ., ·-~·-·.-:.. ·t~ ... ~ ..... -~
Introduction
Ex. Differential pressure transmitter A differential pressure transmitter IS a htghly-
engmeered mstrument that IS specifically designed to measure liqmd or gas flow rate,
pressure data and liqmd level data, and transmit the data to another locatwn.
Combmed with a contractmg mechamsm (such as an onfice and a flow nozzle),
because the transmitter detects the pressure difference between two pomts m a process
(differential pressure), one differential- pressure transmitter can be used for measurmg
flow rate.
One transmitter can also be employed to measure multiple process vanables such as
pressure and liqmd level.
Electromc differential pressure transmitters enJOY widespread use. Such mstruments
offer sigmficant benefits to end-users and constructiOn engmeenng compames. The
mstruments have a umfied structure that consists of a pressure receivmg umtwhich
senses high pressure and low pressure-and a transmitting umtwhich transmitting the
differential pressure. Before transmiSSion, the mstrument converts a differential
pressure value mto electrical signals (4-20 rnA DC).
Operating prmc1ple
A typical electromc differential pressure transmitter has a composite semi-conductor
sensor.
High pressure and low pressure m the process are transmitted to the diaphragm
mounted on the both sides of the pressure receivmg umt. These diaphragms are m
constant with the liquid, and transmit the pressure VIa a special flmd, to the composite
semiconductor sensor mside.
This sensor IS strained according to the difference between high pressure and low
pressure (differential pressure). For transmission, another umt sends out a signal
corresponding to the stram.
At the same time, two auxiliary sensors, a temperature sensor and a static pressure
sensor, come mto actiOn. These sensors are formed on the sensor chip. They sense the
Appendix A-2 ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter
Yamatake Corporation AppedixA
ambient temperature and the static pressure, which values are also digitalized and sent
to the transmittmg umt.
Dig1tal s1gnal
Meter body
ST3000 Ace - Smart Transmitter Electromc Differential Pressure Transmitter Appendix A-3
Appedix A Yamatake Corporation
Appendix A-4 ST3000 Ace -Smart Transmitter Electromc Differential Pressure Transmitter
Document Number: CM2-DST800-2001
Document Name: ST3000 Ace Smart Transmitter Electronic Differ-
ential Pressure/ Pressure transmitter
Model JTD, JTG, JTA, JTC , JTE , JTH , JTS
User's Manual
Date: Mar. 1999 (First issue)
June 2006 (Rev. 2)
Issued/Edited by: Yamatake Corporation
~m~T~KE
Yamatake Corporation Savemation
Advanced Automation Company Sm•i11g tluvug,h Auwmatiml
1- 1-32 ew Stage Yokohama, Shin-urashima-c ho,

Kanaga wa-ku. Yokohama. Kanagawa-kcn 22 1-0031. Japan
Te l · 18 /-45-46/-8631
Fax : +8 1-45-461-2658
http: //www.yamatake.com/
fh1s has been pnnted on recycled paper.
SAFETY,OPERATING & MAINTENANCE
INSTRUCTIONS
EXHAUST GAS ECONOMIZER

KS,KF SERIES
E992-9807 -1 1
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ECONOMIZER
Exhaust Gas Economizer

KS,KF
Operation Manual
Introduction
Thank you for selecting KS,KF Exhaust Gas Economizer.
This operation manual contains instructions for safe,proper use of KS,KF Exhaust Gas Economizer.
Prior to using Exhaust Gas Economizer, be sure to appoint an operation supervisor(engineer),then
study and understand manual throughly. This manual should be kept close by when operating this
system .
This operation manual gives an overview of KS,KF model Exhaust Gas Economizer; main func-
tions,operating procedures,safety inspections,troubleshooting and countermeasure.
The operating methods and safety instructions are to be used for specific purposes; do not operate
·Exhaust Gas Economizer in any other manner.We are not responsible for any consequences due
to misuse of Exhaust Gas Economizer.
Because of our continued efforts to improve design,some details in this manual may differ from those
of your Exhaust Gas Economizer. Thank you for understanding that contents of this manual is also
changed without notice.
For any questions on your Exhaust Gas ·Economizeror contents of this operation manual , please
feel free to contact Miura anytime.
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CONTENTS
~ 1. Terms ························································································································3
~ 2. Warning Label · · · ·· · · ·· ·· · ·· · ·· · ·· · ·· · · · · ·· ·· · · ·· · · · · ·· · · · · ·· · ·· ·· · · ·· · ·· · ·· · ·· · ·· · · · · ·· ··· · ·· · ·· ·· ·· · · ·· · · · · · ·· · · · · · · · · · ·4
~ 3. Basic Safety Precautions ····················:···· ····································································5
4. Outline Drawing of Economizer ;.......... .. ........ .................. ...................... ... .. ............... ... 6
5. Internal Structure of the Economizer ·········· ···· ···· ····· ·· ········· ·· ··········································7
6. Structure, Names, Inspection and Operation of the Device········· .. ·····································8

6-1 Soot Blower ··· ··· ············ ···· ····· ········ ············ ········· ····································· ·· ··· ····· ·· 8
6-2 Excess Steam Escape Valve · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1 0
7. Operation of the Exhaust Gas Economizer ············ ··············· ··· ······· ······· ······ ···· ··· ·········11
7-1 Fluctuation of the Water Level · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·11
7-2 AirVent· ··· ···· ··· ··· ······· ············ ····· ·············· ··· ·· ············· ·········································11
8. Operating Manual of the Exhaust Gas Economizer · ·· · · ·· · ·· ·· · ·· · ·· ·· · ·· ··· · ·· · ·· · ·· ··· · · · · ·· · · · · · · · · · · · · ·12

