Boiler

INSTRUCTION MANUAL
FOR
Auxiliary Boiler &
SDR-350 Burner
CUSTOMER : Hanjin Heavy Industries Co.,Ltd.
HULL NO. : P0123
SERIAL NO. : PAW14HJ0123
Classification : GL+RINA
江林重工業 (株) HEAVY INDUSTRIES CO.,LTD.
昌原工場 CHANGWON FACTORY

慶南昌原市城山區延德路 76 76, YEONDEOK-RO, CHANGWON-SI, KOREA
TEL. : +82-55-269-7700 TEL. : +82-55-269-7700
FAX. : +82-55-269-7795 FAX. : +82-55-269-7795
E-MAIL : [email protected] E-MAIL : [email protected]
江林인슈(株) INSULATION CO.,LTD.
釜山工場 BUSAN FACTORY

釜山市沙下區多大路 170地,56 56, DADAE-RO 170 BOON-GIL, BUSAN-SI, KOREA
TEL. : +82-51-220-6000 TEL. : +82-51-220-6000
FAX. : +82-51-220-6006 FAX. : +82-51-220-6006
Customer : Hanjin Heavy Industries Co., Ltd. Specification
Model No. - PA0101P12 x 1 set/ship
Hull No. : P0123~5 Capacity - 3,500 kg/hr
Working pressure - 7 kg/cm²
Classification : GL/RINA
Burner type - SDR-350 x 1 set/ship
Work Order No. : PAW14HJ0123~5
Auxiliary Boiler
76, YEONDEOK-RO, CHANGWON-SI, KOREA

TEL : 055) 269 ~ 7700(REP) / 7760(DIR)
FAX : 055) 269 ~ 7795~9
E-MAIL: [email protected]
CONTENTS
1. DESIGN DATA
2. DRAWINGS
3. F.W. SYSTEM WITH ACCESSORIES
4. BURNER SPECIFICATION
5. F.O. SYSTEM WITH ACCESSORIES
6 CONTROL PANEL
6.
7. SPARE PARTS AND TOOLS
8. PART INSTRUCTION MANUAL
*NOTE
If we may be of further assistance, please do not hesitate to contact. Mr. Hyun-Sang, Cho at 82-55-269-7899.
PLAN HISTORY
0 15.04.27 FOR FINAL H.S.CHO - K.J.AHN

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

DESIGN DATA
1. DESIGN DATA

DESIGN DATA
LIST OF DESIGN DATA
NO DRAWING NO. TITLE REV. REMARK
1 - Technical data 0
2 MB-TE-01 Design data
- Information table of insturments 0
- Proposal water level 0
- Proposal drum pressure setting point 0
- Thermal expansion of boiler 0
3 MB-INT-001 Installation 0
4 MB-MN-02 Preservation 0
5 MB-MN-05 Soda boiling procedure 0

DESIGN DATA
TECHNICAL DATA
1. Design data
Number of boiler / ship 1 Set
Steam production 3,500 kg/hr
Working pressure / Design pressure 7/9 kg/㎠.G
Feed water temperature 65 ℃
2. Oil fired section data

Fuel oil consumption (at H.F.O) 262 kg/hr
Air consumption at 45℃ 4,262 kg/hr
Flue gas flow 4,508 kg/hr
Flue gas temperature Max. 450 ℃
Recommend for flue gas duct draft loss Max. 15 mmAq
3. Dimension
Diameter excl. of insulation 1,950 mm
g excl. of smoke uptake
Height p 5,060 mm
Water volume at normal water level 6.80 m³
Weight of boiler including of burner and fittings (dry) 13.8 Ton
Total operation weight 20.6 Ton
4. Classification
Hull No. P0123~5 GL+RINA
5. Paint color
Boiler Body Heat resistance paint silver

DESIGN DATA
Information table of instruments
NO. Item Unit Meas. Range Part No. Set Point Location
Diff. pressure transmitter

1 mmAq -400 ~ +400 A29 - Boiler
for water level
Level switch
2 mmAq - A31 -220 Boiler
for low low water level
Pressure transmitter
3 kg/㎠.G 0~16 A32 - Boiler
for steam drum
Pressure switch
4 kg/㎠.G 1~10 A32 8.5 Boiler
for high steam pressure
Temperature transmitter
5 °C 0~500 G01 (450) Flue. duct
for high flue gas temperature
Salinity indicator
6 PPM 0~200 W03 (80) F.W pipe
for high content of natrium chloride
Oil detector Feed. W
7 - - W04 -
for level of sediments Filter Tank
Thermostat
8 ℃ 20~150 F13 (55) F.O pipe
for high M.G.O temperature
* NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

** NOTE : REGARDING THE ALARM & SAFETY TABLE, PLEASE SEE PART6-CONTROL PANEL.

DESIGN DATA
Proposal water level
(20 mA)
+400 mmAq
High Water Level (17.6 mA)

BOILER LEVEL GAUGE C TO C : 800
+250 mmAq
(
Normal Water Level (10.7 mA))
0 mmAq
Low Water Level (7.5 mA)

-180 mmAq
Low Low Water Level (6.9 mA)

-220 mmAq
(4 mA)
-400 mmAq

DESIGN DATA
Proposal drum pressure setting point
☞ 9.0 Safety valve open / Design pressure
☞ 8.5 High steam pressure
☞ 7.7 Dumping v/v open
☞ 7.5
7 5 Burner stop
☞ 7.0 Boiler working pressure
☞ 6.5 Burner start
☞ 5.5 Low steam pressure
PRESSURE UNIT : kg/㎠.G

DESIGN DATA
Thermal expansion
Design specification
Boiler type : Water tube type
Boiler steam production (Oil fired) : 3,500 kg/hr
Boiler working / Design pressure : 7 / 9 kg/㎠.G
Steam temperature at W.P / D.P : 169.8 / 179.2 ℃
Ambient temperature max. : 45 ℃
Unit : mm
Point Design length Expansion at W.P Expansion at D.P
H1 4,760 7.0 7.8
H2 5,060 7.5 8.3
H3 5,895 8.7 9.7
L1 1,187 1.8 2.0

INSTALLATION OF BOILER
1. Transportation and Handling of Boiler
As a standard the boiler plant is delivered in a 20 feet flat rack container.

(It is only applied to deliver to oversea by ship. In case of the domestic delivery, it
can be delivered without container)
The boiler is secured to the container to keep it fastened during transportation.
Before the boiler is removed from the container, the supports securing the boiler
are to be dismounted. The boiler should be lifted out of the container and placed on
the ground as shown on Figure 1. If the boiler is placed on the quay or somewhere
else before it is mounted in the ship it is important that the boiler is placed on a
plane foundation. This secures that the boiler foundation and/or shell is not
deformed. Before turning the boiler into an up-right position the transportation
supports on which the boiler has rested during transport should be loosened.
The boiler is then to be turned into an up-right position by the use of two cranes as
shown on Figure 2.
Finally the boiler can be placed in the hull by lifting it as shown on Figure 3.
FIG.1 Lifting of the boiler from the transport container

FIG.2 Turning the boiler into an up-right position
FIG.3 Lifting the boiler into the hull

*CAUTION*
If the boiler is to be stored for a period before it is mounted in the ship it is
very important that the boiler is covered with a tarpaulin and stored in an
indoor store room. This is to protect the boiler against corrosion caused by
rain or pollution.
2. Installation
1) Welding to Deck/Ship Structure
The following instructions assume that the deck or ship structure, onto which the
boiler is to be welded, is sufficient flat and has the adequate strength to support the
boiler.
Furthermore, the boiler foundation in the ship must have the sufficient stiffness to
avoid tat vibrations from the ship are transformed to the boiler.
As shown on Figure 4, the boiler is to be welding all around the outer side of the
boiler. The cut-outs the foundation of the boiler may under no circumstances be
covered or sealed. This is due to the fact that there should always be an air
circulation below the boiler.
FIG.4 Welding at the boiler and thermal expansions

2) Support of boiler
Because of the height and the weight of the boiler as well as the high position of
the centre of gravity it is very important that the boiler is supported at the top to
relieve stress at the foundation.
The support is to be arranged both longitudinally and transversally. In order to lift,

turn, and transport the boiler it is provided with lifting irons. When the boiler is
delivered with installation 2 pcs. of “type C” and 3 pcs. of “type D”lifting eyes are
fitted.
As regards“type C”only the lower“eye”is to be used when staying the boiler. We

ask the yard to inform us where additional fixing irons should be placed.
Detail of lifting eye Detail of lifting eye

( "type C" ) ( "type "D" )
When fixing the boiler it is very important that the beams used are provided with
links in each end and that the beams are mounted as horizontally as possible so
that the boiler has the possibility of free movement during heat expansion. In every
single case the position of fixing points and beams is to be decided at the
construction of the ship, but as a general rule at least one beam is to be mounted
longitudinally and one transversally.
Furthermore, the beams are to be as short as possible. The distance from boiler to
the nearest fixing bulk head will decide whether the longitudinally support is to be
placed on the fore or aft edge of the boiler, and whether the transverse support is to
be placed in st'bd or port side. If the transverse support cannot be placed directly
transversally, it might be advantageously to use two transverse beams to secure
the boiler, see Figure 6.

FIG.5 Support of boiler installed limitation for angle and length
In order to reduce the influence of the thermal expansion between the boiler,
beam(pipe), and bulkhead, the optimal installation angle of a beam(pipe) is -15°
with a length of at least 500mm. However, angle between ±20° from the optimal
angle position can be accepted.
FIG.6 Schematic drawing for support of boiler

*CAUTION*
In double boiler installations, the boiler must not be linked together.
3) Fastening the boiler to it's foundation.

Will as standard execution be done by means of welding to the deck. The weld to
be run along the whole shell edge. The existing penings will secure the circulation
of air below the boiler bottom.
4) Ship's construction
It is the responsibility of the building yard to make sure that the foundation for the
boiler has the necessary load capacity, and that the ship’s fixing points for the boiler
support can obtain the reactions (expansions, torsion, etc.) which may occur during
boiler operation/movement of ship.

PRESERVATION OF BOILER
The following preservation, it is procedure which is a long period for lay up after operating/
installation of boiler. Before operating/installation the boiler, it will be provided according to
KangRim rust prevention procedure.
1. General
Boiler to be held out of service must be carefully handled and closely watched in
order to minimize any tendency of corrosion of parts.
The casing and other exterior parts of the boilers should be kept free from dirt and
soot. They should be kept as clean and dry as possible.
Outer steel casing should not be cleaned with abrasives or acids. The tops of the
casings should be properly protected against corrosion caused by drippings from air
vents, stop valves or other sources. The spaces at the back and sides of the boilers
should be kept clear to allow access to all parts and nothing wet or combustible
stowed over or around them.
The air spaces in air-encased boilers, uptake enclosures, and the air ducts and
casings of forced-draft systems should be examined frequently and any
accumulation of dirt or rust therein prevented.
- FIRE SIDE -
A boiler which is to be held out of service for any period should have the fireside
thoroughly cleaned and dried. Soot on the boiler surfaces will absorb moisture from
the air and cause external corrosion. The furnace and burner air registers of all idle
boilers should be kept closed except for occasional. Every effort should be made to
maintain the firesides and the interior surfaces of the casings of idle boilers in as
dry a condition as possible.
- WATER SIDE -
If a boiler is to be held out of service more than four days duration; usually for a
period of several weeks or months. it is recommended that it be laid up in
accordance with the water fill method.
If no water is available, a dry layup method should be used as outlined below.
Laying up of the watersides can be accomplished by the following wet or dry
methods.
- Wet method : Water Fill Method

- Dry method : Absorption Agent

2. Method
1) Lay-up by Water Fill Method -Long Term
A long term lay-up is considered a time period longer than four days duration;
usually for a period of several weeks or months.
But, the temperature of fire side shall be kept over freezing always.
a) Inject appropriate quantities of chemicals for boiler water treatment and

sodium sulfite into the boiler's water side using Chemical dosing unit so that
the boiler water will be pH10.8~11.3 (Alkalinity : 300~400ppm), about 50ppm
in phosphoric-acid(PO4) content and 80~100ppm in sodium
sulfite(Na2SO3).The water concentration should be remained at extremely
high level during wet storage period compared with what it is when in service.
b) When the pressure of the boiler has gone down to nearly zero(0) bar., open
the air vent valve and fill the boiler with distilled water until it effuse from air
vent pipe, then close the air vent valve.
c) Put the hydrostatic pressure of 3.5~5bar g. on the boiler. Hold this pressure
until the boiler has cooled to surrounding temperature then bleed the boiler
using air vent valve and to be sure all air is out. Hold the hydrostatic pressure
of 2~3
2~3.5bar
5bar gg. on the boiler
boiler.
Maintaining the alkalinity at uniform level throughout respective boiler parts is an

important consideration, so periodically sample the boiler water for analysis during
lay up and replenish what have been spent of alkalinity and sodium sulfite.
- CAUTION -
Machinery space to be installed the boiler shall not be lower than 5 deg.C so
as to prevent from boiler water freezing.

2) Lay up by Use Of absorption agent.

In case water is not available, this(Dry lay up) method can be used.
a) Drain out the boiler water while boiler is fairly warm and make sure no water
is left in the water side of boiler. All parts where water is liable to accumulate in
pockets should be blown out with an air hose.
b) If necessary, burn the coke or charcoal in the furnace of boiler to promote the
internal surface drying.
c) When completely dried, open the manhole and put the absorption agent (VCI
or Silica gel) in the boiler and close quickly.
Use 2~5kg VCI(Volatile Corrosion Inhibitor) for 1,000kg of boiler water or
1.8kg of silica gel for 1,000kg of boiler water.
d) Be sure to close securely all mounting valves, manhole and access door.
e) Check the absorption agent every 1~2 weeks at the beginning and every 1~2
months thereafter at the circumstances call for and renew deteriorated
absorption agent.
The length
g of time the silica g
gel remains effective will depend
p upon
p atmospheric
p
conditions and how tightly the boiler is closed up. It is recommended that a couple
of bags be examined after two weeks. When the silica gel becomes saturated it can
be dried by baking at a temperature of about 150 deg.C. The relative humidity
within the boiler must be held below 30 percent to insure adequate protection.
- CAUTION -
All connections on the boiler shall be kept close tightly so as to avoid
entering of air to boiler.

SODA BOILING PROCEDURE
1. Soda boiling procedure

The main object of soda boiling is to remove oil and grease sticking to the boiler
pressure parts in the preparation of a new boiler or an old boiler after major repair of
boiler pressure parts. At the same time, considerable amount of mill scale and rust can
be removed.
Soda boiling is to be done after making sure that the boiler is free from leakage by
hydrostatic test after installation or repair.
2. Preparation
1) Carefully clean the inside of the steam drum and wipe off, dust and grease
(especially, where grease is used, thoroughly wipe grease off the tube ends). Be
sure that tools and other foreign objects are at left in the boiler.
2) Full open the upper and lower level gauge, pressure gauge valve, and air bleeding
valves of the steam drum and close all the other valves and manholes.
3) Since the packings are attacked by alkali, preferably use temporary Where it is
difficult to replace all the packings, at least replace the packings of the large
diameter manholes.
4) Be sure that the auxiliary machines used for soda boiling operate normally.
5)) Full close the sensing
g side stop
p valves of the heat control instruments susceptible
p
to alkali.
6) Open the manhole of the steam drum and fill water until water is visible in the
drum. Close the air bleeding valves of the headers when water if filled.
7) Store chemicals indoors on the plates laid on the ground, covered with a sheet so
that the chemicals will not absorb water. Add the chemicals safety by using rubber
gloves, polyvinyl chloride buckets, ladle, goggles, canvas or other sheet.
8) On completion of adding chemicals, close the manhole and fill water until appears
at the bottom of the level gauge.
INFORMATION
The standard amounts of the following Sodium carbonate or Sodium phosphate is
2kg per water 1,000 kg.
Determine the amounts according to the amount of water needed to fill the boiler.
Name of chemicals Amounts Remark

Sodium carbonate(Na2CO3) 2kg/1000kg Water
Sodium phosphate (Na3PO4) 2kg/1000kg Water
The amounts of chemicals shown in the table are standard any may be altered
depending on the amount and type of oil and grease sticking to the interior surfaces of
the boiler.

3. Soda boiling operation

1) Use the heavy residue burner and adjust the damper so as to obtain adequate
combustion at the low rate firing for soda boiling. Shift the burner position at
regular intervals so that the boiler will be heated evenly.
2) The heating rate is 55 ℃/hr.

During heating, pay attention to the temperature of the evaporator not to be
damaged.
3) When the internal pressure of the boiler reaches 0.5 kg/cm2G close the air
bleeding valves.
4) Though the water level increases with the time, blow down so as to maintain the
water level high in the visible range of the level gauge and increase the pressure to
the level shown below, then maintain the pressure.
Maximum Operating Pressure Pressure in Soda Boiling Remark

2 2
Less than 16 kg/cm G 4 to 7 kg/cm G
2 2
From 16 below 55 kg/cm G 10 to 16 kg/cm G
2 2
55 kg/cm G or over 14 to 16 kg/cm G
5) After 4 to 5 hours from reaching the desired pressure, quench the burner once and
blow by opening the blow-off valves of the boiler proper, water wall header, etc. in
order. Lower the water level 100mm to 140mm by blow down and again feed water
up tp 50mm above the middle of the level gauge.
6) Again ignite the burner and raise the pressure gradually up to the soda boiling
pressure of the steam and water drum. After maintaining the soda boiling pressure
for 5 to 6 hours, quench the burner and blow down by opening the blow off valve.
Repeating the above cycle, remove oil, grease, rust and dust.
7) On completion of soda boiling, quench the burner and cool down the burner and
cool down the boiler naturally with the boiler shut-off.
8) When the internal pressure of the drum is reduced down to 0.5 kg/cm2G, open the
air bleeding valve.

4. Operation after completion of soda boiling

On completion of soda boiling, quench the burner and cool down the boiler naturally
with the boiler shut off. When the steam pressure near the atmospheric, drain all the
boiler water and clean the boiler as quickly as possible in the following steps.
1) When the water temperature is reduced to about 70℃, blow down alkali solution
while cleaning with water of approx. 70℃
Although it is generally enough to wash off residual alkali solution with water.
2) Wash the inside of the steam drum with water and throughly wash off the residual
sticking to the interior. The internal components shall be taken out of the boiler for
cleaning.
3) In the inspection and cleaning operation inside the drum, take out everything out of
pockets of working cloth worn by the persons. Confirm the number of tools in the
tool box to prevent tools being left behind in the drum and exercise care not to drop
tools and other things on the water tubes of the boiler proper.
4) On completion of cleaning the entire boiler, again wash all the internal surfaces
with fresh water once.
5)) Cleaning brushes may be used in the above cleaning processes.
5. Inspection procedure
On completion of internal cleaning, inspect in the following.
1) Since inflammable gas or toxic gas may stagnate in the furnace, ventilate the
furnace, ventilate the furnace enough before entering into it.
2) Before entering into the drum, close and lock the valve through which steam or
water may enter into the drum, to prevent hazards.
3) Check the straight tubes and the tubes of less bending visually by irradiating the
tube insides with a flash light from the bottom of the tubes.
6. Restoration
1) On completion of inspection, clean the inside of the boiler with fresh water.
2) Remove all the pipes temporarily installed.
3) Carefully tighten the mounting bolts of the internal components of the drum so that
the bolts and nuts will not come off.
4) Replace the gaskets for manhole and handhole.
5) Close the manholes and handholes.

