Auxiliary Boiler Aalborg MISSION OM 25 Instruction Manual

SL,SJ Series Safety Valves (FUKUI) A12E1
SL, SJ SERIES SAFETY VALVES

INSTRUCTION MANUAL
For Maintenance
SL TYPESL100SL300
SJ TYPESJ100SJ300
PRECAUTIONS ON SAFE OPERATION

DO NOT FAIL TO READ THROUGH THE FOLLOWING PRECAUTIONS
PRIOR TO USING SAFETY VALVE, AS IT IS ARRANGED TO ENSURE SAFE
OPERATION OF THE EQUIPMENT.
FUKUI SEISAKUSHO CO., LTD. is a professional manufacturer of safety valves,

and has provided customers with many safety valves.
The instruction manual describes the warning and safety precautions at its beginning,
so that the safety valves can be used in safe and under reliable conditions.
If these warnings and precautions are fully read prior to handling, repair or
maintenance, it will be possible to minimize any unstable conditions which may be
caused due to accident, incorrect handling or unsafe operation.
It is absolutely impossible for FUKUI to assure/predict all possible dangers or risks
which may occur at the customer, user or maintenance/repair company, and
therefore to provide them with advise.
When performing maintenance, repair or operation, using any other method or tool,
which is not covered in the manual, it is necessary to fully acknowledge, that the
safety of the operator himself or the safety valve may be compromised.
Since high-pressure/high temperature fluid is used for testing, or during installation
and/or prior to removal of safety valve, it is necessary to put on the protective
glasses, earplugs, safety gloves, etc.
Since the work environment for FUKUIs product, including danger which may be
present during such work may be extremely diversified, it is not possible for FUKUI
to predict the provable injury or damage. It is to be acknowledged that the warning,
precautions, etc. are recommendations only for a safety procedure and are provided
as an aid for safety.
Language UK Page 1 - 1 - 1/26

PREVENTIVE MEASURES FOR SAFETY

DO NOT FAIL TO OBSERVE THE FOLLOWING PRECAUTIONS, TO
ENSURE THE SAFETY DURING TEST, INSTALLATION, MAINTENANCE,
ETC. OF SAFETY VALVE.
1. Do not stand in front of safety valve outlet while the safety valve is being tested or
operating.
2. Be sure to put on earplugs while the safety valve is being tested or operating.
3. Never attempt to look through the valve outlet carelessly during adjustment or
valve seat leakage test.
4. Never install the safety valve horizontally, i.e., the valve inlet centerline shall be
vertical with base of valve facing down.
5. Be sure to lead the drain piping to safe place from the safety valve should a
connection be provided.
6. Secure a proper space at the circumference of safety valve, to allow the accessing
in 360, plus another space at the upper side, to allow the disassembling for test
or maintenance.
7. When removing the safety valve from the equipment, make sure that the internal
pressure is fully relieved, make it a rule to stand at a safe position, and put on the
proper protective clothes, and safety glasses as the residual fluid may be splashed,
onto your body.
8. Be sure to put on the test gag if provided always during ring adjustment. After
testing, the gag must be removed.
9. For the safety valve provided with a lift lever, attach such valve with its lever
located at a proper position, so that the lever should not be pulled up accidentally.
10. Keep the discharge port of the back pressure adjustment needle pointed in the
direction free of danger. If possible, it is desirable to connect the discharge port to
the discharge pipe if it is not subject to excessive back pressure. Consult with
FUKUI for suggestions and recommendations. Do not attempt to execute
excessively long piping for this discharge connection.

CONTENTS
1 Storage and Handling

1-1 For Handling 4
1-2 For Storage 4
2 Installation
2-1 Safety Valve Installation 5
2-2 Circumference Inlet Pipe 5
2-3 Discharge Pipe 6
3 Hydrostatic Pressure Testing of Vessel 7
4 Field Setting of Safety Valves
4-1 Adjustment of Set Pressure 9
4-2 Variation Rate of The Set Pressure 9
4-3 Tolerance of Set Pressure 10
4-4 Adjustment of Blow Down 10
4-5 Adjustment of Simmer 12
4-6 Standard Positions of Upper and Lower Rings 13
4-7 Trouble Shooting. 14
4-8 Trouble Shooting for Other Diffcult Problems 16
4-9 Leaking of Safety Valve 17
5 Maintenance
5-1 Removal 17
5-2 Disassembly Procedure 18
5-3 Checking 19
5-4 Lapping 20
5-5 Cleaning 23
5-6 Reassembly 23
5-7 Changing the Set Pressure 25
6 Spare Parts 25
7 Maintenance Tools and Supplies
7-1 Lapping Blocks 25
7-2 Lapping Compounds 26

SL (SL 100-SL300)
SJ (SJ 100-SJ300)
1 Storage and Handling

Fukui safety valve is, unlike its sturdy appearance, a highly sensitive device which is
machined highly precisely on dimensional torelances for its main parts, to keep high
quality performance. And also, our safety valves are manufactured under our strict
quality control due to stable functional performance and perfect sealing effect, and
then they are delivered from our shop after they passed our severe performance test
in accordance with our test/inspection standards. Take care of the following
necessary items for storage and handling the safety valve.
Moreover, please refer to specified rules (both mandatory and nonmandatory) in the
JIS B 8210, API RP 520, ASME Sec PG71, ASME Sec Appendix M, etc.
1.1 For Handling
(1) Don't perform rough unpacking, rough handling or sharp impact, if not so, the
main parts of safety valve are damaged or subjected to shock, the centering will
be out of alignment, resulting in unsatisfactory operation and seat leakage.
(2) When unpacked safety valves (open type) are transfered to the site, special care
should be taken not to hook the part of which function and adjustments could
be interfered with (i.e. lifting lever, inside of york, etc.,) by use of a rope, a
hook or the like because they are subjected to malfunction. Never rope or hook
the spring to lift.
1.2 For Storage
(1) Since safety valves are, in many cases, delivered at several months prior to
installation, the protective plates should never be removed just before the safety
valves are installed on the site or perfomed the acceptance test, and they should
be stored in the clean room to be free of dirts and low humidity condition.
In the cases there are very long period before the safety valves are installed on
the equipment after acceptance test, reinstall the protective plates on both inlet
and outlet flanges of the safety valves, and then store them as above mentioned.
(2) Safety valves should not be piled up along with other products and should
always be kept with the inlet down.

2 InstaIIation
2-1 Safety Valve Installation
(1) Prior to installation of safety valves, a visual inspection should be carefully

carried out, and the protective plate of inlet and outlet, the temporary
attachments of inner portions of nozzle seat and outlet of valves (so that the
inlet and outlet portions of the valves may contain bags of desiccant) and others
etc., are all removed.
(2) If foreign materials are in the internal of the nozzle seat, that should be removed
by using a cloth or blown away by compressed air. Accumulation of foreign
materials in safety valve inlet ports will be carried across the seat (i.e. between
disc and nozzle seat) while the valve is in operation and is frequently the cause
of seat leakage.
(3) A safety valve should be directly installed on the inlet pipe in the vertical
position only. Otherwise, if the center axis of the moving parts is put out of
alignment, which will affect the valve performance. Normal tolerance on
vertical installation is 1.
(4) When a flanged valve is installed, ensure that a gasket size perfectly matches
the flange size, not to reduce the valve inlet and outlet port area. Also, the
flange bolts must be fastened eavenly.
2-2 Peripheral Equipment of Inlet Piping
(1) Just before installing a safety valve, the protective fitting on inlet and outlet
shall be removed. And also, particularly in case of a newly installed boiler or
vessel, there are many possibilities of spatter, slag produced at the time of
welding, dust, rust and other foreign matters being present inside, therefore such
boiler or equipment including pipe line should be cleaned as thoroughly as
possible before the safety valve is installed.
(2) Inlet pipings on boiler and or vessel to be fitted with a safety valve must be
made as short in length as possible, and then its inlet pipe entrance (diameter is
D) must be rounded to a radius as large as possible (at least 1/4 D) and its inner
diameter must be larger than inlet size of safety valve, the pressure loss of
safety valve's upstream should not be exceeded 2 of set pressure.
(3) Safety valves should be installed at least eight and more pipe diameters down
stream from any bend or any regulator valve in a pipe line.
(4) The space for maintenance working in Fig.1 must be kept as sufficient as
possible to work for adjusting and/or maintenance of safety valves.
(5) For 4 inches and larger safety valve, it facilitate to provided a hanger hook
at upper of it, for working, installing, removing and disassembling a safety

valve and minimizing the risk of personal injury.
Fig.1 Example of Good Installation
2-3 Discharge Pipe
(1) The size of the discharge piping should never be less than the valve outlet size,
and its pipe line while having large curved section, should be led to out door,
and then the arrangement should also be as short as possible. In case where
discharge piping is longer inevitably, use a straight pipe as possible and increase
its nominal diameter by 1/2 to 1 inch for every 5 meter of pipe length from
standard position.
(2) The distance from the center of safety valve to the center of discharge pipe shall
be limited to a valve less than or equal to 4(four) outside diameter of discharge
elbow.
(3) Where more than one discharge pipe are required to be connected to common
main line, the converging angle should be kept at 45or less and the area of the
main line not be less than the combined area of the discharge pipes.
(4) An exclusive expansion joint for the discharge line should be installed so that it
will not impose undue stress or bad effect on the safety valve when considering
thermal expansion of a boiler, a vessel or a discharge pipe. And then, the
discharge piping to insert to the drip pan of expansion joint should be anchored
to support the building structure as not to press the drip pan.
(5) For safety valve in the steam line, due to discharge drain water which is
condensed during blow off, ample provision for drain shall be made in the valve
body or in its outlet piping and this drain should be piped to a safe discharge
area. And also provide a drain pipe for the drip pan of expantion joint.

3 Hydrostatic Pressure Testing of Vessel

FKI steam safety valves employ a disc structure of a feather lip type for low and
medium pressure services, and of a thermal lip type for high pressure/ high
temperature services, respectively. In addition, the valve inlet is of a flanged type
for low and medium pressure services, and of a welded type for high pressure/ high
temperature services. Perform hydraulic pressure testing on the pressure vessel
(boiler) with these valves mounted, in accordance with the following procedure.
(1)For flanged type safety valves

Conduct hydrostatic pressure testing on the vessel with a blind plate provided
between the valve bottom and the nozzle stub. (Note: For safety valves equipped
with a hydrostatic pressure test plug before delivery, observe Step (2) below.)
(2)For welded type safety valves (See

the document "Handling the
hydrostatic pressure test plug"
attached hereto.)
Safety valves of this type are
delivered with a hydrostatic
pressure test plug built in, and
a caution plate attached as
shown in Fig. 2.(1)
(excluding some safety valves
for low pressure service). For
details, see the approved
drawing(s), etc.
Fig.2(1) Tag Plate
Upon completion of the pressure test, keep this test plug with care in the
specified accessories box, for reuse at the time of periodic inspection.
When conducting a pressure test at a pressure lower than the valve set pressure,
it may be carried out using a test gag alone without using this test plug. On the
other hand, however, to perform a test at a pressure above the set pressure, be
sure to use the test plug. For safety valves delivered with a test plug attached, it
is pre-loaded and therefore tightening the test gag slightly is good enough.
Furthermore, when testing safety valves for set pressure adjustment purposes,
take care not to hook the test gag before a boiler is ignited (namely, when the
boiler is cold). If the spindle is not in a state of being freely expandable in
accordance with changes in temperature, it may be caused to bend or other
internal parts damaged.
(3)Handling the test gag

This test gag is used to prevent non-test valves from operating when testing is
carried out on a specific safety valve for set pressure adjustments. The use of this
gag is similar to that used in a hydrostatic pressure test. Use the test gag as
instructed below.

When raising the pressure

When the pressure has reached
about 80% of the valve set pressure,
tighten the test gag shown in Fig.
2(2), and further tighten it in
gradual degrees as the pressure
increases. At this time, take care
that excess tightening may bend the
spindle or cause damage to the
nozzle seat or other problems. If a
seat leak should occur due to
insufficient tightening of the test
gag, then temporarily decrease the
pressure to the point where the leak
stops, and retighten the gag.
Fig.2(2) Test Gag and Plug
Be sure to observe this procedure because failing to do so makes it difficult to stop
the leak, as well as leads possibly to damaging the nozzle seat.
When lowering the pressure

In contrast with the above case of raising the pressure, loosen the test gag when the
pressure has decreased to about 80% of the set pressure.
When the hydrostatic pressure has been completed, remove the test gag and the
hydrostatic pressure test plug accordingly.
4. Field Setting of Safety Valves

The field setting of safety valve is dangerous work, it is very important to pay due
attention to prevent a risk of personal injury or a hazard. Adjustment of all safety
valves manufactured by us is performed by ourselves at our works, but where the
valves are adjusted by yourselves at the field, any adjustment may be necessary for
blocking it. Make adjustments of safety valves in the following manner. When
adjusting a safety valve, first lower the pressure in the equipment (i.e. boiler and or
pressure vessle) at 85 or less of the set pressure of a safety valve to prevent hazard,
and make necessary adjustments on each adjusting part of a safety valve.
In case where two or three safety valves are installed on equipment, fasten the test
gags of all valves other than a blocking and adjusting valve at 70 to 80 of the set
pressure. (The test gags are fastened lightly using fingers to prevent bending of the
valve spindle.) For the order, the test gag of lower set pressure valves is fastened in
advance usually.
Furthermore, perform hand-blowing of each safety valve at about 90 of the set

pressure before allowing the initial popping actipn to take place.
When they have passed some months after the safety valves were installed on the
equipments, that are considered that forein matters enter in that and adhere to main
parts. Therefore that are recommend that the safety valves are disassembled and

main parts are maintain at just before the field setting. This procedure shall be
refered to Item 4.9.
4.1 Adjustment of the Set Pressure
All of the safety valves have been adjusted accurately by us at our works with steam
pressure so that there will be no need of further adjustments. In case that further
adjustment is required, remove the cap, and adjust in the steps as followings.
Table1
Intended State of Operation Adjusting Method
Turn the adjusting screw clockwise (When viewed
To raise the set pressure
from above) and tighten it up.
Turn the adjusting screw counterclockwise to
To lower the set pressure
loosen it.
Fasten the lock nut each time after the set pressure is adjusted.
4.2 Variation Rate of The Set Pressure
In the following table the variations in percent per one turn of the adjusting screw
are shown.
Table2
SL Type Orifice Letter DF G H J K L M N P Q R T
Variation () 22 17 13 11 9 7 6 6 5 4 3 2
Table3
SJ Type Orifice Letter F2 G2 H2 J2 L1 M N3 P2 Q2 Q3 R T
Variation () 22 13 11 9 7 6 5 5 4 4 3 2
[For example]
Type SL Type
Size 8T10
Set pressure 8 f/cm2 G
[Answer]
Variation in percent for Orifice Letter
T:2
Variation per one turn:
8 f/cm2 G20.16 /cm2 G
Fig.3

4.3 Tolerance of Set Pressure

2
Table4 unit:MPa (kgf/cm)
Set pressure Tolerance
0.5(5) or less 0.014(0.14)

above 0.5(5), below 2.3(23) 3 of set pressure
above 2.3(23), below 7(70) 0.07(0.7)
above 7(70) 1 of set pressure
(Note) Above mentioned table is based on table 1 of Item 4, JIS B 8210 1994.
Provided that where it is not allowed to exceed the set pressure,
the tolerance of plus() side can be added to the minus() side.
4.4 Adjustment of Blow Down
(1)Adjustment by upper ring

Because the closing pressure has relation with the capacity and resistance in the
piping, it is difficult to set it in the test stand at our shop so that it will accurately
fit the situation in the field though all valves are adjusted on the our test stand
and delivered to user.
For this reason, it is common practice to adjust the closing pressure of a safety
valve of a boiler locally after the valve is installed on the boilers.
The main adjusting device used for adjustment of the closing pressure is the
upper ring provided at the bottom part of the guide. This upper ring imparts a
lifting force to disc after the disc has been popped up. To make the adjustment,
first remove the lock bolt provided at the side wall of the valve body, through this
screw hole, insert the adjusting rod as shown in Fig.5 and or rod like a screw-
driver and turn the teeth provided along the external circumference of the upper
ring by using it, where upon the upper ring will be moved vertically.
Table5
Intended state of operation Method of adjustment
Peeping through the screw hole, rotate the

upper ring with the adjust. Rod to the right by
To raise the closing pressure
0.5 turn to move it upward. Or throttle the
opening area of the back pressure adjust needle.
Peeping through the screw hole, rotate the
upper ring with the adjust. Rod to the left by
To lower the closing pressure
0.5 turn to move it down. Or enlarge the
opening area of the back pressure adjust needle.
JIS B 8210-1994 mentioned above also specifies the closing pressure tolerances for
steam-service safety valves as shown in the next table. The tolerance for closing
pressure exceeding 0.3MPa(3 f/cm2) of steam-service safety valves that are to be
used in once-through boilers, reheaters, piping, etc. can be determined as 10 of set
pressure or less.