8-1 Circulating Water Pump Operation ·· · · · ··· ···· ·· ··· · · · · ·· ·· · · · · · · · ·· · · ·· · · · ··· · ·· · ·· · ·· ·· ·· ·· · ·· ·· · · · · · · · · · · ·12
8-2 Steam Pressure Adjustment· ··· ··· ········· ························································· ····· ··· ·· ·13
8-3 Boiler Water Treatment · ···· · ·· · ··' · · · · ·· ·· · ·· · · · · · ·· ·· · ·· · ·· ·· · · ·· · ·· ·· · ··· · ·· · · · · ·· · ·· · ·· ·· · · ·· · · · · · · · · · · · · · · · ·13
9. Maintenance of Exhaust Gas Economizer ··· ·········· ···· ······· ·········· ············· ····· ··· ···· ··········14
9-1 Soot Blow ··························· ····· ······················ ···· ···· ······· ············ ············ ······· ···· ·14
9-2 Water Cleaning ···:·······························································································14
9-3 Treatment Method for Damaged Heating Coils ····· ···································· ·········· ······15
9-4 Acid Cleaning of exhaust gas economizer · · ·· ·· ·· · · · ·· ··· · · · · · ·· ·· · · · · ·· · · ·· · ·· · ·· ·· · ·· · · ·· · ·· · · · · · · · · · ·17
9-5 Treatment for long time nonuse of boiler · · · ·· ·· · ··· · · · ·· · · · · · ·· · ·· · · · · ·· · ·· ··· · ·· · ·· ·· · · · · · ·· · ·· · · · · · · · · · ·17
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1. Terms
The following terms are used in this manual for your safe and efficient operation.
& WARNING
• Indicates any condition or practice which may cause death
or a serious injury to the operator if not observed.
& CAUTION
• Indicates any condition or practice which may result in
damage or destruction of the property and/or minor
personal injury.
NOTE
• Indicates cautions for preventing the failure of the devices,
and points for effective operation.
• Number in the pointing hand sign indicates the page for

related items.
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ECONOMIZER
2. Warning Labels
~ WARNING
The following warning labels are adhered to some areas on the main body and accessory components of
KS,KF Exhaust Gas Economizer.
2-1. High Temperature Warning Label

This is adhered to the area of high temperature which .may burn you if touched . (the area of 60"C or
higher)
2-2. Catch Warning Label

This is adhered to the area where there is a( structural gap in a rotating. device that finger may enter into or
get caught in.
2-3. Electric Shock Warning Label

This is adhered to the area of the electric part which cannot be insulated (or covered) completely.
2-4. Crush Warning Label

This is adhered to rotating devices similar to the catch warning label.
2-5. Damage Warning Label

This is adhered to the area where devices such as level gauge that may be damaged by using for a long
time.
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3. Basic Safety Precautions
~ WARNING
During operation of KS,KF Exhaust Gas Economizer, observe the safety precautions that are instructed in
Operating Manual. Non-observance may cause a serious accident.
3-1. Carry out -confirmation before operation.

Confirm piping systems on final drawings andl systems of the ship . Operation with wrong system can
cause a serious accident and stop dangerous operation .
Refer to final drawing for specifications and other information.
When operating Exhaust Gas Economizer, we suggest that you appoint a member in charge of the
Exhaust Gas Economizer and let him read safety cautions on Operating Manual throughly to understand
them completely, before starting operation and maintenance.
3-2. Wear appropriate clothes and protective wear

Do not begin operation an~ maintenance wearing loose clothes and hanging jewelry that can get caught
in valves and machine parts. Do not wear clothes stained with oil, because these may ignite very easily.
Wear helmet, goggles, safety shoes and gloves when it is necessary, especially while working near a
high-temperature area. When operating with chemical , do not forget to wear goggles and gloves because
chemical is spattered and put on hand and eyes.
3-3. Do not make any modifications, Use genuine parts.

Do not make any modifications without our approval. We may not be able to permit such modification by
regulations and it has safety problem. Use Miura genuine products for parts and chemical.
*MIURA will not take responsibility for any unauthorized modifications.
3-4. Do not place combustibles near Exhaust Gas Economizer.

Do not place combustibles near exhaust gas economizer because there is a danger for them to ignite.
Keep combustibles on safety place away from heat, and confirm storage place and handling method of
fire extinguishers to use in case of emergency.
3-5. Provide fire extinguisher and first-aid kit.

Install fire extinguisher to provide against fire , and understand how to use it.
Determine the best location for first-aid kit and install it.
Determine appropriate emergency procedures in case of fire or accident.
3-6. When Re-installing or Selling Vessel

To operate Exhaust Gas Economizer properly, system must be correctly installed and prepared .
Be sure to contact us before moving or selling Exhaust Gas economizer.
Improper installation and preparation may lead to bodily injury.
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4. Outline Drawing of Economizer

KS type
Exhaust Gas Outlet
7) t 8)
2)
1) 3)
9)
1 0)
5)
6)
~
4)
7)
1 Thermometer Seat 6 Soot Blower

2 Safety Valve 7 Manhole
3 Outlet Header 8 Air Vent Valve
4 Drain Valve 9 Rolling Stay
5 Inlet Header 10 Body Cover
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ECONOMIZER
5. Internal Structure of Economizer
Outlet Header Outlet
Inlet Header
KS type KF type
KF type Heating Coil
Inside of exhaust gas economizer, heating coils are welded to inlet and outlet header as shown in the
above picture, and it has structure that absorbs exhaust gas energy of main engine efficiently. KS type
has small curvature radius of heating coils, that enables its shape (especially height) to be smaller com-
pared with the same square measure of heat conduction ; therefore, KS type is suitable for installing at
limited space .
KF type economizer has special fins equipped on heating coils to raise efficiency of heat absorption .
Diameter of KF type heating coil is larger than KS type ; special fins are orderly welded to heating coils
and absorb heat efficiently.
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6. The Structure, Names, Inspection and Operation of Each Device

6-1. Soot Blower
The soot adheres to heating coils of economizer by exhaust gas of the main engine. When soot is
adhered , evaporation is decreased, and vent loss is increased; this may cause corrosion of heating coils.
Because low quality oil is used for the main engine recently, soot fire may occur depending on soot condition .
Therefore, soot blower is installed to reduce soot adhesion and to improve thermal efficiency. Soot blower
is installed at the bottom part of heating coil; by turning handle, it can adjust the angle of injection nozzle
of inside to any direction. During sailing, operating time and the number of times of operation needs to be
decided by experience. (Condition of soot adhesion depends on the ship and how it is used.); however, try
soot blow at least once a day and keep down adhesion of soot as small as possible .
(1) Procedure of soot blower

1) Before opening steam valve of soot blower, discharge drain completely.
2) Keep steam pressure as high as possible. (During soot blow, stop using steam for other parts tem-
porally to keep steam pressure high. This is because soot blow is less effective when it is per-
formed with low steam pressure.)
3) Open steam valve gradually. Do not open it suddenly.
4) Turn handle of soot blower right and left to about 45· and change angle of injection nozzle so that
it can cover whole heating coil.
5) During soot blow, check direction and ve.locity of wind in advance so that large amount of soot will
not fall on board.
6) After soot blowing, close steam valve and open drain valve for checking water leakage from steam
valve.
Exhaust ~
Gas
Outlet
Exhaust Gas Economizer
' (Injection Nozzle of /