7. Sequence for chemical cleaning
FLOW CHART
Pre-assembly for Boiler
Water heating & chemical insert
Boiler firing( working pressure )
Firing for about 5 to 6 hours
After firing finishes, leave it till cooled down
Drain
Re-installation for Boiler

DRAWINGS
2. DRAWINGS

DRAWINGS
LIST OF DRAWINGS
NO DRAWING NO. TITLE REV. REMARK
1 PA-PI-01 P & I DIAGRAM 0
2 PA-GA-01 GENERAL ARRANGEMENT 0
3 PA-TH-01 TOP GRATING & HANDRAIL 0
4 PA-BF-01 BASE & FOUNDATION 0
5 PA-OI-01 OUTSIDE INSULATION 0
6 PA-SU-01 SMOKE UPTAKE 0
7 STD-003 STANDARD LIFTING LUG - TYPE "C" 0
8 STD-004 STANDARD LIFTING LUG - TYPE "D" 0

F.W. SYSTEM WITH ACCESSORIES
3. F.W. SYSTEM WITH ACCESSORIES

PART LIST OF F.W. SYSTEM
PART NO. DRAWING NO. TITLE TYPE / SPEC. QT'y REV.
< Mounting List >
A01 MB-DP-01 Safety valve with drip pan JIS B8210, 20K-40/65A 2 0
A02 MB-JF-7314 Main steam valve JIS F7314, 20K-125A 1 0
A04 MB-JF-7313 Feed water valve JIS F7313, 20K-40A 2 0
A05 MB-JF-7473 Feed water check valve(SDNR) JIS F7473, 20K-40A 2 0
A06 MB-JF-7313 Scum valve JIS F7313, 20K-40A 1 0
A07 MB-JF-7473 Scum check valve(SDNR) JIS F7473, 20K-40A 1 0
A08 MB-JF-7313 Blow down valve JIS F7313, 20K-40A 1 0
A09 MB-JF-7473 Blow down check valve(SDNR) JIS F7473, 20K-40A 1 0
A11 MB-JF-7303 Water level regulation valve JIS F7303, 16K-25A 2 0
A12 MB-JF-7303 Low water level switch valve JIS F7303, 16K
16K-25A
25A 4 0
A13 MB-JF-7421 Sampling valve JIS F7421, 20K-15A 1 0
A14 MB-JF-7388 Air vent valve JIS F7388, 20K-6A 1 0
A15 MB-JF-7388 Pressure gauge valve JIS F7388, 20K-6A 1 0
A16 MB-JF-7388 High pressure switch valve JIS F7388, 20K-6A 1 0
A17 MB-JF-7367 Furnace side drain valve JIS F7367, 5K-40A 1 0
A38.01 MB-ST-02 Safety valve for heating coil 15A 1 0
A38.02 MB-JF-7303 Heating coil inlet valve JIS F7303, 16K-25A 1 0
A38.03 MB-JF-7303 Heaing coil outlet valve JIS F7303, 16K-25A 1 0

Condensate reservoir
A27/28 MB-CR-01 - 1 0
& Connection bend
A29 MB-DT-01 Differential pressure transmitter PMD75 1 0
A30 MB-LG-01 Water leve gauge C to C 800, Reflex Type 1 0
A31 MB-LS-01 Water level switch C to C 525 1 0
A32 MB-GB-01 Gauge board AA Type 1 0

PART LIST OF F.W. SYSTEM
PART NO. DRAWING NO. TITLE TYPE / SPEC. QT'y REV.
< Loose supply List >
A01.01 MB-EG-01 Remote device for safety valve - 2 0
A03 MB-SCV-01 Swing check valve 20K 125A 1 0
E06 MB-RL-01 Remote water level indicator 144SPDA 1 0
E07 MB-SP-01 Remote steam pressure indicator 0~16 Kg/㎠ 1 0
G01 MB-TT-03 Temperature transmitter PT100Ω , 0~600°C 1 0
S02 MB-SIS-01 Steam injection system INS-25 1 0
S06 MB-SC-01 Sampling cooler 100A 1 0
S11 MB-DST-01 Steam trap 16K-15A 1 0
W01 MB-PC-02 Pneumatic control valve 16K-25A, L-Type 1 0
W02 MB-DU-01 Chemical dosing unit SP-A20

SP A20 1 0
W03 MB-SI-01 Salinity indicator SI-2008 1 0
W04 MB-OD-01 Oil detector CLS-113 1 0
E01 - Control panel - 1 0

Sheet No 1 OF 1 Rev No 0
Shipyard Hanjin Heavy Industries Co., Ltd
Pressure Safety & Relief Valve Project No. 0
Specifications Date 2013-12-19 By H.S.CHO
Checked K.J.AHN Approved B.J.KIM
Item No. 1
Tag No. 2 Y-R 175
Service Line 3 CALCULATION
GENERAL
Number Required 4 1
Nozzle Type. Full or Semi 5 Full Nozzle
Design Type 6
A.Safety, Safety Relief or Relief Safety & Relief Valve * Calculation of Area
B.Conventional or Bellows Conventional
C.Full Bore,Low Lift or High Lif Full Bore W1
A1 =
Bonnet Type.Open or Close 7 Open 0.5145 * C * K * (P*1.03+1) * 0.9
Size. Inlet / Outlet 8 40 x 65A
CONN'
Inlet. Rating/Facing 9 JIS B 8210 20K RF 1,750

=
Outlet. Rating/Facing 10 JIS B 2210 10K FF 0.5145 * 1 * 0.864 * (9 * 1.03+1) * 0.9
Body/Bonnet 11 SC480 / SC480
Seat SCS13 (STELLITED) 425.918 mm2
MATERIALS
12 =
Disc 13 SCS13 (STELLITED)
Resilient Seat seal 14 -
Gasket 15 -
Spring 16 SWOSC * Calculation of Capacity
Bellows 17 -
Cap. Screwed or Bolted 18 Bolted W = 0.5145 * C * K * A * (P*1.03+1) * 0.9
CCESS
Lever. Plain or Packed 19 Lever

Gag 20 = 0.5145 * 1 * 0.864 * 706.858 *
AC
Paint Color 21 Silver (9 * 1.03 + 1) * 0.9

Code 22 KS B 6216
BASIC
Fire 23 = 2,904 Kg/h

Other 24
Fluid and State 25 STEAM
Required Capacity Kg/h 26 1,750
Mol.weight or specific Gravity 27
Viscosity Cp 28 W = Valve Capacity…………………… Kg/h
Operating/Set Pressure Kgf/cm2 29 7 / 9
Operaing/Blowout Temp ℃ 30 169.78 / 179.18 W1 = Required Capacity………………… Kg/h
SERVICE
Constant Back Pressure Kgf/cm2 31

Variable Back Pressure Kgf/cm2 32 P = Set Pressure……………… 9Kg/cm2
Total Back Pressure Kgf/cm2 33
Closing Pressure Kgf/cm2 34 8.1 A1 = Calculated Area……………..…… mm2
Hydrostatic Test Kgf/cm2 35 13.5
Allowable overpressure % 36 3 A = Selected Area……………….…… mm2
Compressibility Factor 37
Ratio of Specific Heat 38 K = Coefficient of Discharge………… 0.864
Calculated Area mm2 39 425.918
ORIFICE
Selected Area mm2 40 706.858 C = Steam Correction Factor …..…… 1

Orifice Designation 41 H
Valve Capacity Kg/h 42 2,904 Remark
Model No 43 JSV-FF21
S.T Lapping Tool 44
Disc 45
SPARE
PART
Spring 46
Gasket 47
BURNER SPECIFICATION
4. BURNER SPECIFICATION

No. DATE
SUNFLAME KR-1312 12 DEC. 2013
SPEC TYPE ； SDR-350
BURNING APPARATUS CHIEF CHARGE
Noguchi
Rev. DATE
HISTORY
1. Classification
1-1 Order KANGRIM HEAVY INDUSTRIRS CO., LTD.
1-2 Yard HANJIN HEAVY INDUSTRIES & CONSTRUCTION CO., LTD.
2. General specification
2-1 Rule GL / RINA
2-2 Control system Full automatic, ON/OFF & PI control system

2-3 Fuel oil
1) For cold-starting
2
Marine gas oil 2 [mm /s at 40℃] or more
2
2) For usually Marine heavy fuel oil Under 850 [mm /s at 50℃]
Calorific value (Low) 40.2 [MJ/kg-fuel]
2
3) Enviro. friendly Marine gas oil 2 [mm /s at 40℃] or more
2-4 Electric source
1) Input power source AC440V 60Hz 3φ
2) －－－－－－－－－
3) Control source AC220V 60Hz 1φ by down transformer
DC24V by AC/DC converter
2-5 Air temperature 45 ℃
2-6 The others
1) Unit Metric
2) Name plate English
Caution plate English
3) Painting colour 7.5BG7/2
3. Boiler specification
Maker name KANGRIM HEAVY INDUSTRIES CO., LTD.
Type PA
Number 1 boiler/ship
Evaporation 3,500 [kg/h]
2
Steam pressure Design 9.0 [kg/cm ]
2
Normal 7.0 [kg/cm ]
Steam temperature Saturated temperature
Feed water temp. 65 [℃]
Furnace pressure 80 [mmAq]
F.O. consumption 262.3 [kg-fuel/h]
2
4. Burner specification
Name FORCED DRAFT ROTARY-CUP ATOMIZING SYSTEM
Burner type SDR-350
Rated capacity of combustion 290 [kg-fuel/h] 319 [L-fuel/h]
2
F.O. pressure 3 [kg/cm ] at burner inlet
This value will have to change according to the resistance of piping.
2 2
Viscosity of F.O. Under 50 [mm /s] , Normal 19 [mm /s] for atomizing
2
Under 250 [mm /s] for inlet of equipment
5. Equipment on the burner

5-1 Wind box 1 [set]
Type SDR-350
Installed direction Combustion air inlet is lower side
Burner hinge Left side
Connection box Right side
5-2 Burner unit 1 [set]
Type SDR-350
5-3 Burner motor 1 [p.c]
Specification DC48V 250W direct drive
5-4 Main pneumatic valve 2 [p.cs]
Type MV-1500 AC220V
5-5 Return pneumatic valve 1 [p.c]
Type MV-1500 AC220V
5-6 M.G.O. mix device 1 [set]
1) M.G.O. mix. solenoid valve 1 [p.c]
Type EV210B-4.5B AC220V
2) Flow setting valve 1 [p.c]
Type HT-728N-03
5-7 Ignition device 1 [set]
1) Pilot burner 1 [p.c]
Type IB-25
Atomizer 2G（6.5kg/h) / 45deg
Fuel Marine diesel oil , Marine gas oil ,
Normal pressure is 7.0 [kg/cm2]
2) Sol. Valve for pilot burner 1 [p.c]
Type EV210B-4.5B AC220V
3) Ignition transformer 1 [p.c]
Type EBI4MS052F4045
Specification 15,000 V
5-8 F.O. Flow control device 1 [set]
1) F.O. Flow control valve 1 [p.c]
3
Type SDR-350 BLOCK PIPING SYSTEM
2) Control motor 1 [p.c]
Type MY6050A1001 DC24V
Specification 90 [deg] , 150 [s]
Control signal CW/CCW
Position feed back 135 [ohm] QY9010A
3) Flow checker 1 [p.c]
Type SDR-350 BLOCK PIPING SYSTEM
5-9 Combustion air flow control device 1 [set]
1) Primary air flow control device 1 [p.c]
Type Air damper in the wind box
2) Secondary air flow control device 1 [p.c]
Type Air damper in the wind box
3) Control for primary air damper 1 [p.c]
Operated by second air damper with linkage
4) Secondary air damper control motor 1 [p.c]
Type CM-101RPCC AC220V
Specification 90 [deg] , 18 [s] , 12.5 [N-m]
Control signal CW/CCW
Position feed back 135 [ohm]
Internal switch Use for start position
5-10 Flame eye 1 [p.c]
Type SFE-1 ( It has independent two circuits.)
5-11 Pressure gauge for F.O. 1 [p.c]
2
Specification 0 －10 [kg/cm ]
5-12 Pressure gauge for Pilot burner 1 [p.c]
2
Specification 0 －15 [kg/cm ]
5-13 Limit switch for BNR. Hinge open 1 [p.c]
Type SDR-350 standard
5-14 Pressure switch for primary air pressure 1 [p.c]
Type LGW-50
5-15 Pressure switch for secondary air pressure 1 [p.c]
Type LGW-50
5-16 Thermostat for wind box temperature 1 [p.c]
Type JP72
5-17 Pressure switch for F.O. PRESS. LOW TRIP 1 [p.c]
Type MBC-5100
5-18 Pressure switch for F.O. PRESS. STAND-BY START 1 [p.c]
Type MBC-5100
5-19 Thermostat for F.O. TEMP. LOW TRIP 1 [p.c]
Type MBC-8100
5-20 Trace heater 1 [p.c]
Specification 10QTVR1-CT AC220V
4
5-21 Shut-off valve 1 [p.c]
Specification Ball valve with long lever
5-22 Strainer
1) M.G.O. side 15A , Y-type, #100 1 [p.c]
2) F.O. side 25A , Y-type, #60 1 [p.c]
5-23 Flow meter 1 [p.c]
Type VZO-20
6. Supply unit of combustion air

6-1 Forced draft fan
1) Fan 1 [set]
Name COMPOUND-TUBO FAN
Type OSC-6-85H
Spec.(1st-AIR) 6 [Nm3/min] 1000 [mmAqa]
Spec.(2nd-AIR) 85 [Nm3/min] 350 [mmAq]
2) Fan motor 1 [p.c]

Specification 3φ 440V 60Hz, 15kW 2P , Insulation class is F
6-2 Connection duct for burner inlet of primary air 1 [p.c]

Type Rubber type
Counter flange One for burner side
6-3 Connection duct for burner inlet of secondary air 1 [p.c]

Type Canvas type
Counter flange One for burner side
6-4 Connection duct for deriver side of air fan (primary) 1 [p.c]
Type Rubber type
Counter flange One for fan side
6-5 Connection duct for deriver side of air fan (secondary) 1 [p.c]
Type Canvas type
Counter flange One for fan side
5
7. Supply unit of fuel oil
7-1 Air separatr (for HFO & MGO) YARD supply 2 [sets]
7-2 Strainer (for HFO & MGO) 2 [sets]

Name Duplex basket screen and flange type strainer
Type 32A , 60 mesh
Inlet JIS 10K 32A
Outlet JIS 10K 32A
7-3 Pump unit (for HFO & MGO) 4 [sets]

1) Pump unit 1 [p.c]
Name Trochoidal gear pump
Type TOP-216-VB
Capacity 1,000 [kg/h]
2
Pressure 5 [kg/cm ]
2) Pump motor 1 [p.c]
Specification 3φ 440V 60Hz, 0.75kW , 6Pole , Insulation-class F
3) SPACE HEATER 1 [p.c]
4) Compound pressure gage 1 [p.c]
2
Specification AUΦ60×1/4 , -1 － 2 [kg/cm ]
5) Pressure gage 1 [p.c]
2
Specification AUΦ60×1/4 , 0 － 10 [kg/cm ]
5) Connection of pump unit
Flange (suc. side) JIS 10K32A
Flange (del. side) JIS 10K 25A
7-4 Oil heater (Steam heating type) BOILER MAKER supply 1 [set]
6
7-5 Ignition burner pump set for pilot burner 1 [set]
1) Pump unit 1 [p.c]
Name Trochoidal gear pump
Type GFH-V3L
Capacity 100 [kg/h]
2
Pressure 7 [kg/cm ]
2) Pump motor 1 [p.c]
Specification 3φ 440V 60Hz, 0.4kW , 2Pole , Insulation-class F

3) Pressure gage 1 [p.c]
2
Specification AUΦ60×1/4 , 0 － 15 [kg/cm ]
4) Relief valve 1 [p.c]
2
Specification 8A , 10 [kg/cm ]
5) Connection
Flange (suc. side) JIS 10K 15A
Flange (der. side) JIS 10K 15A
7-6 Relief valve (for HFO & MGO) BOILER MAKER supply 2 [p.cs]
8. Control panel
8-1 Local control panel 1[set]
Name plate English
Caution plate English
Painting colour 7.5BG7/2
Protection IP-44
Type Full automatic, ON/OFF & PI control system
9. Spares and tools
9-1 List of spares and tools 1[set]
7
TABLE １ INDICATOR and ALARM
1) Burner trip list
BNR. Trip Delay External terminal for

Item Indicator Alarm
(F.O. Cut) time ind./Alarm (To ECC)
N51-B51
Emergency stop ○R ○ *1 ○ *2 ○ *3
EM1-EM2
Water level too low ○R ○ *1 ○ *2 15 sec. ○ *3 N51-B52
Steam pressure too high ○R ○ *1 ○ *2 ○ *3 N51-B53
Burner hinge open ○R ○ *1 ○ *2 ○ *3
Supply air pressure low
○R ○ *1 ○ *2 ○ *3
(Combustion & atomizing air)
Wind box temperature high ○R ○ *1 ○ *2 ○ *3
Fire in furnace ○R ○ *1 ○ *2 ○ *3
Flame / ignition failure ○R ○ *1 ○ *2 ○ *3 N51-B54
F.O. temperature too low ○R ○ *1 ○ *2 ○ *3 N51-B55
Oil pressure too low ○R ○ *1 ○ *2 ○ *3 N51-B56
F.O. pump failure ○R ○ *1 ○ *2 ○ *3
M.G.O. pump failure ○R ○ *1 ○ *2 ○ *3
CUP motor failure ○R ○ *1 ○ *2 ○ *3
F.D fan failure ○R ○ *1 ○ *2 ○ *3 N51-B57
Power failure
○*6 －－－ ○ *2 ○ *3
(operation power failure)
Common contact for trip sign. －－－ ○ *1 ○ *2 ○ *3 N50-B50
Note ; ○ Ready ○R manual reset
○ *1 By LED ○ *2 By ships alarm system
○ *3 By common contact for trip (Trip to OPEN) ○ *6 Restart of the control source
8
2) Alarm （warning) list
Delay External terminal for
Item Reset Indicator Alarm
time ind./Alarm (To ECC)
Water level low ○R ○ *4 ○ *2 15 sec. ○ *3
Water level high ○R ○ *4 ○ *2 15 sec. ○ *3
M.G.O. temp. high ○R ○ *4 ○ *2 ○ *3
Steam press. low ○R ○ *4 ○ *2 ○ *3 N51-B61
Stand-by F.O. pump running ○R ○ *4 ○ *2 ○ *3 N51-B63
Stand-by M.G.O. pump running ○R ○ *4 ○ *2 ○ *3 N6C-B6C
Exh. gas temp. high ○R ○ *4 ○ *2 ○ *3 N51-B64
Oil content high alarm ○R ○ *4 ○ *2 ○ *3 N6A-B6A
Salinity content high alarm ○R ○ *4 ○ *2 ○ *3 N6B-B6B
F.O. temp. high (heater stop ) ○R ○ *1 ○ *2 ○ *3 N51-B62
Common contact for alarm sign. －－－－－－－－－ --- N60-B60
Note ; ○R manual reset ○ *1 By LED
○ *2 By ships alarm system ○ *3 By common contact for trip (Trip to OPEN)
○ *4 By programmable terminal
Note; TIME CHART of Common contact for alarm sign.
PLC source
1sec
Alarm1
Alarm2
2sec 2sec 3sec
Common contact for alarm sign.
9
3) Indicator list without TRIP & ALARM
Operation power －－－ ○*1 －－－－－－
Burner standby －－－－－－－－－
○*1
Burner automatic －－－－－－－－－ N42-B42
Combustion －－－ ○*1 －－－－－－ N43-B43
F.O. temp. detect cancel －－－ ○*2 －－－－－－
F.D. fan running －－－ ○*4 －－－
IG. BNR. pump running －－－ ○*4 －－－－－－
No.1 F.O. pump running －－－ ○*4 －－－－－－ N70-B70
No.2 F.O. pump running －－－ ○*4 －－－－－－ N70-B71
No.1 M.G.O. pump running －－－ ○*4 －－－－－－ N72-B72
No.2 M.G.O. pump running －－－ ○*4 －－－－－－ N72-B73
No.1 F.W. pump stop －－－ ○*4 －－－ N6D-B6D
No.2 F.W. pump stop －－－ ○*4 －－－ N6E-B6E
H.F.O. －－－ ○*4 －－－－－－ N45-B45
M.G.O. －－－ ○*4 －－－－－－ N46-B46
Note ; ○ *1 By LED ○*2 By lighting switch
○*4 Programmable terminal
4) Output signal to ECC

Water level indication －－－－－－－－－－－－ L11 - L12
Steam press. indication －－－－－－－－－－－－ P11 - P12
AUX. boiler stop －－－－－－－－－－－－ N44 - B44
10
TABLE 2 Set value of sensing device
1) Water level
Range(Span)
Item Equipment Set value Note
-400 mm +400 mm
Water level transmitter R745 4mA 20mA －－－
Water level low alarm 7.5mA -180 mm Note1)
SDC
Water level high alarm 17.6mA +250 mm Note1)
Water level low trip 6.9mA -220 mm Note1)
Water level low alarm BPC 7.5mA -180 mm Note1)
Water level high alarm 17.6mA +250 mm Note1)
Water level low trip R709 －－－－－－ -220 mm Note1)
Note1) This value is set by the boiler specification.
2) Steam presssure
Range(Span)
0kg/cm2 16kg/cm2
Steam pressure transmitter
R717 4mA 20mA －－－
2
Combustion start 10.5mA 6.5 kg/cm
2
Set point (PI control) R717 & 11mA 7.0 kg/cm
Combustion stop BPC 11.5mA 7.5 kg/cm2
Low alarm －－－－－－ 5.5 kg/cm2
High trip R704 1 kg/cm
2
10 kg/cm2 8.5 kg/cm2
3) Oil presssure
Range(Span)
－－－－－－
F.O. pressure set value R237 －－－－－－ 3 kg/cm2
M.G.O. pressure set value R237G －－－－－－ 3 kg/cm2 Note2)
Oil pressure standby start R627 －－－－－－ 2 kg/cm2
F.O. Pressure low trip R605 －－－－－－ 1.8 kg/cm2 Note2)
Note2) This value is depending on the condition onboard.
11
4) Oil temperature
Range(Span)
Name Equipment Set value Note
Min. Max.
Burner inlet thermometer R812 0℃ 150 ℃ －－－
F.O. temperature set point R301 －－－－－－ 130 ℃ Note 1)
MGO temp. high R628G 20 ℃ 150 ℃ 55 ℃
F.O. temp. high R610 －－－－－－ 150 ℃
F.O. temperature low trip R603 －－－－－－ 80 ℃
Note2) This value is depending on the condition onboard.
5) Air pressure
Range(Span)
Min. Max.
Pirmary air pressure low trip R711 25 mmAq 500 mmAq 100 mmAq Low to OFF
Secondary air pressure low trip R712 25 mmAq 500 mmAq 100 mmAq Low to OFF
6) Other temperature
Range(Span)
Min. Max.
Exhaust up-take gas temp. high R428 0℃ 500℃ 450℃
Wind-box temp. high R721 FIXED 130℃ High to OFF
TABLE 3 Set value of thermal relay
Item Number Capacity Rated curr. Set value Note