Table6 unit:MPa ( f/cm2 )

Set pressure Blowdown
0.4 (4) 0.03 (0.3)
0.4 (4) 74of blow-off pressure
Notes:
1) Blowdown for steam-service safety valves shall be differential pressure between
blow-off pressure and closing pressure.
2) The value in parentheses can be used if agreed between the parties concerned.
The following table shows the limits of number of notches for upper ring vertical
movement from the upper end surface of nozzle seat. For the standard set position of
upper ring, please refer to the Item 4.6.
Table7
Upper lower Upper lower
No. of No. of
SL Type Limit of Limit of SJ Type Limit of Limit of
Notches Notches
Orifice Adj. Adj. Orifice Adj. Adj.
for 1 for 1
Letter Notch Notch Letter Notch Notch
Turn Turn
No. No. No. No.
DF 39 78 26 F2 30 90 30
G 30 90 30 G2 55 148 37
H 55 148 37 H2 82 164 41
J 82 164 41 J2 85 136 34
K 85 136 34 L1 117 195 39
L 117 195 39 M 126 210 42
M 126 210 42 N3 175 250 50
N 147 210 42 P2 216 240 48
P 216 240 48 Q2 200 250 50
Q 297 270 54 Q3 297 270 54
R 434 310 62 R 434 310 62
T 558 310 62 T 558 310 62
(2)Adjustment by Adjust Needle

Safety valves SL & SJ are equiped
with an adjust needle shown in Fig.4
as an auxiliary for adjustment of
closing pressure. Back pressure on the
back side of the disc is adjusted by
varying the opening area of the adjust
needle and this back pressure controls
the closing pressure of the safety
valves. The closing pressure raised up
by means of closing the adjust needle
and lowered by means of opening, but
never totally close.
Fig.4

Moreover, it is recommended not to connect a pipe to a discharge opening of adjust

needle. Even if connect to it, only elbow and a pipe (shooter than 50 ).
Adjust Needle Standard Position, Normal Dimensions of Screw Threads for Adjust
Needle Opening.
Table8
Adjust
Types and Orifice Designation Dimension
Needle
of screw
Standard
threads
SL100, 200 SL300 SJ100, 200 SJ300 Position
in Rp
H
D,E,F,G D,E,F F2 1/2 27
H,J G G2,H2 F2,G2 3/4 35
K,L,M J,K J2,L1,M H2,J2 1 45

L,M,N, N3,P2,Q2, L1,M,N3,
N,P,Q,R 1-1/4 51
P,Q,R Q3,R P2,Q2,Q3,R
T T T 1-1/2 55
4.5 Adjustment of Simmer
If the simmer is too large, raise

the lower ring one notch at a
time. To accomplish this, cut
the seal wire, remove the lock
bolt, insert an adjusting rod
into this bolt hole and turn the
notches on the outer
circumference of the lower ring
to clock wise using the above
rod. If so, the lower ring moves
upward by screw. Refer to
Fig.5. The following table
shows the limits of number of
the adjusting notches for lower
ring vertical movement from
upward end surface of nozzle
seat.
For the standard set position of
lower ring, please refer to Item 4.6.
Fig.5

Table9
Upper lower Upper lower
No. of No. of
SL Type Limit of Limit of SL Type Limit of Limit of
Notches Notches
Orifice Adj. Adj. Orifice Adj. Adj.
for 1 for 1
Letter Notch Notch Letter Notch Notch
Turn Turn
No. No. No. No.
DF 3 36 36 F2 3 28 28
G 3 28 28 G2 3 33 33
H 3 33 33 H2 3 30 30
J 3 30 30 J2 3 38 38
K 3 38 38 L1 4 42 42
L 4 42 42 M 4 32 32
M 4 32 32 N3 4 37 37
N 4 36 36 P2 4 40 40
P 4 40 40 Q2 4 48 48
Q 5 52 52 Q3 5 52 52
R 5 46 46 R 5 46 46
T 5 46 46 T 5 46 46
After the adjustments of the upper

ring and the lower ring have been
completed, arrange that the grooves
on the teeth provided on both the
upper and lower rings are facing the
center of the screw hole for the lock
bolt.
After insuring this correct positioning,
replace the lock bolt and tighten it.
If the positions of the grooves of both
rings were not correct, the tip of the
lock bolt presses the ring with undue
force, thereby deteriorating the function
of safety valve.
Fig.6 Lock Bolt & Adjusting Ring
Groove Positions
4.6 Standard Positions of Upper and Lower Rings
The standard positions of both upper and lower rings of types SL and SJ valves are
shown the following table.
Upper ring standard position;

The notches number of out-side circumference of upper ring from upper end
surface of nozzle seat
Lower ring standard position;
The notches number of out-side circumference of lower ring from contacting
bottom surface of disc.
Symbol() shows downward travelling.

Table10 Type SL Table11 Type SJ

Orifice Upper Lower Orifice Upper Lower
Letter Ring Ring Letter Ring Ring
DH 30 4 F2J2 30 4
JK 40 8 L1P2 40 6
LP 50 10 Q2Q3 50 8
QT 60 12 RT 60 8
4.7 Trouble Shooting.
Table12
Problem Phenomenon Probable Cause Corrective Action
If the blowdown is too

large, raise the upper
Upper ring ring 1 turn.
Lift is obtained,
position is too
but blowdown is
low, lifting force If the blowdown is
large.
is too large. slightly large, raise the
upper ring 0.5 by 0.5
turn.
Lift is obtained,
Upper ring
but it falls after
position is too Move the upper ring 0.5
a short duration,
high, lifting force by 0.5 turn downward.
and blowdown is
is too small.
large.
Back pressure on
Lift is attained the disc is too Throttle the adjust
but blowing does small. needle.
not stop
immediately Lower ring Move the lower ring 1
before closing. position is too 2 notch turn downward.
high.

Problem Phenomenon Probable Cause Corrective Action
Lift can't be
obtained and
blowdown is Upper ring Move the upper ring 0.5
small. position is too 1 turn downward.
high.
Lift can't be If safety valve doesn't
obtained and Lifting force is close, perform hand
blowdown is too small. blow.
large.
Upper ring
To correct this, first
position is too
Chattering soon lower the pressure by
high.
after the hand blow, and then
opening. move the upper ring 0.5
Lifting force is
1 turn downward.
too small.
The back
pressure of disc To correct this, first
Lift is is too high, lower the pressure by
satisfactory, but because the hand blow, and then
flutter occurs discharge pipe is move the back pressure
during opening. too long and/or adjust needle 0.51
equipped with turn upward.
silencer.
The pressure Increase the blowdown

loss at the inlet pressure. Decrease the
pipe is larger lift. Decrease the
Hunting occurs
than blowdown. pressure loss at the
immediately
inlet pipe. Move the
after opening.
The back back pressure adjust
pressure on the needle 0.51 turn
disc is too high. upward.

4.8 Trouble Shooting for Other Diffcult Problems
Table13
Problem Probable Cause Corrective Action
Lapping surfaces of disc and Disassemble valve, lap surfaces of

nozzle seat are damaged. disc and nozzle, if required replace
disc by Instruction Manual.
Discharge pipe is bound on If necessary, remove undue stress

outlet, and valve is imposed on safety valve.
with undue stress.
The parts of safety valve are Disassemble valve, inspect contact

Valve leaking misaligned. area of disc and nozzle seat,
and/or exhibits spring washers and spindle,
miss popping adjusting screw, spindle
action. straightness. If necessary, repair
or replace them.
Disc reseat insufficiently. First, tighten lightly the valve

spindle using test gag, and then
hammer lightly the connecting
area of yoke.
If necessary, disassemble valve
and check disc for proper
reseating.
Foreign materials are Disassemble safety valve, and

entrapped between guide remove the foreign materials
and disc holder. using sand paper or the like, and
No action. correct any abnormal condition.
Valve does not Upper ring position is too Adjust upper ring as outlined in
open full lift. high. the manual.
Lower ring position is too Adjust lower ring as outlined in

low. the manual.
Forein materials. Disassemble safety valve, and

remove foreign materials.
Valve does not
close from full lift
Lower ring position is too Move the lower ring 1 notch turn
or hang up.
high. to downward per adjustment until
problem is eliminated.
Connecting pipe lines are Investigate and eliminate cause.

vibrating.
Simmer
Lower ring position is too Adjust lower ring as outlined in
low. the manual.

4.9 Leaking of Safety Valve
Whenever leaking is observed at less than normal operating pressure, find out its
cause as soon as possible and it must be removed. If as it is while long times, the
damage of safety valve will become greater.
(1)Leaking of valve seat and disc by foreign matter

If foreign matter (i.e. welding bar, scale of pipe etc.,) from equipment or piping
system is caught between the nozzle seat and the disc, the leaking will be caused.
However, such foreign matter may sometimes be blow off when the safety valve
is opened again (or by means of handling the lifting lever as required), thereby
leaking is stopped. If not so, leaking is continue and the valve seating surface is
badly damaged, then lap and repair the sisc and the seat is required.
(2)Reaction Force From Discharge Piping

Leaking may be caused if the out let of safety valve and the discharge pipe are
connected unevenly and then they impose undue stress on the out let of safety
valve. However this can be corrected by improving the installation of the
discharge piping in early time. The acceptable load of safety valve is only a
weight of the short discharge elbow itself and its flange.
(3)Difference between Operating Pressure and Set Pressure

After safety valves are comfirmed to be free from leaking at the seat surface at
90 of set pressure in air tightness testing to be carried out at shop, they are
delivered. In case where operating pressure is higher than 90 of set pressure,
leaking may be caused. In this case, decrease operating pressure to equal and less
than 90 of set pressure as soon as possible.
5. Maintenance
Carry out the most proper service and repair to taking a knowledge of the condition
of safety valve so that the safe, reliable operation of all valve products is kept.
Proper maintenance manual are recommended as follows.
5.1 Removal
Firstly, be sure that there is no pressure in the vessel and remove a safety valve from
vessel, next transfer it in a clean room and perform next procedure.
In case where a safety valve is disassembled at near place of the vessel or boiler due
to weld with inlet pipe on the vessel and or difficulty of transportation of the valve,
it is recommended to provide of small boxes and to put small parts of valve into
these boxes. This manner is effective method of prevention of confusion with parts
of other valves, loss and dropping.

5.2 Disassembly Procedure
(1) Disassembly for Overhall

Unlock or remove the seal, pull out the split pin and the
fork lever pin to remove the fork lever. Then, loosen the
set screw, and remove the cap.
Remove spindle lock nut, lifting washer and adjusting
screw. In this time, take records or put matching marks
on the adjusting screw to facilitate the reassembly.
Remove the spring cover. Remove the nut that connects

the yoke with the body, and lift up the block composed
of the yoke, upper spring washer, spring and lower
spring washer. Be careful not to bend the spindle in
this lifting up process. Make matching marks in the
axial line on both flange yoke and body, and then pull
out the spindle.
Pull out the disc from the guide. Pay special attention
this time not to cause damage to the disc and nozzle
seat surface.
Remove the upper and lower lock bolt. Then put the
matching marks on the ring or record the number of
notches moved, to facilitate the reassembly.
How to Record
Upper ring
Record the number of notches moved by turning the upper
ring upwards (i.e. clockwise viewed from outlet side of
valve) until it reaches the dead end.
Lower ring
Record the number of notches moved by turning the lower
ring upwards (i.e. clockwise viewed from outlet side of
valve) until it reaches the dead end.
Pull out upward the block consisting of the guide and

upper and lower ring. Thus the disassembling is
completed.
Fig.7
(2)Disassembling Procedure for only Inner Parts of Valve Body

(i.e. partial disassembling of the disc and nozzle seat or replacement of disc etc.,)
For checking or maintaining of the valve inner parts such as only lapping of
disc and nozzle seat, or replacement of the disc only, if its disassembly is
carried out in following order, it can be done very easily without readjusting
the set pressure. Procedure to remove cap is the same as above mentioned(1).
At once, remove spindle nut and lifting washer from spindle, to insert a pipe
or nut (these are a little larger dia. than spindle) in the space between lifting
washer and upper end of adjusting screw. And then screw down spindle nut
and lifting washer.

Make matching mark in axial line on both flange yoke and body and then
remove the nuts that connect yoke to the body, lift up the yoke block consist of
sprin, spring washers and spindle slowly in perpendicular direction. In this
case, take care not to bend spindle to hit the other.
Thereafter, follow (5) and (6) in Item 1. Disassembly For Overall described
above.
5.3 Checking
Check all the parts disassembled one by one. Particularly, the following items are
important.
(1)Seating Surface of Disc and Nozzle Seat

If an inspection of the parts shows the valve seating surface to be badly damage,
bite or scratch, the lapping will be required.
(2)Sliding Surface between Disc Holder and Guide

If damages, dirts, foreign matters and the like are appeared on the sliding
surface between disc holder and guide, it is very important to remove them
from these surfaces by using of fine sand paper. In this time, take care not to
rub their seat surfaces with sand paper. And then should do checking if
smoothly moving could be attained by means of sliding the disc holder and
guide after having repaired.
The Clearance between Disc Holder and Guide
Check if the clearance between the out side of the disc holder and the guide as
shown Fig.8 is within the limit as describe below table.
Table14
Out Dia. of Disc AB
50 0.15 0.30
50 O.D 100 0.20 0.38
100 O.D 150 0.25 0.47
150 O.D 200 0.30 0.56
200 O.D 0.40 0.75
Fig.8

(3)Checking Spindle Concentricity

In order to transmit the spring load to the disc without lateral bending, the spindle
of the safety valve must be straight. Since the valve spindle may be bent by rough
handling or over gagging at the test, check the spindle for bend by the following
manner. Checking the block on a lathe as shown in Fig.9, to fix the end of the
spindle, and support the other end with the tail stock center. With this setting,
rotate the spindle gently, and apply a dial gage at the center part of the spindle,
and then measure the deflection of the spindle. The value of this deflection to be
0.15 or smaller per is a allowable. If there is the deflection more than this, it
must be repaired or replaced with spare.
Fig.9 Checking Spindle Concentricity with lathe
(4)Flange Engagement of the Valve Body and the Yoke

If there are the damages, dirts and foreign matters on the claws or groove made
on the flange engagement of the valve body and yoke, remove completely them.
If they remain, the performance of safety valve may be badly affected as a
resulting of misalignment will be caused easily on their concentricity.
(5)Rust or Corrosion on the Body, etc.

When there is a excessive rust or heavy corrosion on the inside or outside surface
of the valve body etc., they should be removed from it by the brush and so on,
and then it is recommended to coating the anti corrosive paint (where is high
temperature, to be coated the heat resisting paint). As a resulting of this
procedure, the maintenance after next time will be done easily. But do not coat
the paint on the engaging flange engagement surface.
(6)Corroded Spring
If spring is corroded or has a crack, it is recommended that spring should be
examined by means of magnetic particle test if possible or liquid penetrant test.
If its defect is large as like that spring is considered to broken it during the
operation, replace its spring with spare parts.
5.4 Lapping
In a majority of cases, the parts which a safety valve lapping are required are
surfaces of disc and nozzle seat. As a result of to done with most carefully, lapping
may be accomplished easily.