Soot Blower) (
Steam b_j
Exhaust l
Gas Inlet I
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ECONOMIZER
(2) Section "A" Detail Drawing
1 Body 11 Packing Stopper

2 Inlet Tube 12 Packing Support(2)
3 Bolt 13 Socket
4 Name Plate 14 Set Bolt
5 Handle Stopper 15 Lock Nut
6 Handle 16 Bolt
7 Cover 17 Bolt
8 Packing Support(1) 18 Socket
9 Washer 19 Gland Bush
10 Grand Packing
NOTE
Inspect Item 10, 13, 14 and 15 periodically, we recomend early exchange parts.
Check gas leakage from 10 Grand packing regularly, and tighten 19.
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ECONOMIZER
6-2. Excess Steam Dump Valve
The pressure of the steam that is generated by exhaust gas economizer depends on the steam balance of
the ship. When steam pressure is low, it can be adjusted with additional stroke of auxiliary boiler (parallel
oparation); however, when steam pressure is increasing rapidly, it cannot be adjusted with exhaust gas vol-
ume. Therefore, steam pressure is controlled by letting excess steam to dump to drain cooler. In other
words, excess steam dump valve is installed between the main steam line and drain cooler, and it allows
excess steam to dump to drain cooler when the pressure exceeds set pressure.
From load From Exhaust

Gas Economizer
Main Steam
Valve
By- Pass Valve
Cascade
Tank
To Exhaust Gas
Economize r
There are two types of excess steam dump valve ,

reducing type dump valve and air control type dump
valve. One of these valve is installed depending on
the types of the ship. The reducing type dump valve
has the same structure as one kind of pressure
reducing valve. (Refer to drawing below) To adjust
set pressure, take off cap 11) on the top of damp
valve, loosen the lock nut 22) and adjust the adjust-
ing screw 21 ). Watch pressure gauge when adjust-
ing.
The air control type dump valve adjusts steam pres-
sure by detecting the steam pressure, transmit the dif-
ference of actual steam pressure and set pressure
into air signal, and starting diaphragm control valve .
1) Body 13) Pilot Valve

2) Pilot Body 14) Pilot Valve Seat
3) Spring Chamber 15) Pilot Valve Spring
4) Top Diaphragm Case 16) Seal Bellows
5) Bottom Diaphragm Case 17) Pilot Diaphragm
6) Main Valve 18) Spring
7) Main Valve Seat 19) Top Spring Plate
8) Main Spindle 20) Bottom Spring Plate
9) Retainer 21) Adjusting Screw
10) Main Diaphragm 22) Lock Nut
11) Spring 23) Sensing Pipe
12) Screen
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ECONOMIZER
7. · Operation of Exhaust Gas Economizer

The operation of exhaust gas economizer is usually done by operation of circulating water pump and each
valves while auxiliary boiler is in automatic operation. While load of the main engine is low after starting ,
parallel operation with auxiliary boiler continues because steam generation at the exhaust gas economizer
is low. When load of the main engine increases and steam pressure reaches to the set pressure of auxil-
iary boiler, exhaust gas economizer is able to be operated by itself. However, because auxiliary boiler is in
automatic operation (even when exhaust gas economizer is operated by itself) , parallel operation of auxil-
iary boiler and exhaust gas economizer continues.
When load is stable and exhaust gas economizer can supply enough evaporation by itself, you may turn
OFF auxiliary boiler; however, when evaporation at exhaust gas economizer decreases, auxiliary boiler
cannot start automatic operation , and turn ON auxiliary boiler beforehand is necessary. Also , in this case, if
auxiliary boiler is using C heavy oil, check that the heating temperature of fuel oil is normal and fuel is circu-
lated properly.
7-1. Fluctuation of Water Level
In operating exhaust gas economizer, exhaust gas economizer and auxiliary boiler is connected , so when
exhaust gas economizer is empty, boiler water may pressed up into economizer and water level falls
down suddenly. Because boiler water level is controlled with ON-OFF control of electrode holder, feedwa-
ter pump operation cannot be in time and wate r level may become low. To avoid such condition , open
delivery valve of circulating water pump at last and adjust opening, so that boiler water is not fallen down
suddenly. Exhaust gas economizer starts evaporation as the main engine starts; at that time, the part up
water inside flows into boiler owing to generated bubbles and boiler water level may raise temporally.
Boiler with high water level alarm can recognize this condition ; however, if situation is bad , adjust it by
blow-off of boiler water. The water level will be stable as load of the main engine settles. On the contrary,
when load is variable, such as during S/B when fluctuation of load is high , fluctuation of water level
becomes high too. It cannot be adjusted with normal water level control, and high or low water level alarm
may start ..
7-2. Air vent

When operating exhaust gas economizer, release enough air from air vent at outlet header. There is no
need to vent air after this, but perform air vent every time you operate exhaust gas economizer (after cir-
cu lating pump is started) .
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8. Operating Manual of Exhaust Gas Economizer
~ WARNING
To prevent soot fire accidents, follow instructions when operating circulating water pump.
8-1. Circulating Water Pump Operation
Before starting the main engine, it is necessary to start circulating water pump and circulate water through
exhaust gas economizer. Prior to operating ciculating water pump be sure to study and understand
attached circulating water pump manual.
[Before Starting the Main Engine]

1) Open valves on circulating line.
Open valves A), B), C), E), F), and G) on the
Economizer ~==l:::::r:,
line gradually.
Pay attention to fluctuation of boiler water
level and open delivery valve C) of pump at
last. Orifice Unit for flow control is equiped on
circulating water pump secondary side as
standard. Always H) J) should be fully -
opened, K) should be fully closed.
2) Turn operating switch ON and start circulating
water pump. Pay attention to suction and Q)r-
delivery pressure. When fluctuation of water -- ®
level is large, adjust water level with delivery ®
f-
valve C).
Boiler
3) After operating circulating wate r pump, open Circulating
water pump
airvent valve D) and release air. After released
® ©
..:;:.
air, close air vent valve D).
4) When operating circulating water pump, check
·t CD m Flashing Cooler
circulation of cooling water, and make sure ® Jll

that there are no abnormalities.
[ ) Refer to Manual for "Circulating water pump MCT-N"
[Before the Main Engine Starts]

As the main engine is started and load increases, steam is generated from exhaust gas economizer. The
water level of auxiliary boiler changes with the load.
·1) Check suction and delivery pressure, abnormal sound , and heat generation for abnormalities.
2) Until load of the main engine becomes stable at normal revolution, steam pressure and load of circulat-
ing water pump is changing, too; pay attention to them. Because clogging of suction side strainer may
decrease circulation quantity carry out regular cleaning.
12
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IIVIIIU RA
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ECONOMIZER
[After the Main Engine Stops]