Cup motor 1 250w 7A 7A
Forced draft fan 1 15kW 24.4A 25A
D.O. pump 1 0.4kW 0.9A 0.9A
F.O. pump 2 0.75kW 1.8A 1.8A
M.G.O. pump 2 0.75kW 1.8A 1.8A
12
F.O SYSTEM WITH ACCESSORIES
5. F.O SYSTEM WITH ACCESSORIES

F.O. SYSTEM WITH ACCESSORIES
PART LIST OF F.O. SYSTEM
PART NO. DRAWING NO. TITLE TYPE / SPEC. QT'y REMARK
< Loose supply List >
Vo-1 BNR-BV-01 3-Way valve with L/S for HFO 16K-25A 1 F01.01
3-Way valve with L/S for
Vo-A BNR-BV-01 16K-25A 1 F01.02
HFO&MGO
3-Way valve with L/S for
Vo-B BNR-BV-01 16K-25A 1 F01.03
HFO&MGO
Ls-mm BNR-BV-02 2-Way valve with L/S for MGO 16K-25A 1 F28
R102 BRM-10124 Rotary-cup burner out-line SDR-350 1 -
R103 KSH01-01 H.F.O. heater KSH-01 1 F32
R104/104G Mp-10015 Oil pump unit Trochoidal gear type 2/2 -
R107 BRJ-17963 Junction box out-line - 1 -
R108 BRI-10002 Ignition burner a’ssy SSR/SDR-TYPE 1 -
R114 Mp-10049 Oil pump (IG.BNR.PUMP) Trochoidal gear type 1 -
R120 Mf-10143 Forced draft fan OSC-6-85H 1 -

Push button box for IGN. BNR
R137D KB-E-701 - 1 -
pump
R137F KB-E-801 Push button box for H.F.O. pump - 1 -
R137G KB-E-801 Push button box for M.G.O. pump - 1 -
R179G BRJ-18067 SOURCE CHANGE-OVER BOX - 1 -
Duplex basket screen & Flange

R201/201G Ms-10006(E) 16K-32A 2 -
type strainer
Relief valve (Oil press. adj. F15.01 /

R237/237G BNR-AV-01 20A 2
valve) F15.02
R301 BNR-TC-01 Temp. control valve 16K-15A 1 F17
R302 BNR-OS-01 Y-strainer 16K-15A 1 F03
Flexible hose & Canvas

R516/7/9 GR-10034 - 1/1/1 -
for rotary-cup burner
R610 BNR-TS-01 Thermostat “K” TYPE 1 F13.01
R628 BNR-TS-01 Thermostat “K” TYPE 1 F13.02
F25 BNR-MC-01 MGO cooler FP 16-23-1 1 F25

MODEL NO. OSC-6-85H
PRIMARY
CAPACITY 一次側： 6 Nm³/min.
風量 SECONDARY
二次側： 85 Nm³/min.
PRIMARY
STATIC PRESSURE 一次側： 9.8 kPa／1000 mmAq
風圧 SECONDARY
二次側： 3.4 kPa／350 mmAq
MOTOR
15kW 2P [F]
電動機
FITTING HOLES
20
DETAIL OF FLANGE
600
560
349
321
285
16-10HOLES
6-19HOLES
260
20
20 355 355 20 296

750 324
859 460 440

280 80 499
t6
440
620
370
945
167
506
215
25b
124
190 50
300 450 SPG 65A 600
750 550
CHECKED BY
DRAWING HISTORY 図面来歴 DRAWING NAME
承認印
図面名称 FORCED DRAFT FAN
改正符号改正内容改正日改正者
DRAWN BY
製図
押込ファン
Y.Takahashi DRAWING NO.
SCALE 図番 Mf-10143
尺度
1/17
DATE SUNFLAME CO., LTD
日付
2009/11/18
株式会社サンフレム
It is prohibited to divert or distribute the document anywhere other than the submitting purpose. 提出した目的以外に本書を転用・配布する事を禁ず。
R137D
R137F
R137G
NO. NAME OF PART Q'TY MATERIAL REMARKS NO. NAME OF PART Q'TY MATERIAL REMARKS
1 BODY 2 FCD400 CAST IRON UPPER CARBON
11 2 SS400
2 COVER 2 FCD400 CAST IRON ELEMENT RING STEEL
3 COCK CASE 1 FCD400 CAST IRON LOWER CARBON
12 2 SS400
4 COCK 1 FCD400 CAST IRON ELEMENT RING STEEL
PACKING 13 SPRING 2 SUS304 STAIN. STEEL
5 1 FCD400 CAST IRON
GLAND PUNCHING CARBON
14 2 SS400
6 GUT 2 FCD400 CAST IRON PLATE STEEL
THRUST 15 SCREEN 2 SUS304 STAIN. STEEL
7 1 CuP CUPPER PLATE
WASHER 16 DRAIN PLUG 4 FCMB340 CAST IRON
8 HANDLE 1 FCD400 CAST IRON 17 BLIND PLUG 1 FCMB340 CAST IRON
O-RING O-RING
9 1 VITON RUBBER 18 2 VITON RUBBER
P-36(3.5x35.7) G-85(3.1x84.4)
O-RING CARBON
10 1 VITON RUBBER 19 BOLT 2 SS400
G-60(3.1x59.4) STEEL
CARBON
20 BOLT 2 SS400
STEEL
90
°
2
2 ※ 2
※
2
°
90
NOM. SIZE 32 (1・1/4) JIS 10K

DRAIN [ PT ] 3/4
218 3
BLIND PLUG [ PT ] 1/2
WEIGHT [ kg ] 24.5
FILTERING AREA [ cm2 ] 207.4
RATIO TO NOZZLE AREA 24.4
249
215 19
4
2-AIR VENT VALVE 6
OD Ø6 Cut 20
APPROX 156
2 4-Ø19
5
18
9
455 ※1
IN OUT
Ø100
Ø135
13
11
226
150
10
195
14 20t
7
22t
16
12
23 17 Ø70 15 120 3
1 4-Ø15
150
17
※1 SPACE FOR ELEMENT REMOVAL
※2 WORKING RANGE OF THE LEVER
CHECKED BY
DRAWING HISTORY 図面来歴 DRAWING NAME DUPLEX BASKET SCREEN
承認印
図面名称 & FLANGE TYPE STRAINER
Working range of the lever is added. DRAWN BY
2 2012/04/03 Y.Takahashi 製図
複式バスケット・フランジ形ストレーナ
A.Sasaki DRAWING NO.
SCALE 図番 M s - 1 0 0 0 6 (E) ∆2
尺度
1/7
日付
2009/06/11
Specification sheet
Unit: FP 16-23-1-NH
Technical data Hot side Cold side

Fluid M.G.O F.W
Mass flow rate [kg/h] 1000.00 --- [kg/h] 3304.92

3 3
Volume flow rate [m /hr] 1.124 --- [m /hr] 3.334
Inlet temperature [℃] 60.00 --- [℃] 36.00
Outlet temperature [℃] 38.00 --- [℃] 39.00
Physical properties
Dynamic viscosity [cP] 4.000 4.000 0.707 0.668
3
Density [kg/m ] 890.0 890.0 991.8 990.6
Specific heat capacity [kJ/kg℃] 1.883 1.883 4.179 4.177
Thermal conductivity [W/m℃] 0.126 0.126 0.633 0.634
Condensation enthalpie [kJ/kg] --- --- --- ---
Vapor pressure [bar] --- --- --- ---
Operating pressure [barg] --- [barg] ---
P.H.E characteristic values
Heat duty [kW] 11.51
Eff. heat transfer area [㎡] 3.15
Log. mean temperature difference [℃] 8.08
Heat transfer coefficient reqd./act. [W/㎡℃] 452 / 561
Overdesign [%] 24.12
Pressure loss [bar] 0.01 [bar] 0.05
No. of passes in series 1 1
No. of Plate total 23
Mix of Channeltype 11*HH
Construction
Weight Dry/Wet [kg] approx. 119/126
Volume [L] 3.850 3.850
Design / Test pressure [barg] 6.0 / 9.0
Max. working temperature [℃] 60.0
Material Plates SUS316L ( 0.5 mm )
Gaskets NBR HT
Frame SS400
Painting Munsell No. 7.5 BG 7/2
Connection Hot side F1 => F2:

Unlined, 50A for Flange JIS5K
Cold side F3 => F4:

Unlined, 50A for Flange JIS5K
DWG No. 1 OF 1
MGO Cooler
BNR-MC-02 CODE
CONTROL PANEL
6. CONTROL PANEL

SPARE PART AND TOOLS
7. SPARE PART AND TOOLS

PART INSTRUCTION MANUAL
8. PART INSTRUCTION MANUAL

CONTENTS
OPERATION AND MAINTENANCE
SAFETY VALVE
DIFF. PRESS. TRANSMITTER
PNEUMATIC CONTROL VALVE
CHEMICAL DOSING UNIT
SALINITY INDICATOR
OIL DETECTOR
FUEL OIL PUMP
BURNER
BOILER CONTROL PANEL

INSTRUCTION MANUAL

TABLE OF CONTENTS
PAGE
1. General ---------------------------- 3
2. Preparation for service ---------------------------- 3
3. Lighting-up and service ---------------------------- 4
4. Taking out of service ---------------------------- 6
5. Cleaning ---------------------------- 7
6. Boiling out ---------------------------- 9
7. Limits of chemical concentration ---------------------------- 10
8. Repair of pin tube element ---------------------------- 11
9. Preservation procedure of boiler ---------------------------- 12
2
1. General
1.1 It rests with the boiler attendant to see to service and supervision of the boiler
plant. He is to see to it that all parts of the plant are properly maintained, if the task
has not been assigned to other persons. On sea-going vessels the tasks and
responsibility of the boiler attendant rest with the ship's officer from the machine
section on duty.
1.2 The boiler attendant is to follow the below working and operation instructions. If
there are interruptions of service and damages and other irregularities this must be
reported to the nearest superior after, of course, the operational measures, which
are necessary in order to obviate a situation of danger, have been carried out.
2. Preparation for service

2.1 Before filling of water it must be checked that all strange objects have been
removed from the interior of the boilers, that all drain mountings are closed, that all
loose parts have been fastened, and that built–in blind flanges, if any, have been
removed. If the boiler has been out of service fore quite a long time the walls are
to be examined for possible damages arisen during the standstill period. The
temperature of the water which is to be led into the boiler is to be fairly
corresponding to the temperature of the walls. If there is a bigger difference than
about. 50℃ the boiler is to be filled quite slowly.
2.2 Before heating is begun it must be checked if the gas openings are open (danger
of explosion), that all safety devices are OK, accurately adjusted and ready for
service, and that the water in the boiler is between the lowest and normal water
level.
2.3 Valves and shut-off devices ought to be served slowly, connection pipes must, if
necessary, be emptied of water and ventilated.
( water chock, coolings, at sudden differences in temperature ).
2.4 Before the boiler is used for the first time it must be boiled out in order to remove
all protecting materials and dirt in pipes and drums.
See paragraph about boiling out.
2.5 During the first filling with boiler water the water level indicators to be controlled by
opening the blow–off valve and upper and lower water level valve to open by turns.
a weak air flow should then be heard.
3
3. Lighting - up and service

3.1 This boiler is provided to work :
A) As a separate oil fired boiler.

B) As a combined oil fired / exhaust gas boiler.
C) As a separate exhaust gas boiler
The mode of operation of A) and B) will required constant water level of the boiler.
Because of danger of burning down in operation. Constant water level is not
required at C). However, this is recommended, as the most favorable water
circulation and most be stable operating conditions will be obtained. As to the
construction and the strength it is fully proper at C) to lover the water level of the
exhaust tube section and even empty the boiler from water, while the whole gas
volume flows through the tube section. The boiler will in such case, gradually, get
the same temperature as that of the exhaust gas.
The boiler should be cooled before refilling it with feed water. where this could not
be done the feed water is to be preheated, and the feeding should commence very
carefully ( slowly ).
3.2 When the boiler has been ignited the lighting-up rate must not be speeded up too
much in order not unnecessarily to overstrain the boiler material by quick, uneven
temperature rises.
The lighting–up time ought to be about. 1 1/2 hours.
3.3 The air escape valve at the boiler is to be kept open until a heavy steam jet is
flowing out, this occurs at a steam pressure of abt.1, 5 bar.
3.4 The pressure gauge and its connecting pipe line are regularly to be tested
carefully as regards free passage. By this must be stated if the indicator can reach
the O-point without obstructions at slow relief of the pressure gauge, and if it can
reach its former position at slow load.
Further, it must be stated if the pressure gauge shows the indicated allowable
working pressure. At and after every blow-through of the connecting pipe line the
pressure gauge may not be connected until sufficient steam is condensed in the
pipe loop.
4
3.5 During service the water level may not fall below the mark for lowest water level. If
the water level cannot with certainty be said to be sufficient the firing must be
stopped at once ( see also paragraph 4.1 ) and the nearest superior informed
immediately.
If the water level goes beyond the top visible water level without perceptible
reason the firing must be stopped at once if you cannot with other measures again
reduce the water level.
3.6 All the water level indication instruments are currently used and have, therefore, to
be kept clean.
The same thing applies for water level regulator and limiter.
Cocks and valves are to be opened slowly and to be closed in the same way.
Lacks, especially obstructions, are to be removed at once.
3.7 Before the boiler is connected it is necessary that the safety valves are
adjusted so that they can begin to function at the prescribed pressure. Alteration of
the adjustment is to be carried out only by an expert from the local classification
society.
If the steam pressure rises above the allowable working pressure, which is
marked by a red line, the firing I reduced and the feeding intensified.
If the safety valves do not blow, they are to be checked at once.
If the
th cause isi nott stated
t t d the
th firing
fi i mustt be
b stopped
t d and
d the
th superior
i iinformed.
f d
3.8 One or more times daily, solid impurities are blown out from the boiler through the
bottom blow-down valve until clear water is coming. Such solid impurites disturb
the heat exchange process and become a cause of overheating, which can be a
source of accidents if left unattended.
3.9 If priming takes place as a consequence of pollution of oil or the like in the boiler
water ( is normally seen as a brown layer in the water gauge glasses), the
impurities are blown out through the scum valve.
( see paragraph about boiling out )
3.10 Should the firing fail, for some reason, during a heavy steam demand period, then
the steam outlet valve is to be closed immediately, and the feed pump is to kept in
service until a normal water level is reached.
3.11 If priming takes place because of a sudden pressure drop in the pipe, the firing to
be reduced, the feeding increased and if necessary the steam outlet to be reduce,
too.
3.12 Do not reduce operating pressure of such boiler from designed pressure. This
become fatal reason of sulfur corrosion in low temperature, so it must be strictly
prohibited.
5
4. Taking out of survice

4.1 The boiler must be taken out of service immediately and the superior informed as
soon as possible if you have a suspicion that something dangerous is arising.
The applies especially when :
A) Heating or deformation of the boiler walls are found somewhere

B) A big loss of water is noted.
C) The feed water system is unable to provide the necessary feed water amount
due to failure of parts.
D) The safety valve cannot function
E) Sudden cracks or big damages are noted in the refractory on the furnace side,
or steam or moisture is coming out of the refractory.
This can also be the case when pipe damages, plate crack or the like ( l. e. at
steam outlet ) are stated.
4.2 If the boiler is to be taken out of service in emergency the fuel supply is The
steam valve is to be closed gradually and the boiler must stand until it is cooled.
The safety valves may not be touched.
Parallel working boilers are to be disconnected at once
once.
4.3 If part of the heating surface has been glowing or the boiler shows recognizable
deformations the supervising authorities must be informed, and the boiler is not to
be used until approval from these authorities is available.
4.4 When stopping the service, so much feed water to be filled on that a suitable
water level is present at next firing ( between lower and normal water level ).
6
5. Cleaning of fired section

5.1 If the feed water is properly treated the possibility of impurities
at the water and steam side of the boiler should be minimal.
5.2 Deposits in the tubes are notoriously extremely small owing to the heavy water
circulation.
If impurities which cannot be boiled out should come inside the tubes, the tubes
can be cleaned by scraper and brush.
5.3 Once a day mud is blown from the boiler through the bottom blow–off valve until
clear water is coming.
5.4 If the oil burner is functioning correctly and the combustion is complete the soot
deposit on the tubes will be minimal, but in practice it can hardly be avoided that
soot will deposit in the course of time, I. e. due to the starting periods of the oil
burner. Attached soot deposits can be removed by water washing with a 10
percent soda solution through the inlet door in the uptake, drain pipe at the bottom
of the fire box is available.
5.5 Cleaning of exhaust gas fired section outside the tubes are to be cleaned by
boiling out, possible by using scraper and brush.
5.6 Inside the tubes can be cleaned for attached soot deposits by washing with water
with a 10 percent soda solution through the inlet door of the uptake, drain pipe at
the bottom of the boiler is available.
The cleaning can possibly be mode by brushes mounted in chains.
5.7 Cleaning of pin tubes

The outside of pin tubes shall be inspected visually and cleaned up, the flue gas
temperature is too high compared with the temperature at Normal operation as
well as dry docking time or periodic inspection time.
7
The cleaning procedure (caution: be careful not to scald yourself)

A. Turn off the burner and wait for hours until cool down.
B. Swing out the burner to access to furnace.
C. Open drain valve and access door of smoke uptake.
D. Jet directly the pin tubes with fresh water (6bar, 50 l/min ).
E. Check that drain pipe is blocked and repeat water washing.
F. After all washing water is drained away, close the drain valve and door.
G. Turn on the burner (Approx. 5 minutes ).
H. Open the drain valve to remove residual water.
I. Close the valve and turn on the burner (Approx. 15 minutes ).
J. Check that the flue gas temperature correct . And check that all door and
valve are closed.
8
6. Boiling out
The boiling out is made in the following way :
6.1 In the boiler is to be filled a solution consisting of 4-5 kg.