If the parts are damaged as like that can not reconditioning by means of lapping, this
parts should be exchanged with spare parts.
(1)Lapping Precaution
During the lapping of nozzle seat and disc seat it should be done in clean
environment, free of dirt and dust, observing the following instructions.
The valve disc, nozzle seat and the lapping tools should be cleaned off. (i.e.
free of dirt and dust)
Always use a fresh compound mixed to the proper hardness, and apply a
very thin layer of compound the block, and then the lapping should be
done. Applying too much compounds tends to round off the both edges of
the seat and form a mountain shape.
Perform the lapping of each surface of disc and nozzle seat while keeping
them holizontally.
To determine if the surfaces of disc or nozzle seat are sufficiently flat, the
ample exprience is necessary. As for handy method an optical light is
emplyed. When light is on the lapping surface, the concave parts on the
surface appears like shadow in contrast to the bright parts. Therefore, the
lapping work is considered to be finished when such shadowed spots have
disappeared to present a uniform surface has been attained.
The surface of the block should be reconditioned at timely. When a
appearance of the surface where is defaced by means of lapping the disc or
seat is different from the other areas and or the sufficiently flat is not felt
by put a finger on, recondition the surface of the block.
(2)The Required Tools for Lapping

Lapping block
3(three) kinds of lapping block (i.e. Rough, Medium, Finishing) are
necessary. It is recommended to use with corresponded compound as a unit.
Refer Fig.10(1).
Block for the Reconditioning Lapping
Block Surface
The lapping surface of the block after
accomplished a lapping of the valve nozzle
seat and disc is required reconditioning of
its surface at all times. In this case, the use
of with two block can be done the
recondition of their surface, but it is
recommended to adopt of the block for
recondioning lapping block surface as more
efficiently. Refer Fig.10(2). Fig.10(1)
Compound for Lapping
# 600 for rough lapping
#1200 for medium lapping
#3000 for finishing lapping
Lapping Oil for mixing the compound
Fig.10(2)

(3)Lapping of Valve Disc

For a valve disc, set up as shown in Fig.11, and lap in the order as described
below.
Fix the lapping block on the table to set horizontally.
Apply compound #600 that is mixed up at the proper hardness with
lapping oil thinly and uniformly over the block. Put the disc on the block
as shown in Fig.11, and
perform lapping by pressing
lightly against the block and
turning little by little. In this
case, be careful not to apply
too much force in lapping
until the fitting surfaces have
come to fit well each other.
The disc seat surface shall be
finished up to complete flat
by means of eccentric circular
motion.
Fig.11
When a lapped surface of the
disc has become as such as a
surface of the fruits of pear
uniformly, wipe the its
surface clean and remove the
leaving compound on it. It is
efficient to use the thinner
oils and the like. The lapping
times shall be increased or
decreased in accordance with
the surface condition of disc.
It is the standard that the
damage or scratch of lapped
surface is repaired completely.
Fig.12 Lapping of Nozzle Seat
Next, lap again using the compound #1200 mixed with oil by means of
above mentioned procedure. Use the proper block for medium lapping as
possible.
The final finishing lapping is done applying the compound #3000. If oil
content on the lapping surface is small, the lapping face may cause to stick
on the block. To avoid this, be careful to keep that oil film is remained at
all times on the lapping block while the lapping work is done. Use the
proper block for the final finishing as possible.
(4)Lapping of Nozzle Seat

In lapping a nozzle seat arrange each part as shown in Fig.12, and lap the nozzle
seat properly as same as in order of lapping procedure of disc. For the lapping
block, it is recommended to use the block corresponding the lapping compound
as same as a case of disc.

5.5 Cleaning
It is dessirous the valve disc and nozzle seat which have been lapped and other parts
which have been repaired be cleaned carfully with a washing liquid as like trichlene,
thinner and or etc..
5.6 Reassembly
(1)For procedure overholed

Reassembly should be done nearly in reverse order to that of the disassembly.
In the internal of safety valve body, especially, lapping seat

surface of disc and nozzle seat should be cleaned by using a soft
cloth, and certainly apply an antiseize compound once more
again to the space to had coated it. (i.e. thread, tip of spindle,
adjusting screw, upper and lower spring washer etc..)
Thread the adjusting ring on to nozzle until lower position than
end of nozzle seat surface, and then restore itself at its original
position after reassembling disc.
Reinstall the guide in the valve body after to set the upper
adjusting ring at position where is recorded on disassembly. In
this time, make sure that there are no the foreign matters on the
valve body inner surface where the guide is inserted.
Wipe again both surfaces of disc and nozzle seat and make sure
that there are no foreign matters and the like on the sliding
surface that they are a disc out side and a guide inner side, and
after to insert the disc in the guide put it on the nozzle seat
gently.
To put the lower spring washer, spring and upper spring washer
in the central of yoke by visual measuring and then insert the
spindle on which is reinstalled lift stopper from under side of the
yoke, provisionally reassemble them as one block.
Next, reinstall this on the valve body after to apply with
antiseize compound on the tip of spindle and to taking care so
that it does not hit with other.
Slightly turn the yoke from side to side two or three times so
that it is confirmed to thoroughly-reassembed the yoke onto the
setting part of valve body. If the yoke does not turn smoothly in
the clearance between stud bolts and stud holes of yoke, it is this
cause that there are the foreign matters or damages and the like
on the surface of engaging parts and so this cause shall be
removed immediately. After that, fasten alternately and equally
the stud nuts located at symmetrical positons with each other so
that the flange will be even.
Install adjusting screw onto the spindle, keep the dimmentions
measured on the disassembly and thread clock wise until the
spring is pressed to determined compression.

When installed the

adjusting ring lock bolt, it
should be threaded in for
taking care as so that a top
of adj. ring lock bolt is
inserted into the groove of
adjusting ring out side.
Please refer to Fig.13.
And then, after adjusting
for operation of the safety
valve are finished, install the cap and seal it.
Fig.13. Adj. ring Lock Bolt
(2)For Procedure without Disassembling the Upper Parts including Yoke.

To apply antiseize compound on the tip of spindle and taking care so that it does
not hit the other install them (i.e. upper parts including yoke) on the valve body.
After that, the reassembly should be done as same as procedure below Item
5.6.(1) above mentioned.
By above described, the reassembly of safety valve is finished at all.
(3)If the matchmark have been disappeared and or the records of orignal position of
adjusting ring have been lost, provisionally set and adjust by means of procedure
discribed below.
Measure and record the height from the nozzle seat to the upper edge
surface of valve guide as shown in Fig.10, Dimmension B.
Determine the height from bottom line of upper adjusting ring to the upper
edge surface of guide by the following formula. Refer to Fig.14.
A=B+2
(equivalent to about 28 to 52 notches, depending upon the valve sizes)
And then provisionally reinstall the upper adjusting ring at this
position and start the adjusting.
Lower the top of lower adjusting by 0.4 (equivalent to about 7 to 10
notches, depending upon the valve sizes) from the upper level of the
nozzle seat to downward. And then make sure this height from the top of
lower adjusting ring to upper engaging surface is 0.4 larger than
Dimension B when to measure the B value.

Fig.14
5.7 Changing the set pressure
If it becomes necessary to change the revised set pressure from the value specified
on the nameplate, the spring must be replaced. Since spring has great influence on
the performance of a safety valve, springs that fit for the revised set pressure are
designed. Therefore, any change in the set pressure, please contact with us (i.e.
manufacturer) and then make sure the spring to be replaced is appropriate for
revised pressure. In replacing spring, both upper and lower spring washer should be
replaced simultaneously since they need to fit for the spring. It is necessary to
restamped on the nameplate or to replaced with new name plate.
6 Spare Parts
As regards the safety valve spare parts, it is necessary to store the proper quantities
of the requested spare parts depending upon the used condition. In maintenance for
safety valve, if enough quantities of spare parts are not stored and then it becomes
necessary to repair or to replace the parts, it may be required to shut down the
operation of the equipment for a long time or to make expediently repairs,
considerable amount of loss may be happened. Usually, the spare parts are springs
including upper and lower spring washer, discs and nozzles seat. It is recommended
to store the parts which may be corroded as spare parts at all times. Furthermore,
although spring and discs as spare parts exactly fit in specified condition, these parts
shall be not used for other than appropriate safety valves even if the size and the set
pressure is available. When ordering spare parts, please inform us (manufacturer)
the part name, and serial number size and set pressure which are stamped on the
nameplate of safety valve required.
7 Maintenance Tools and Supplies

The following tools and supplies are required for proper maintenance of the safety
valves. These tools and supplies may be purchased separately from FUKUI
SEISAKUSHO CO., LTD..
7.1 Lapping Blocks
Lapping blocks fitted for size, shape of disc and nozzle seat.
(Refer to Fig.10 and Fig.12).

7.2 Lapping compounds
(1)Lapping compounds
(# 600) Mark:LP-1
(#1200) Mark:LP-2
(#3000) Mark:LP-3
Mark:LP-4
(2)Lapping oil
Fig.15
note: Lapping compound kit may be transported just as exsiting condition because a
foamed poly-styrene resin material is fulled in this kit.

JKK WATER LEVEL GAUGE A31E1
JKK WATER LEVEL GAUGE

(REFLEX TYPE)
INSTRUCTION MANUAL
(TYPE RZ)
1 Packages
This water level gauge (reflex type) is usually sent out from our factory in the
following packages:
1 Water level gauge (with lower cap nut)
2 Upper cock, lower cock and drain cock
(The drain cock is set with the lower cock.)
3 Marine parts: Wire
Wire parts (shackles, wire courses and wire clips)
Handles (6 handles)
Handle stoppers (to be mounted to the cock flanges)
4 Spares: Water level gauge
Gauge glass (with gasket)
Sleeve packing
Gland packing
Copper sheet packing (for only the lower lead pipe)
5 Tool: Sleeve packing replacing tool
2 Hydraulic Test before Operation

A complete water tightness test has been carried out for this instrument with the
specified water pressure before the shipment from our factory.
However, checks have to be made for any changes in transit and in handling.
When this instrument is mounted for a newly installed boiler or a boiler in shutdown,
carry out the following water tightness test for the water level gauge including the
gauge cocks at the time of the boiler starting test.
1 Open the drain cock and close the upper and lower cocks. First, check the gas
tightness of the upper and lower cocks (especially the opening and closing
elements).
2 Next, close the drain cock and open the upper and lower cocks. Make the
tightness checks for the whole of the water level gauge and cocks.
3 If any leakage is found in the test, take the corrective actions in accordance
with Item 4, Maintenance.
LanguageUK Page 1 - 1 - 1/6

3 Precautions for operation
1 In the water level gauge sent out from our factory, there is a balance kept
between the bolt tightening force and the gas tightness of each part by the
hydraulic test under the ordinary temperature. Therefore, when the pressure and
temperature are raised from the ordinary conditions along with the boiler
pressure increase, take care to avoid a rapid pressure and temperature
application to the water level gauge.
2 In operation and in pressure raise, use caution to find out leakage. Give a
tightening to the bolt and nut of the part where any leakage occurs.
Also after the pressure is raised to the specified value, check for any leakage.
Even if there is no leakage, give a slight tightening to each bolt of the water
level gauge.
3 At the start-up of the boiler, repeat water blowing until clean water is
recognized so that the good conditions for the water level gauge will be kept in
the boiler system.
During operation, expect when the water is polluted, water blowing is not
desirable so far as the water level is fluctuating.
4 When the boiler is in operation, always make a leakage check and give a
tightening when necessary.
Thus, parts consumption must be minimized.
4 Maintenance
4-1 Disassembly and Construct of Water Level Gauge
After the lapse of the service life, the prism surface of the reflex type gauge glass
wears out and loses reflectivity and as a result the water level becomes invisible.
As the gauge and sheet packing are damaged, it becomes impossible to stop leakage
with tightening of the water level gauge bolts and nuts.
In such a case, disassemble the water level gauge and replace the worn-out parts in
the following procedure.
1 Detach the water level gauge from the upper and lower cocks.
Disassemble the water level gauge preferably when it is still in hot condition
(this will facilitate the removal of the packing).
2 Place the water level gauge on a working bench, loosen the bolts and nuts and
remove the cover.
3 As the gauge glass is sticking to the level gauge body through packing, slightly
rap the side with wooden hammer to remove the glass.
If this disassembly is made in an early time, the gauge glass may be re-used if
only the packing are replaced.
4 Remove the packing carefully not to damage the gas tightness of the water
level gauge body (the surface of contact with the packing).
Clean out the residual dirt.

For the Construct of the water level gauge, the above procedure is to be Reversed
Follow the below instructions, referring to Figure A.
1 Attach the sheet packing to the gas tight surface of the water level gauge, using
the following precautions:
2 Be sure to apply graphite paste to both sides of the sheet packing.
It will facilitate the removal of the packing when gauge is disassembled.
3 As the sheet packing is hollowed out in the center part, it is likely to deform to
narrow the cut-out area.
4 When the packing is placed, care should be take to keep the specified level
gauge window area.
5 On the sheet packing, place the gauge glass with the prism side directed
toward the liquid chamber.
6 Then, attach the cushion packing to the gauge cover and connect the gauge
cover to the gauge glass.
For setting the gauge cover, set the U-bolt at the center to fix the cover
temporarily and then set the other U-bolts.
As there is some allowance between the gauge glass and glass groove, carefully
center the cover, gauge glass, and water level gauge body.
7 For tightening the bolts and nuts, follow the instructions of Item 4-2.
4-2 Tightening of Level Gauge Bolts and Nuts
Troubles such as gauge glass breakage and early-time leakage from the gauge glass
in boiler operation are said to be, in most cases, caused by uneven tightening of bolts
and nuts in construct of the level gauge.
This means that the tightening of the bolts and nuts is the most important of various
water level gauge maintenance works.
Follow the below instructions:
1 Note that the water level gauge contains glass-ware and it belongs to delicate
measuring instruments.
Therefore, the tightening of the bolts and nuts must be made with the utmost
care.
2 Set all the bolts and nuts hand-tight with an even torque. It is important to
tighten them suitably to the extent that leakage can be prevented. Avoid uneven
tightening.
3 Tightening is to be repeated several times with light hand motion as follows:
For the first and second tightening, follow the numerical order given in the
below sketch (the order from the center to the ends).
For the third and fourth tightening, reverse the numerical order (i.e. from the
ends to the center).
4 For the fifth and sixth tightening, again follow the numerical order (i.e. from
the center to the ends).

5 In the last tightening, leave some tightening allowance by saving the hand force.
If any leakage is found after the level gauge has been placed in service, give an
additional tightening in the manner specified above.
6 In reassembly, too strong tightening can cause the gauge cover to bend or cause
the gauge glass to break due to pressure application heat expansion in service.
7 In the last tightening, take case so that the tightening torque of the uppermost
and lowermost bolts (4 bolts) will be kept at half the torque of the other
intermediate bolts.
The reason is that, as seen in the sketch, the uppermost and lowermost bolts (4
bolts) are located outside the gauge glass and, therefore, too strong tightening
may cause the glass ends to break when the gauge is placed in service.
4-3 Additional Tightening and Replacement of Sleeve Packing
When the inside surfaces of the sleeve packing wear out with the cock plug opening
and closing motion, leakage will occur from the cover nut or tightening nut (shown
in Figure B).
In such a case, give an additional tightening or replace the packing in accordance
with the following instructions:
1 Tighten the tightening nut.
The sleeve packing will be pressed toward the cock plug so as to recover the
gas tightness and stop the leakage.
2 Even time when leakage is found, immediately give an additional tightening.
3 If such an additional tightening cannot stop the leakage, it indicates the loss of
elasticity of the packing.
Replace the sleeve packing, following the below procedure:
4 Remove the handle, tightening nut and cover nut.
5 Extract the cock plug toward the handle side.
If it cannot be extracted by hand, apply an iron bar of about 10mm in length to
the bottom of the cock plug and rap the bar to extract it out.
6 Then, apply the sleeve packing replacing tool (shown in Figure C) to the
bottom of the packing.
Rap out the packing toward the handle side.
7 For insertion of new sleeve packing, use the sleeve packing replacing tool and
drive the packing into the cock body from the handle side.
8 Put the packing boss just in the groove of the cock body and insert the packing
so that the periphery of the packing will be located at the position 11mm deep
from the cock body periphery.
9 Mount the cover nut, and keep a clearance of about 1mm between the cover nut
and cock body.
10 Then, the cock plug is inserted.
Apply the iron bar to the bottom of the cock and drive in.
11 Mount the cover nut and tightening nut.
12 Mount the handling.
13 Make an air (or water) passage test.