1) When restarting the main engine shortly after stop, keep operating circulating water pump and the line.
2) When lord of the main engine changes in entering port S/B, supplementary burning of auxiliary boiler
begins due to water level fluctuation and falling down of steam pressure.
3) Keep operating circulating water pump for about 6 hours after the main engine stops completely (F/E) to
prevent soot fire . Do not shut down breaker since pump operates for 6 hours by timer after pressing stop
button. Keep flowing jacket water of flushing cooler for circulating water pump. After that, stop circulating
water pump and close inlet and outlet valves B) , C) of pump, and inlet and outlet valves E), A) of boiler.
8-2. Steam Pressure Adjustment
As it is noted in excess steam dump valve section, steam pressure increased as the main engine start
operating. Open dump valves A), C) and check that excess steam is dumping to drain cooler when the set
pressure of dump valve B) is attained. If load is too high and steam pressure does not increase to the set
pressure, reduce load or lower the set pressure of dump valve and make sure that dump valves operate
properly. When a lot of prior drain is stagnated on excess steam dump valve inlet because of steam and
drain piping system , open bypass valve gradually to dischange and control drain .
From Exhaust Gas

Economizer
-To Circulating Water Pump
8-3. Boiler Water Treatment
During operation of exhaust gas economizer, auxiliary boiler practically does not generate any steam, and
device operates as drain separator (except for supplementary burning); therefore, most of generate<Cl
steam evaporates by exhaust gas economizer. Since boiler water treatment affects efficiency and life
(corrosion) of exhaust gas economizer, inspect boiler water regulc;trly and maintain water in good
condition. About water management, there are details on manual for water treatment.
[]=>Refer to "Manual for Water Treatment" for detailed information.
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I ECONOMIZER I
9. Maintenance of Exhaust Gas Economizer

9-1. Soot Blow
As it is explained in soot blower section , some adhesion of soot from exhaust gas of the main engine is umi.void-
able, because of its structure, when exhaust gas economizer is used. Adhesion of soot hinders heat transmis-
sion and may cause corrosion of heating coil, or other troubles such as soot tire.
Carry out soot blow regularly to prevent soot to adhere to heating coil. [IT) 6-1 Soot Blow
Lt CAUTION
Be careful of drain water and not to flow drain to supercharger. After docking , soot adhesion amount
increases sometimes at early operation by lubricant amount of the main engine. Confirm soot adhesion
condition and try early sool blow.
Fresh air inflow at opening manhole may cause tire of accumulated soot. Do not stop circulating water pump
right after stopping exhaust gas economizer.)
9-2. Water Cleaning of Exhaust Gas Economizer
During sailing (while exhaust gas economizer is operating) , it is necessary to carry out soot blowing at
least twice a day to prevent soot adhesion; however,it is impossible to get rid of all soot in exhaust gas
economizer with daily soot blow. Therefore check soot adhesion condition regularly (every 1 to 3 months)
and perform water cleaning during docking, to prevent soot tire in advance.
(A) (B) (C)

cb
Ql Ql
CJl CJl
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E~ :£.g
NOTE
The drain scupper pipe tor water cleaning may (figure (A)) or may not (figure (B)) be set,in accordance with
models and installation of economizers.lt the pipe is set as figure (A) , cleaning is easily carried out by
opening drain valve on the bottom of exhaust gas economizer and opening fresh water valve. However it
there is no pipe as in the tigurre (B) , drain flows directly into the main engine,since there is no drain valve
on the bottom of exhaust gas economizer. In such a case,put on drain scupper pipe and other appliances as
figure (C) and carry out soot blow during docking .
14
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ECONOMIZER
[Water Cleaning Procedure]

Following is water cleaning procedure for exhaust gas economizer with drain valve .
1) Open manhole door on the top of exhaust gas economizer and check soot adhesion condition.
2) Open drain valve (or temporary drain valve) at the bottom of exhaust gas economizer. This drain
valve and other pipes are likely to be clogged with soot, so make sure that drain 'water flows
through valve and pipes. If it is clogged , drain flows into the main engine and supercharger.
3) Open manhole at the bottom of exhaust gas economizer. Cover opening of exhaust pipe of main
engine with canvas, so that drain water will not flow into exhaust pipe .
4) If there is injection device for water cleaning, open fresh water root valve and inject water. Check
injection condition of water from manhole that injection nozzle is not clogged. In case that there is
no injection device for water cleaning , wash inside with a hose or high pressure cleaning device.
5) Check soot riddance from the upper manhole and decide washing time. Check condition of soot
removal from the bottom manhole as well.
6) It is effective to carry out water cleaning when body of exhaust gas economizer is still warm , that
is, right after stopping the main engine . Using warm water for cleqning is more effective.
9-3. Treatment method for damaged heating coils
& WARNING
Operate without failure to check that no residual pressure exists for stopper treatment, otherwise it may
cause burns.
When water leaks from heating coils of exhaust gas economizer, emergency treatment (stopper treatment) or
replacement of heating coils should be carried out according to following procedures.
1) Confirmation of leaking heating coils

1.Pay attention because for boilers having drain pipes , leaked wat~r flows out from drain pipe when
water leaks from heating coils. In this case , if drain pipe is blocked, leaked water may flow into turbo
charger or the main engine through exhaust pipe. In addition , pay particularly attention because for
boilers without drain pipes, leaked water flows into turbo charger or the main engine directly.
2. In the case of a small leak amount, leak may not be recognized because leaked water evaporates
during sailing (during operation of the main engine); however, if the main engine is stopped , check boil-
er carefully.
3. To check water leaks, open manhole at exhaust gas economizer lower part and operate circulating
pump so as to pass water through exhaust gas economizer. (A water leak is detected the only by
applying boiler pressure.) If you cannot detect water leak, even though you have carried out these pro-
cedures, or there is no manhole at exhaust gas economizer lower part, open the main body door and
remove header insulation filling, check it carefully, because the re are many cases where it is difficult to
confirm from which heating coils a water leak even though water leak can be detec~ed.
15
•
lVI lURA
•
ECONOMIZER
2) Emergency treatment (stopper treatment)