Tri-sodiumphosphate ( Na3 Po4 ) per 1000kg water.
It is preferable to add the chemicals through the manhole.
Then water is filled in, until the solution is just visible in the water gauge.
Untreated water can be use.
6.2 The boiler is slowly brought on working pressure and kept on this pressure in abt.
6-8 hours with closed main stop valve, after which fat and other impurities should
be boiled out of the interior surfaces of the boiler.
6.3 Then to be skimmed of ( through the scum valve ), However, it must be seen that
before the water level is 20-30 mm above the scum funnel. If the boiler is equipped
with automatic water level control it may be necessary to close for this unit during
the skimming.
6.4 After the boiling out the burner is switched off, and after abt.1 quarter the bottom
blow-off valve and the air valve at the boiler top is to be opened, and all the water
is to be blown out of the boiler.
Then the boiler is washed and brushed inside, and the bottom blow-off valve is
examined in such a way that possible oxide scales and welding pearls, which have
been collected there, can be removed ( if necessary the bottom blow-off valve is to
be dismounted ).
The hand-holes in the bottom of the boiler is to be opened and the boiler
cleaned.
6.5 Treated, softened water to be added to a little below normal water level when the
bottom valve and hand-holes have been closed.
6.6 If the boiler shows a tendency to priming it is recommended to carry out an boiling
out. Besides, it is recommended to carry out another boiling out after a time of
operation of 2 to 3 months with a subsequent inside cleaning and inspection.
9
7. Limits of chemical concentration.
Boiler water Feed water to boiler

PH(at 25°C) 10.8~11.3 7.0~9.0
Phenolphthalein Alkalinity(CaCO3) Max.500 -
Total Alkalinity(CaCO3) / ppm Max.600 -
Chloride (Cl-) /ppm Max.300 -
Total solid / ppm Max.2000 -
Excess Phosphate (PO₄² )/ ppm 20~40 -
Hardness(CaCO3) / ppm - Max.1.0
Oxygen / mg/l - Max.0.5
Hydrazine / mg/l - -
Table .1] Recommend limits of chemical concentration.
NOTICE!
Estimate the pH value from alkalinity tends to give pH readings varying
with silica, Ca, Mg, and other salt contents of boiler water and hence is
not necessarily deemed appropriate : resort to this method only as a
means to obtain a rough guide (alkalinity serves merely as an auxiliary
means in determining the pH level). Also, be sure to control pH to the
target value while, on the other hand, Keeping alkalinity at the minimum
necessary level. Limiting the P alkalinity to within a certain range would
make it possible to inhibit the alkali corrosion even if boiler water
concentration should take place on the heating surface, etc.
10
8. Repair of pin tube element

8.1 In case of leakage on a pin tube, the pressure is to be removed from the and the
oil burner is to be dismantled.
8.2 If the tube in question cannot be pointed out immediately, the boiler is to be put on
pressure by means of the feed pump so that the leakage will which tube has been
damaged.
8.3 The boiler is emptied of water, and the manhole cover is dismantled.
8.4 The gas pipe and pin tube inside are cleaned and two holes in the gas pipe are
cut. ( Ref. to Fig. 1 )
8.5 The plugging plates are welded and check for leaks when the boiler is pressured.
( Ref. to Fig. 1)
** Note **
A) A new pin tube element should be replaced as soon as possible.
B) The boiler should not be operated with more than one plugging tube.
C) If flue gas temperature exceeds 450℃ the burner must be stopped or at low load.
11
9. Preservation procedure of boiler

The boiler shall be preserved properly as mentioned below, If the boiler is not
used for a long time or short period.
9.1 Shut-down for a period of 30 days or less.
Filled up the boiler with boiler water to prevent corrosion.
The boiler should be cleaned before filling.
9.2 Lay-up for more than one month

The one of following methods shall be applied to prevent corrosion:
A. Dry preservation.
B. Nitrogen preservation.
C. Wet preservaiton.
The work procedures for these preservation are described in the following:
9.2.1. Dry preservation

a) Open the bottom blow down valve at 3-5 bar pressure to empty of the boiler
and drain out, if water is remaining in the boiler.
b) Open Manhole doors and hand hole covers to cool down and if there is water
left in the bottom it should be removed.
c) Drying the boiler by either circulating dried air from a fan or by placing bags
of silica-gel in the boiler.
d) Put a tray with burning charcoal to remove oxygen before
closing manhole doors and hand hole covers.
e) Close manhole doors with new gaskets as soon as you have placed the
charcoal.
f) Alternatively, VCI (Volatile Corrosion Inhibitor) can be used after cooling
and careful draining, and the boiler shall be closed completely.
12
9.2.2. Nitrogen preservation

The boiler should be drained, dried and sealed in the same way as mentioned
above for Dry Preservation.
a) Open a air vent valve on the top of the boiler.

b) Make a connection for nitrogen supply to the bottom of the boiler.
c) Connect cylinders with nitrogen to the bottom via reduction valve and
purge the boiler until you are sure that no oxygen is left in the boiler.
d) Close air vent valve.
e) Leave a cylinder with nitrogen connected to the boiler via reduction valve
and keep an overpressure of approx. 0.2 bar in the boiler.
9.2.3. Wet preservation
This method can be used for a short period (1-3 months) of lay up but shall not be
applied when the surrounding temperature of the boiler is lower than 0℃ to avoid
frost damage.
a) Open a air vent valve at top of the boiler.

b) Filled up with treated boiler water and hydrazine is added until
concentration is obtained 100-200 PPM.
c) The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen.
d) Check the hydrazine concentration and add the necessary amount to

have an excess of 100-200 PPM. Other oxygen binding agents can be
used too.
The pH-value should be kept 9.5-10.5.
** The boiler shall be completely drained and refilled with boiler feed water
before re-operation.
13
SAFETY VALVE
INSTRUCTION MANUAL
SAFETY VALVE

SAFETY VALVE
TABLE OF CONTENTS
PAGE
1. Design/Construction -------------------------- 3
2. Operating Cycle -------------------------- 6
3. Installation -------------------------- 8
4. Caution on Hydraulic Test -------------------------- 10
5. Adjustment -------------------------- 11
g
6. Troubles and Shooting -------------------------- 13
7. Repair and Lapping -------------------------- 14
8. Reassembly -------------------------- 15
2
SAFETY VALVE
1. DESIGN / CONSTRUCTION
Full Bore Type is provided that Seat Opening Diameter (SOD) is not less than
1.15 times the throat Opening Diameter(TOD), and that the steam passage area of
the seat when opened is not less than 1.05 times of the throat opening area, and
that the area of the valve inlet and the connection nozzle are not less than 1.7
times of the throat opening area.
Those valves have a unique Nozzle Seat which provides maximum capacity
obtainable. The discharge through this nozzle enters a body chamber which is
carefully proportioned in the internal contours and in the ratio of inlet to outlet area
to minimize flow restriction and body pressure.
Especially for the positive proper adjustment of operating characteristic on fluid,

One Ring is adopted to obtain substantial adjustment to its pop action.
For easy access to resume normal seating face. if need due to failure of its
trueness, the most important characteristic of Flat Seat Nozzle Valve is the ease
with which seating surface can be reconditioned the slight deviation from the
specific angles can lead leakage and faulty operation.
All important part are thermally balanced and precisely machined, thus assuring
accurate
t alignment
li t regardless
dl off ttemperature
t variation.
i ti
1.1 Valve trim

Trim parts in a safety relief valve include disc and nozzle seat only.
1) Disc
A disc acts as the top guide and is guided by a cylindrical valve guide, standard
construction of safety relief valves includes metal-to-metal seats in a view of
tightness which provide commercial tightness acceptable for most applications or
special bubble tightness under certain conditions.
For reinforcement of seating faces both on disc and nozzle seat to insure their
trueness from violent and rapid shout down force during operating,
3
SAFETY VALVE
Surfaces are carefully stilted and precisely lapped.

Maintaining the necessary operating clearance between disc and its guide
assures free movement under a certain temperature ranges given.
Please refer to limiting service conditions for keeping them from exposing thermal
expansion trouble as specified in catalog.
2) Nozzle seat
As the nozzle seat is fully and tightly screwed up into the main body keeping
seating face same contour parallel, it will not come out of the position and any
deviation from disc contacting center.
Also, with a view to avoid any malfunction, leaks, or other problems which may be
caused by stress from the outlet piping or by thermal strains, the seat surface is
designed to occupy a position at the center of the body cylinder and separated as
far as possible from the contact position with body.
Since the fluid channel from the throat to the valve seat is the most important part
determining the performance of the valve, a logical Shape is provided so that there
will be no interruption in the fluid expansion.
4
SAFETY VALVE
1.2 Adjust Ring

The ring screwed onto the circumference of nozzle seat,
The area expansion due to a small amount of fluid leakage just before the blow-
off produces pressure enough to lift the disc. this force causes a quick popping
action of the valve. The ring adjusts the simmer of the fluid.
The other name is (popping) Control Ring or Nozzle Ring.
1.3 Body
The body maintains tightness with its precise finishing and its stout construction
ensures safety against thermal stress due to the rapid variation in the temperature
of the fluid to be blown off as well as securing it against the reaction strength
resulting from a large amount of fluid blown off.
1.4 Bonnet
Standard construction of bonnet includes closed one to protect the internal spring
and support the adjusting screw.
On model SSRF open and yoke bonnet can be provided to ensure safety against
thermal stress due to rapid variation in the temperature of the discharging flow
during blowing off.
1.5 Cap construction and Lever

Standard caps for pressure relief valve are screwed or Bolted Top and Open
Lever Top to provide periodical test, for usage of which hermetic sealing is not
required (with most uses for steam and air) Adopted Test Gag on two kinds o top
cap, when required, is handy for use in hydraulic test.
On standard open lever, Fork lever are adopted to larger size valve.
5
SAFETY VALVE
1.6 Adjust cock (or needle)

When the safety valve is blowing off fluid, back pressure is applied to the back of
disc and the guide. The back pressure interferes with the valve when it is being
lifted but assists it when the valve is being closed.
To apply the back pressure most effectively, on additional cock which can be
handled from the outside, can be provided. Safety valve can be suitable provided
with the adjust needle on construction of open bonnet to prevent any trouble in the
operation of it even if the throttle is closed too much.
2. OPERATING CYCLE
All of safety-relief valves are of the direct spring loaded construction. The
operating mechanism of each type is as follows:
Should the pressure upstream of the valve rise abnormally and reach near to the
set pressure, it cause the balanced spring to push upward and the valve disc be
slightly lifted up to make an initial opening. Steam or gas gushing out of this initial
opening will be guided by the properly adjusted lower ring to exert dynamic
pressures on the valve disc and the valve disc will be lifted quickly, the valve will
start to discharge.
In case of the Full Bore Type
y Valve. operating g characteristic of which is controlled
by the ring, fluid discharged by the initial blowing-out will be deflected in a
downward direction through upper ring and this deflection as well as pressure
generated between two ring are exerted on the face of the valve disc to lift it to a
higher position.
As the Low-Lift Type Valve is not provided with an upper ring, the fluid is deflected
through a chamber formed by the lower face of the valve disc and the lower ring.
The valve disc is lifted by static and dynamic pressure.
2.1 when inner pressure is lower than set pressure, the valve disc keeps the condition
of full close due to differential power between the fluid pressure and the condition
of full close due to differential power between the fluid pressure and the counter-
pressure by the adjusted spring
6
SAFETY VALVE
2.2 Initial open

(Commence-to-blowout)
In case that the inner fluid pressure reaches near the set pressure, the power
retaining valve closed by the spring will be gradually overcome by the inner
pressure allowing a little fluid leakage into accumulating chamber which is formed
between the lower and upper rings.
2.3 Full open

The pressure condensed in the accumulating chamber makers greater force to lift
the disc upward against spring force. This pressure leads popping action to lift up
the disc quickly in this case, the full open can be easily attained at the given
overpressure above the set pressure.
2.4 Re-seating
Re-seating will be duly obtained at the adjusted ring mechanism after
enhancement of blow-off.
7
SAFETY VALVE
3. INSTALLATION
3.1 Storage and Conveyance
Safety-relief valve are often off hand at the job site several months before they
are actually installed. Unless they are properly stored and protected their
performance may be affected deadly. Roughness in handling may damage valve
appearance sharp, worst to crack, or cause misalignment of the valve part.
Furthermore carrying by pulling up the lever may cause change of the spring set
pressure and alignment of the stem.
3.2 Inlet side piping

It is the best practice to directly mount the safety and safety-relief valve in vertical
position on a nozzle of pressure vessel or a short connection which smooth flow of
fluid.
Where rounded or beveled approaches can not be provided ahead of the safety-
relief valve, it is recommended that one size larger riser or fitting be used. The
pressure drop in the valve inlet piping should not exceed 3% of the set pressure.
Valves are sometimes badly damaged just as they go into service because of
failure to clean the connections.
It is essential that the boiler, pressure vessel, valve inlet, and all connections
should be cleaned thoroughly before the valve is mounted.
1) Caution at inlet piping

Most of leak on valve performance are caused from failure to clean. Many valve
are damaged when first placed in service or even hydraulic pressure test under
undue preparation due to failure to properly clean the connections and piping when
installed.
3.3 Outlet side piping

When arranging the discharge piping, pay due attention to the following points
talking into consideration that discharge piping should be simple and direct :
1) Minimize the length and the number of bends of discharge piping so as to reduce
the back pressure of the valve to a minimum. Especially, when a silencer is used,
note that the discharge pipe tends to be long and gives a large pressure drop due
to discharge exceed 10% of the set pressure
8
SAFETY VALVE
2) Discharge piping should be so designed that the weight of the piping will at no
time be taken up by the valve body.
A sufficient flexibility to the discharge piping is also essential to avoid strain on the
valve caused by thermal pipe expansion.
3) Care on multi installation

When two more valves are installed to discharge into a common header the
discharge pressure due to the opening pressure of the remaining valves in the
system.
a. Valve with bonnet not vented

The discharge line pressure of these valves will increase the opening
pressure by the amount (kg/cm2) of the discharge pressure.
b. Valve with bonnet vented

The set pressure of the remaining valves in the system will be reduced by the
amount (kg/cm2) of the discharge pressure.
9
SAFETY VALVE
※ Where either of the above conditions are unacceptable, the use of balanced
bellows valves is recommended.
Conventional valve with vented bonnet is not suitable for continuous back
pressure. Therefore never try to arrange discharge pipe from two or more valves
into a common header.
4. CAUTION on HYDRAULIC TEST

When hydraulic pressure test on the pressure vessel is conducted without
removing the safety valve installed on it. increase inner pressure of the vessel to
80 to 90% of the set pressure of the valve, then mount the test gag to hold the end
of the stem lightly in order to protect the valve from damage caused by undue
load.
Removal of the gag shall also be conducted at 80 to 90% of the set pressure.
When several valves are installed on a vessel or pipe line and one of the valves is
being on adjustment. The same caution should be taken at the mounting of the
test gag or gags on the other valve or valves to prevent it or them from blowing off.
4.1 Cautions
The test gag can not be mounted on the ordinary type caps. Therefore, the caps
should be replaced with those made for the purpose.
In case of pressure test for pressure vessels without using test gag, test them
without the safety valves for safety of it.
Removed valve should be covered at the flange parts against intrusion of dusts,
etc.
Replace with a plug and gasket in case of closed top (or take off when open top)
after the test, otherwise the valve will not operate thereby creating a dangerous
situation.
10
SAFETY VALVE
4.2 Test gag
- Test gag should be used only when hydrostatic testing is performed

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

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

unit : kg/cm2
SET PRESSURE TOLERANCE
5 excl. and under ± 0.14
over 5 and 23 excl. ± 3% (of set pressure)
12
SAFETY VALVE
6. TROUBLES and SHOOTINGS

6.1 Leakage
The most frequent causes of leakage are from damages on the valve seat and
adhering of foreign materials on it. In these cases, pull the lever to blow off the dirt
sticking from the seat. If the leakage does not stop, the seat must have been
damaged.
To avoid seating surfaces damaged by foreign materials. care should be taken
thoroughly from storage to installation which is the best practice after completely
flushing out.
Refer to, when it is need, the repair and lapping procedures in para 7 for
reconditioning.
6.2 Incorrect popping pressure

If the safety valve does not operate at specified pressure, a major cause is
accumulation of dirt or scale between the disc and the guide or the change of the
spring load due to bent of stem. in the case, cleaning or dismounting for servicing
is required.
6.3 Unstable operation
Unstable operation often results from wrong adjustment. the followings are the
state of unstable operation and its remedy.
1) Simmer
When a simmer is present raise the lower ring(push the notches to the right while
viewing in front of notch) by one noter at a time. ( Never set the lower ring in
contact with the valve disc) this is the case of the slightly weakening dynamic
power to lower accumulation not enough to lift up the disc.
2) Chattering
This is a rapid reciprocating variations in valve lift during which the disc repeatedly
contacts the seat. It is because popping power is weak. In this case, bring up the
lower ring (closer to the bottom face of the disc but never contact each other)
3) Hunting
This is the states where the disc repeats violent vertical motion during operation
as if it beat the seat violently. This is often caused when there is much flow
restriction in the piping connected with inlet and discharge side of the safety valve
or when blowdown is excessively too short, in this case, open the gland cock or
needle valve or bring down the upper ring to increase blowdown.
If hunting is not ceased despite the above adjustment, rechecking of the piping is
necessary.
13
SAFETY VALVE
7. REPAIR and LAPPING

In practice, the main necessary repair work will be lapping on the sealing
surfaces of disc and nozzle seat. Its procedure is as follows:
7.1 Kind of
No. 1 Lapping compound:
Pasty mixture of compound No. 200 kneaded with rape oil into a cream
form.
Pasty mixture of compound No. 800 kneaded with rape oil into a form
between cream and liquid.
Pasty mixture of compound No. 4000 kneaded with rape oil into a form
between cream and liquid.
7.2 Lapping procedure

1) Coat a surface of lapping block thinly with No.1 lapping compound.
Elliptically move the lapping block to remove large scratches.
pp g compound
2) Use No.2 lapping p and make lapping
pp g in the same manner as
procedure 1 to reduce scratches in size.
3) Finish with No.3 lapping compound. The lapping manner is the same as
procedure 1.
4) Finally, use No.3 lapping compounds and make mutual lapping of the valve
disc and the valve seat to finish them.
Mutual lapping is effected by lightly turning and reversing the valve disc on
the valve seat. The width of turning and reversing motion is 5 to 10mm, and
mutual lapping should not be continued too long. If it is continued too long,
the outer side of the seating surface will become dull. When the lapping is
felt heavy by hand, stop doing it.
7.3 Washing
Carefully wash the valve seat and valve disc with cleaning oil or liquid after
lapping to make them completely free from lapping compound.
7.4 Inspection of lapped surfaces
Inspection of lapped surface is extremely difficult. Try the following method:
Lighten the lapped surface. If the brightness is even all over the surface,
the lapping is complete. If any shady portion is present, the lapping is
incomplete.
14
SAFETY VALVE
Especially the following attention should be paid:

a) Pay extra care not to damage or soil the lapped surfaces of valve disc and
valve seat.
b) Properly center the tip end of the valve spindle on the valve disc.
c) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
8. REASSEMBLY
Reassembly will be made following the reverse order of disassembly.
Especially the following attention should be paid:
1) Care should be taken not to damage or soil the lapped surfaces of valve
disc and valve seat.
2) Properly center the tip end of the valve spindle on the valve disc.
3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
15
Operating Instructions
Deltabar S FMD76/77/78, PMD70/75
Differential pressure measurement
BA00270P/00/EN/15.13
71204581
valid from Software version:
02.11.zz
Overview documentation Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
Overview documentation
Device Documentation Content Remarks
Deltabar S Technical Information TI00382P Technical data The documentation is available on the Internet.
4...20 mA HART → See: www.endress.com → Download
Operating Instructions BA00270P – Identification – The documentation can be found on the

– Installation supplied documentation CD.
– Wiring – The documentation is also available via the
– Operation Internet. → See: www.endress.com
– Commissioning, Description of
Quick Setup menus
– Maintenance
– Trouble-shooting and spare parts
– Appendix: Illustration of menu
Operating Instructions BA00274P – Examples of configuration for – The documentation can be found on the
pressure, level and flow supplied documentation CD.
measurement – The documentation is also available via the
– Description of parameters Internet. → See: www.endress.com
– Trouble-shooting
– Appendix: Illustration of menu
Brief Operating Instructions KA01018P – Installation – The documentation is supplied with the
– Wiring device.
– Operation on-site – The documentation can be found on the
– Commissioning supplied documentation CD.
– Description of Quick Setup menus – The documentation is also available via the
Internet. → See: www.endress.com
Leporello KA00218P – Wiring – The documentation is supplied with the

– Description of operating elements device. See cover of the terminal
– Operation HistoROM®/M-DAT compartment.
– The documentation can also be found on the
supplied documentation CD.
Functional Safety Manual SD00189P – Safety function with Deltabar S – The documentation can be found on the
– Behaviour in operation and failure supplied documentation CD.
– Commissioning and iterative tests It applies to the devices showing version "E" in
– Settings feature 100 "Additional options 1" or in
– Technical safety characteristic feature 110 "Additional options 2".
quantities → See also Technical Information TI00382P,
– Management Summary chapter "Ordering information".
2 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Table of contents
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . 4 8.2 Response of outputs to errors . . . . . . . . . . . . . . . . . 72
8.3 Confirming messages . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.2 Installation, commissioning and operation . . . . . . . . 4
8.5 Repair of Ex-certified devices . . . . . . . . . . . . . . . . . 75
1.3 Operational safety and process safety . . . . . . . . . . . . 4
8.6 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.4 Notes on safety conventions and icons . . . . . . . . . . . 5
8.7 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Identification . . . . . . . . . . . . . . . . . . . . 6 8.9 Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Device designation . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 Technical data . . . . . . . . . . . . . . . . . . . 80
2.3 CE mark, declaration of conformity . . . . . . . . . . . . . 9
2.4 Registered trademarks . . . . . . . . . . . . . . . . . . . . . . . 9
10 Appendix . . . . . . . . . . . . . . . . . . . . . . . 80
3 Installation . . . . . . . . . . . . . . . . . . . . . 10 10.1 Operating menu for on-site display, FieldCare and HART
handheld terminal . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Incoming acceptance and storage . . . . . . . . . . . . . . 10
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . 10
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 10
3.4 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 22
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Connecting the device . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Connecting the measuring unit . . . . . . . . . . . . . . . 25
4.3 Potential matching . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Overvoltage protection (optional) . . . . . . . . . . . . . . 27
4.5 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 27
5 Operation . . . . . . . . . . . . . . . . . . . . . . 28
5.1 On-site display (optional) . . . . . . . . . . . . . . . . . . . . 28
5.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 On-site operation –
on-site display not connected . . . . . . . . . . . . . . . . . 33
on-site display connected . . . . . . . . . . . . . . . . . . . . 37
5.5 HistoROM®/M-DAT (optional) . . . . . . . . . . . . . . 39
5.6 Operation via SFX100 . . . . . . . . . . . . . . . . . . . . . . 43
5.7 FieldCare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.8 Locking/unlocking operation . . . . . . . . . . . . . . . . . 44
5.9 Factory setting (reset) . . . . . . . . . . . . . . . . . . . . . . 45
6 Commissioning. . . . . . . . . . . . . . . . . . 47
6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Selecting language and measuring mode . . . . . . . . 47
6.3 Position adjustment . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4 Flow measurement . . . . . . . . . . . . . . . . . . . . . . . . 49
6.5 Level measurement . . . . . . . . . . . . . . . . . . . . . . . . 52
6.6 Differential pressure measurement . . . . . . . . . . . . . 59
7 Maintenance. . . . . . . . . . . . . . . . . . . . 62
7.1 Exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8 Trouble-shooting . . . . . . . . . . . . . . . . 63
8.1 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Endress+Hauser 3
Safety instructions Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
1 Safety instructions
1.1 Designated use

The Deltabar S is a differential pressure transmitter for measuring differential pressure, flow and
level.
The manufacturer accepts no liability for damages resulting from incorrect use or use other than that
designated.
1.2 Installation, commissioning and operation

The device has been designed to operate safely in accordance with current technical, safety and EU
standards. If installed incorrectly or used for applications for which it is not intended, however, it is
possible that application-related dangers may arise, e.g. product overflow due to incorrect
installation or calibration. For this reason, the instrument must be installed, connected, operated
and maintained according to the instructions in this manual: personnel must be authorised and
suitably qualified. The manual must have been read and understood, and the instructions followed.
Modifications and repairs to the device are permissible only when they are expressly approved in
the manual. Pay particular attention to the technical data on the nameplate.
1.3 Operational safety and process safety

Alternative monitoring measures must be taken to ensure operational safety and process safety
durng configuration, testing and maintenance work on the device.
1.3.1 Hazardous areas (optional)

Devices for use in hazardous areas are fitted with an additional nameplate (→ ä 6). If the device is
to be installed in an explosion hazardous area, then the specifications in the certificate as well as all
national and local regulations must be observed. The device is accompanied by separate "Ex
documentation", which is an integral part of this Operating Instructions. The installation
regulations, connection values and Safety Instructions listed in this Ex document must be observed.
The documentation number of the related Safety Instructions is also indicated on the additional
nameplate.
• Ensure that all personnel are suitably qualified.
1.3.2 Functional Safety SIL3 (optional)

If using devices for applications with safety integrity, the Functional Safety Manual (SD00189P)
must be observed thoroughly.
4 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Safety instructions
1.4 Notes on safety conventions and icons

In order to highlight safety-relevant or alternative operating procedures in the manual, the following
conventions have been used, each indicated by a corresponding icon in the margin.
Safety conventions
#
Warning!
A warning highlights actions or procedures which, if not performed correctly, will lead to personal
injury, a safety hazard or destruction of the instrument.
"
Caution!
Caution highlights actions or procedures which, if not performed correctly, may lead to personal
injury or incorrect functioning of the instrument.
!
Note!
A note highlights actions or procedures which, if not performed correctly, may indirectly affect
operation or may lead to an instrument response which is not planned.
0
Device certified for use in explosion hazardous area
If the device has this symbol embossed on its nameplate, it can be installed in an explosion
hazardous area or a non-explosion hazardous area, according to the approval.
Explosion hazardous area
- Symbol used in drawings to indicate explosion hazardous areas.