4-4 Replacement of Gland Packing
When the cap nut tightening cannot stop the leakage from the gauge cock and level
gauge connecting part, replace the gland packing, following the below instructions:
1 Remove the upper and lower cap nuts and packing gland, and push up the
gland packing.
2 Disconnect the lower lead pipe from the lower cock, and extract the upper lead
pipe.
3 Smash the gland packing with use of a chisel, and remove them completely.
Clean the stuffing box.
4 Drive in new gland packing to the position just lower than the specified
position of the upper lead pipe.
Then, plunge the upper lead pipe into the upper cock.
5 Gland packing must be replaced every time when the water level gauge is
disassembled.
However, copper packing can be re-used after they are annealed.
6 Then, carefully drive the gland packing into the stuffing box and mount the
packing gland and upper cap nut.
7 Tighten the cap nuts of lower and upper.
4-5 Other Precautions
At periodical maintenance, disassemble the water level gauge and carry out the
replacement of consumables and the cleaning of the gas (water) passage holes.
Apply graphite paste to each threaded part before construct.
Check the gas tight surface of the water level gauge for any distortion or erosion.
When necessary, repair or replace them.
5 Parts Ordering Instructions

For replacement parts, please place an order with JKK (Nihon Keiki Co., Ltd.) the
agent with the necessary information as requested below:
(1) Parts name, material and type
Example : JKK sleeve gauge cock SF N-ABS Type
(2) Parts name and size
Example : Sleeve packing AB/18
Gland packing Inner diameter 16
Gauge glass No. B


FEED WATER REGULATOR F17E0
FEED WATER REGULATOR

(CONTINUOUS CONTROL)
INSTRUCTION MANUAL
1 Outline
This Feed water Regulator continuously controls the water level through continuous
detection of boiler water level and by maintaining predetermined range. The
equipment mainly consists of the following Five components:
Level Condenser (A31)

Provided in order to make the standard water level.
Differential Pressure Transmitter (DPT) (A42)
Detects the standard water level and the boiler water level and transmits
them by converting them into electrical signals.
Level Controller
Receives signals from the D.P.T and sends out control signals of boiler
water level to Diaphragm control valve. And sends out alarm signal for
lowest water level of boiler water level.
2-way Diaphragm Control Valve (A44)
Receives the signals from the level controller and regulates feed water
volume.
Water Level Indicator (A41)
Receives signals from the DPT and indicates the boiler water level.
As to the connections of various devices, kindly confer the attached System

Drawing.
In piping, following cares should be exercised :
In making connections of the DPT, the one indicated by HP should be

connected to the level condenser side and LP to the boiler shell side.
As to the piping between DPT and the level condenser, the pipe should be
given more than 1/4 inclination to the DPT.
In making piping, care should be exercised so that there shall be no air
holder within the steam pipe.
Air pipes are connected to various devices but prior to making connections
to them, air should be blown into so as to remove completely all dirts within
the piping.

FEED WATER REGULATOR F17E0
2 Working
The following table indicates the increase or decrease or valve opening or closing by
the electrical signals from various devices in accordance with the fluctuations of the
boiler water level:
Name of Equipment Working
Boiler water level shifting direction Rising
Level Controller Increase
Valve opening or closing Closing
3 Methods of Regulation and Operation

They are carried out according to the following sequence:
Inspect throughout the cable system and confirm that there shall be no
wrong wirings.
Completely close the valve attached to the DPT.
When the boiler pressure exceeds 0.20MPa (2kg/c G), open the main
valve for water level detection and make blowing by blow valve.
Tighten the main valve for water level detection and the blow valve and fill
the level condenser with water fully.
Set the supply air pressure of Diaphragm control valve to the value indicated
in the drawing.
Open the main valve for water level detection and open the equalizing valve
of the DPT.
Next open the valve on the HP side, tighten the equalizing valve and then
open the valve on the LP side.
Make confirmation that the minimum value of detective water level is
electrical signal 4mA and the maximum value is 20mA.
By the above-mentioned operations the Differential Pressure Transmitter enters into

running condition.
This Differential Pressure Transmitter is already adjusted in accordance with the

predetermined conditions.
As to the adjustment of individual devices, kindly confer the instructions for them to
be described subsequently.

PRESSURE TRANSMITTER ST3000 G17E0
ST3000 Ace Smart Transmitter

Electronic Differential Pressure /
Pressure Transmitter
INSTRUCTION MANUAL

TABLE OF CONTENTS
1 Functions, Configurations, and Structures of DSTJ 3000 Ace

1-1 Function and Configuration of the Transmitter
1-1-1 Function and Configuration of the Transmitter 3
1-1-2 Parts Names of the Transmitter 5
2 Installation
2-1 Installation Environment
2-1-1 General Environmental Conditions 6
2-2 Installation
2-2-1 Installation the Transmitter 7
2-3 Piping
2-3-1 Liquid Level Measurement -- Piping
2-3-1-1 Piping 8
2-3-1-2 Enclosed Tank -- Piping 9
2-4 Electrical Wiring
2-4-1 Wiring for Transmitter -- Regular Model 10
2-5 Process Connection Port -- Change Port Position
2-5-1 Bottom Port to Top Port 12
3 Maintenance
3-1 External Zero Adjustment 14
3-2 Disassembly and Assembly
3-2-1 Before You Start 16
3-2-2 Dismount/Mount Center Body Cover 17
3-2-3 Washing the sensor 18
Appendix A
Specifications, Model Number, and Exterior View 19

1 Functions, configurations, and Structures

of DSTJ 3000 Ace
Overview of Section 1
Basic functions, structures, and configurations of a Smart Transmitter.
1-1 Function and Configuration of the Transmitter
1-1-1 Function and Configuration of the Transmitter
Introduction
This transmitter offers a range of functions that assist in the measurement of
differential pressure. A differential pressure sensor is mounted on a composite,
semiconductor sensor for the transmission of flow rate, pressure, and liquid level
data.
A composite semiconductor sensor includes a static pressure sensor and a
temperature sensor for the measurement of changes in static pressure and ambient
temperature. These changes can affect accurate differential pressure measurement.
By measuring static pressure and ambient temperature data, the transmitter
compares the measured differential pressure against a true differential pressure,
stored in memory. The sensors are installed in the meter body along with a
multiplexer, an A/D converter, a microprocessor in the transmitter unit, various
storage devices, and a D/A converter.
Function and configuration

The following illustration shows the basic functions and configuration of this
transmitter:
Figure 1-1. Block Diagram of the Transmitter

Flow rate, pressure, and liquid level of the process fluid are transmitted to the
differential pressure sensor on the composite semiconductor chip, in the meter body.
The sensor output is converted from analogue to digital signals simultaneously with
the temperature and static pressure that are sensed with the temperature sensor and
the static pressure sensor, mounted on the composite semiconductor sensor.
The A/D converted signals are processed in the microprocessor, and output (after
conversion to 4 ~ 20 mA DC analogue signals corresponding to the set range.)
PROM : The data stored in this memory includes the input/output, temperature,
and static pressure characteristics of the meter body, the model, and
the valid range of range settings.
EEPROM : This is a non-volatile memory that retains various setting data of the
transmitter even during the power-off state.
A/D : This converter converts analogue signals to digital signals.
D/A : This converter converts digital signals to analogue signals.

1-1-2 Parts Names of the Transmitter
Introduction
This transmitter consists mainly of a terminal board, an electronics module, a
transmitter unit case, an indicator, and a center body.
Structure and parts names

The following illustration shows the structure and parts names of this transmitter:
Figure 1-2. Structure of the Transmitter (JTD)
Center body :
Consists of a composite semiconductor sensor, a pressure diaphragm, an
excessive pressure protection mechanism, etc.
Center body cover :

Two center body covers sandwich the center body. Connect a connecting pipe
to this part.
Bolt & nut : Fixing the center body between covers, are a series of bolts and nuts.
Electronics module :
Consists of electronic circuits having functions for processing differential
pressure and other signals, and transmitting them.
Transmitter unit case : Houses the electronics module and the terminal board.
Case cover : Encloses the transmitter unit case.
Terminal board : Derives electric signals from within the instrument.

2 Installation
Instructions for the installation of pipes and cables associated with this transmitter.
Also covers installation of the transmitter. For users that are responsible for
installation work.
2-1 Installation Environment
2-1-1 General Environmental Conditions
Introduction
Install under environmental conditions specified here, to fully exploit transmitter
performance over long periods.
Always install an explosion-proof transmitter where regulations demand such
precautions.
Environmental conditions
Select a location to meet the following conditions:
Temperature fluctuations should be as small as possible.
Avoid installing in locations that are exposed to radiated heat from other plant
equipment.
Insulate against freezing in the measured fluid or sealing liquid.
Select a location where shocks and vibrations are as small as possible.
Avoid installing in corrosive atmospheres.
External zero-adjustment function is an option that may be subject to output

fluctuations if installed near to sources of strong magnetic interference. Install
such models at least 1m remote from plant equipment producing strong magnetic
interference as over 10 gauss measured where a motor or a pump is installed.

2-2 Installation
2-2-1 Installing the Transmitter
Before you install the transmitter

Prepare the following items:
2-inch pipe
Mounting bracket (U-bolt, nut, mounting bolt)
The transmitter can be installed by the following two methods:

Installation with pipe stanchion (Refer to Figure 2-1.)
Fix the transmitter to a vertical or horizontal 50A pipe with a U-bolt using a
mounting bracket. Mount the transmitter on a bracket using the four bolt holes on
the reverse side of the pressure receiving part. Fix the pipe firmly to the foundation
and make sure that it is stable.
Note) As for the procedure for mounting a transmitter on the 2-inch pipe, note
that the sequence of assembling the transmitter, the bracket, and the 2-inch
pipe depends on the installation direction.
Figure 2-1. Installing the transmitter
No special restriction is imposed on the installation position, it is the best to install

the transmitter main unit in such a way as to set the pressure receiving diaphragm
vertically.

2-3 Piping
2-3-1 Liquid Level Measurement -- Piping
2-3-1-1 Piping
Introduction
For measurement by JTD type of liquid level in a tank, piping method depends on
whether the tank is open or enclosed. For enclosed tanks, piping is modified
according to whether you use the gas sealing method (dry leg) or the liquid sealing
method (wet leg).
High-pressure mark (JTD type)

H indicating high pressure is marked on the center body of this transmitter. Check
the mark during piping work. The low-pressure side has no mark.
Figure 2-2. High-pressure mark on center body
Before you start

The following parts are requirements for piping work. Refer to illustration.
3-way manifold valve
Pipe
Main valve
Union or flange
Tee
Drain valve
Drain plug
Seal pot (for enclosed tank and wet-leg only)

2-3-1-2 Enclosed Tank -- Piping
Recommended piping for wet leg -- Example

When using the wet-leg method, connect the high-pressure side of this transmitter to
the sealing pipe of the tank. Connect the low-pressure side to the lower part of the
tank.
After completing piping work, check for pressure leaks around the connecting pipe,
the transmitter, and the 3-way manifold valve. The illustration shows a typical
installation.
Be sure to connect the low-pressure side of this transmitter to the lower part of the
tank.
Install this transmitter below the lowest liquid level to be measured.
Figure 2-3. Enclosed Tank -- Piping (Wet-leg Sealing Example)

2-4 Electrical Wiring
2-4-1 Wiring for Transmitter -- Regular Model
Introduction
Following wiring instructions when no explosion-proof standards apply.
Wiring
Wire and cable this transmitter as shown in the illustrations.
Figure 2-4. Wiring

Conduit pipe for cables

Lead cables into the transmitter case, as follows:
Mount a conduit pipe in the conduit hole (G1/2 female thread) provided on the side
of a transmitter, and lead cables through the pipe.
Seal the part that contacts with the conduit pipe. Use a sealing agent or a seal plug to
positively prevent entry of water.
Install transmitter so that the cables lead into it, from the bottom.
If required, use a special elbow to change cabling direction (G1, G2, or G3 in the
appendix).
Grounding
Two ground terminals are provided. One terminal is on the terminal board, and the
other is outside the transmitter. Ground either one.
Connect a ground terminal to a type-D ground (Ground resistance not higher than
100 ?) or better ground.
Welding in close proximity to transmitter

Directly ground welding machine and transformer, for its power supply.
Never connect such equipment by the ground terminal to the stanchion pipe that
holds a transmitter. Welding current may influence measurements.
Supply power and external load resistance

Confirm the relationship between the external load resistance and the supply voltage.
As shown in the illustration, the relationship should be inside the shaded area.
External resistance: the total resistance connected to the output terminals of a
transmitter (includes resistances of all cables in the loop plus the internal resistance
of instruments).
Horizontal axis represents supply voltage of a transmitter, and vertical axis represent
external load resistance.
Figure 2-5. Supply Voltage and External Load Resistance -- Relationship

2-5 Process Connection Port -- Change Port Position
2-5-1 Bottom Port to Top Port
Introduction
The process connection port is built on the transmitters center cover.
The port position is included among the user specifications, but it may be changed at
any time to suit your needs. Instructions for changing the process connection port
from top to bottom are here.
Figure 2-6. Change Process Connection Port Position
Procedure
Step Description
1 Remove four bolts fixing left and right adapter flanges.
2 Remove both (left and right) vent drain plugs.
3 Fix with bolts, both adapter flanges to the top of the transmitter.
Tighten bolts to the specified torque.
Specified torque: SNB 7, SUS 630 : 201
Nm
SUS 304 : 100.5
4 Apply sealing tape around the screws of the vent drain plugs.
Spray with lubricant.
5 Screw vent plugs into the bottom part of the transmitter.

Tighten plugs to the specified torque.
Specified torque: 50.3 Nm
Use the identical procedure to change the port position from top to bottom.

3 Maintenance
This section explains the maintenance of the DSTJ 3000 Ace.
Instructions for disassembly and assembly procedures.

3-1 External Zero Adjustment
External zero adjustment
Introduction
A transmitter with external zero-adjustment function enables on-site zero point
adjustment work.
Adjustment range
Set to any value an output corresponding to the current input. Set within the range of
-1.25% (3.8 mA) and +105% (20.8 mA).
Procedure
Figure 3-1. External Zero Adjustment
How to adjust zero point.
Step Description
1 Make sure that the differential pressure to be set is applied to the

transmitter.
2 Using a flat-blade screwdriver, turn the zero-adjustment trimmer

to the desired direction (+ or -) until it stops while pushing it
down. Adjusting operation will begin. Adjust it so that the
output becomes the set value.
Procedure for increasing output: Turn the trimmer fully in the
positive (+) direction while pushing it down.
Procedure for decreasing output: Turn the trimmer fully in

the negative (-) direction while pushing it down.
Caution
(1) Turning the adjustment trimmer too far will break it.
(2) Do not remove the cross-recessed screw. Adjusting unit
may break and cause personal injury.

Output Adjustment Value

The output adjustment value changes according to the period during which the
adjustment trimmer is kept in the fully-turned state, as shown.
Figure 3-2. Output Adjustment Value and Duration of Trimmer Operation
The longer the duration, the larger the output adjustment value. (See illustration,
above.)
The longer the duration, the more quickly the adjustment value increases or
decreases. (See illustration, above.)