1. When you have confirmed from which heating oil water leaks, stop circulating pump and close
respective valves of circulating lines of exhaust gas economizer.
2. After open air drain valve at the upper header and drain valve at the lower header of exhaust gas
economizer to drain pressure and water in exhaust gas economizer.
3. Open air drain valve after con1firming that pressure gauge of exhaust gas economizer indicates 0
Mpa.
4. Remove header insulation filling , cut heating coils at an angle of b (approximately 40° ), insert stop-
per (spare item) in the header side , and carry out seal-welding. Refer to the figure below.
Open respective valves of circl,llating water line, operate boiler pressure pump or circulating water
pump to conduct an air passing test or water pressure test to confirm that leaks have stopped.
rta
Weld the entire circumference of the stopper and

heating coils.
stopper
Figure viewed from a
3) Replacement method of heating coils

Replacement of leaking heating coils is subject to inspection work performed by the Register of
Shipping and a shipping bureau , accordingly, replacement of heating coils should be carried out in
compliance with instructions by an inspector.
Contact Miura's service engineer for replacement of heating coils.
*For replacement of heating coils , use original heating coils approved by MIURA or the Register of Shipping .
16
•
lVI lURA
•
ECONOMIZER
9-4. Acid cleaning of exhaust gas economizer
~ CAUTION
Pay atten.tion sufficiently to handle chemicals. For details, please contact Miura's service engineer.
Adhesion of scale to inner surface of exhaust gas economizer lowers efficiency of heat transfer and may
cause trouble such as corrosion or overheating.
Accordingly, water controls should be carried out sufficiently to prevent adhesion of scales. In terms of
structure of exhau-st gas economizer, scales cannot be removed physically, and it is common to remove
scales by acid cleaning .
Appropriate treatment is required in accordance with scale adhesion condition of heating coils for carryi ng
out acid cleaning; therefore, please conduct acid cleaning according to instructions by Miura or chemical
maker.
9-5. Treatment for long time nonuse of boiler
When exhaust gas economizer is not used for a comparatively long time (over 48 hours), in order to pre-
vent corrosion on inner surface of heating coils and headers, it is preferable to fill water containing a boiler
chemical in boiler and apply a pressure of 0.1 MPa or more. If corrosion is caused by oxygen in air or sup-
plied water once, advancement quickens, and leaks in heating coils occur unexpectedly. If this should
occur during sailing , the main engine must be stopped for emergency treatment. As responsibility of
exhaust gas economizer operator, you must attempt to manage exhaust gas economizer through appro-
priate treatments to exercise maximum performance.
NOTE
On heating tube replacement and stopper maintenance, perfect weld technique is necessary; do not forget
to inform Miura's service engineer. Use genuine heating tube that is certified by societies of classification.
17
•
11\1111 U RA
•
ECONOMIZER

*HEAD OFFICE:
MIURA CO.,LTD.
SHIP MACHINERY DEPT. 7,Horie, Matsuyama, Ehime, TEL: (+81 )89 979 7066
Japan, 799-2696 FAX: (+81 )89 979 7067
*BRANCH:
TOKYO MAINTENANCE DIV. 2-15-35 Takanawa , Minato-Ku, TEL: (+81 )3 5793 1047
Tokyo , Japan 108-0074 FAX: (+81)3 5793 1045
Fukuoka, Japan 812-0893 FAX: (+81)92 432 3278
N. Y.CO.,LTD. 1-4-26, Takanawa Minato-Ku, TEL: (+81}3 3449 3821
Tokyo, Japan, 108-0074 FAX: (+81)3 3440 0944
CHUOKIKI CO.,LTD. 4-28-2, Abraya-Cho, Minato-Ku , TEL: (+81}52 383 3166
Nagoya, Aichi , Japan, 455-0824 FAX: (+81 }52 383 3607
MIURA SOUTH EAST ASIA PTE. LTD. 26 Boon Lay Way #01-81 Tradehub21 , TEL: (+65)6465 1147
Singapore 609970 FAX: (+65)6465 1148
OVERSEAS NETWORK
1.CHINA 6.TAIWAN
Minsheng Rd, Pudong New Area , Shanghai , 200135, No.18, Lane 5, Chung Chwan Rd . Keelung , Taiwan
P.R.Ch ina Tel : (+886) 2 24225747
Tel : (+86)21 6351 8029 Fax: (+886) 2 24261018
Fax: (+86)21 6351 8028 MING YUNG MACHINERY.,LTD.
"Fruchthof" Oberhafenstr.1 20097 Hamburg, Germany Tel : (+886)7 521 6266
Tel : (+49)40 32 1305 Fax: (+886)7 521 9368
#10-11 ,2Ka Myeong-Ryun-Dong Dongrae-Ku Susan , Tel : (+31 )10 2380999
Korea Fax: (+31 )10 2380990
Tel : (+82}51 552 6503 FUJI TRADING (MARINE) B.V.
MSK (MIURA SERVICE KOREA) Tel : (+31 )10 429 8833
103-1, Sando Skyview 122 Gwangjang-5Gil , Dong-Gu, Fax: (+31)10 429 5227
Fax: (+82)51 961 7772 P. 0. Box 19227, Dubai, U.A.E .
4.PHILIPPINES Tel : (+971)4 347 4444
PHIL-NIPPON KYOEI CORP. Fax: (+971)4 347 2771
S-705 Royal Plaza Twin Towers 684 Remedios St. , 9.USA
Tel : (+63)2 400 5778 5709 Old Spanish Trail Houston , TX 77023, U.S.A.
Fax: (+63}2 400 9130 Tel : (+ 1)713 928 5700
S.SINGAPORE Fax: (+ 1)713 928 5795
102, Pandan Loop, Singapore 128310 23132 East Echo Lake Rd ., Snohomish , WA 98296,
Tel : (+65)6777 5856 U.S.A.
Fax: (+65)6779 6711 Tel : (+1}206 6241171
FUJI HORIGUCHI ENGINEERING PTE.LTD. Fax: (+1)206 483 91 12
24 Chia Ping Rd ., Singapore 619976 . 10.VIETNAM
Tel : (+65)6863 6368 SHM-VLK CO.,LTD
Fax: (+65)6863 8310 64 02 Street, Van Thanh Bac Precinct, Ward 25,
Tel : (+84)8 3512 8379
18
L

EXHAUST GAS ECONOMIZER - KS, KF SERIES
Published by MIURA Co. ,Ltd . Ship Machinery Dept. July 1998.
11 •h edition Aug. 2009. No. E992-9807-11
All rights reserved , Copyright © 2009 MIURA Co., Ltd .