– Devices used in hazardous areas must possess an appropriate type of protection.
Safe area (non-explosion hazardous area)
. Symbol used in drawings to indicate, if necessary, non-explosion hazardous areas.

– Devices used in hazardous areas must possess an appropriate type of protection. Lines used in
hazardous areas must meet the necessary safety-related characteristic quantities.
% Direct voltage
A terminal to which or from which a direct current or voltage may be applied or supplied.
&
Alternating voltage
A terminal to which or from which an alternating (sine-wave) current or voltage may be applied
or supplied.
)
Grounded terminal
A grounded terminal, which as far as the operator is concerned, is already grounded by means of
an earth grounding system.
*
Protective grounding (earth) terminal
A terminal which must be connected to earth ground prior to making any other connection to the
equipment.
+
Equipotential connection (earth bonding)
A connection made to the plant grounding system which may be of type e.g. neutral star or
equipotential line according to national or company practice.
Temperature resistance of the connection cables

t >85°C
States, that the connection cables must be resistant to a temperature of at least 85 °C (185 °F).
Safety instruction
For safety instructions refer to the manual for the appropriate instrument version.
Endress+Hauser 5
Identification Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
2 Identification
2.1 Device designation
2.1.1 Nameplate
! Note!
• The MWP (maximum working pressure) is specified on the nameplate. This value refers to a
reference temperature of 20°C (68°F) or 100°F for ANSI flanges.
• The pressure values permitted at higher temperatures can be found in the following standards:
– EN 1092-1: 2001 Tab. 18 1)
– ASME B 16.5a – 1998 Tab. 2-2.2 F316
– ASME B 16.5a – 1998 Tab. 2.3.8 N10276
– JIS B 2220
• For PMD70 and PMD75, the MWP applies for the temperature ranges specified in the Technical
Information TI00382P in the "Ambient temperature range" and "Process temperature limits"
sections.
• The test pressure corresponds to the over pressure limit (OPL) of the device = MWP x 1.5.
• The Pressure Equipment Directive (EC Directive 97/23/EC) uses the abbreviation "PS". The
abbreviation "PS" corresponds to the MWP (maximum working pressure) of the measuring
device.
1) With regard to their stability-temperature property, the materials 1.4435 and 1.4404 are grouped together under 13EO
in EN 1092-1 Tab. 18. The chemical composition of the two materials can be identical.
Aluminium housing (T14/T15) and stainless steel housing (T14)
R1 55
1
Order Code: 2
4
Ser.-No.: 3 6
23,5
MWP 5 Span 7
8 15
14
2,5
9 U= 11
Mat. 10
12 13
2,1 -0,1
26
P01-XMX7Xxxx-18-xx-xx-xx-000
Fig. 1: Nameplate
1 Device name
2 Order code
See the specifications on the order confirmation for the meanings of the individual letters and digits.
3 Serial number
4 Degree of protection
5 MWP (Maximum working pressure)
6 Symbol: Note: pay particular attention to the data in the "Technical Information"!
7 Minimum/maximum span
8 Nominal measuring range
9 Electronic version (output signal)
10 Wetted materials
11 Supply voltage
12 GL-symbol for GL marine certificate (optional)
13 SIL-symbol for devices with SIL3/IEC 61508 Declaration of conformity (optional)
14 Approval ID and ID numbers
15 Address of manufacturer
6 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Identification
Devices for use in hazardous areas are fitted with an additional nameplate.
1
2
4 5 Dat.: 6
P01-xMD7xxxx-18-xx-xx-xx-002
Fig. 2: Additional nameplate for devices for hazardous areas

1 EC type examination certificate number
2 Type of protection e.g. II 1/2 G Ex ia IIC T4/T6
3 Electrical data
4 Safety Instructions number e.g. XA00235P
5 Safety Instructions index e.g. A
6 Device manufacture data
Devices suitable for oxygen applications are fitted with an additional nameplate.
Bei Sauerstoffeinsatz/
for oxygen service
Pmax 1 3
Tmax 2
P01-xxxxxxxx-18-xx-xx-xx-000
Fig. 3: Additional nameplate for devices suitable for oxygen applications

1 Maximum pressure for oxygen applications
2 Maximum temperature for oxygen applications
3 Layout identification of the nameplate
Endress+Hauser 7
Identification Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
Hygenic stainless steel housing (T17)
13
1 19
2 20
Order Code: 3 21
Ser.-No.: 4
MWP 5 22
6
Span 7
8 23
9 U= 10
Mat.
24 - 25
11
12 Dat.: 26
15 16 Bei Sauerstoffeinsatz/for oxygen service:

14 17
13 Tmax 27 Pmax 28
18 13
P01-XMX7Xxxx-18-xx-xx-xx-001
Fig. 4: Nameplate
1 Device name
2 Address of manufacturer
3 Order code
See the specifications on the order confirmation for the meanings of the individual letters and digits.
4 Serial number
5 MWP (Maximum working pressure)
6 Symbol: Note: pay particular attention to the data in the "Technical Information"!
7 Minimum/Maximum span
8 Nominal measuring range
9 Electronic version (output signal)
10 Supply voltage
11 Wetted materials
12 Degree of protection
Optional:
13 Approval ID and ID numbers
14 3A-symbol
15 CSA-symbol
16 FM-symbol
17 SIL-symbol for devices with SIL3/IEC 61508 Declaration of conformity
18 GL-symbol for GL marine certificate
19 EC type examination certificate
20 Type of protection
21 Approval number for WHG overspill protection
22 Temperature operating range for devices for use in hazardous areas
23 Electrical data for devices for use in hazardous areas
24 Safety Instructions number
25 Safety Instructions index
26 Device manufacture data
27 Maximum temperature for devices suitable for oxygen applications
28 Maximum pressure for devices suitable for oxygen applications
2.1.2 Identifying the sensor type

See parameter "Sensor Meas.Type" in Operating Instruction BA00274P. The Operating Instruction
BA00274P can be found on the supplied documentation CD.
8 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Identification
2.2 Scope of delivery

The scope of delivery comprises:
• Deltabar S differential pressure transmitter
• For PMD70 and PMD75 with side flanges made of AISI 316L or C22.8: additional 2 vent valves,
AISI 316L
• PMD75 with side flanges made of AISI 316L or C22.8 and side vent: additional 4 locking screws,
AISI 316L
• For devices with the "HistoROM/M-DAT" option:
CD-ROM with Endress+Hauser operating program and documentation
• Optional accessories
Documentation supplied:
• The Operating Instructions BA00270P and BA00274P and the Safety Instructions, Functional
Safety Manual and brochures can be found on the supplied documentation CD.
See also → ä 2, "Overview documentation" chapter.
• Brief Operating Instructions KA01018P
• Leporello KA00218
• Final inspection report
• Also Safety Instructions with ATEX, IECEx and NEPSI devices
• Optional: factory calibration form, test certificates
2.3 CE mark, declaration of conformity

The device is designed to meet state-of-the-art safety requirements, has been tested and left the
factory in a condition in which it is safe to operate. The device complies with the applicable
standards and regulations as listed in the EC declaration of conformity and thus complies with the
statutory requirements of the EC Directives. Endress+Hauser confirms the successful testing of the
device by affixing to it the CE mark.
2.4 Registered trademarks
KALREZ, VITON, TEFLON

Registered trademarks of E.I. Du Pont de Nemours & Co., Wilmington, USA
TRI-CLAMP
Registered trademark of Ladish & Co., Inc., Kenosha, USA
HART
Registered trademark of the HART Communication Foundation, Austin, USA.
Endress+Hauser 9
Installation Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
3 Installation
3.1 Incoming acceptance and storage
3.1.1 Incoming acceptance

• Check the packaging and the contents for damage.
• Check the shipment, make sure nothing is missing and that the scope of supply matches your
order.
3.1.2 Transport
" Caution!
Follow the safety instructions and transport conditions for devices of more than 18 kg (39.69 lbs).
Transport the measuring device to the measuring point in its original packaging or at the process
connection.
3.1.3 Storage
The device must be stored in a dry, clean area and protected against damage from impact
(EN 837-2).
Storage temperature range:
• –40 to +90°C (–40 to +194°F)
• On-site display: –40 to +85°C (–40 to +185°F)
• Separate housing: –40 to +60°C (–40 to +140°F)
3.2 Installation conditions
3.2.1 Dimensions
→ For dimensions, please refer to the Technical Information for Deltabar S TI00382P, "Mechanical
construction" section. → ä 2 "Overview documentation.
3.3 Installation instructions

! Note!
• Due to the orientation of the Deltabar S, there may be a shift in the measured value, i.e. when
the container is empty, the measured value does not display zero. You may correct this zero point
shift either directly on the device using the "E"-key or by remote operation. → ä 31, "Function
of the operating elements – on-site display not connected" or → ä 48, "Position adjustment".
• For FMD77 and FMD78, please refer to → ä 17, Section 3.3.4 "Installation instructions for
devices with diaphragm seals (FMD78)".
• General recommendations for routing the impulse piping can be found in DIN 19210 "Methods
for measurement of fluid flow; differential piping for flow measurement devices" or the
corresponding national or international standards.
• Using a three-valve or five-valve manifold allows for easy commissioning, installation and
maintenance without interrupting the process.
• When routing the impulse piping outdoors, ensure that sufficient anti-freeze protection is used,
e.g. by using pipe heat tracing.
• Install the impulse piping with a monotonic gradient of at least 10%.
• To ensure optimal readability of the on-site display, it is possible to rotate the housing up to 380°.
→ ä 22, Section 3.3.9 "Rotating the housing".
• Endress+Hauser offers a mounting bracket for installing on pipes or walls. → ä 20, Section 3.3.7
"Wall and pipe-mounting (optional)".
10 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Installation
3.3.1 Installation for flow measurement
! Note!
For more information about flow measurement with the Deltabar S differential pressure transmitter
• Deltabar S with orifice plate (TI00422P, Deltatop DO6x)
• Deltabar S with Pitot tube (TI00425P, Deltatop DP6x)
Flow measurement in gases with PMD70/PMD75
➁
➂
+ – ➃
P01-PMD75xxx-11-xx-xx-xx-000
Fig. 5: Measuring layout for flow measurement in gases with PMD75

1 Deltabar S, here PMD75
2 Three-valve manifold
3 Shut-off valves
4 Orifice plate or pitot tube
• Mount the Deltabar S above the measuring point so that the condensate can run off into the
process piping.
Flow measurement in steam with PMD70/PMD75
➁
➂ ➂
➃
+ –
➄ ➄
➅ ➅
➆
Fig. 6: Measuring layout for flow measurement in steam with PMD75

1 Condensate traps
3 Shut-off valves
5 Separator
6 Drain valves
• Mount the Deltabar S below the measuring point.

• Mount the condensate traps at the same level as the tapping points and at the same distance to
the Deltabar S.
• Prior to commissioning, fill the impulse piping to the height of the condensate traps.
Endress+Hauser 11
Flow measurement in liquids with PMD70/PMD75
➁ ➁
+ ➂ –
➃ ➃
➄ ➄
➅
Fig. 7: Measuring layout for flow measurement in liquids with PMD75

2 Shut-off valves
4 Separator
5 Drain valves
• Mount the Deltabar S below the measuring point so that the impulse piping is always filled with
liquid and gas bubbles can run back into the process piping.
• When measuring in media with solid parts, such as dirty liquids, installing separators and drain
valves is useful for capturing and removing sediment.
3.3.2 Installation for level measurement
Level measurement in an open container with PMD70/PMD75
patm
min. + patm ➀
➃ ➁
➄
➂
Fig. 8: Measuring layout for level measurement in open containers with PMD75
1 The negative side is open to atmospheric pressure
3 Shut-off valve
4 Separator
5 Drain valve
• Mount the Deltabar S below the lower measuring connection so that the impulse piping is always
filled with liquid.
• The negative side is open to atmospheric pressure.
12 Endress+Hauser
Level measurement in an open container with FMD76/FMD77
patm
min.
+ ➀
–
patm
➁
P01-FMD76xxx-11-xx-xx-xx-003
Fig. 9: Measuring layout for level measurement in open containers with FMD76
1 Deltabar S, here FMD76
2 The negative side is open to atmospheric pressure
• Mount the Deltabar S direct on the container. → ä 19, Section 3.3.5 "Seal for flange mounting".
• The negative side is open to atmospheric pressure.
Level measurement in a closed container with PMD70/PMD75
–➀
max.
min. ➀
+
➁
➂ ➂
➃ ➃
➄
Fig. 10: Measuring layout for level measurement in a closed container with PMD75
1 Shut-off valves
2 Deltabar S, PMD75
3 Separator
4 Drain valves
filled with liquid.
• Always connect the impulse piping of negative side above the maximum level.
Endress+Hauser 13
Level measurement in a closed container with FMD76/FMD77
➀
–
max.
min.
➁
+ ➂
➃
Fig. 11: Measuring layout for level measurement in a closed container with FMD76
1 Shut-off valve
2 Separator
3 Drain valve
Level measurement in a closed container with FMD78
–
max.
➀
+
min.
Fig. 12: Measuring layout for level measurement in a closed container with FMD78
• Mount the Deltabar S below the lower diaphragm seal. → ä 17, Section 3.3.4 "Installation
instructions for devices with diaphragm seals (FMD78)".
• The ambient temperature should be the same for both capillaries.
! Note!
Level measurement is only ensured between the upper edge of the lower diaphragm seal and the
lower edge of the upper diaphragm seal.
14 Endress+Hauser
Level measurement in a closed container with superimposed steam with PMD 70/
PMD75
– ➀
max.
➁
min. ➁
+
➂
➃ ➃
➄ ➄
➅
Fig. 13: Measuring layout for level measurement in a container with superimposed steam with PMD75
1 Condensate trap
2 Shut-off valves
4 Separator
5 Drain valves
filled with liquid.
• A condensate trap ensures constant pressure on the negative side.
Level measurement in a closed container with superimposed steam with FMD 76/
FMD77
– ➀
max.
➁
min.
➂
+ ➃
➄
Fig. 14: Measuring layout for level measurement in a container with superimposed steam with FMD76
1 Condensate trap
2 Shut-off valve
3 Separator
4 Drain valve
Endress+Hauser 15
• A condensate trap ensures constant pressure on the negative side.
3.3.3 Installation for differential pressure measurement
Differential pressure measurement in gases and steam with PMD70/PMD75
➁
+
➂ ➂
➃
Fig. 15: Measuring layout for differential pressure measurement in gases and steam with PMD75
3 Shut-off valves
4 e.g. filter
• Mount the Deltabar S above the measuring point so that the condensate can run off into the
process piping.
Differential pressure measurement in liquids with PMD70/PMD75
➀
➁ ➁
+ –
➂
➃ ➃
➄ ➄
➅
Fig. 16: Measuring layout for differential pressure measurement in liquids with PMD75
1 e.g. filter
2 Shut-off valves
4 Separator
5 Drain valves
• Mount the Deltabar S below the measuring point so that the impulse piping is always filled with
liquid and gas bubbles can run back into the process piping.
16 Endress+Hauser
Differential pressure measurement in gases, steam and liquids with FMD78
➀
➁ ➁
+ –
➂
➃
Fig. 17: Measuring layout for differential pressure measurement in gases, steam and liquids with FMD78
1 Diaphragm seal
2 Capillary
3 e.g. filter
• Mount the diaphragm seal with capillaries at the top or on the side on the piping.
• For vacuum applications: mount the Deltabar S below the measuring point. → ä 17,
Section 3.3.4 "Installation instructions for devices with diaphragm seals (FMD78)", "Vacuum
application" part.
• The ambient temperature should be the same for both capillaries.
3.3.4 Installation instructions for devices with diaphragm seals

(FMD78)
! Note!
• The diaphragm seal, together with the pressure transmitter, forms a closed, calibrated system,
which is filled through openings in the diaphragm seal and in the measurement system of the
pressure transmitter. This openings are sealed and must not be opened.
• Do not clean or touch diaphragm seals with hard or pointed objects.
• Do not remove the protection of the process isolating diaphragm until shortly before installation.
• When using a mounting bracket, sufficient strain relief must be ensured for the capillaries in order
to prevent the capillary bending down (bending radius ≥ 100 mm (3.94 in)).
• Please note that the hydrostatic pressure of the liquid columns in the capillaries can cause zero
point shift. The zero point shift can be corrected. → ä 48, Section 6.3 "Position adjustment".
• Please note the application limits of the diaphragm seal filling oil as detailed in the Technical
Information for Deltabar S TI00382P, Section "Planning instructions for diaphragm seal systems".
→ → ä 2 "Overview documentation".
In order to obtain more precise measurement results and to avoid a defect in the device, mount the
capillaries as follows:
• vibration-free (in order to avoid additional pressure fluctuations)
• not in the vicinity of heating or cooling lines
• insulate if the ambient temperature is below ore above the reference temperature
• with a bending radius of ≥100 mm (3.94 in).
• The ambient temperature and length of both capillaries should be the same when using two-sided
diaphragm seal systems.
• Two diaphragm seals which are the same (e.g. with regard to diameter, material, etc.) should
always be used for the negative and positive side (standard delivery).
Endress+Hauser 17
–
≥ 100 mm
+ –
Fig. 18: Mounting Deltabar S, FMD78 with diaphragm seals and capillary, recommended mounting for vacuum
applications: mount pressure transmitter below the lowest diaphragm seal!
Vacuum application (FMD78)

For applications under vacuum, Endress+Hauser recommends mounting the pressure transmitter
underneath the lower diaphragm seal. A vacuum load of the diaphragm seal caused by the presence
of filling oil in the capillaries is hereby prevented.
When the pressure transmitter is mounted above the lower diaphragm seal, the maximum height
difference H1 in accordance with the illustration below on the left must not be exceeded. The
maximum height difference is dependent on the density of the filling oil and the smallest ever
pressure that is permitted to occur at the diaphragm seal on the positive side (empty container), see
illustration below, on the right.
12.0
Low temperature oil
10.0
Height difference H1 [m]
Vegetable oil
8.0
– Silicone oil
6.0
High temperature
– + oil
4.0
+ –
H1 Inert oil
2.0
+
0.0
50 100 200 300 400 500 600 700 800 900 1000
Pressure, diaphragm seal positive side [mbarabs]
P01-FMD7xxxx-11-xx-xx-xx-001 P01-FMD7xxxx-05-xx-xx-xx-002
Fig. 19: Installation above the lower Fig. 20: Diagram of maximum installation height above the lower
diaphragm seal diaphragm seal for vacuum applications dependent on
the pressure at the diaphragm seal on the positive side
18 Endress+Hauser
3.3.5 Seal for flange mounting
➀ ➁
P01-FMD7xxxx-11-xx-xx-xx-002
Fig. 21: Mounting the versions with flange or diaphragm seal