3-2 Disassembly and Assembly
3-2-1 Before You Start
Dismount and mount the case cover

This transmitter has a locking structure. Before dismounting the case cover, unlock
the mechanism using a hexagonal wrench (included).
When remounting, insert the case cover fully and lock it, using a hexagonal wrench.
Caution
After mounting the case cover, ensure that no dust or rain gains
ingress into the transmitter case.
Figure 3-3. Locking Case Cover

3-2-2 Dismount/Mount Center Body Cover
Dismount cover
Remove the four sets of bolt & nut, shown in the illustration.
Remarks:
After dismounting, handle the center body cover carefully. Avoid damage to the
diaphragm.
Figure 3-4. Center Body Cover Fixing Bolts
When mounting the center body cover, tighten the bolts to the following torque.
Replace the seal gasket, if it is damaged.
Mount cover
Cover Bolts/Nuts and Tightening Torque
Bolt/Nut tightening torque (Nm)

Bolt/Nut
Model No. Bolt/Nut
material When new When existing
gasket is used gasket is reused
JTD920A M10 Carbon steel 222 171
SUS630
SUS304 152 101

3-2-3 Washing the sensor
Introduction
The transmitter and its mounting pipes must be kept clean to maintain transmitter
accuracy and to assure satisfactory performance. Deposits accumulating in the
pressure chamber of the transmitter will result in measurement errors.
Rinsing the center body

Rinse the center body following this procedure:
(1) Remove the hexagon head bolts from the center body and remove the cover.
(2) Wash the diaphragm and the inner surface of the cover with a solvent and a soft
brush. Take sufficient care to avoid or damaging the diaphragm.
(3) When reassembling the center body, replace the cover gasket with a new gasket
as necessary.
(4) Tighten the cover bolts to the specified tightening torque.
Maintenance in cold region

If you stop the maintenance operation after measuring a liquid that can freeze such
as water, drain water from the center body (by loosening the drain plug.)

Appendix A
Specifications
Measuring span/setting range/working pressure range:

See Table 1.
Output/communication:
Analog output (4 to 20 mA dc)
Analog FSK output (4 to 20 mA dc)
(Frequency shift keying signal transmission system)
Digital output (DE protocol)
Supply voltage and load resistance:

10.8 to 45 V dc. A load resistance of 250 or more is necessary
between loops. (See Figure 1)
Sealing liquid: Silicone oil for general purpose models

Fluorine oil for oxygen and chlorine models
Ambient temperature range:

Normal operating range:
-40 to 85 for general purpose models
-15 to 65 for general purpose model (JTD910A)
-10 to 75 for oxygen and chlorine models
-20 to 70 for models with digital indicators
Operative limits:
-40 to 70 for general purpose model (JTD910A)
-30 to 80 for models with digital indicators
JIS special explosion-proof models: -20 to 60
JIS intrinsically safe models: -10 to 60
Temperature ranges of wetted parts:

Normal operating range:
Operative limits:
JIS special explosion-proof models: -20 to 110
JIS intrinsically safe models: -10 to 100
Ambient humidity range:

5 to 100% RH

Stability against supply voltage change:

0.005% FS/V
Lightning protection:
Peak value of voltage surge: 100 kV
Peak value of current surge: 1000 A
Dead time: Approximately 0.4 sec
Damping time constant:

Selectable from 0 to 32 sec in ten stages
Waterproof/dustproof structure:
JIS C0920 watertight: NEMA3 and 4X
JIS F8001 class 2 watertight: IEC IP67
Explosion-proof structure:
JIS special explosion-proof models: (Exds II CT4)
JIS intrinsically safe models: (i3aG4)
Measuring Span Setting Range Working Pressure Range

JTD920A 0.75100kPa -100100kPa 2.0kPa abs14MPa
{7510160mmH2O} {-1016010160mmH2O} {15mmHgabs140kgf/cm2}
Table 1 Measuring Span, Setting Range, and Working Pressure Range (for
negative pressure in the working pressure range, see Figure 2.)
Note 1) With PVC wetted parts, the maximum working pressure is 1.5
MPa {15 kgf/cm2}.
Note 2) With SUS304 bolts and nuts, the maximum working pressure is 7
MPa {70 kgf/cm2}.
Process pipe connection:

Rc1/2, 1/2NPT internal thread and Rc1/4, 1/4NPT internal thread
Electrical conduit connection:

G1/2 internal thread and 1/2NPT internal thread
Materials:
Center body: SUS316
Transmitter case: Aluminium alloy

Wetted parts materials:

Meter body cover:
Carbon steel (SF440A), galvanized
Carbon steel (SF440A), nickel plated
SUSF316, PVC
Wetted parts of center body:
SUS316 (Diaphragm: SUS316L)
Hastelloy C, tantalum, etc.
Vents and plugs:
SUSF316, PVC
Gaskets for wetted parts:
FEP
Bolts and nuts material (for fastening meter body cover):

Carbon steel (SNB7), SUS304, SUS630
Finish: Housing: light beige (Munsell 4Y7.2/1.3)

Cap: dark beige (Munsell 10YR4.7/0.5)
Corrosion-resistant finish:
Standard: Corrosion-resistant paint (Baked acrylic paint)
Corrosion-resistant finish:
Corrosion-resistant paint (Baked acrylic paint), fungus-proof
finish
Corrosion-proof finish:
Corrosion-proof paint (Baked epoxy paint), fungus-proof finish
Corrosion-resistant finish (silver paint):
Transmitter case is silver-painted in addition to the above
corrosion-resistant finish.
Burnout feature:
Choice of three states at abnormal condition:
Burnout of output values: none
upper limit
lower limit
Grounding: Class 3 grounding (grounding resistance 100 max.)
Installation: Can be installed on a 2-inch horizontal or vertical pipe (can be

directly mounted on a process pipe)
Weight: Approx. 4.4 kg
Optional Specifications
External zero adjustment function:

The transmitter can be easily zero-adjusted in the field with a flat-
blade screwdriver.

Test report: The test report indicates the results of appearance, I/O
characteristics, insulation resistance, and breakdown voltage tests.
Performance
Shown for each item are the upper limit (URV)(*1) and the lower limit (LRV)(*2) of
the calibration range or the percentage ratio of the maximum value of the span to
(kPa).
JTD920A (Material for Wetted Parts: SUS316)
Accuracy (*3) Linear output: 0.1% (5.0kPa {500mmH2O})

(0.025+0.075 5.0

)% (5.0kPa {500mmH2O})
Square-root output: When output is 50 to 100%: same as the linear output

When output is 7.1 to 50%: linear output 50
square-root output %
When output is less than 7.1%: dropout
12.5
Temperature characteristics Zero shift: (0.25+0.3 )%
(Shift from the set range) (*3)
Combined shift: 0.8% (12.5kPa {1250mmH2O})
(including zero and
Change of 55 (0.35+0.4512.5 )% (12.5kPa {1250mmH2O})
span shifts)
Static pressure effect Zero shift: 0.18% (20.0kPa {2000mmH2O})

(Shift with respect to setting (0.18 20.0 )% (20.0kPa {2000mmH2O})

range) (*3)
Combined shift: 0.33% (20.0kPa {2000mmH2O})
Change of 7 MPa {70 kgf/cm2} (including zero and
(0.3320.0 )% (20.0kPa {2000mmH2O})
span shifts)
Notes) (*3): Within a range of URV 0 and LRV 0

ST3000 Ace Differential Pressure Transmitter (JTD) for Standard Differential

Pressure/High Differential
Pressure/Supper High Differential Pressure

Dimensions
JTD920A

Control Valves AGVB/AGVM G31E0
CV3000 Alphaplus Series

Control Valves
Model : AGVB/AGVM
Instruction Manual

Preface
Introduction
Thank you for purchasing the Yamatake Corporation CV3000 Alphaplus control
valve.
The model AGVB/AGVM top-guided single-seat control valve features accurate
flow control performance and reduced cost. It has a new lighter valve body design
and multi-spring loaded actuator and is 20% lighter and smaller than conventional
models. Minimize space, installation costs, and maintenance are assured when you
choose the CV3000 Alphaplus.
Additionally, the flow shutoff performance equals that of an emergency shutoff

valve. The CV3000 Alphaplus thus plays a dual role in your process: control,
normal flow control and emergency shutoff of process fluid.

Unpacking and Inspecting Your CV3000 Alphaplus

Unpacking the CV3000 Alphaplus
CV3000 Alphaplus is a precision instrument and should be handled with care to
prevent damage or breakage.
After unpacking CV3000 Alphaplus, verify that the following items are included:
CV3000 Alphaplus
Ordered accessories
Verifying the specifications

The specifications of your CV3000 Alphaplus are written on an name plate attached
actuator.
Enquiries
If you have any questions regarding the specifications of your CV3000 Alphaplus,
contact your nearest Yamatake Corporation office or Yamatake Corporation
representative. When making an enquiry, make sure to provide the model number
and product number of your CV3000 Alphaplus.

Storing your CV3000 Alphaplus

Precautions
An unused CV3000 Alphaplus should be stored:
indoors at normal temperature and humidity and in a place safe from vibration
or shock.
In the same condition and container as shipped.
Procedure
Used CV3000 Alphaplus valves must be treated before storage using the following
procedure:
Step Action
Rinse the inside of the control valve body with water to remove
1 residual fluids, then allow to dry. Anti-corrosive treatment is
recommended for control valves with carbon steel bodies.
Attach caps to air piping connections, electrical conduit
2
connections of accessories to prevent moisture from entering.
3 Protect flange surface with flange-caps or other safeguards.
Store the CV3000 Alphaplus indoors at normal temperature and
4
humidity in a place safe from vibration or shock.

Table of Contents
1 General Description
1-1 Scope 6
1-2 Major Components 6
1-3 Structures 7
2 Installation
2-1 Maximum Lifting Loads of Eyebolts 8
2-2 Installing the Valve on Process Pipe 9
2-3 Check After Installation and Before Starting Operation 9
3 Inspection and Maintenance

3-1 Inspection 10
4 Disassembly and Assembly

4-1 Detaching Actuator from Valve Body 10
4-2 Disassembly and Assembly of Valve Body 11
4-3 Disassembly and Assembly of Actuator 16
5 Adjustment 37
6 Trouble-shooting 38
Appendix A DIMENSIONS 39

1 General Description
1-1 Scope
This manual contains the instructions for top-guided single-seated control valves
(model AGVB/AGVM).
For the valve positioner instructions, refer to the following Operators Manuals:
G25E1 (for model HTP)

G29E1 (for model HEP)
G26E0 (for model VPE)
G32E0 (for model AVP)
1-2 Major Components
Each control valve comprises two major components a valve body and an actuator.
Combinations of valve body and actuator sizes, pressure ratings, types of materials,
and actuator sizes are selectable according to process requirements.

1-3 Structures
A typical CV3000 Alphaplus series control valve is shown in Figure 1-1.
The valve body is connected to the bonnet by stud bolts and nuts. Gaskets mounted
between body and bonnet act as a seal for the internal fluid, making the valve body a
pressure vessel.
The valve plug is supported by the guide bushing and driven by the actuator. The
multi-spring actuator and a diaphragm convert the pneumatic control signal into a
mechanical control action that positions the valve plug.

2 Installation
2-1 Maximum Lifting Loads of Eyebolts
The diaphragm case has a pair of eyebolts for lifting the valve. The allowable
maximum lifting loads are shown in Table 2-1, so before moving the valve check
that the total weight of the control valve (including accessories) is less than the total
allowable maximum lifting load of the eyebolts.
Table 2-1 Maximum Lifting Loads of Eyebolts

Weight (kg) (Standard Bonnet)
Body size Actuator Allowable maximum
(inches) model Without With side lifting load of eyebolts (kg)
hand-wheel hand-wheel
1/2, 3/4, 1 PSA1D, R 18 25
160
PSA2D, R 21 28
1-1/2 PSA1D, R 28 35
PSA2D, R 31 38 160
PSA3D, R 51 78
PSA4D, R 69 96 220
2 PSA1D, R 29 36
PSA2D, R 32 39 160
PSA3D, R 52 79
PSA4D, R 70 97 220
2-1/2 PSA3D, R 76 103 160
PSA4D, R 94 121 220
PSA6R 196 231 220 (Actuator only)
3 PSA3D, R 80 107 160
PSA4D, R 98 125 220
4 PSA3D, R 105 132 160
PSA4D, R 123 150 220
NOTE
When lifting a CV3000 Alphaplus by its eyebolts, please use extreme
care to prevent shock to either actuator or valve body.

2-2 Installing the Valve on a Process Pipe
1 Before installing the valve, remove scales, welding chips or any other
contaminants from both upstream and downstream sides of the process pipe.
2 Confirm that the direction of process fluid flow conforms to the arrowhead
mark on the valve body.
3 Ensure that the pipe connection gaskets do not intrude the process pipe.
Gasket materials suitable for the process fluid must be selected with care.
4 Ensure that excessive stress is not transferred from the process pipe to the valve
body. Uniformly tighten the bolts on the process pipe connection flanges.
5 Before connecting pneumatic pipes to the actuator and positioner, blow through
the pipes to clean them.
6 Do not install any heating or cooling equipment on the bonnet.
2-3 Check After Installation and Before Starting Operation
1 Check for leakage from any air pipes.

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

Valve sem diameter Yarn packing Nm PTFE chevron packing
(mm) {kgf-cm} Nm {kgf-cm}
13 5 {50}
16 12 {125} 0.8 {8}
30 32 {320}
Note: These tightening toques are only reference values, and may vary
depending on the packing used.

3 Inspection and Maintenance
3-1 Inspection
Inspect and service the control valve as follows:

1 Tightening the gland:
Tighten the gland approximately every 6 months. Follow the tightening
procedures given in subsection 2.3.
2 Check for valve position hunting. Refer to Section 6, Trouble-shooting.
3 Check for abnormal noise and vibration. Refer to Section 6, Trouble-
shooting.
4 Disassembly and Assembly

This section covers the disassembly and assembly procedures for its overhaul or
modification.
4-1 Detaching Actuator from Valve Body
1 Apply air pressure to the actuator so that the valve position pointer is at 10% to
20% over fully closed position.
2 Loosen the clamping bolts on of the stem connector and remove it. Detach the
actuator stem from the valve stem.
3 Remove the yoke clamping unit.
4 Raise the actuator to detach it from the valve body.
Caution
1 Before detaching the actuator from a valve that has already been
installed on the process pipe, be sure to shut down the process and
release the process pressure.
2 Ensure that the valve body is cool before detaching.
3 Loosen all process piping bolt and nuts so that excessive stress is
not transferred to the eyebolts when detaching the control valve from
the process pipe.

4-2 Disassembly and Assembly of Valve Body
To disassemble or assemble the valve body, refer to Figures 4-2 through 4-4 and
proceed as described below.
Disassembly Procedure
1 Loosen the hex nuts on the packing flange.
2 Remove the hex nuts (1) on the bonnet.
3 Raise and detach the bonnet from the valve body.
4 A seat ring is threaded in to the valve body. To remove the seat ring special
tools (available as an options) are required.
Caution
If the valve plug comes out together with the bonnet, remove the plug
from the bonnet by rotating the plug. When doing this, be careful not to
damage the valve stem.
Inspection
Inspect the disassembled parts for damage before assembly. If any damage is found,
replace the parts. When ordering parts, refer to the PROD. No. of the valve indicated
on the nameplate.
1 Do not reuse the gland packing once it has been removed, but use new packing
when reassembling the valve. In case of vacuum service, verify the gland
packing composition as shown in Fig. 2-1.
2 Check that the seating surfaces of the plug and seat ring are not damaged.