No part of th is publication may not be reproduced , transmitted , distributed or
publisher MIURA Co ., Ltd .
Visit us at www.miuraz .co.jp and get the latest information and Service News!
Printed in Japan
SAFETY,OPERATING & MAINTENACE
INSTRUCTIONS
CIRCULATING WATER PUMP

MCT-N
E970-011 0-07
•
lVI lURA
•
Circulating Water Pump

MCT-N
Operation Manual
Introduction
Thank you for selecting MCT-N Circulating water pump.
This operation manual contains instructions for safe ,proper use of MCT-N Circulating Water Pump.
Prior to using Cirulating Water Pump, be sure to appoint an operation supervisor(engineer), then
study and understand the manual throughly. This manual should be at hand when Circulating Water
Pump is be operating.
This operation manual gives an overview of MCT-N Circulating Water Pump; main functions , operat-
ing procedures,safety inspections and troubleshooting .
The operating methods and safety instructions are to be used for specific purposes; do not operate
Circulating Wate r Pump in any other manher. We are not responsible for any consequences due to
misuse of Circulating Water Pump.
Because of our continued efforts to improve design, some details in this manual may differ from those
of your Circulating Water Pump. Thank you for understanding that contents of this manual is also
changed without notice.
For any questions on your system or the contents of this operation manual ,please feel free to con-
tact Miura anytime.
lVI lURA
•
•
CONTENTS
1. Terms ·················· ···· ············ ···················· ·· ······· ··· ······················································3
2. Features · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·4
3. _Specifications · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·4
4. Installation ·· · ·· · ·· ·· ·· · · · · · · ·· · · · · · · · ·· · · · · · · · ·· · ·· · · · ··· · · · · ·· · ·· ··· · · · ·· · · · · · · · ·· · · ·· · · · · ··· · ·· · · · ·· · · · · · · · · · ·· · · · · · · ·· ·· ·5
5. During Pump Operation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6
6. Guidelines for Assembly and Disassembly··· ········· ·· ····· ··················································?
2
•
lVIII U RA
•
1. T~rms
Following guide terms are used in this manual for your safe and efficient operation .
& WARNING
• Indicates any condition or practice which may cause death
or a serious injury to the operator if not observed.
& CAUTION
• Indicate any condition or practice which may result in
damage or destruction of the property and I or minor
personal injury.
NOTE
• Indicates cautions for preventing the failure of the devices,
and points for effective operation .
• Number in the pointing hand sign indicates the page for

related items.
3
•
lVI lURA
•
MCT-N series is a new type of water circulation pump for exhaust gas economizers that has been
developed primarily to reduce burden of regular maintenance of crew members on the vessel. This new
product is much more maintainable than convention~! products, and offers following special advantages.
2. Features
(1) Because this is mechanical seal type, there is no need to replace or add gaskets , like grand packing
type; it is very easy to maintain and manage. Mechanical seal is cooled by flushing. (Flushing is that
supplies cooling water around seal surface, and makes there cool.)
(2) This product has pull-out type that can be disassembled without removing pipes from pump nozzle
inlet and outlet; it is easy to disassemble and reassemble .
(3) Because pump is connected directly to motor, coupling is not required ; this makes unit compact.
3. Specifications
MCT-25N MCT-32N MCT-40N I MCT-50N
Pump head 0.2MPa 0.3MPa
Flow volume 1.6m /h
3
4.0m /h
3
6.5m /h
3
I 12.0m3/h
Max. Temperature 1so·c
Liquid Water
Shaft seal Mechanical seal
Connection sizes diameter
32X25 32X32 40X40
(inlet X outlet)
Motor capacity 0.75kW 1.5kW 2.2kW I 3.7kW
Voltage 440V(220)
Frequency 60Hz
4
•
lVI lURA
•
4. Installation
(1) Pump needs to be installed 3-4 meters (one deck) below boiler head.
(2) Heat exchanger needs to be installed next to pump (that is, within 2-meter radius of pump).
Flow for flushing pipe needs to be set up as follows:

<Flushing Pipe Flow>
This diagram shows flow for one pump. For actual pipelines and pipe diameters, refer to official
diagram.
@
1-) Y-type strainer
(#40,1OA,SUS,16K)
® £ _ 5 Flushing
Intake for_~...l.........i t--+.....,..---+--1 1 water
flushing 1 pump 2) Orifice <D 2.5 or <D 2.8
water inlet (10A,SUS)
3) Heat exchanger
4) Thermometer
5) Globe valve
Jacket Jacket
water outlet water inlet · 6) Check valve
(3) Fasten pump base with bolts completely.
(4) Use H-TPYC-2 for wiring.
(5) Protect motor from overloading with overload protector(thermal relay) . Value for thermal setting
should be determined from following chart:
MCT-25N MCT-32N MCT-40N MCT-50N
1.6A(3.0) 3.0A(5.9) 4.2A(8.3) 6.5A(13.5)

440V(220V)
(6) Suction pipe should be as short as possible.
(7) Load should be kept down by inserting flexible tube and expanding it inside pump so that thermal
distortion of pipe does not affect pump body..
(8) Do not use pump to flush inside of pipe. This might cause some foreign substance to enter pump and
damage it.
(9) Provide for maintenance space of at least 200 mm behind motor. (If there is no such space,
mechanical seal cannot be replaced).
(1 0) Refer to drawing on following page for adjusting position of pump pipes and base.
(11) Be.cafeful not to be on pump body during maintenance.
5
•
lVI lURA
•
5. During Pump Operation

(1) Confirm that motor turns in the right direction before starting operation .
(2) Confirm that cooling water is flowing through flushing cooler. Reguiring condition of cooling water tem-
peratme is 80t or less at inlet, 85'C at outlet, and 50 liters/min (during operation).
(3) When starting motor, open discharge valve gradually and make sure that it is set at the right
discharge pressure.
(4) Temperature of flushing water at flushing cooler outlet needs to be not more than 83'C. Temperature
conditions of flushing water needs to be 175'C and 3 liters/min.
(5) Clean Y-type strainer that is installed on flushing line regularly. Pump is damaged at the early stage if
cleaning is neglected.
~ CAUTION
When flushing water temperature exceed 83'C, there is possibility that mechanical seal fails or breaks down
at the early stage. Check temperature regularly during operation.
~ CAUTION
Do not be on the top of pump or motor at any time while it is be operating or repairing.
b
IN(COOLING WATER)
10A
--.,- Q) sue
Suction
308 50 200
a ~+-----=-=-=---~
338 300
Suction. Delivery flange standard

a b c d e Suction flange side Delivery flange side
MCT-25N 87 85 73 165 305 16K 32A 16K 25A
MCT-32N 98 96 89 180 350 16K 32A 16K 32A
MCT-40N 98 96 89 180 350 16K 40A 16K 40A
MCT-50N 98 96. 89 180 350 16K 40A 16K 40A
6
,. '
NIIURA
•
•
6. Guidelines for Assembly and Disassembly