1 Process isolating diaphragm
2 Seal
# Warning!
The seal is not allowed to press on the process isolating diaphragm as this could affect the
measurement result.
3.3.6 Heat insulation – FMD77

The FMD77 must only be insulated up to a certain height. The maximum permitted insulation
height is labelled on the devices and applies to an insulation material with a heat conductivity
≤ 0.04 W/(m x K) and to the maximum permitted ambient and process temperature (→ see table
below). The data were determined under the most critical application "quiescent air".
TA λ ≤ 0.04 W
m•K
TP
P01-FMD77xxxx-11-xx-xx-xx-000
Fig. 22: Maximum permitted insulation height
FMD77
Ambient temperature (TA) ≤ 70°C (158°F)
Process temperature (TP) max. 400°C (752°F), depending on the

diaphragm seal filling oil used (→ see Technical
Information TI00382P Deltabar S)
Endress+Hauser 19
3.3.7 Wall and pipe-mounting (optional)

Endress+Hauser offers a mounting bracket for installing the device on pipes or walls. A bracket with
mounting accessories for pipe mounting is included with the device.
! Note!
When using a valve block, the block's dimensions must be taken into account.
37.5
➀
12
135
74
12 74
4 6
10
Fig. 23: Mounting bracket for wall and pipe mounting

1 Device mounting
Please note the following when mounting:

• Devices with capillary lines: mount capillaries with a bending radius of ≥ 100 mm (3.94 in).
• To prevent the mounting screws from scoring, lubricate them with a multi-purpose grease prior
to mounting.
• In the case of pipe mounting, the nuts on the bracket must be tightened uniformly with a torque
of at least 30 Nm (22.13 lbf ft).
20 Endress+Hauser
3.3.8 Assembling and mounting the "separate housing" version
5
7
4
1 r ³ 120 mm
Fig. 24: "Separate housing" version

1 In the "separate housing" version, the sensor is supplied with process connection and cable fitted.
2 Cable with connection jack
4 Plug
5 Locking screw
6 Housing fitted with housing adapter, included
7 Mounting bracket suitable for wall and pipe mounting, included
Assembly and mounting

1. Connect plug (item 4) into the corresponding connection jack of the cable (item 2).
2. Plug the cable into the housing adapter (item 6).
3. Tighten the locking screw (item 5).
4. Mount the housing on a wall or pipe using the mounting bracket (item 7). When mounting
on a pipe, tighten the nuts on the bracket uniformly with a torque of at least 5 Nm (3.69 lbs ft).
Mount the cable with a bending radius (r) ≥ 120 mm (4.72 in).
Endress+Hauser 21
3.3.9 Rotating the housing

The housing can be rotated up to 380° by loosening the Allen screw.
max. 380°
Fig. 25: Aligning the housing

– T14 and T15 housing: Loosen setscrew with a 2 mm (0.08 in) Allen key.
Hygenic T17 housing: Loosen setscrew with a 3 mm (0.12 in) Allen key.
– Rotate housing (max. up to 380°).
– Retighten setscrew with 1 Nm (0,74 lbf ft).
3.3.10 Close cover on a hygenic stainless steel housing (T17)
! Note!
When closing the housing cover, please ensure that the thread of the cover and housing are free
from dirt, e.g. sand.If you feel any resistance when closing the cover, check the thread on both again
to ensure that they are free from dirt.
Close cover on a hygenic stainless steel housing (T17)
+–
Fig. 26: Close cover
The covers for the terminal and electronics compartment are hooked into the casing and closed with
a screw. These screws should be finger-tightened (2 Nm (1.48 lbf ft)) to the stop to ensure that the
covers sit tightly.
3.4 Post-installation check

After installing the device, carry out the following checks:
• Are all screws firmly tightened?
• Are the housing covers screwed down tight?
• Are all locking screws and vent valves firmly tightened?
22 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Wiring
4 Wiring
4.1 Connecting the device

# Warning!
If the operating voltage is > 35 VDC: Dangerous contact voltage at terminals.
Risk of electric shock!
In a wet environment, do not open the cover if voltage is present.
# Warning!
Risk of electric shock and/or explosion in hazardous areas! In a wet environment, do not open the
cover if voltage is present.
! Note!
• When using the measuring device in hazardous areas, installation must comply with the
corresponding national standards and regulations and the Safety Instructions or Installation or
Control Drawings.
• Devices with integrated overvoltage protection must be earthed.
• Protective circuits against reverse polarity, HF influences and overvoltage peaks are installed.
• The supply voltage must match the supply voltage on the nameplate. (→ ä 6, Section 2.1.1
"Nameplate".)
• Switch off the supply voltage before connecting the device.
• Remove housing cover of the terminal compartment.
• Guide cable through the gland. Preferably use twisted, screened two-wire cable.
• Connect device in accordance with the following diagram.
• Screw down housing cover.
• Switch on supply voltage.
➀ ➅ 10.5 V DC
➆ 11.5 V DC
4…20 mA
Test
Test
➁ 4... 20mA Test
➂ ➄
➇
4... 20mA Test
➃
P01-xMx7xxxx-04-xx-xx-xx-001
Fig. 27: Electrical connection 4...20 mA HART

→ Observe also sSection 4.2.1 "Supply voltage", → ä 25,.
1 Housing
2 Jumper for 4...20 mA test signal.
→ ä 25, Section 4.2.1 "Taking 4...20 mA test signal" part.
3 Internal earth terminal
4 External earth terminal
5 4...20 mA test signal between plus and test terminal
6 minimum supply voltage = 10.5 V DC, jumper is inserted in accordance with the illustration.
7 minimum supply voltage = 11.5 V DC, jumper is inserted in "Test" position.
8 Devices with integrated overvoltage protection are labelled OVP (overvoltage protection) here.
Endress+Hauser 23
Wiring Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
4.1.1 Connecting devices with Harting plug Han7D
+ – 7
– 8 6
1
2 5
Han7D 3 4
+ –
P01-xxx7xxxx-04-xx-xx-xx-001
Fig. 28: Left: electrical connection for devices with Harting plug Han7D
Right: view of the plug connector at the device
4.1.2 Connecting devices with an M12 connector
PIN assignment for M12 connector
PIN Meaning
1 Signal +
4 3 –
2 Not assigned
3 Signal –
1 + 2 nc
4 Earth
A0011175
24 Endress+Hauser
4.2 Connecting the measuring unit
4.2.1 Supply voltage
! Note!
• All explosion protection data are given in separate documentation which is available upon
request. The Ex documentation is supplied as standard with all devices approved for use in
explosion hazardous areas.
• When using the measuring device in hazardous areas, installation must comply with the
corresponding national standards and regulations and the Safety Instructions or Installation or
Control Drawings.
Electronic version Jumper for 4...20 mA test signal in Jumper for 4...20 mA test signal in
"Test" position (Delivery status) "Non-Test" position
4...20 mA HART, for non-hazardous 11.5...45 V DC 10.5...45 V DC

areas
Taking 4...20 mA test signal

A 4...20 mA signal may be measured via the positive and test terminal without interrupting the
measurement. The minimum supply voltage of the device can be reduced by simply changing the
position of the jumper. As a result, operation is also possible with lower voltage sources. To keep
the measured error below 0.1%, the current measuring device should display an internal resistance
of < 0.7 Ω. Observe the position of the jumper in accordance with the following table.
Jumper position for test signal Description
– Taking 4...20 mA test signal via plus and test terminal:

Test possible. (Thus, the output current can be measured without
interruption via the diode.)
– Delivery status
– minimum supply voltage: 11.5 V DC
– Taking 4...20 mA test signal via plus and test terminal:

Test not possible.
– minimum supply voltage: 10.5 V DC
4.2.2 Cable specification

• Endress+Hauser recommends using twisted, screened two-wire cables.
• Terminals for wire cross-sections 0.5...2.5 mm2 (20 to 14 AWG)
• Cable external diameter: 5...9 mm (0.2 to 0.35 in)
Endress+Hauser 25
Wiring Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
4.2.3 Load
➀ RLmax ➁ RLmax
[Ω] [Ω]
Test 1500 Test
1456
1282 1239
847 804
➃ ➃
413
➂ 369
➂
10.5 20 30 40 45 U 11.5 20 30 40 45 U
[V] [V]
U – 10.5 V U – 11.5 V
RLmax ≤ RLmax ≤
23 mA 23 mA
Fig. 29: Load diagram, observe the position of the jumper and the explosion protection (→ ä 25, Section 4.2.1
"Taking 4...20 mA test signal".)
1 Jumper for 4...20 mA test signal inserted in "Non-Test" position
2 Jumper for 4...20 mA test signal inserted in "Test" position
3 Supply voltage 10.5 (11.5)...30 V DC for 1/2 G, 1GD, 1/2 GD, FM IS, CSA IS, IECEx ia, NEPSI Ex ia
4 Supply voltage 10.5 (11.5)...45 V DC for device for non-hazardous areas, 1/2 D, 1/3 D, 2 G Ex d,
3 G Ex nA, FM XP, FM DIP, FM NI, CSA XP, CSA Dust Ex, NEPSI Ex d
RLmaxMaximum load resistance
U Supply voltage
! Note!
When operating via a handheld terminal or via PC with an operating program, a minimum
communication resistance of 250 Ω must exist within the loop.
4.2.4 Screening/potential matching

• You achieve optimum screening against disturbances if the screening is connected on both sides
(in the cabinet and on the device). If you have to reckon with potential equalisation currents in
the plant, only earth screening on one side, preferably at the transmitter.
• When using in hazardous areas, you must observe the applicable regulations.
Separate Ex documentation with additional technical data and instructions is included with all Ex
systems as standard.
4.2.5 Connecting Field Xpert SFX100

Compact, flexible and robust industry handheld terminal for remote parametrization and measured
value inspection via the HART current output (4-20mA).
For details refer to Operating Instructions BA00060S/04/EN.
4.2.6 Connecting Commubox FXA195

The Commubox FXA195 connects intrinsically safe transmitters with the HART protocol to a
computer's USB port. This allows remote operation of the transmitter using Endress+Hauser's
FieldCare operating program. Power is supplied to the Commubox through the USB port. The
Commubox is also suitable for connection to intrinsically safe circuits. → See Technical Information
TI00404F for further information.
26 Endress+Hauser
4.2.7 Connecting Commubox FXA291/ToF Adapter FXA291 for

operation via FieldCare
Connecting Commubox FXA291

The Commubox FXA291 connects Endress+Hauser field instruments with CDI interface (=
Endress+Hauser Common Data Interface) to the USB interface of a personal computer or a
notebook. For details refer to TI00405C/07/en.
! Note!
For the following Endress+Hauser instruments you need the "ToF Adapter FXA291" as an additional
accessory:
• Cerabar S PMC71, PMP7x
• Deltabar S PMD7x, FMD7x
• Deltapilot S FMB70
Connecting ToF Adapter FXA291

The ToF Adapter FXA291 connects the Commubox FXA291 via the USB interface of a personal
computer or a notebook to the following Endress+Hauser instruments:
• Cerabar S PMC71, PMP7x
• Deltabar S PMD7x, FMD7x
• Deltapilot S FMB70
For details refer to KA0271F/00/a2.
4.3 Potential matching

Ex applications: Connect all devices to the local potential matching.
Observe the applicable regulations.
4.4 Overvoltage protection (optional)

Devices showing version "M" in feature 100 "Additional options 1" or feature 110 "Additional
options 2" in the order code are equipped with overvoltage protection (see also Technical
Information TI00382P "Ordering information".
• Overvoltage protection:
– Nominal functioning DC voltage: 600 V
– Nominal discharge current: 10 kA
• Surge current check î = 20 kA as per DIN EN 60079-14: 8/20 μs satisfied
• Arrester AC current check I = 10 A satisfied
# Warning!
Devices with integrated overvoltage protection must be earthed.
4.5 Post-connection check

Perform the following checks after completing electrical installation of the device:
• Does the supply voltage match the specifications on the nameplate?
• Is the device connected as per section 4.1?
• Are all screws firmly tightened?
• Are the housing covers screwed down tight?
As soon as voltage is applied to the device, the green LED on the electronic insert lights up for a few
seconds or the connected on-site display lights up.
Endress+Hauser 27
Operation Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
5 Operation
Feature 20 "Output; operation" in the order code provides you with information on the operating
options available to you.
Versions in the order code Operation
A 4...20 mA HART; external operation, LCD Via on-site display and 3 keys on the exterior of the device
B 4...20 mA HART; internal operation, LCD Via on-site display and 3 keys on the inside of the device
C 4...20 mA; internal operation Without on-site display, 3 keys on the inside of the device
5.1 On-site display (optional)

A 4-line liquid crystal display (LCD) is used for display and operation. The on-site display shows
measured values, dialog texts, fault messages and notice messages.
The display of the device can be turned in 90° steps.
Depending on the installation position of the device, this makes it easy to operate the device and
read the measured values.
Functions:
• 8-digit measured value display including sign and decimal point, bargraph for current display
• simple and complete menu guidance thanks to separation of the parameters into several levels and
groups
• each parameter is given a 3-digit ID number for easy navigation
• option for configuring the display according to individual requirements and desires, such as
language, alternating display, contrast setting, display of other measured values such as sensor
temperature
• comprehensive diagnostic functions (fault and warning message, peak-hold indicators, etc.)
• rapid and safe commissioning with the Quick Setup menus
Measured value display Parameter

Identification
Function name Value number
Header line
Main line
Unit
Information
line
– + E Symbol
Bargraph
Editing modes
Operating keys
Selection
options
Value that
can be edited
Current measured value

28 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Operation
The following table illustrates the symbols that can appear on the on-site display. Four symbols can
occur at one time.
Symbol Meaning
Alarm symbol
– Symbol flashing: warning, device continues measuring.
– Symbol permanently lit: error, device does not continue measuring.
Note: The alarm symbol may overlie the tendency symbol.
Lock symbol
The operation of the device is locked. Unlock device, → Section 5.8.
Communication symbol
Data transfer via communication
Note: The alarm symbol may overlie the communication symbol.
Square root symbol

Active measuring mode "Flow measurement"
The root flow signal is used for the current output.
Tendency symbol (increasing)

The measured value is increasing.
Tendency symbol (decreasing)

The measured value is decreasing.
Tendency symbol (constant)

The measured value has remained constant over the past few minutes.
Endress+Hauser 29
5.2 Operating elements
5.2.1 Position of operating elements

With regard to aluminium housings (T14/T15) and stainless steel housing (T14), the operating keys
are located either outside the device under the protection cap or inside on the electronic insert. In
hygenic stainless housings (T17), the operating keys are always located inside on the electronic
insert.
➃➄
t ➅
on
➀
➀ ➁
off
➂
1 2
PC
P01-xxxxxxxx-19-xx-xx-xx-056 P01-xxxxxxxx-19-xx-xx-xx-104
Fig. 30: Operating keys, external Fig. 31: Operating keys, internal
1 Operating keys on the exterior of the device under 1 Operating keys
the protective flap 2 Slot for optional display
3 Slot for optional HistoROM®/M-DAT
4 DIP-switch for locking/unlocking measured-value-
relevant parameters
5 DIP-switch for damping on/off
6 Green LED to indicate value being accepted
30 Endress+Hauser
5.2.2 Function of the operating elements –

on-site display not connected
Press and hold the key or the key combination for at least 3 seconds to execute the corresponding
function. Press the key combination for at least 6 seconds for a reset.
Operating key(s) Meaning
Adopt lower range value. A reference pressure is present at the device.

→ ä 33, Section 5.3.1 "Pressure measuring mode", → ä 34, Section 5.3.2 "Level
measuring mode" or → ä 36, Section 5.3.3 "Flow measuring mode".
Adopt upper range value. A reference pressure is present at the device.

→ ä 33, Section 5.3.1 "Pressure measuring mode", → ä 34, Section 5.3.2 "Level
measuring mode" or → ä 36, Section 5.3.3 "Flow measuring mode".
Position adjustment
Reset all parameters. The reset via operating keys corresponds to the software reset code
and and 7864.
Copy the configuration data from the optional HistoROM®/M-DAT module to the device.
and
Copy the configuration data from the device to the optional HistoROM®/M-DAT module.
and
– DIP-switch 1: for locking/unlocking measured-value-relevant parameters

τ on Factory setting: off (unlocked)
– DIP-switch 2: damping on/off,
Factory setting: on (damping on)
1 2 off
Endress+Hauser 31
5.2.3 Function of the operating elements –

on-site display connected
Operating key(s) Meaning
O – Navigate upwards in the picklist

– Edit the numerical values and characters within a function
S – Navigate downwards in the picklist

– Edit the numerical values and characters within a function
F – Confirm entry
– Jump to the next item
Contrast setting of on-site display: darker
O and F
Contrast setting of on-site display: brighter
S and F
ESC functions:
– Exit edit mode without saving the changed value.
– You are in a menu within a function group. The first time you press the keys
simultaneously, you go back a parameter within the function group. Each time you press
O and S the keys simultaneously after that, you go up a level in the menu.
– You are in a menu at a selection level. Each time you press the keys simultaneously, you
go up a level in the menu.
Note: The terms function group, level and selection level are explained in section 5.4.1,
page 37.
32 Endress+Hauser

on-site display not connected
! Note!
To operate the device with a HistoROM®/M-DAT module → ä 39, Section 5.5 "HistoROM®/M-
DAT (optional)".
5.3.1 Pressure measuring mode

If no on-site display is connected, the following functions are possible by means of the three keys
on the electronic insert or on the exterior of the device:
• Position adjustment (zero point correction)
• Setting lower range value and upper range value
• Device reset, → ä 31, Section 5.2.2 "Function of the operating elements – on-site display not
connected", Table.
! Note!
• The operation must be unlocked. → ä 44, Section 5.8 "Locking/unlocking operation".
• The device is configured for the Pressure measuring mode as standard. You can switch measuring
modes by means of the MEASURING MODE parameter. → ä 47, Section 6.2 "Selecting
language and measuring mode".
• The pressure applied must be within the nominal pressure limits of the sensor. See information
on the nameplate.
Carry out position adjustment.1) Setting lower range value. Setting upper range value.
Pressure is present at device. Desired pressure for lower range Desired pressure for upper range
value is present at device. value is present at device.
↓ ↓ ↓
Press "E"-key for 3 s. Press "–"-key for 3 s. Press "+"-key for 3 s.
↓ ↓ ↓
Does the LED on the electronic insert Does the LED on the electronic insert Does the LED on the electronic insert
light up briefly? light up briefly? light up briefly?
Yes No Yes No Yes No
↓ ↓ ↓ ↓ ↓ ↓
Applied pressure Applied pressure Applied pressure Applied pressure Applied pressure Applied pressure
for for position for for for for
position adjustment has lower range value lower range value upper range value upper range value
adjustment has not been has been has not been has been has not been
been accepted. accepted. accepted. accepted. accepted. accepted.
Observe the input Observe the input Observe the input
limits. limits. limits.
1) Observe "Warning" on page 47 in Chapter 6 "Commissioning".
Endress+Hauser 33
5.3.2 Level measuring mode

• Set the lower and upper pressure value and assign to the lower and upper level value
connected", Table.
! Note!
• The "-" and "+"- keys only have a function in the following cases:
– LEVEL SELECTION "Level Easy Pressure", CALIBRATION MODE "Wet"
– LEVEL SELECTION "Level Standard", LEVEL MODE "Linear",
CALIBRATION MODE "Wet"
The keys have no function in other settings.
The following parameters are set to the following values in the factory:
– LEVEL SELECTION: Level Easy Pressure
– CALIBRATION MODE: Wet
– OUTPUT UNIT or LIN. MEASURAND: %
– EMPTY CALIB.: 0.0
– FULL CALIB.: 100.0.
– SET LRV: 0.0 (corresponds to 4 mA value)
– SET URV: 100.0 (corresponds to 20 mA value)
These parameters can only be modified by means of the on-site display or remote operation such
as the FieldCare.
on the nameplate.
• → ä 52, Section 6.5 "Level measurement". For parameter description see Operating Instructions
BA00274P.
• LEVEL SELECTION, CALIBRATION MODE, LEVEL MODE, EMPTY CALIB., FULL CALIB, SET
LRV and SET URV are parameter names used for on-site display or remote operation such as
FieldCare for instance.
34 Endress+Hauser
Carry out position adjustment.1) Setting lower pressure value. Setting upper pressure value.
Pressure is present at device. Desired pressure for lower pressure Desired pressure for upper pressure
value (EMPTY PRESSURE2)) is value (FULL PRESSURE1) is present
present at device. at device.
↓ ↓ ↓
Press "E"-key for 3 s. Press "–"-key for 3 s. Press "+"-key for 3 s.
↓ ↓ ↓
Does the LED on the electronic insert Does the LED on the electronic insert Does the LED on the electronic insert
light up briefly? light up briefly? light up briefly?
Yes No Yes No Yes No
↓ ↓ ↓ ↓ ↓ ↓
Applied pressure Applied pressure The pressure The pressure The pressure The pressure
for for position present was saved present was not present was saved present was not
position adjustment has as the lower saved as the as the upper saved as the
adjustment has not been pressure value lower pressure pressure value upper pressure
been accepted. accepted. (EMPTY value. Observe (FULL value. Observe
Observe the input PRESSURE1) and the input limits. PRESSURE1) and the input limits.
limits. assigned to the assigned to the
lower level value upper level value
(EMPTY (FULL CALIB.1).
CALIB.1).