3 Check that the gasket-contacting surfaces of valve body and bonnet are not
damaged. Do not reuse the same gasket, but use a new gasket when
reassembling the valve.
4 Check that the plug guide section, the stem, and the internal guiding sections of
the guide bushing are not damaged.
Assembly Procedure
1 Securely fasten the seat ring onto the threaded valve body, using the special
(optional) tools. For the tightening torque, see Table 4-1. Apply lubricant
Neverseize to the threaded sections, except for oil free valves.
2 Place the plug on the seat ring.
3 Put the bonnet on the valve body and check that the bonnet is properly mated
with the indented section of the valve body. Tighten the nuts alternately and
evenly. For the tightening torque, see Table 4-2.
4 Insert the gland packing as shown in Figure 2-1.
Note: When yarn packing sheets are used, overlap the sheets so that their cut ends
are alternately positioned.
5 Install the packing follower and packing flange, and tighten the nuts. For the
tightening torques, see Table 2-2.
6 Check that the external O-Ring of the packing follower is installed to the bonnet
gland box.
Table 4-1 Seat Ring Tightening Torques

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

Body size (inches) Bolt size Torque Nm {kgf-cm}
1/2, 3/4, 1 M10 140 {1400}
1-1/2, 2 M16 210 {2100}
2-1/2, 3 M16 340 {3500}
4 M16 590 {6000}




4-3 Disassembly and Assembly of Actuator
Normally, the actuator should require no adjustment. However, at certain times the
actuator should be disassembled and reassembled. Reassembly is recommended
when installing it on a valve body, when modifying its specifications, or when
replacing damaged parts. The disassembly and reassembly procedures for the
actuator in such cases are covered in subsections 4.3.1 and 4.3.2
Notes Before Disassembly

1 Only the nuts for the eyebolts are made of stainless steel. Keep these nuts
separate from the other nuts when assembling the diaphragm case.
2 Make locating marks on the top and bottom diaphragm cases before
disassembling the valve. This will help you to easily find the air piping
connector location.
3 Store the removed parts in a clean place.
Caution
Use extreme care when removing the bolts and nuts form the actuator.
The actuator contains powerful compressed springs that may cause
injuries or other damage. When removing the bolts and nuts, be sure to
closely follow the instructions given for disassembly and assembly
procedures of the actuator and top hand-wheel.
4-3-1 Disassembly and Assembly of Model PSA 1, 2, 3, 4
Disassembly Procedure
A. Direct Action model (see Figure 4-5 or 4-6)
1 Disconnect the air piping and detach the accessories from the actuator.
2 Remove the stem connector.
3 Remove the clamping bolts (except the pair of eyebolts) form the diaphragm
case.
4 Alternately and evenly loosen the pair of eyebolts. The initial setting of the
springs is achieved using these eyebolts.
5 Remove the diaphragm case. Pull the actuator rod out and upward together
with the diaphragm.
6 Take out the springs.
B. Reverse Action model (see Figure 4-7 or 4-8)
1 Disconnect the air piping and detach the accessories from the actuator.
2 Remove the stem connector.
3 Remove the clamping bolts (except the pair of eyebolts) from the diaphragm
case.

4 Alternately and evenly loosen the pair of eyebolts. The initial setting of the
springs is achieved using the eyebolts.
5 Remove the diaphragm case. Take out the spring.
6 Pull the actuator rod out and upward together with the diaphragm.


Assembly Procedure
Before assembly, check the parts for scratches, damage, deformation, peeling paint
and other abnormalities. To assemble the actuator, proceed as follows:
A. Direct Action models
See Figures 4-5 and 4-6.
1 Secure the diaphragm case (bottom) with the four bolts to the yoke.
At the some time, set the air vent hole as shown in Figure 4-9.
For PSA1D and PSA2D actuators, secure the spring plate to the diaphragm
case and yoke.
2 Fasten the spring plate and install springs in the spring plate (see Figure 4-9.)
3 Insert the actuator rod (with diaphragm connected) into the bushing.
Be careful to prevent the bushings inside surface or dust seal from being
damaged by the threaded section of the rod. If possible, cover the threaded
section with adhesive tape.
4 Rotate the actuator rod, locating the diaphragm plate stopper as shown in
Figure 4-9.
5 Place the top diaphragm case and secure it with the pair of eyebolts.
Note: Set the air pipe connection port in the location shown in Figure 4-9.
Tighten the pair of eyebolts uniformly and alternately. The initial
setting of the springs is completed by tightening these eyebolts.
6 Clamp the diaphragm case with clamping bolts.
7 Install the stem connector. Connect the air pipe to its connection port in the
top diaphragm case.
8 After completing assembly, check the following:
Apply air pressure of 490kPa{5 kgf/cm2} through the air pipe connection
port in the top diaphragm case, and check the diaphragm periphery for air
leakage with soapy water.
Check that the actuator operates smoothly through its full stroke by
operating it as an independent unit.
Caution
Install packing for the rod and dust-seal in the correct direction.
Refer to Figures 4-5 and 4-6.



A. Reverse Action models

See Figures 4-7 and 4-8.
1 Secure the bottom diaphragm case with the four bolts to the yoke.
At the same time, set the air pipe connection port in the location shown in
Figure 4-10.
2 Insert the actuator rod (with diaphragm connected) into the bushing.
Be careful to prevent the bushings inside surface or dust seal the threaded
section of the rod. If possible, cover the threaded section with adhesive tape.
3 Rotate the actuator rod, locating its diaphragm plate stopper as shown in
Figure 4-10.
4 Fasten the spring plate and install springs in the spring plate (see Figure 4-
10.)
5 Place the top diaphragm case and secure it with the pair of eyebolts.
Note: Set the air vent hole in the location shown in Figure 4-10.
Uniformly and alternately tighten the eyebolts. The initial setting of the
springs is completed by tightening these eyebolts.
6 Clamp the diaphragm case with clamping bolts.
7 Install the stem connector.
8 Install the rain cap on the air vent port.
9 Connect the air pipe to its connection port in the bottom diaphragm case.
10 After completing of assembly, check the following:
Apply air pressure of 490kPa{5 kgf/cm2} through the air pipe connection
port in the bottom diaphragm case, and check the diaphragm periphery for
air leakage with soapy water.
Check that the actuator operates smoothly through its full stroke by
operating the actuator as an independent unit.
Caution
Install packing for the rod and dust-seal in the correct direction.
Refer to Figures 4-7 and 4-8.





4-3-2 Disassembly and Assembly of Model PSA6 Actuator
1. General
Structure
This actuator consists of cylinder, spring unit, lift stopper, spring retainer, hexagon
stay, yoke, manual hand-wheel and single action positioner.
For external appearance of the actuator, refer to Fig.4-13, External Appearance of
PSA6R.
Assembly on valve body

Assembling nuts integral to the valve body assembles yoke and valve body. Stem
connector connects actuators rod and valve stem.
Air piping connection

The tubing is connected to single action positioner when used as control valve. Refer
to the following instruction manuals for details of single action positioner.
Pneumatic positioner (Model HTP) G25E1
Electro-pneumatic positioner (Model HEP) G29E1
Electro-pneumatic positioner (Model AVP300/301) G32E0

Calibration
This actuator does not need calibration.
When connecting valve stem of the valve body with actuators rod with stem
connector, due adjustment should be made to seat the valve plug on the seat ring.
Then screws on actuators scale plate are loosened, stroke and index matched to
properly position the scale plate.
Caution in operation and handling
Caution
When automatically operating an actuator with manual hand-wheel,
verify that the AUTO/MANUAL switchover pin is inserted into pin
holder, chain is engaged on the hand-wheel and the indicator is in
AUTO position before start of operation.
When disassembling and assembling, always hold the actuator in
upright position (spring unit on top and yoke on bottom)
While eyebolts are used to suspend actuator, assembled valve should
not be suspended by eyebolts only
2. AUTO/MANUAL switchover of manual hand-wheel

Refer to Fig.4-14 for details of AUTO/MANUAL switchover of hand-wheel. With
an actuator with AUTO/MANUAL switchover functions, switchover between
automatic operation and manual operation by hand-wheel are available.
AUTO/MANUAL switchover can be made at any optional moment during operation.

Step Procedure
1 Pull out AUTO/MANUAL switchover pin out of holder and disengage

chain, which binds hand-wheel from the wheel.
2 Verify operating label on hand-wheel and turn the handle to the direction
of SHUT and lower slide screw.
3 Match the round holes of slide screw and actuators rod, and insert pin.
Push it all the way in and fix it there.
4 Verify OPEN, SHUT arrows on label, and turn the hand-wheel to either
direction to open or close the valve. The turning torque should be under
127N (13kgf)
5 When the hand-wheel does not turn any further, check valve opening and
end operation.
Caution
Do not apply undue force on valve when it
reaches mechanical stop. Otherwise valve
stem may be damaged. Refer to 10.
Trouble shooting for remedial action.
6 To resume automatic operation, remove the switchover pin, turn hand-

wheel until.
The slide screw stop reaches AUTO position (refer to Fig. 4-16 below).
Run the chain on the pin through in order to restrict hand-wheel movement
and fix the pin on holder. Resume automatic operation after verifying this
condition.

3. Disassembly and assembly of actuator

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

Refer to 4-1, page 11.
Disassembly of actuator
<disassembly procedure>
Disassembly procedure of actuator is described herein.
Refer to and Figures 4-17 and 18 or Table 4-4 for information.
Marking and protection

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

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

Removing spring retainer

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

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

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

Step Procedure
1 Remove in the sequential order of bearing holder No.27, single column
angular bearing, (upper) No.32, worm wheel No.33, and single column
angular bearing (lower) No.32.
2 Loosen hexagon head bolts No.12 (four bolts), which fasten gear, case
No.30 and yoke and remove.



Disassembling spring unit

<disassembly procedure>
Disassembly procedure of spring unit is described herein.
Refer to page 33, Figures 4-18 for disassembling information.
Disassembling is not required if only pistons sealing parts (tape liner, O-ring) are
replaced.
Removing spring unit

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

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

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

Assembly of actuator with manual hand-wheel

<assembly procedure>
Refer to page 32, Figure 4-17 for assembly information.
Assembly procedure, manual hand-wheel and cylinder assembly

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

Step Procedure
1 Install eyebolts on threaded hole (M12 x 2) on the top of spring retainer
No.59 on the piston unit, suspend by crane and lift upright.
2 While suspended upright, assemble lubricated O-ring No.8 and tape liner
No.7 on piston No.57.
3 Assemble piston unit in cylinder No.21 from the top. See to it that the
round hole of rod No.58 appears front.
4 Assemble lift stopper O-ring No.5 in the slot on the top of cylinder No.21.
5 Insert lift stopper No.20 from the top and fix by hexagon stay No.4, No.9
(four). Screw on the ones of same length diagonally.

6 Assemble so that the hexagon stays No.4, No.9 are fit into holt holes of
spring retainer No.17.
7 Fix spring retainer No.17 with hexagon head nuts No.2 (four)
8 Install eye nuts No.1 (two) on hexagon stay No.4
Assembly of actuator without manual hand-wheel

When assembling actuator without manual hand-wheel, follow the procedure in
Assembly of actuator with manual hand-wheel on page 35 except the applicable
parts to actuator.
4. Major replacement parts
Actuators parts have been designed to withstand prolong usage. However, it is

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

Table below shows tightening torque of actuator assembling. Refer to Fig. 4-20,
tightening torque of actuators threaded parts.
Table. 4-5
Key No. Size Tightening torque [N-m{kgf.cm}]
M14 80120 {800 1200}
M20 270360 {2700 3650}
M24 300410 {3050 4150}
M14 80120 {800 1200}
M12 5060 {500 600}

5 Adjustment
As a general rule, diaphragm control valves do not require adjustment. However,
adjustment of travel (stroke) is necessary when coupling an actuator to a valve body,
after removing the actuator for overhaul, or for other purposes.
For this adjustment, refer to Figures 4-1 and 5-1 and proceed as follows:
1 Connect the actuator to the valve body by securely tightening the yoke
clamping nut use a chisel and hammer.
2 Connect an adjustable air pressure source (with a pressure regulator) to the
actuator to the top diaphragm case (direct action) or to the bottom
diaphragm case (reverse action).
3 Lower the valve seat and check that it comes into contact with the valve seat.
A. Direct Action models
4 Apply the maximum air pressure to the actuator corresponding to the spring
range indicated on the nameplate.
5 Increase the air pressure to the supply pressure and check that the actuator
stem responds by moving 1 to 2 mm. This movement represents the stroke
allowance.
6 Decrease the air pressure once. Then increase it again to the maximum value
corresponding to the spring range, in the increasing direction.
7 In the above state, align the actuator stem and valve stem on a straight line,
adjust so that the thread of the stem connector mates with those of the
actuator stem and valve stem, and securely tighten the clamping bolts of the
stem connector. (See Figure 5-1.)
B. Reverse Action models
4 Apply the minimum air pressure to the actuator corresponding to the spring
range indicated on the nameplate, and check that the actuator stem moves by
1 to 2 mm in response.
5 Increase the air pressure once. Then decrease it again to the minimum value
corresponding to the spring range, in the decreasing direction.
6 Perform a procedure identical with that of Step (7) of Item A Direct Action
models. (See Figure 5-1.)

6 Trouble-shooting
This section covers the symptoms, causes, and remedies of problems. Parts may
need to be replaced. For further assistance, please contact your Yamatake
Corporation representative.
Table 6-1 Troubleshooting

Symptom Cause and Remedy
Unstable Valve Operation CV value is too large.
Reduce CV value.
Valve hunts when almost fully For a single seat valve, the valve is installed in the reverse
closed flow direction.
Large pneumatic equipment is hooked up to the same air
supply line.
Check air supply capacity, piping capacity, and restriction
Air supply pressure is unstable capacity are appropriate.
Supply air pressure regulator is inadequate or not operating
properly.
Controller is not properly tuned.
Properly tune the controller (properly set the proportional
Signal pressure is unstable band and other parameters).
Check that the controller output does not change
abnormally.
Hunting output of positioner itself.
Valve hunts even when signal Check and repair or replace the positioner.
Being affected by pressure change of process fluid as power
pressure is stable of the actuator is insufficient. Replace the actuator with a
larger model.
Vibration of Valve Piping vibrates.
Securely fasten the piping.
Valve vibrates (generates
Check for other sources of vibration.
noise) at any position of valve Worn valve plug or guides.
plug Check the parts and replace them as required.
Valve vibrates (generates Check for changes in process fluid flow conditions (change
in restriction orifice, CV value, etc.)
noise) only when valve plug is Check for changes in plug configuration (change in flow
set at a certain position control characteristics.)
Air leak from piping.
Air leak from actuator.
Foreign matter trapped in guide section of valve plug.
Sluggish valve operation or Aged and hardened gland packing, causing increased
inoperative valve hysteresis.
Malfunctioning positioner (check the positioner by
operating it directly on an air supply known to be operating
normally).
Fluid leakage from gland Check for loose nuts of bonnet.
section Check for damaged valve shaft.
Air leak at actuator section.
Apply the air supply pressure or atmospheric pressure to the
Even when valve plug is in actuator. Check the air supply source and positioner.
closed position, large flow leak Check whether the valve plug is actually in the closed
to downstream side position.
Check the plug seat ring for corrosion and erosion.
Check the guide sections for binding.