Interior structure of pump is shown in drawing below. When disassembling pump , follow the listed
guidelines below. Make sure to conduct inspection and maintenance after replacing defective parts so that
pump is operated at the best performance all the time.
On replacing mechanical seal , note that pump must be completely disassembled ; therefore , follow
di rections that is given in assembly/disassembly manual.
<Drawing of water circulation pump>
1)
2) --r----1.<:::
3) -==t=-=-===i;~Ef=-=>-fr
4) ----1--~"""IQJII-1
5)
28)
1) Casing 11) Liner ring 2 21) Flange

2) Impeller nut 12) Hexagon socket set screw (M6X8) 22) Hexagon bolt (M1 OX30)
3) Impeller key 13) Sleeve 23) Motor
4) Liner ring 1 14) Hexagon socket set screw (M6X8) 24) Hexagon socket set screw (M5X10)
5) plug (10A) 15) Q · ( 25NP20 ) 25) Drain board
nng 32N:40N ,50N:G25
6) Impeller 16) Mechanical seal (roating ring) 26) Support Board
7) Hexagon bolt (M16X65) 17) Mechanical seal (fixed ring) 27) Hexagon bolt (M8X16)
8) 0 · esN·G130 ) 18) Screw (M5X8) 28) Pump base
nng 32N:40N,50N:G155
9) Plug (8A) 19) Cover 29) Lock Washer
10) Casing cover 20) Hexagon bolt (M10X25) 30) Hexagon bolt (M12X35)
7
•
lVI lURA
•
(1) Close valves at the inlet and outlet of pump. Remove flushing water pipe and electrical wiring , then
take off hexagon bolt (M16X65) 7) and hexagon bolt (MBX 16) 27) and remove motor from casing 1)
in the direction of A. At this time, DO NOT remove supporting board 26) . (It is easier to remove motor
when support board is in place).
Flushing water A
*-
(2) Remove 2 pes of hexagon bolt (M1 OX30) 22) from motor that is taken out in step (1 ), and remove
supporting board 26) . Put motor on a level surface for working , then insert flat-head ("minus")
screwdriver into shaft groove in rear of motor to keep shaft from turning. Remove impeller nut 2), and
take out lock washer 29) and impeller 6) in the direction of D.
D
t-~ F li
~ - di
G~ -\__
-
=
- L 1--
When impeller is taken off, take off impeller nut after press and extend C-area that lock washer is bended .
When impeller is assembled, do not forget to bend C-area of lock washer and fasten impeller nut, after
impeller nut is inserted.
Lock Washer
Impeller nut
c
8
,~·
lVI lURA
•
•
(3) Take off screw 18) and remove cover 19). Remove hexagon bolt (M1 OX25) 20) , and make flange to
be free. Take out 2 pes of remaining hexagon bolt (M10X30) 22) and pull out casing cover 10) in the.
E direction. At this time, take care not to dallilage mechanical seal.
(4) Remove hexagon socket set screw (M6X8)12) , and pull out unit G (consisting of mechanical sleeve
and mechanical seal rotating ring) and unit H (consisting of flange and mechanical seal fixed ring)
toward the direction F. Remove hexagon socket set screw (M5X10) 24) , and pull out drain board 25)
in the direction F.
.--.--
~
~&
-
I--
1- !- 1 - t-
I--
~lf
~
rr-
F
=
-
-
c:::z;
}-- - - -
-
~
(5) The unit G consisting of mechanical sleeve and mechanical seal rotating ring;
Remove hexagon socket set screw (M6X8) 14), and take mechanical seal rotating ring apart from
mechanical sleeve in the direction of arrow.
--------- ------ ------
c--=ur;;:r==== ~ ·
9
MIURA
•
•
The unit H consisting of flange and mechanical seal fixed ring;

Take mechanical seal fixed ring 17) apart from flange 21) in the direction of arrow.
* Reassembly should be done in exactly the opposite procedure as disassembly; note

following points:
ewhen mechanical seal rotating ring 16) is inserted back into mechanical sleeve, fasten it with hexagon
socket set screw 14) after mechanical seal rotating ring is inserted at the point to step 1.
---------
r~....l__..-J,~
u Hiiii?'n
ewhen inserting unit G (consisting of mechanical sleeve and mechanical seal rotating ring) back into
motor shaft, insert it until step 2 of mechanical sleeve touchs step of shaft in the J direction , and fasten it
with hexagon socket set screw 12). At this time , make sure to fit 0-ring 15) into groove of mechanical
sleeve bore.
10
MEMO
•
IIVi IURA
•