2) Parameter name used for the on-site display or remote operation such as the FieldCare.
Endress+Hauser 35
5.3.3 Flow measuring mode

• Set the maximum pressure value and assign it to the maximum flow value
connected", Table.
! Note!
• The "-"- key does not have any function.
on the nameplate.
• → ä 51, Section 6.4.3 "Quick Setup menu for the Flow measuring mode" and Operating
Instructions BA00274P, parameter descriptions MAX. PRESS. FLOW, MAX. FLOW, SET LRV –
Flow and LINEAR/SQROOT.
Carry out position adjustment.1) Setting maximum pressure value.

Pressure is present at device. Desired pressure for the maximum
pressure value (MAX. FLOW2)) is
present at device.
↓ ↓
Press "E"-key for 3 s. Press "+"-key for 3 s.
↓ ↓
Does the LED on the electronic insert Does the LED on the electronic insert
light up briefly? light up briefly?
Yes No Yes No
↓ ↓ ↓ ↓
Applied pressure Applied pressure The pressure The pressure

for for position present was saved present was not
position adjustment has as the maximum saved as the
adjustment has not been pressure value maximum
been accepted. accepted. (MAX. PRESS pressure value.
Observe the input FLOW1) and Observe the input
limits. assigned to the limits.
maximum flow
value (MAX.
FLOW.1).

2) Parameter name used for the on-site display or remote operation such as
the FieldCare.
36 Endress+Hauser

on-site display connected
If the on-site display is connected, the three operating keys are used to navigate through the
operating menu, → ä 32, Section 5.2.3 "Function of the operating elements – on-site display
connected".
5.4.1 General structure of the operating menu

The menu is split into four levels. The three upper levels are used to navigate while you use the
bottom level to enter numerical values, select options and save settings. The entire menu is
illustrated in section 10.1 "Menu for on-site display, FieldCare and HART handheld terminal".
The structure of the OPERATING MENU depends on the measuring mode selected, e.g. if the
"Pressure" measuring mode is selected, only the functions necessary for this mode are displayed.
Measured value
GROUP SELECTION
LANGUAGE MEASURING MODE QUICK SETUP OPERATING MENU
➁
➀ SETTINGS DISPLAY
POSITION ADJUSTMENT BASIC SETUP EXTENDED SETUP
POS. ZERO ADJUST
➂
➃ POS. INPUT VALUE
CALIB. OFFSET
Fig. 32: Structure of the operating menu

1 1. Selection level
2 2. Selection level
3 Function groups
4 Parameter
! Note!
The LANGUAGE and MEASURING MODE parameters are only displayed via the on-site display on
the 1st selection level. In the digital communication, the LANGUAGE parameter is displayed in the
DISPLAY group and the MEASURING MODE parameter is displayed in the QUICK SETUP menus
or in the BASIC SETUP function group. → See also Section 10.1 "Operating menu for on-site
display, FieldCare and HART handheld terminal".
Endress+Hauser 37
5.4.2 Selecting an option

Example: select "English" as the language of the menu.
On-site display Operation
German is selected as the language. A ✓in front of the

menu text indicates the active option.
Select English with "+" or "–".
1. Confirm your choice with "E". A ✓ in front of the

menu text indicates the active option. (English is now
selected as the menu language.)
2. Jump to the next item with "E".
5.4.3 Editing a value

Example: adjusting DAMPING VALUE function from 2.0 s to 30.0 s. → ä 32, Section 5.2.3
"Function of the operating elements – on-site display connected".
The on-site display shows the parameter to be changed.

The value highlighted in black can be changed. The "s" unit
is fixed and cannot be changed.
1. Press "+" or "–" to get to the editing mode.

2. The first digit is highlighted in black.
1. Use "+" to change "2" to "3".

2. Confirm "3" with "E". The cursor jumps to the next
position (highlighted in black).
The decimal point is highlighted in black, i.e. you can now

edit it.
1. Keep pressing "+" or "–" until "0" is displayed.

2. Confirm "0" with "E".
The cursor jumps to the next position. ↵ is displayed
and is highlighted in black. → See next graphic.
38 Endress+Hauser
Use "E" to save the new value and exit the editing mode.
→ See next graphic.
The new value for the damping is now 30.0 s.

– Jump to the next parameter with "E".
– You can get back to the editing mode with "+" or
"–".
5.4.4 Taking pressure applied at device as value

Example: configuring upper range value – assign 20 mA to the pressure value 400 mbar.
The bottom line on the on-site display displays the pressure

present, here 400 mbar.
Use "+" or "–" to switch to the "Confirm" option. The active

selection is highlighted in black.
Use "E" to assign the value (400 mbar) to the GET URV
parameter. The device confirms the calibration and jumps
back to the parameter, here GET URV (see next graphic).
Switch to the next parameter with "E".
5.5 HistoROM®/M-DAT (optional)

HistoROM®/M-DAT is a memory module, which is attached to the electronic insert and fulfils the
following functions:
• Back-up copy of configuration data
• Copying configuration data of a transmitter into another transmitter
• Cyclic recording of pressure and sensor-temperature measured values
• Recording diverse events, such as alarms, configuration changes, counters for measuring range
undershooting and exceeding for pressure and temperature, exceeding and undershooting the
user limits for pressure and temperature, etc.
# Warning!
Detach HistoROM®/M-DAT from the electronic insert or attach it to the insert in a deenergised
state only.
Endress+Hauser 39
! Note!
• The HistoROM®/M-DAT module may be retrofitted at any time (Order No.: 52027785).
• The HistoROM data and the data in the device are analysed once a HistoROM®/M-DAT is
attached to the electronic insert and power is reestablished to the device. During the analysis, the
messages "W702, HistoROM data not consistent" and "W706, Configuration in HistoROM and
device not identical" can occur. For measures, → ä 63, Section 8.1 "Messages."
5.5.1 Copying configuration data
➁
on
t
off
➀
1 2
PC
R
HART
250002271-–
FIELD COMMUNICATION PROTOCOL
HW-Version: 1
SW-Version: 2
Abb. 33: Electronic insert with optional HistoROM®/M-DAT memory module

1 optional HistoROM®/M-DAT
2 To copy configuration data from the HistoROM®/M-DAT module to a device or from a device to a HistoROM®/
M-DAT,, the operation must be unlocked DIP-switch 1, Position "off" ,parameter INSERT PIN NO. = 100). Observe
page 44, section 5.9 "Locking/unlocking operation".
On-site operation – on-site display not connected

Copying configuration data from a device to a HistoROM®/M-DAT module:
! Note!
The operation must be unlocked.
1. Disconnect device from supply voltage.
2. Attach the HistoROM®/M-DAT module to the electronic insert.
3. Reestablish supply voltage to the device.
4. Press "E" and "-"-keys (for at least 3 seconds) until the LED on the electronic insert lights up.
5. Wait approx. 20 seconds. Configuration data are loaded from the device to the HistoROM®/
M-DAT. The device is not restarted.
6. Disconnect device from the supply voltage again.
7. Detach memory module.
40 Endress+Hauser
Copying configuration data from a HistoROM®/M-DAT to a device:
! Note!
2. Attach the HistoROM®/M-DAT module to the electronic insert. Configuration data from
another device are stored in the HistoROM®/M-DAT.
4. Press "E" und "+"-keys (for at least 3 seconds) until the LED on the electronic insert lights up.
5. Wait approx. 20 seconds. All parameters except DEVICE SERIAL No, DEVICE DESIGN.,
CUST. TAG NUMBER, LONG TAG NUMBER, DESCRIPTION, BUS ADDRESS and the
parameters in the POSITION ADJUSTMENT and PROCESS CONNECTION group are loaded
into the device by HistoROM®/M-DAT. The device is restarted.
6. Before removing the HistoROM®/M-DAT again from the electronic insert, disconnect the
device from supply voltage.
On-site operation via on-site display (optional) or remote operation

Copying configuration data from a device to a HistoROM®/M-DAT:
! Note!
2. Attach the HistoROM®/M-DAT module to the electronic insert.
4. The DOWNLOAD SELECT. parameter setting has no influence on an upload from the device
into HistoROM.
(Menu path: (GROUP SELECTION →) OPERATING MENU → OPERATION)
5. Using the HistoROM CONTROL parameter select the option "Device → HistoROM" as the
data transfer direction.
(Menu path: GROUPSELECTION → OPERATING MENU → OPERATION)
M-DAT. The device is not restarted.
7. Disconnect device from the supply voltage again.
8. Detach memory module.
Endress+Hauser 41
Copying configuration data from a HistoROM®/M-DAT to a device:
! Note!
2. Attach the HistoROM®/M-DAT module to the electronic insert. Configuration data from
another device are stored in the HistoROM®/M-DAT.
4. Use the DOWNLOAD SELECT parameter to select which parameters are to be overwritten
(Menu path: (GROUPS SELECTION →) OPERATING MENU → OPERATION).
The following parameters are overwritten according to the selection:

– Configuration copy (factory setting):
all parameters except DEVICE SERIAL No., DEVICE DESIGN, CUST. TAG NUMBER,
LONG TAG NUMBER, DESCRIPTION, BUS ADDRESS and the parameters in the
POSITION ADJUSTMENT, PROCESS CONNECTION, CURR. TRIM (SERVICE /SYSTEM
2), SENSOR TRIM and SENSOR DATA group.
– Device replacement:
all parameters except DEVICE SERIAL No., DEVICE DESIGN and the parameters in the
POSITION ADJUSTMENT, PROCESS CONNECTION, CURR. TRIM (SERVICE/SYSTEM
2), SENSOR TRIM and SENSOR DATA group.
– Electronics replace:
all parameters except the parameters in the CURR. TRIM (SERVICE/SYSTEM 2) and
SENSOR DATA group.
Factory setting: Configuration copy
5. Using the HistoROM CONTROL parameter select the option "HistoROM → Device" as the
data transfer direction.
(Menu path: GROUP SELECTION → OPERATING MENU → OPERATION)
M-DAT. The device is restarted.
7. Before removing the HistoROM®/M-DAT again from the electronic insert, disconnect the
device from supply voltage.
42 Endress+Hauser
5.6 Operation via SFX100

Compact, flexible and robust industry handheld terminal for remote parametrization and measured
value inspection via the HART current output (4-20mA).
For details refer to Operating Instructions BA00060S/04/EN.
5.7 FieldCare
FieldCare is an FDT-based system asset management tool from Endress+Hauser. With FieldCare,
you can configure all Endress+Hauser devices as well as devices from other manufacturers that
support the FDT standard. Hardware and software requirements you can find on the internet:
www.endress.com → select your country → Search: FieldCare → FieldCare → Technical Data.
FieldCare supports the following functions:
• Configuration of transmitters in online operation
• Loading and saving device data (upload/download)
• HistoROM®/M-DAT analysis
• Documentation of the measuring point
Connection options:
• HART via Commubox FXA195 and the USB interface of a computer
• HART via Fieldgate FXA520
! Note!
• → ä 26, Section 4.2.6 "Connecting Commubox FXA195".
• Further information on the FieldCare can be found on the Internet (http://www.endress.com,
Download → Search for: FieldCare).
Endress+Hauser 43
5.8 Locking/unlocking operation

Once you have entered all the parameters, you can lock your entries against unauthorised and
undesired access.
You have the following possibilities for locking/unlocking the operation:
• Via a DIP-switch on the electronic insert, locally on the display.
• Via the on-site display (optional)
• Via digital communication.
The -symbol on the on-site display indicates that operation is locked. Parameters which refer to
how the display appears, e.g. LANGUAGE and DISPLAY CONTRAST can still be altered.
! Note!
• If operation is locked by means of the DIP-switch, you can only unlock operation again by means
of the DIP-switch. If operation is locked by means of the on-site display or remote operation e.g.
FieldCare, you can only unlock operation again by means of the on-site display or remote
operation.
The table provides an overview of the locking functions:
Locking via View/read Modify/write via1) Unlocking via

parameter
On-site Remote DIP-switch On-site Remote
display operation display operation
DIP-switch Yes No No Yes No No
On-site display Yes No No No Yes Yes
Remote operation Yes No No No Yes Yes
1) Parameters which refer to how the display appears, e.g. LANGUAGE and DISPLAY CONTRAST can still be altered.
5.8.1 Locking/unlocking operation locally via DIP-switch

Damping [t]
Damping [t]
➀
➁ ➂
on on
1 2
PC
1 2 1 2
off off
R
HART
250002271-–
FIELD COMMUNICATION PROTOCOL
HW-Version: 1
SW-Version: 2
– + E
Fig. 34: DIP-switch position "Hardware locking" on the electronic insert

1 If necessary, remove on-site display (optional)
2 DIP-switch is at "on": operation is locked.
3 DIP-switch is at "off": operation is unlocked (operation possible)
44 Endress+Hauser
5.8.2 Locking/unlocking operation via on-site display or remote

operation
Description
Locking operation 1. Select INSERT PIN NO. parameter,

Menu path: OPERATING MENU → OPERATION → INSERT PIN NO.
2. To lock operation, enter a number for this parameter between 0...9999 that is ≠100.
Unlocking operation 1. Select INSERT PIN NO. parameter.

2. To unlock operation, enter "100" for the parameter.
5.9 Factory setting (reset)

By entering a certain code, you can completely, or partially, reset the entries for the parameters to
the factory settings. (→ For factory settings refer to the Operating Instructions BA00274P "Cerabar
S/Deltabar S/Deltapilot S, Description of device functions". → ä 2, "Overview documentation".)
Enter the code by means of the ENTER RESET CODE parameter (Menu path: (GROUP SELECTION
→) OPERATING MENU → OPERATING).
There are various reset codes for the device. The following table illustrates which parameters are
reset by the particular reset codes. Operation must be unlocked to reset parameters (→ ä 45,
Section 5.9).
! Note!
Any customer-specific configuration carried out by the factory is not affected by a reset (customer-
specific configuration remains). If, after a reset, you wish the parameters to be reset to the factory
settings, please contact Endress+Hauser Service.
Reset code Description and effect

1846 Display reset
– This reset resets all parameters which have to do with how the display appears (DISPLAY
group).
– Any simulation which may be running is ended.
– The device is restarted.
62 PowerUp reset (warm start)

– This reset resets all the parameters in the RAM. Data are read back anew from the
EEPROM (processor is initialised again).
2710 Measuring mode level reset

– Depending on the settings for the LEVEL MODE, LIN MEASURAND,
LINdMEASURAND or COMB. MEASURAND parameters, the parameters needed for
this measuring task will be reset.
Example LEVEL MODE = linear and LIN. MEASURAND = Height
• HEIGHT UNIT = m
• CALIBRATION MODE = wet
• EMPTY CALIB. = 0
• FULL CALIB. = Sensor end value converted to mH2O, e.g. 5.99 mH2O for a 500 mbar
(7,5 psi) sensor
333 User reset

– Affects the following parameters:
– Function group POSITION ADJUSTMENT
– Function group BASIC SETUP, except for the customer-specific units
– Function group EXTENDED SETUP
– Function group TOTALIZER SETUP
– Group OUTPUT
– Function group HART DATA: BUS ADDRESS and PREAMBLE NUMBER
Endress+Hauser 45
Reset code Description and effect
7864 Total reset

– Affects the following parameters:
– Function group POSITION ADJUSTMENT
– Function group BASIC SETUP
– Function group EXTENDED SETUP
– Function group LINEARISATION (an existing linearisation table is erased)
– Function group TOTALIZER SETUP
– Group OUTPUT
– Function group PEAK HOLD INDICATOR
– Function group HART DATA
– All configurable messages ("Error" type) are set to factory setting.
→ ä 63, Section 8.1 "Messages" and page → ä 72, Section 8.2 "Response of outputs
to errors".
– Function group USER LIMITS
– Function group SYSTEM 2
8888 HistoROM reset

The measured value memory and event memory are cleared. During the reset, the
HistoROM must be attached to the electronic insert.
46 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Commissioning
6 Commissioning
# Warning!
• If a pressure smaller than the minimum permitted pressure is present at the device, the messages
"E120 Sensor low pressure" and "E727 Sensor pressure error - overrange" are output in
succession.
• If a pressure greater than the maximum permitted pressure is present at the device, the messages
"E115 Sensor overpressure" and "E727 Sensor pressure error - overrange" are output in
succession.
• Messages E727, E115 and E120 are "Error"-type messages and can be configured as a "Warning"
or an "Alarm". These messages are configured as "Warning" messages at the factory. This setting
prevents the current output from assuming the set alarm current value for applications (e.g.
cascade measurement) where the user is consciously aware of the fact that the sensor range can
be exceeded
• We recommend setting messages E727, E115 and E120 to "Alarm" in the following instances:
– The sensor range does not have to be exceeded for the measuring application.
– Position adjustment has to be carried out that has to correct a large measured error as a result
of the orientation of the device (e.g. devices with a diaphragm seal).
! Note!
The device is configured for the Pressure measuring mode as standard. The measuring range and
the unit in which the measured value is transmitted correspond to the specifications on the
nameplate.
6.1 Function check

Carry out a post-installation and a post-connection check as per the checklist before commissioning
the device.
• "Post-installation check" checklist → see Section 3.4
• "Post-connection check" checklist → see Section 4.5
6.2 Selecting language and measuring mode
6.2.1 On-site operation

The LANGUAGE and MEASURING MODE parameters are located on the top menu level. → See
also → ä 37, Section 5.4.1 "General structure of the operating menu".
The following measuring modes are available:
• Pressure
• Level
• Flow
6.2.2 Digital communication

The MEASURING MODE parameter is displayed in the digital communication in the QUICK
SETUP menus and in the BASIC SETUP function group (OPERATING MENU → SETTINGS →
BASIC SETUP).
The following measuring modes are available:
• Pressure
• Level
• Flow
The LANGUAGE parameter is arranged in the DISPLAY group (OPERATING MENU → DISPLAY).
• Use the LANGUAGE parameter to select the menu language for the on-site display.
• Select the menu language for FieldCare by means of the "Language Button" in the configuration
window. Select the menu language for the FieldCare frame via the "Extra" menu → "Options" →
"Display" → "Language".
Endress+Hauser 47
Commissioning Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
6.3 Position adjustment

Due to the orientation of the device, there may be a shift in the measured value, i.e. when the
container is empty or partly filled, the measured value parameter does not display zero. There are
three options to choose from when performing position adjustment.
(Menu path: (GROUP SELECTION →) OPERATING MENU → SETTINGS → POSITION
ADJUSTMENT)
Parameter name Description
POS. ZERO ADJUST (685) Position adjustment – the pressure difference between zero (set point) and the measured
Entry pressure need not be known.
Example:
– MEASURED VALUE = 2.2 mbar (0,032 psi)
– Correct the MEASURED VALUE via the POS. ZERO ADJUST parameter with the
"Confirm" option. This means that you are assigning the value 0.0 to the pressure
present.
– MEASURED VALUE (after pos. zero adjust) = 0.0 mbar
– The current value is also corrected.
The CALIB. OFFSET parameter displays the resulting pressure difference (offset) by which
the MEASURED VALUE was corrected.
Factory setting:
0.0
POS. INPUT VALUE (563) Position adjustment – the pressure difference between zero (set point) and the measured
Entry pressure need not be known. To correct the pressure difference, you need a reference
measurement value (e. g. from a reference device).
Example:
– For the POS. INPUT VALUE parameter, specify the desired set point for the
MEASURED VALUE, e.g. 2.0 mbar (0,029 psi).
(MEASURED VALUEnew = POS. INPUT VALUE)
– MEASURED VALUE (after entry for POS. INPUT VALUE) = 2.0 mbar (0,029 psi)
– The CALIB. OFFSET parameter displays the resulting pressure difference (offset) by
which the MEASURED VALUE was corrected.
CALIB. OFFSET = MEASURED VALUEold – POS. INPUT VALUE,
here: CALIB. OFFSET = 0.5 mbar (0,0073 psi) – 2.0 mbar (0,029 psi) = – 1.5 mbar
(0,022 psi))
Factory setting:
0.0
CALIB. OFFSET (319) Position adjustment – the pressure difference between zero (set point) and the measured
Entry pressure is known.
Example:
– Via the CALIB. OFFSET parameter, enter the value by which the MEASURED VALUE
should be corrected. To correct the MEASURED VALUE to 0.0 mbar, you must enter
the value 2.2 here.
(MEASURED VALUE new = MEASURED VALUEold – CALIB. OFFSET)
– MEASURED VALUE (after entry for calib. offset) = 0.0 mbar
Factory setting:
0.0
48 Endress+Hauser
6.4 Flow measurement
6.4.1 Preparatory steps
! Note!
• The Deltabar S PMD70 or PMD75 is usually used for flow measurement.
• Before calibrating the Deltabar S, the impulse piping must be cleaned and filled with fluid. → See
the following table.
Valves Meaning Preferred installation
1 Close 3.
2 Fill measuring system with fluid. 6 7

Open A, B, 2, 4. Fluid flows in. I
3 Clean impulse piping if necessary1): + –

– by blowing out with compressed air in the case of gases
II 3
– by rinsing out in the case of liquids.
Close 2 and 4. Block off device. 2 4
Open 1 and 5.1 Blow out/rinse out impulse + –

piping. A B
Close 1 and 5.1 Close valves after cleaning.
4 Vent device.
Open 2 and 4. Introduce fluid.