Appendix A DIMENSIONS
Unpacking the CV3000 Alphaplus


Smart Valve Positioner AVP300/301/302/200/201/202 G32E0
SVP3000 Alphaplus
Smart Valve Positioner
Model:AVP300 / 301 / 302
AVP200 / 201 / 202
Instruction Manual

Table of Contents
1 Introduction
1-1 SVP models 3
1-2 System structures
Without position transmission output (Models AVP300 and AVP200) 5
Position transmission output (Models AVP301 and AVP201) 5
HART communication (Models AVP302 and AVP202) 6
1-3 Communication
Manual communication 7
Using a Smart Field Communicator (SFC) 7
Using a HART communicator 7
1-4 Structures and functions of SVP
Main components 8
2 Installation
2-1 Site Selection 13
2-2 Installing SVP
Procedure 14
Examples 14
Connecting the feedback pin and the feedback lever 16
Space allowance for maintenance 17
Connecting the Air Supply 17
2-3 Installing a remote type SVP (Model AVP200/201/202)
Disconnecting the SVP and feedback cable 19
Connecting the SVP and feedback cable 20
Changing the feedback lever direction 20
Attaching the valve travel detector to an actuator 21
Installing the SVP main unit 22
2-4 Installing a double-acting SVP for spring-less actuators
Reversing relay 23
Installing the relay 23
Installing a double-acting SVP with a KZ03 air pressure regulator with filter
25
Installing a double-acting SVP without an air pressure regulator 26
Procedure for air pipe connection 27
Installing a double-acting SVP onto diaphragm actuator 27
Installing a double-acting SVP onto a rotary actuator 28
2-5 Electrical wiring
Wiring for waterproof SVP 29
Wiring for explosion-proof SVP 34
Wiring for Intrinsically-safe SVP 35
2-6 Control signal 36
2-7 Travel transmission and load resistance 37

2-8 Cable gland and flameproof universal elbow for JIS Flameproof apparatus
Structure of the cable gland 38
Structure of the flameproof universal elbow 40
Mounting example 41
Mounting procedure for cable gland 42
Mounting procedure for flameproof universal elbow 43
Lead-in of cable for flameproof models other than models in accordance with JIS
43
1 Introduction
1-1 SVP models
The SVP is an intelligent valve positioner that can be connected to a 4-20 mA

controller output signal line. Since all adjustments can be performed electrically, the
relationship between the input signal and the position of the control valve can be set
arbitrarily. Split range and other special settings are also easy to set up.
There are two types of SVP, the integral type and the remote. For each type there are
three models each having different communication functions.
Integral type
Model AVP300: Analog signal (4 to 20 mA DC) without travel transmission
Model AVP301: Analog signal (4 to 20 mA DC) with travel transmission
Model AVP302: HART communication protocol model
Remote type
Model AVP200: Analog signal (4 to 20 mA DC) without travel transmission
Model AVP201: Analog signal (4 to 20 mA DC) with travel transmission
Model AVP202: HART communication protocol model

An overview of an SVP3000 system is shown below.

1-2 System structures
Without position transmission output (Models AVP300 and AVP200)
This figure shows the structure of a system in which the SVP position transmission
function is not used.
Position transmission output (Models AVP301 and AVP201)
Analog output
This figure shows an example of the structure of a system in which the position is
output as a 4-20 mA DC analog signal.
In this system, the analog signal from the SVP is directly output to the host
monitoring system.
DE protocol
This figure shows the structure of a system in which the position detected by the
SVP, the values of the SVP settings, and the results of self diagnostics are output in
the DE (Digital Enhancement) protocol*, which is a protocol for transmission of
digital signals.
In this system structure, the digital signals in the DE protocol* transmitted from the
SVP are output to a monitoring system that can directly input these signals.

STIM II (Smart Transmitter Interface Module)

Interface module for digital signals in the DE protocol*.
PM100 (Process controller R20 or later model)
A process controller on the UCN. Simultaneously performs functions such as
adjustment control, sequencing, calculation, and process I/O.
CAUTION
If the STIM II is used and the position transmission output signal from the SVP is
output as PV value, set the valve forcibly closed (SHUT OFF) value to -0.2% or
higher so that the position signal STI point PV value is not taken to be BadPV.
*DE and DE protocol are registered trademark of Honeywell, Inc.
Note Switching the output format

The output format provided by the SVP is specified by the user in the
settings data specified when ordering the SVP. The SVP is set up at the
factory for either analog output specifications or digital output
specifications.
Note, however, that the output format can be switched freely by the user
using the Smart Field Communicator (SFC).
HART communication (Models AVP302 and AVP202)
This figure shows the structure of a system in which the position detected by the
SVP, the values of the SVP settings, and the results of self diagnostics are output in
the HART communication protocol.

1-3 Communication
There are three ways to communicate with the SVP: manually, using a Smart Field
Communicator (SFC) or using a HART communicator.
Manual communication
Initial SVP configuration is typically performed using a screwdriver. Auto-Setup

and travel calibration, which detect the characteristics of the valve, as well as
Zero/Span adjustment can all be performed manually.
Without further configuration, the SVP provides valve travel from fully open to
fully closed from a 4-20 mA analog signal (refer to ordered specifications) or
analogous HART signal.
Using a Smart Field Communicator (SFC)
Yamatake Model SFC160/260 Smart Field Communicators can be used for all
configuration, calibration and maintenance of the SVP. SVP-specific communicator
functions are documented fully in this manual. See the SFC Smart Field
Communicator Manual to learn more about the SFC.
Using a HART communicator
Emerson Electric HART communicator model 275 can be used for all
configuration, calibration and maintenance of model AVP302/202 SVP-specific
communicator functions are documented fully in this manual. See the HART
communicator manual to learn more about the HART communicator.

1-4 Structures and functions of SVP
Main components
The main SVP components are shown below.
Integral type (model AVP300/301/302)

Remote type (model AVP200/201/202)

Names parts and functions of main components
Part Description
Main unit Holds the electronics module, EPM (electro-pneumatic
converter module), and VTD (position sensor).
Pilot relay Amplifies the pneumatic signal from the EPM (electro-
pneumatic converter module) and converts it to a
pneumatic signal for the actuator.
Feedback lever Acquires the motion of the control valve lift and
transmits it to the VTD (position sensor).
Auto/Manual switch Switches the control method for the pneumatic output
between the automatic operation state and the manual
operation state.
External zero/span Allows the zero and span to be adjusted and auto setup
adjustments Auto-setup to be performed with just a flat-bladed screwdriver
switch without using the SFC.
Supply air pressure gauge Indicates the supplied air pressure.
Output air pressure gauge Indicates the pressure of the output air.
Air supply connection The air supply is connected to this connector.
Labelled SUP.
Output air connection The output air is sent to the actuator from this connector.
Labelled OUT.
Mounting plate (option) Used to mount the actuator on the SVP itself.
The shape of this part will differ depending on the
specifications (the type of actuator).
Reversing relay Used when a double-acting actuator is used.
The reversing relay is added at the output air connector
of the SVP. The reversing relay provides two outputs:
output air pressure 1 (OUT1), which is the SVP output
air pressure without modification, and output air
pressure 2 (OUT2), which is the SVP output air pressure
with air pressure supplied to the reversing relay (SUP)
subtracted from OUT1. Connecting these outputs to the
two cylinder chambers of the double-acting cylinder
allows that cylinder to function as a double-acting
positioner.
Output air connection The air output from this connector is delivered to the
(OUT1) actuator.
O1 is written on the lower section of the reversing relay.
Output air connection The air output from this connector is delivered to the
(OUT2) actuator.
O2 is written on the lower section of the reversing relay.
Feedback cable Connect the VTD and the main unit of SVP.
Valve travel detector Senses a valve position through the feedback lever.

Terminal box

Names parts and functions of terminal box
Part Description
Terminal box cover The cover features a pressure-resistant explosion proof
structure.
Cover locking screw Must be tightened down when an explosion proof model
SVP is used in a hazardous area.
Terminal of input signal Labelled I IN.
Connect the signal cable from the host controller.
Terminal of output signal Marked I OUT.
Connect the position transmission signal cable.
This terminal screw is not present in the model
AVP300/200, which do not have a position transmission
function.
External grounding Ground this pin as stipulated in the specifications.
Internal grounding When using the SVP, use either the internal or the
external ground terminal, but be sure not to create a 2-
point ground.
Conduit connection (1) Port for connection cables.
The stipulated pressure-resistant packing type cable
adaptor (available as an option) must be used if an
explosion proof model SVP is used in a hazardous area.
Conduit connection (2) Port for connection cables.
The stipulated pressure-resistant packing cable adaptor
(available as an option) must be used if an explosion
proof model SVP is used in a hazardous area.
This port is normal sealed with a blind plug.
Pin for SFC The SVP can communicate with an SFC if the SFC
communication cable hooks are connected to these pins.

2 Installation
2-1 Site Selection
The SVP is designed to withstand severe operating conditions. It is designed to

operate:
Ambient temperature range conforming to the requirements for explosion-
protection.
In relative humidity of 10 to 90%
Where there is no chance of sudden temperature or humidity changes
Where magnetic field induction is not more than 400 A/m (Avoid locations near
large-scale transformers, high-frequency furnaces, and similar equipment.)
Vibration under 19.6 m/s2 (5 to 400 Hz) (model AVP300/301 and AVP200/201
main unit)
Vibration under 98 m/s2 (5 to 2000 Hz) (model AVP200/201 position detection
unit)
Note The vibration conditions for this equipment is stipulated for the vibration
at the positioner.
2-2 Installing SVP
Yamatake Smart Valve Positioners are designed for use in combination with a
control valve that uses a direct- or reverse-acting or rotary actuator. The main SVP
unit weighs about 2.5kg. It should be attached in the same way you would attach a
conventional current-pneumatic positioner.
CAUTION
Do not install the SVP near a large transformer, high-frequency furnace, or other
equipment that generates a magnetic field. Unexpected operation can result.
Incorrect settings can reduce the SVPs effectiveness and cause damage to or
failure of the SVP.
When installing a control valve, provide adequate clearance around the valve for
maintenance (piping, wiring, and adjustment), and verify that the valve is
oriented correctly.
Transport the SVP in its original packing to as close to the point of installation
as possible.
Do not apply excessive force to the feedback lever or bend the feedback pin
when installing the valve.
Be sure to tighten bolts and nuts securely on the SVP and control valve.

WARNING
To avoid physical injury, use caution when attaching the SVP:
Be aware of sharp edges, such as the threaded edges of the terminal box cover
and any sharp edges on the unit.
The type and size of the actuator and the SVP settings determine the type of
mounting plate to be used. If you ordered your SVP with the actuator type
specified, then the SVP should come with the proper mounting kit, and the
correct actuator settings should already be programmed into the SVP. The Auto-
Setup program is then used to calibrate the SVP.
Procedure
Step Procedure
1 The SVP comes with an actuator mounting kit appropriate to your
control valve and actuator. Fasten the mounting plate to the SVP
securely, using the two hexagon head bolts and spring washers provided.
2 Fasten the SVP (mounting plate) securely to the actuators mounting
structure using the bolts and washers provided. During this operation,
pass the actuators feedback pin through the slot in the SVP feedback
lever.
3 For the SVP remote type (model AVP200/201/202), refer to 2-3:
Installing a remote type SVP (model AVP200/201/202) on page 19.
Note For the installation of the actuators, refer to the assembly diagram inside
the package.
Examples
With HA1 actuator

With HA24, PSA14, 6, VA16 actuators
With VR1, VR2, VR3, RSA2 actuators

Connecting the feedback pin and the feedback lever
The following points must be observed when connecting the SVP feedback lever
and the feedback pin on the actuator. These parts must be connected correctly.
(1) Only a 6 mm diameter pin may be used.
(2) The pin must be caught between the guide and the spring.
(3) The angle between the feedback lever and the pin must be 90when seen from
above.
(4) Assemble the feedback lever and the SVP using the two hex socket bolts
provided. The feedback lever rotates up to 20form the horizontal (40travel).
If this limit is exceeded, then the SVP will not operate properly.

(5) For large actuators, use the included feedback lever extension.
Space allowance for maintenance
The SVP has a nozzle flapper structure at the rear of the main unit. The SVP is
designed so that the nozzle flapper structure can be accessed by removing the pilot
relay cover at the back of the main unit when cleaning the flapper and adjusting the
EPM balance.
When designing mounting bracket, consider the adequate clearance to remove the
pilot relay cover for maintenance.
Connecting the Air Supply
Clean and dry supply air ensures long-term stability of the SVP.
The air supply must be clean; it should not contain foreign substances (moisture, oil,
or dust). The air must be dry, with a dew point at least 10 {18F} lower than the
SVPs lowest site operating temperature. For example, if the lowest environmental
temperature the SVP is exposed to is 0 {32F}, then supply air should not
condense at temperatures under -10{14F}.
Pressure regulator with 3m or better filter must be installed between the air supply
and the SVP as close as possible to the SVP unit. The Pressure regulator with filter.

Pressure regulator with filter

The control valve can be operated manually by using this regulator in
conjunction with the Auto/Manual switching function.
Use a 3m or better filter to solid-state particulate matter from the air supply.
If a filter is not provided on the regulator, insert a separate 3m or better filter
immediately before the regulator.
Shutoff Valve
This valve is used to temporarily shut off air supply to the SVP.
The shutoff valve enables disconnection of the SVP from the control valve for
ease of maintenance.
Recommended piping practices

Air supply pipes should have an inside diameter of 6mm {1/4 inch} (8mm {3/8
inch} outside diameter tubing recommended).
Pipes should match the installation environment, i.e. for a corrosive environment,
use vinyl-covered copper pipes.
Use joints that precisely fit the pipes.
Sealing tape is preferable to solid or liquid sealants for pipe joints to SVP air
connections. Prevent sealing tape/sealant from entering pipes.
Use the right length of piping; avoid excess lengths.
Completely flash pipes before use, checking for burrs and other problems.
Check for leaks after installation.

2-3 Installing a remote type SVP (Model AVP200/201/202)
Refer to 2-2 : Installing SVP on page 13.
Disconnecting the SVP and feedback cable
(1) Unscrew the cable connector from the housing.

(2) Gently pull the connector assembly out of the housing.
(3) Remove the connector by lifting the locking tab of the connector slightly using
a flat-head screwdriver and pulling the plug from the receptacle.
CAUTION
While connecting and disconnecting any wiring and disassembly of the travel
detector, make sure that no water or foreign objects enter the travel detector
assembly or SVP conduits as this may adversely affect operation.
Periodically tighten the waterproof gland and pressure-resistant packing type
cable adaptor. Failure to do so may allow rainwater to enter the equipment and
cause malfunctions.
The cable cannot be removed from the position detector unit. However, the
waterproof gland or pressure-resistant packing type cable adaptor can be
removed.
Please contact a Yamatake representative prior to adjusting the cable length.

Connecting the SVP and feedback cable
(1) Insert the connector plug into the receptacle.

(2) Gently push the connector assembly into the housing.
Screw the cable connector into the housing tightly so that the waterproof gland will
keep water out. If you cannot screw it tight, unscrew it and move the connector
assembly around inside so that it does not obstruct tightening of the cable connector.
After connecting the connectors, push the connector into the positioner. To insure
that the stipulated water resistance is maintained, push the cable adequately far into
the position detector and correctly assemble either a waterproof gland or cable gland
at the entry point.
If an electrical cable conduit is to be attached, remove the waterproof gland before
attaching the conduit.
(If the product is purchased preassembled with a Yamatake actuator, the cable on the
positioner unit is already removed. There will be a blind plug attached to the
positioner unit connection screw. Remove the blind plug and then attach the cable.)
Changing the feedback lever direction
Before attaching the valve travel detector to an actuator, you can change the
mounting direction of the feedback lever.
(1) Loosen the feedback lever hex bolt until the feedback lever can be removed.
(2) Remove the feedback lever.
(3) Rotate the position sensor shaft 180.
(4) Reattach the feedback lever to the position sensor shaft and tighten the feedback
lever hex bolt, making sure that the tip of the feedback lever hex bolt is
touching the flat side of the position sensor shaft at a right angle.
Note Do not loosen the two hex socket bolts that fasten the position sensor to the
valve travel detector housing.

Attaching the valve travel detector to an actuator
(1) Attach the valve travel detector to the actuator.

(2) Set the valve at 50% opening either with an air pressure regulator or by using
the valves hand-wheel.
(3) Adjust the position of the feedback pin and valve travel detector so that the
center of the valve travel detector and the feedback lever form a right angle
(refer to Connecting the feedback pin and the feedback lever on page 16).
(4) Fasten the valve travel detector to the mounting plate with the included hex bolt
and washer.
Note Do not point the cable removal port upwards.