*HEAD OFFICE:
MIURA CO.,LTD.
SHIP MACHINERY DEPT. 7,Horie, Matsuyama, Ehime, TEL : (+81 )89 979 7066
Japan, 799-2696 FAX: (+81)89 979 7067
*BRANCH:
TOKYO MAINTENANCE DIV. 2-15-35 Takanawa, Minato-Ku, TEL: (+81)3 5793 1047
Tokyo, Japan 108-0074 FAX: (+81)3 5793 1045
KYUSHU MAINTENANCE DIV. 3-21-45 , Naka, Hakata-ku, TEL: (+81 )92 432 3277
Fukuoka, Japan 812-0893 FAX: (+81)92 432 3278
N.Y.CO.,LTD. 1-4-26, Takanawa Minato-Ku, TEL: (+81)3 3449 3821
Tokyo, Japan, 108-0074 FAX: (+81)3 3440 0944
CHUOKIKI CO.,LTD. 4-28-2, Abraya-Cho, Minato-Ku, TEL: (+81)52 383 3166
Nagoya, Aichi , Japan, 455-0824 FAX: (+81)52 383 3607
MIURA SOUTH EAST ASIA PTE. LTD. 26 Boon Lay Way #01-81 Tradehub21 , TEL: (+65)6465 1147
Singapore 609970 FAX: (+65)6465 1148
OVERSEAS NETWORK
1.CHINA 6.TAIWAN
Minsheng Rd , Pudong New Area, Shanghai, 200135, No.18, Lane 5, Chung Chwan Rd. Keelung , Taiwan
China Tel : (+886) 2 24225747
Tel : (+86}21 6351 8029 Fax: (+886) 2 24261018
Fax: (+86)21 6351 8028 MING YUNG MACHINERY.,LTD.
2.GERMANY 27.Shin Shing St. , Yan Cherng District Kaohsiung,
"Fruchthof" Oberhafenstr.1 20097 Hamburg, Germany Tel : (+886)7 521 6266
Tel : (+49)40 32 1305 Fax: (+886)7 521 9368
#1 0-11 ,2Ka Myeong-Ryun-Dong Dongrae-Ku Susan, Tel : (+31 )1 0 2380999
Korea Fax: (+31 )1 0 2380990
Fax: (+82)51 557 4830 Kortenoord 2-8 3087 AR Rotterdam, The Netherlands
MSK (MIURA SERVICE KOREA) Tel : (+31 }1 0 429 8833
103-1 , Sando Skyview 122 Gwangjang-5Gil, Dong-Gu, Fax: (+31)10 429 5227
Fax: (+82)51 961 7772 P. 0 . Box 19227, Dubai , U.A.E.
4.PHILIPPINES Tel : (+971 )4 347 4444
PHIL-NIPPON KYOEI CORP. Fax: (+971 )4 347 2771
Malate Manila, Philippines CISCO BOILER SERVICE CO. , INC.
Tel : (+63}2 400 5778 5709 Old Spanish Trail Houston, TX 77023, U.S.A.
Fax: (+63)2 400 9130 Tel: (+1)713 928 5700
S.SINGAPORE Fax: (+1)713 928 5795
102, Pandan Loop , Singapore 128310 23132 East Echo Lake Rd ., Snohomish , WA 98296,
Tel : (+65}6777 5856 U.S.A.
Fax: (+65)6779 6711 Tel: (+1)206 6241171
FUJI HORIGUCHI ENGINEERING PTE.LTD. Fax: (+1)206 483 9112
12H Enterprise Road , Singapore 627688 10.VIETNAM
Tel : (+65)6863 6368 SHM-VLK CO. ,LTD
Fax: (+65)6863 8310 64 D2 Street, Van Thanh Bac Precinct, Ward 25,
Sinh Thanh District, Ho Chi Minh, S.R. Vietnam
Tel : (+84)8 3512 8379
CIRCULATING WATER PUMP- MCT-N
Published by ryliura Co .,Ltd . Ship Machinery Dept. October 2001 .
71h edition Apr. 2009. No. E970-011 0-07
All rights reserved , Copyright © 2009 MIURA Co. , Ltd.

No part of this publication may not be reproduced , transmitted, distributed or
publisher Miura Co ., Ltd .
Visit us at www.miuraz.co.jp and get the latest information and Service News!
Printed in Japan

Mm-14 Inst. Book For Aux. Boiler & Exh. Gas Economizer

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lVIII URA

MARINE AUXILIARY BOILER

Thank you very much for selecting HB Boiler.

& 1. Terms ···············································································································5

6-17 Thermostat (For fuel oil) ··· · · · ·· · ·· · · · · ·· ··· · ·· · ·· · · · · ·· · · · ·· · · · · · ·· · ·· · · · · ·· · · · · ·· · · · · ·· · ·· · ·· · · · ·· · · · · · · · · · · ·34

6-21 Pressure switch (for steam and fuel oil) ·· · ·· · ·· · · · · · · · · · ·· · · · · · ·· · · · · · · · ·· · · · · ·· · · · · ·· · · · · · · · ·· · ·· · · · · · · · · · ·40

6-23 Duplex strainer (For fuel oil) · .... : · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · ·43

6-25 Sequencer (Programmable controller) · · · · · · · · .. · · · · · · · · .. · · · · · · .. · · .. · · · .. · · .. · · · ... · · · · · · · .. · .. · · · · · · · .. ·46

6-26 Flame detector (FS-1 00) · · · · · · · · · · · · .. · · · .. · · · · · · · .. · · · · · .. · .. · · · · · · .. · · .. · · · .. · · · · · · · · · · · · · · · · · .. · .. · · ···· · .. ·52

7. Automatic operation of the boiler by the sequencer················································ ···54

(2) Feeding water to the boiler .. · .. · · .... · · · · · · · .. · · · · .. · .. .... · · .. · .. · · .. · · · .. · · · · .. · · .. · · · · · · .. · · .... · .. · · .. ·65

(4) Termination with 0 .0 (Heavy oil A) ......... : ........................................................... 65

12-1 Water Feeding System · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·70

4. Number in the pointing hand sign indicates the page for

2-1. Scald warning label

2-3. Electrification warning label

2-4. Trap warning label

2-5. Damage warning label

3-1. Carry out a check before using the device

3-2. Wear proper outfit and protection gears

3-4. Use the designated fuel

3-5. Do not keep flammable goods near the boiler

3-6. Keeping a fire extinguisher and first-aid kit

3-7. Advice on moving the boiler or selling the vessel

4. Boiler's outline drawing

This photo shows the boiler of HB.

1 Main Steam Valve 8 Blower Unit & Motor

4 Fan Duct 11 Manhole (Lower Drum)

1) - - --. 1 Main Burner Details of water tubes fitting

The boiler has a structure with the donut shaped Lipper

6. Structure, part names, inspection and adjustment of each device

7) 5) 6) 8) 9) 10) 11) 12) 14)

1 Wind Box 6 Solenoid Valve(N .O.) 11 Expansion Joint

6-2 Burner Assembly (Boiler top)

6-3 Burner element

1 Primary duct gun holder

1 Primary duct gun holder

6-4 Fuel oil pipring diagram

GLOVE VALVE SOLENOID VALVE M-4 AUTO STRAINER (PILOT)

PUMP THERMOCOUPLE TS-1 THERMOSTAT (LOW TEMP.)

N CHECK VALVE COMPOUND GAUGE SV-2 SOLENOID VALVE (STEAM)

6-5 Flame funnel & Diffusers

Structure of Burner nozzle

Please make sure the direction and the order of

1 ADAPTER 8 0-RING NUT 15 NEEDLE PISTON 22 0-RING

6-7 Primary Air Damper & Diffuser

6-8 Pilot Burner

1 Diffuser for pilot

For this burner. a pilot burner ignition system is

Nozzle Tip for pilot burner

Body Screw Pin Filter

6-9 Combustion control unit

(1) Control system

Flow control valve

[J_ a~rflo~Droller_ ~-~~

(2) Cam motor

(3) Oil Flow control valve

P1 :circulation oil pressure

• • At low combustion , notch goes down and the resis-

Fuel flow control valve

F.O. Oil Flow Adjustment

Once the damper opening determined. adjust the oil flow

& Caution & Warning