Installing the SVP main unit
Fasten the SVP to a 2-inch pole where it will be free of vibration in excess of 2G
(400 Hz).
CAUTION
When attaching an air pressure regulator to the SVP, make sure the regulator air
vent is facing down to prevent the entry of rain.
Note for cable wiring between travel detector and SVP main unit
When connecting the cable between the valve travel detector and SVP, consider the
full operation area needed for the valve and the maximum safety of the Remote SVP
and personnel.
Avoid a situation where the valve travel detector or SVP weighs directly on the
cable. If this cannot be avoided, take steps such as attaching the cable to a
column support.
When you pull the cable upward, do not pull it directly upward. First pull
downward then pull it up.
You must follow the electrical devices technical standards for the cable
construction.
The length of cable between the remote-type AVPs valve travel detector and the
positioner body can be cut to any length and then adjusted.
Adjustment of the length of the cable requires the use of Yamatakes proprietary
tool and must be carried out by an experienced Yamatake service person. Be sure
to contact Yamatake before adjusting the cable length.

2-4 Installing a double-acting SVP for spring-less actuators
When an SVP is installed on a valve with a spring-less (double-acting) actuator, air

pressure is needed on both the bottom and top of the actuator diaphragm to provide
valve opening and closing proportional to a control signal. A reversing relay is used
for this purpose.
Reversing relay
For the output air pressure of a reversing relay, POUT2 is outputted.

OUT2 PSUP OUT1
Installing the relay
(1) Remote the dust plug from the output air connection.
(2) Screw the relay air connection of the reversing relay into the output air
connection on top of the SVP.
Note Sealing tape is preferable to solid or liquid sealants for pipe joints to SVP
air connections. Prevent sealing tape/sealant from entering pipes.

Note Make sure that the air piping connections and air pressure ranges as
inscribed on the bottom of the reversing relay match your SVP.
The reversing relay has two output air connections:

Output air connection 1 (OUT1) which passes through the SVPs output air
pressure
Output air connection 2 (OUT2) with the balance of the supply pressure (minus
SVP output air)

Installing a double-acting SVP with a KZ03 air pressure regulator with filter
A KZ03 air pressure regulator with filter has two output air connections. Connect
one of the output air connections to the supply air connection on the SVP. Connect
the other output air connection on the KZ03 to the supply air connection on the
reversing relay using sealing tape.

Installing a double-acting SVP without an air pressure regulator
Using a T-connector, connect the air supply from the regulator and filter to both the
SVP supply air connection and the supply air connection on the reversing relay
using sealing tape. Make sure to connect only one regulator to an SVP and reversing
relay combination.

Procedure for air pipe connection
Step Procedure
1 Remove the dust plug from the output air connection on SVP.
2 Connect the joint to the air output connection using sealing tape.
Note Sealing tape is preferable to solid or liquid sealant for pipe

joints to SVP air connections. Prevent sealing tape/sealant from
pipes.
3 Connect the other air connection to each joints.
Note Completely flash pipes before use, checking for burrs and
other problems.
Use the right length of piping avoid access lengths.
4 Check for leaks after installation.
Installing a double-acting SVP onto diaphragm actuator
Reverse-Acting Actuator
Connect OUT1 of the reversing relay to the bottom actuator air port.
Connect OUT2 of the reversing relay to the top actuator air port.
Direct-Acting Actuator
Connect OUT1 of the reversing relay to the top actuator air port.
Connect OUT2 of the reversing relay to the bottom actuator air port.

Installing a double-acting SVP onto a rotary actuator
Direct-Acting Actuator (clockwise rotation with increased pressure)

Connect OUT1 of the Reversing Relay to the actuator chamber that rotates the trun-
nion clockwise with added pressure.
nion counter-clockwise with added pressure.
Reverse-Acting Actuator (counter-clockwise rotation with increased pressure)

nion counter-clockwise with added pressure.
nion clockwise with added pressure.
Note If the actual air piping is different than described above, the functions of
the SVP as a positioner will not be affected. However, various valve and
SVP diagnostics usually performed with the SFC will not return accurate
information. To utilize the capabilities of the SVP to the fullest, piping
should match the diagrams and instructions above to maintain the
relationship between the parameter settings described throughout this user
manual.

2-5 Electrical wiring
2-5-1 Wiring for waterproof SVP
WARNING
ELECTRICAL SHOCK HAZARD! Turn off power before performing any
wiring.
When using an explosion-proof SVP in a hazardous location, wiring must be
performed in accordance with the instructions in 2-5-2 : Wiring for explosion-
proof SVP on page 34.
Unused conduit ports must be completely sealed by attaching a blind plug.
Connection points
Electrical wiring types

There are 2 types of electrical wiring that differ by the purpose of the system.
Systems that do not transmit a position signal (2-conductor connection)
Systems that transmit a position signal (4-conductor connection)

Electrical wiring without travel transmitter (Model AVP300/302/200/202)
Use only one of the two ground terminals (internal and external) to ground the
SVP. Perform this work according to all local laws and ordinances governing
electrical work.
With travel transmitter (Model AVP301/201)

Remove the terminal box cover and connect the wires as shown in the figure below.
When a 4-conductor cable is used

When a 2-conductor cable is used
Use the following wiring if the monitoring system is a voltage input (1 to 5V)
device.
Use only one of the two ground terminals (internal and external) to ground the
instrument. Perform this work according to all local laws and ordinances
governing electrical work.

Cables
Use stranded cables having a conductor cross-section of 1.25mm2 and suitable

for 600V such as shown in the conductor table in Article 310 of the NEC
(National Electric Code). Outside diameter on cables must be 1/4 inch to 7/16
inch {7 mm to 12 mm}. Use shielded wires for locations exposed to
electromagnetic noise.
Select a sheath material that can withstand the cable installation environment
(including the ambient temperature, corrosive gasses, corrosive liquids).
Bring the cable to the terminal box through the conduit connection port (G1/2
internal thread, 1/2NPT internal thread, or M201.5 internal thread).
Use cable with an outer diameter between 7 and 12 mm. If a pressure-resistant
packing type cable adaptor is used, only use a packing that matches the outer
diameter of the cable.
We recommend the use of M4 screw size crimp-on terminals with an insulating
sleeve.
The maximum cable length is 1500 meters.
Maximum permissible cable length is 1.5 km.
Use the appropriate special-purpose cables for the wiring between the main unit
at the position detector for separate type models (AVP200/201).
CAUTION
Avoid installing cables near noise-making devices such as large capacity
transformers and motors. Do not lay signal/control cables in the same tray or duct
with noisy switching power cables.
Note We recommend the use of conduits and ducts to prevent water and
mechanical damage to electrical lines.
Also, always use water-tight adaptors at conduit connection ports.
Use conduct and duct for locations exposed electromagnetic noise.
Always follow the technical standards for electrical installation for the
wiring between the main unit at the valve travel detector for remote
type models (AVP200/201/202).

Electrical wiring procedure
Step Procedure
1 Unscrew the Phillips terminal box cover screw on the terminal box
cover.
2 Unscrew the terminal box cover and remove it.
Note Be careful not to scratch painted surfaces with tools at this time.
3 Remove one or both of the supplied Yamatake conduit connection blind
plugs depending on how you plan to wire the SVP.
4 Insert cables into the conduit connection. Strip and attach the appropriate
wires to the terminals, checking for polarity. Crimp contacts with
insulated sleeves are recommended.
Note Be careful not to damage the cable sheath at this time.

5 Tighten the terminal screws fully, to a torque of 1.5 N*m (15 kgf*cm).
6 Apply adequate waterproofing measures to the conduits to prevent the
entry of rainwater or water from any other source.
Note We recommend the use of silicon resin based non-hardening

seal materials.
7 Screw the terminal box cover onto the SVP until it is hand-tight. Use the
Phillips terminal box screw to secure the terminal box cover.
CAUTION
Be careful not to hurt your fingers on the edges of the cover
and the screw threads.
Note Be careful not to scratch painted surfaces with tools at this time.

2-5-2 Wiring for explosion-proof SVP
Guidelines
Explosion-proof requires special precautions and installation methods. Refer also to

2-5-1 Wiring for water-proof SVP on page 29.
WARNING
Tighten the case cover fully, to the end, and lock.
Clearly delineate safety responsibilities in operating procedures. Especially, for
an explosion-proof positioner, specify locking of the cover of the positioner
case.
Locking
Before cabling can be performed. Use a 3mm hexagonal wrench to open the locking
structure.
Leading in external cables
Leading in cables to the equipment

Refer to the instructions in the chapter of About Explosion-proof in the front of this
manual.

2-5-3 Wiring for Intrinsically-safe SVP
Guidelines
The intrinsic safety requires special wiring precautions and installation methods.
Also refer to 2-5-1 Wiring for waterproof SVP on page 29.
WARNING
Protect SVP from electrical or magnetic influence (such as coupling and
induction) from other electrical circuits.
Use certified zener barriers.
Wiring
FM
The wiring should comply with the Installation requirements
KEMA/CENELEC
The barriers should be certified in accordance with the CENELEC standards, with
which the electrical parameters listed below have to be covered.
Item Description
Model AVP300 Input circuit (terminals +/-IN)
Ui=30V, Ii=100mA(resistively limited), Pi=1W
Ci=1nF, Li=0.2mH
Output circuit (terminals +/-OUT)
Ci=1nF, Li=0.3mH
Both circuits shall be considered to be connected to
ground from a safety point of view.
Ci=1nF, Li=0.2mH
Ci=3nF, Li=0.2mH
Ci=33nF, Li=0.2mH
Ci=1nF, Li=negligibly small

NEPSI
SVP should be used with any of the following Zener barriers (which have been
certified by NEPSI):
Model AVP300: Two each of MTL728, Z728, or LB928
Model AVP301: For input signal Two each of MTL728, Z728, or LB928
For valve travel transmitter MTL728, Z728, or LB928
Refer to the users manual of each applicable barrier along with this manual.
The wiring capacitance should not exceed 0.06F.
The wiring inductance should not exceed 1mH.
Use the earthing terminal to connect the earthing conductor.
Configuration of an intrinsically-safe system
System configuration
The system configuration is shown below. The diagram also shows the layout of an
intrinsically-safe system consisting of a SVP, a portable setting display, a field type
current indicator, and a Zener barrier. The system components except those
connected to the non-intrinsically safe side of the barrier, must be certified by an
authorized testing station.
2-6 Control signal
The SVP requires a 4 to 20 mA DC control signal.
CAUTION
Current should never exceed 24mA DC.
The SVP requires a minimum of 3.85 mA DC to operate and SVP.

2-7 Travel transmission and load resistance
The load resistance on the two output terminals must be a least 250 Refer to the
chart below for the prefer resistance.
2-8 Cable gland and flameproof universal elbow for JIS

Flameproof apparatus
JIS Flameproof SVP model is provided with a certified cable gland.

The cable gland seals the cable entering the SVP enclosure to withstand an internal
explosion and protects the cable from damage mechanically and electrically.
Use the dedicated elbow if it is necessary to change the direction of the cable with
these models.
WARNING
The constituent elements of the cable gland used with the integrated models
(AVP300/301) and that used with the separated models (AVP200/201) differ. Be
careful not to misuse these two adaptors.
The explosion-protection of the system will be invalid if any parts are no used
properly.

Structure of the cable gland
The Flameproof cable gland is shown below in assembled and exploded views.


Structure of the flameproof universal elbow
The figure below shows the universal elbow.

Mounting example
The flameproof cable gland and the universal elbow are used to connect the field
wiring cable to the SVP enclosure as shown below.

Mounting procedure for cable gland
The procedure for mounting the flameproof cable gland is shown below.
Step Procedure
1 Firmly tighten the entry body on the connection port and the universal
elbow to hold it in place. Once held in place, tighten the hexa-recess
stopper screw on the entry body (for models AVP300 and AVP301).
Note Apply adequate waterproofing to these parts. We

recommend the use of silicone resin based non-
hardening seal materials.
2 Refer to the illustrations and insert the cable carefully.
CAUTION
If the diameters of the cable and the packing do not match
each other, the propagation of flame cannot be prevented.
Refer to the table below and select a packing adaptor whose
internal diameter matches the outer diameter of the cable.
Table 2-1 Integrated type
Cable outer Packing inner Notes
diameter (mm) diameter (mm)
7.010.0 10 Provided
10.112.0 12 Built in
Table 2-2 Separated type
Cable outer Packing inner Notes
diameter (mm) diameter (mm)
7.09.0 10 Provided
9.111.0 11 Built in
11.112.0 12 Built in
Use the provided
clamp ring.
3 Fit the clamp nut onto the compression element and tighten it down to
hold it in place.
4 Fit the packing case onto the compression element and tighten it down to
hold it in place.
CAUTION
To prevent injury due to spark travel, be sure to tighten down
the packing adequately.
5 Pass the cable through the entry body and insert it into the terminal box.
6 Screw the union nut onto the entry body and tighten it down securely to
hold it in place. Then, tighten the union nuts recess screw.

Mounting procedure for flameproof universal elbow
The procedure for mounting the flameproof universal elbow is shown below.
Step Procedure
1 Align the end surface of the lock nut with the end surface of the O-ring
groove as shown below.
2 Screw the flameproof universal elbow into the terminal box conduit
connection port until the lock nut end surface hits the connection port
end surface.
Note Apply adequate waterproofing to these parts.

3 Turn the flameproof universal elbow to loose in the desired direction.
Note Do not loosen it more than 1 turn.

4 Lock the flameproof universal elbow in place by tightening down the
lock nut using the special tool.
Lead-in of cable for flameproof models other than models in

accordance with JIS
If the SVP is to be used under the authorization other than that for the JIS
Flameproof standards, this the wiring of cables must be performed according to
local regulations for electrical installations in explosive atmospheres.

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SL,SJ Series Safety Valves (FUKUI) A12E1

SL, SJ SERIES SAFETY VALVES

PRECAUTIONS ON SAFE OPERATION

FUKUI SEISAKUSHO CO., LTD. is a professional manufacturer of safety valves,

Language UK Page 1 - 1 - 1/26

PREVENTIVE MEASURES FOR SAFETY

Language UK Page 1 - 1 - 2/26

1 Storage and Handling

Language UK Page 1 - 1 - 3/26

1 Storage and Handling

1.1 For Handling

1.2 For Storage

Language UK Page 1 - 1 - 4/26

2-1 Safety Valve Installation

(1) Prior to installation of safety valves, a visual inspection should be carefully

2-2 Peripheral Equipment of Inlet Piping

Language UK Page 1 - 1 - 5/26

valve and minimizing the risk of personal injury.

Fig.1 Example of Good Installation

2-3 Discharge Pipe

Language UK Page 1 - 1 - 6/26

3 Hydrostatic Pressure Testing of Vessel

(1)For flanged type safety valves

(2)For welded type safety valves (See

(3)Handling the test gag

Language UK Page 1 - 1 - 7/26

When raising the pressure

When lowering the pressure

4. Field Setting of Safety Valves

Furthermore, perform hand-blowing of each safety valve at about 90 of the set

Language UK Page 1 - 1 - 8/26

4.1 Adjustment of the Set Pressure

4.2 Variation Rate of The Set Pressure

Language UK Page 1 - 1 - 9/26

4.3 Tolerance of Set Pressure

0.5(5) or less 0.014(0.14)

4.4 Adjustment of Blow Down

(1)Adjustment by upper ring

Intended state of operation Method of adjustment

Peeping through the screw hole, rotate the

Language UK Page 1 - 1 - 10/26

Table6 unit:MPa ( f/cm2 )

(2)Adjustment by Adjust Needle

Language UK Page 1 - 1 - 11/26

Moreover, it is recommended not to connect a pipe to a discharge opening of adjust

H,J G G2,H2 F2,G2 3/4 35

K,L,M J,K J2,L1,M H2,J2 1 45

4.5 Adjustment of Simmer

If the simmer is too large, raise

Language UK Page 1 - 1 - 12/26

After the adjustments of the upper

4.6 Standard Positions of Upper and Lower Rings

Upper ring standard position;

Language UK Page 1 - 1 - 13/26

Table10 Type SL Table11 Type SJ

4.7 Trouble Shooting.

Problem Phenomenon Probable Cause Corrective Action

If the blowdown is too

Language UK Page 1 - 1 - 14/26

Problem Phenomenon Probable Cause Corrective Action

The pressure Increase the blowdown

Language UK Page 1 - 1 - 15/26

4.8 Trouble Shooting for Other Diffcult Problems