Close 4. Close negative side.
Open 3. Balance positive and negative

side.
A B
Open 6 and 7 briefly, then Fill device completely with
6 7
close them again. fluid and remove air. + I
5 Carry out pos. zero adjustment if the following conditions are
met. If the conditions are not met, then do not carry out the III III
+ –
pos. zero adjustment until after step 6. → ä 51, II
3
Section 6.4.3 and → ä 48, Section 6.3.
Conditions: 2 4
1 5
– The process cannot be blocked off.
– The tapping points (A and B) are at the same geodetic
height. P01-xMD7xxxx-11-xx-xx-xx-002
6 Set measuring point in operation. Fig. 35: Above: preferred installation for gases
Below: preferred installation for liquids
Close 3. Shut off positive side from
negative side. I Deltabar S, PMD70 or PMD75
II Three-valve manifold
Open 4. Connect negative side. Separator
1, 5 Drain valves
Now
2, 4 Inlet valves
– 11, 3, 51, 6 and 7 are closed.
3 Equalising valve
– 2 and 4 are open.
6, 7 Vent valves on Deltabar S
– A and B open (if present).
A, B Shut-off valves
7 Carry out pos. zero adjustment if the flow can be blocked off.
In this case, step 5 is not applicable.
→ ä 51, Section 6.4.3 and → ä 48, Section 6.3
8 Carry out calibration. → ä 50, Section 6.4.2.
1) for arrangement with 5 valves
Endress+Hauser 49
6.4.2 Information on flow measurement

In the "Flow" measuring mode, the device determines a volume or mass flow value from the
differential pressure measured. The differential pressure is generated by means of primary elements
such as pitot tubes or orifice plates and depends on the volume or mass flow. Four flow measuring
modes are available: volume flow, norm volume flow (European norm conditions), standard volume
flow (American standard conditions) and mass flow.
In addition, the Deltabar S software is equipped with two totalizers as standard. The totalizers add
up the volume or the mass flow. The counting function and the unit can be set separately for both
totalizers. The first totalizer (totalizer 1) can be reset to zero at any time while the second
(totalizer 2) totalises the flow from commissioning onwards and cannot be reset.
! Note!
• There is a Quick Setup menu for each of the measuring modes Pressure, Level and Flow which
guides you through the most important basic functions. With the setting in the MEASURING
MODE parameter, you specify which Quick Setup menu should be displayed. → See also
→ ä 47, Section 6.2 "Selecting language and measuring mode".
• For a detailed description of the parameters see the Operating Instructions BA00274P "Cerabar
S/Deltabar S/Deltapilot S, Description of device functions"
– Table 6, POSITION ADJUSTMENT
– Table 12, BASIC SETUP
– Table 17, EXTENDED SETUP
– Table 20, TOTALIZER SETUP.
→ See also → ä 2, section "Overview documentation".
• For flow measurement, select the "Flow" option by means of the MEASURING MODE parameter.
The operating menu is structured appropriately. → Section 10.1.
50 Endress+Hauser
6.4.3 Quick Setup menu for the Flow measuring mode
Measured value
1)
GROUP SELECTION
1) 1)
2)
MEASURING MODE
Pressure Level Flow
POS. ZERO ADJUST
MAX FLOW
MAX. PRESS. FLOW

1) Display via on-site display only
2) Display via ToF Tool, FieldCare and
HART handheld terminal only DAMPING VALUE
Fig. 36: Quick Setup menu for the Flow measuring mode
On-site operation Digital communication

Measured value display Measured value display
On-site display: Switch from the measured value display Select QUICK SETUP menu.
to GROUP SELECTION with F.
GROUP SELECTION MEASURING MODE

Select MEASURING MODE. Select "Flow" option.
MEASURING MODE
Select "Flow" option.
GROUP SELECTION
Select QUICK SETUP menu.
POS. ZERO ADJUST POS. ZERO ADJUST
Due to orientation of the device, there may be a shift in Due to orientation of the device, there may be a shift in
the measured value. You correct the MEASURED the measured value. You correct the MEASURED
VALUE via the POS. ZERO ADJUST parameter with the VALUE via the POS. ZERO ADJUST parameter with the
"Confirm" option, i. e. you assign the value 0.0 to the "Confirm" option, i. e. you assign the value 0.0 to the
pressure present. pressure present.
MAX. FLOW MAX. FLOW

Enter maximum flow of primary device. (→ See also Enter maximum flow of primary device. (→ See also
layout sheet of primary device). layout sheet of primary device).
MAX. PRESS FLOW MAX. PRESS FLOW

Enter maximum pressure of primary device. Enter maximum pressure of primary device.
(→ See also layout sheet of primary device). (→ See also layout sheet of primary device).
DAMPING TIME DAMPING TIME
Enter damping time (time constant τ). The damping Enter damping time (time constant τ). The damping
affects the speed at which all subsequent elements, such affects the speed at which all subsequent elements, such
as the on-site display, measured value and current as the on-site display, measured value and current
output react to a change in the pressure. output react to a change in the pressure.
! Note!
For on-site operation, → ä 32, Section 5.2.3 "Function of the operating elements – on-site display
connected" and → ä 37, Section 5.4 "On-site operation – on-site display connected".
Endress+Hauser 51
6.5 Level measurement
Open container
! Note!
• The Deltabar S PMD70, PMD75, FMD76 and FMD77 are suitable for level measurement in an
open container.
• FMD76 and FMD77: the device is ready for calibration immediately after opening a shut-off valve
(may or may not be present).
• PMD70 and PMD75: before calibrating the device, the impulse piping must be cleaned and filled
with fluid. → See the following table.
Valves Meaning Installation
1 Fill container to a level above the lower tap.
2 Fill measuring system with fluid.
Open A. Open shut-off valve.
3 Vent device. +
Open 6 briefly, then close it Fill device completely with 6
again. fluid and remove air. II I
4 Set measuring point in operation.

B + – patm
Now
– B and 6 are closed. A
– A is open.
Carry out calibration. → ä 55, Section 6.5.2.

5
Fig. 37: Open container
I Deltabar S, PMD70 or PMD75
II Separator
6 Vent valves on Deltabar S
A Shut-off valve
B Drain valve
52 Endress+Hauser
Closed container
! Note!
• All Deltabar S versions are suitable for level measurement in closed containers.
• FMD76 and FMD77: the device is ready for calibration immediately after opening the shut-off
valves (may or may not be present).
• FMD78: the device is ready for calibration immediately.

B
negative side.
Open A and B. Open shut-off valves. + A

3 Vent positive side (empty negative side if necessary).
Open 2 and 4. Introduce fluid on positive 6 7

side. I
Open 6 and 7 briefly, then Fill positive side completely
close them again. with fluid and remove air. + –
II
4 Set measuring point in operation. III 3 III
Now 2 4
– 3, 6 and 7 are closed.
1 5
– 2, 4, A and B are open.
5 Carry out calibration. → ä 55, Section 6.5.2. P01-xMD7xxxx-11-xx-xx-xx-004
Fig. 38: Closed container

I Deltabar S, PMD70 and PMD75
III Separator
1, 2 Drain valves
2, 4 Inlet valves
3 Equalising valve
6, 7 Vent valve on Deltabar S
A, B Shut-off valve
Endress+Hauser 53
Closed container with superimposed steam
! Note!
• All Deltabar S versions are suitable for level measurement in containers with superimposed steam.
• FMD76 and FMD77: the device is ready for calibration immediately after opening the shut-off
valves (may or may not be present).
Open A and B. Open shut-off valves.
B
Fill the negative impulse piping to the level of the condensate
trap. + A
3 Vent device.
Open 2 and 4. Introduce fluid. 6 7

Close 4. Close negative side. I
Open 3. Balance positive and negative + –

side. II
III 3 III
close them again. fluid and remove air. 2 4
4 Set measuring point in operation. 1 5

negative side.
Fig. 39: Closed container with superimposed
Open 4. Connect negative side. steam
Now I Deltabar S, PMD70 and PMD75
– 3, 6 and 7 are closed. II Three-valve manifold
– 2, 4, A and B are open. III Separator
1, 5 Drain valves
5 Carry out calibration. → ä 55, Section 6.5.2.
2, 4 Inlet valves
3 Equalising valve
A, B Shut-off valves
54 Endress+Hauser
6.5.2 Information on level measurement
! Note!
• The Flow, Level and Pressure operating modes each have a quick setup menu which guides you
through the most important basic functions. → ä 57 for the "Level" quick setup menu.
• Furthermore, the three level modes "Level Easy Pressure", "Level Easy Height" and "Level
Standard" are available to you for level measurement. You can select from the "Linear", "Pressure
linearized" and "Height linearized" level types for the "Level Standard" level mode. The table in
the "Overview of level measurement" section below provides an overview of the various
measuring tasks.
– In the "Level Easy Pressure" and "Level Easy Height" level modes, the values entered are not
tested as extensively as in the "Level Standard" level mode. The values entered for EMPTY
CALIB./FULL CALIB., EMPTY PRESSURE/FULL PRESSURE, EMPTY HEIGHT/FULL
HEIGHT and SET LRV/SET URV must have a minimum interval of 1% for the "Level Easy
Pressure" and "Level Easy Height" level modes. The value will be rejected with a warning
message if the values are too close together. Further limit values are not checked; i.e. the values
entered must be appropriate for the sensor and the measuring task so that the measuring device
can measure correctly.
– The "Level Easy Pressure" and "Level Easy Height" level modes encompass fewer parameters
than the "Level Standard" mode and are used for quick and easy configuration of a level
application.
– Customer-specific units of fill level, volume and mass or a linearization table may only be
entered in the "Level Standard" level mode.
– Where the device is intended for use as a subsystem in a safety function (SIL), a "Device
configuration with enhanced parameter security" (SAFETY CONFIRM.) is only possible for the
"Level" operating mode in the "Level Easy Pressure" level mode. All parameters previously
entered are checked after a password is entered. Once the "Level Easy Height" or "Level
Standard" has been selected, the configuration will first have to be reset to the ex-works setting
using the RESET parameter (menu path: (GROUP SELECTION →) OPERATING MENU →
OPERATION) using the reset code "7864". → For further information see the Deltabar S
(SD00189P) Functional Safety Manual.
• See the Operating Instructions BA00274P "Cerabar S/Deltabar S/Deltapilot S, Description of
device functions". See also → ä 2, "Overview documentation" section.
Endress+Hauser 55
6.5.3 Overview of level measurement
Measuring task LEVEL Measured Description Comment Measured value

SELECTION/ variable options display
LEVEL MODE
The measured variable is LEVEL SELECTION: Via OUTPUT UNIT – Calibration with reference – Incorrect entries are The measured value
in direct proportion to the Level Easy Pressure parameter: %, level, pressure – wet calibration, possible display and the LEVEL
measured pressure. volume or mass see Operating Instructions – SIL mode possible BEFORE LIN parameter
Calibration is performed units. BA00274P. – Customised units are show the measured value.
by entering two pressure- – Calibration without not possible
level value pairs. reference pressure – dry
calibration, see Operating
Instructions BA00274P.
The measured variable is LEVEL SELECTION: Via OUTPUT UNIT – Calibration with reference – Incorrect entries are The measured value
in direct proportion to the Level Easy Height parameter: %, level, pressure – wet calibration, possible display and the LEVEL
measured pressure. volume or mass see Operating Instructions – SIL mode not possible BEFORE LIN parameter
Calibration is performed units. BA00274P. – Customised units are show the measured value.
by entering the density – Calibration without not possible
and two height-level value reference pressure – dry
pairs. calibration, see Operating
The measured variable is LEVEL SELECTION: Via LIN. – Calibration with reference – Incorrect entries are The measured value
in direct proportion to the Level standard/ MEASURAND pressure – wet calibration, rejected by the device display and the LEVEL
measured pressure. LEVEL MODE: parameter: see Operating Instructions – SIL mode not possible BEFORE LIN parameter
Linear – % (level) BA00274P. – Customised level, show the measured value.
– Level – Calibration without volume and mass units
– Volume reference pressure – dry are possible
– Mass calibration, see Operating
The measured variable is LEVEL SELECTION: Via LINd. – Calibration with reference – Incorrect entries are The measured value
not in direct proportion to Level standard/ MEASURAND pressure: semiautomatic rejected by the device display and the
the measured pressure as, LEVEL MODE: parameter: entry of linearisation table, – SIL mode not possible TANK CONTENT
for example, with Pressure linearized – Pressure + % see Operating Instructions – Customised level, parameter show the
containers with a conical – Pressure + volume BA00274P. volume and mass units measured value.
outlet. A linearisation table – Pressure + mass – Calibration without are possible
must be entered for the reference pressure: manual
calibration. entry of linearisation table,
see Operating Instructions
BA00274P.
– Two measured variables LEVEL SELECTION: Via COMB. – Calibration with reference – Incorrect entries are The measured value
are required or Level standard/ MEASURAND pressure: wet calibration rejected by the device display and the
– The container shape is LEVEL MODE: parameter: and semiautomatic entry of – SIL mode not possible TANK CONTENT
given by value pairs, Height linearized – Height + volume linearisation table, see – Customised level, parameter show the 2nd
such as height and – Height + mass Operating Instructions volume and mass units measured value (volume,
volume. – Height + % BA00274P. are possible mass or %).
The 1st measured variable – %-Height + – Calibration without
%-height or height must be volume reference pressure: dry The LEVEL BEFORE LIN
in direct proportion to the – %-Height + mass calibration and manual parameter displays the 1st
measured pressure. The – %-Height + % entry of linearisation table, measured value (%-height
2nd measured variable see Operating Instructions or height).
volume, mass or % need BA00274P.
not to be in direct
proportion to the
measured pressure. A
linearisation table must be
entered for the 2nd
measured variable. The
2nd measured variable is
assigned to the 1st
measured variable by
means of this table.
56 Endress+Hauser
6.5.4 Quick Setup menu for Level measuring mode
! Note!
• Some parameters are only displayed if other parameters are appropriately configured. For
example, the EMPTY CALIB. parameter is only displayed in the following cases:
– LEVEL SELECTION "Level Easy Pressure" and CALIBRATION MODE "Wet"
– LEVEL SELECTION "Level Standard", LEVEL MODE "Linear" and
CALIBRATION MODE "WET"
You can find the LEVEL MODE parameter in the BASIC SETTINGS function group (menu path:
(GROUP SELECTION →) OPERATING MENU → SETTINGS → BASIC SETTINGS).
• The following parameters are set to the following values in the factory:
– LEVEL SELETION: Level Easy Pressure
– CALIBRATION MODE: Wet
– OUTPUT UNIT or LIN. MEASURAND: %
– EMPTY CALIB.: 0.0
– FULL CALIB.: 100.0
– SET LRV (BASIC SETTINGS group): 0.0 (corresponds to 4 mA value)
– SET URV (BASIC SETTINGS group): 100.0 (corresponds to 20 mA value).
• The quick setup is suitable for simple and quick commissioning. If you wish to make more
complex settings, e.g. change the unit from "%" to "m", you will have to calibrate using the BASIC
SETTINGS group. → See Operating Instructions BA00274P or → ä 2, "Overview
documentation" section.
Measured value
1)
GROUP SELECTION
1) 1)
2)
LEVEL SELECTION
MEASURING MODE
Pressure Level Flow
LEVEL SELECTION
POS. ZERO ADJUST

3)
2) Display via FieldCare and
EMPTY CALIB.
HART handheld terminal only
3)
3) – LEVEL SELECTION "Level Easy Pressure" and
FULL CALIB.
CALIBRATION MODE "Wet"
– LEVEL SELECTION = "Level Standard",
LEVEL MODE = "Linear" and
DAMPING VALUE
CALIBRATION MODE = "Wet"
Fig. 40: Quick Setup menu for the Level measuring mode


Select MEASURING MODE. Select "Level" option.
MEASURING MODE
Select "Level" option.
LEVEL SELECTION LEVEL SELECTION
Select level mode. For an overview → ä 56. Select level mode. For an overview → ä 56.
GROUP SELECTION
Endress+Hauser 57

EMPTY CALIB. 1) EMPTY CALIB. 1

Enter level for the lower calibration point. Enter level for the lower calibration point.
For this parameter, enter a level value which is assigned For this parameter, enter a level value which is assigned
to the pressure present at the device. to the pressure present at the device.
FULL CALIB. 1 FULL CALIB. 1

Enter level for the upper calibration point. Enter level for the upper calibration point.
For this parameter, enter a level value which is assigned For this parameter, enter a level value which is assigned
to the pressure present at the device. to the pressure present at the device.

1) – LEVEL SELECTION "Level Easy Pressure" and CALIBRATION MODE "Wet"

– LEVEL SELECTION "Level Standard", LEVEL MODE "Linear" and CALIBRATION MODE "Wet"
! Note!
58 Endress+Hauser
6.6 Differential pressure measurement
! Note!
• The Deltabar S PMD70, PMD75 and FMD78 are usually used for differential pressure
measurement.
Valves Meaning Preferred installation
1 Close 3.
2 Fill measuring system with fluid. 6 7

Open A, B, 2, 4. Fluid flows in. I
3 Clean impulse piping if necessary:1) + –

– by blowing out with compressed air in the case of gases
II 3
– by rinsing out in the case of liquids.
Close 2 and 4. Block off device. 2 4
Open 1 and 5.1 Blow out/rinse out impulse + –

piping. A B
Close 1 and 5.1 Close valves after cleaning.
4 Vent device.
Open 2 and 4. Introduce fluid.

Close 4. Close negative side.
Open 3. Balance positive and negative

side.
A B
6 7
close them again. fluid and remove air. + I
5 Set measuring point in operation.
III + – III
II
negative side. 3
Open 4. Connect negative side. 2 4

1 5
Now
– 11, 3, 51, 6 and 7 are closed.
– 2 and 4 are open. P01-xMD7xxxx-11-xx-xx-xx-002
– A and B open (if present). Fig. 41: Above: preferred installation for gases
Below: preferred installation for liquids
6 Carry out calibration if necessary. → ä 60, Section 6.6.2.
I Deltabar S, PMD70 or PMD75
III Separator
1, 5 Drain valves
2, 4 Inlet valves
3 Equalising valve
A, B Shut-off valve
1) for arrangement with 5 valves
Endress+Hauser 59
6.6.2 Information on differential pressure measurement
! Note!
• There is a Quick Setup menu for each of the measuring modes Pressure, Level and Flow which
guides you through the most important basic functions. With the setting in the MEASURING
MODE parameter, you specify which Quick Setup menu should be displayed. → ä 47,
Section 6.2 "Selecting language and measuring mode".
• For a detailed description of the parameters see the Operating Instructions BA00274P "Cerabar
S/Deltabar S/Deltapilot S, Description of device functions"
– Table 6, POSITION ADJUSTMENT
– Table 7, BASIC SETUP
– Table 15, EXTENDED SETUP
• For differential pressure measurement, select the "Pressure" option by means of the MEASURING
MODE parameter. The operating menu is structured appropriately. → See also Section 10.1.
6.6.3 Quick Setup menu for Pressure measuring mode
Measured value
1)
GROUP SELECTION
1) 1)
2)
MEASURING MODE
Pressure Level Flow

POS. ZERO ADJUST
SET LRV
1) Display via on-site display only SET URV

HART handheld terminal only DAMPING VALUE
Fig. 42: Quick Setup menu for Pressure measuring mode


Select MEASURING MODE. Select "Pressure" option.
MEASURING MODE
Select "Pressure" option.
GROUP SELECTION

SET LRV SET LRV

Set the measuring range (enter 4 mA value). Set the measuring range (enter 4 mA value).
Specify a pressure value for the lower current value Specify a pressure value for the lower current value
(4 mA value). A reference pressure does not have to be (4 mA value). A reference pressure does not have to be
present at the device. present at the device.
60 Endress+Hauser
SET URV SET URV

Set the measuring range (enter 20 mA value). Set the measuring range (enter 20 mA value).
The pressure for the upper current value (20 mA value) The pressure for the upper current value (20 mA value)
is present at device. With the "Confirm" option, you is present at device. With the "Confirm" option, you
assign the upper current value to the pressure value assign the upper current value to the pressure value
present. present.

! Note!
Endress+Hauser 61
Maintenance Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
7 Maintenance
Deltabar S requires no maintenance.
7.1 Exterior cleaning

Please note the following points when cleaning the device:
• The cleaning agents used should not attack the surface and the seals.
• Mechanical damage to the process isolating diaphragm, e.g. due to pointed objects, must be
avoided.
• Observe degree of protection. See therefor nameplate if necessary (→ ä 6).
62 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Trouble-shooting
8 Trouble-shooting
8.1 Messages
The following table lists all the possible messages that can occur.
The device differentiates between the error types "Alarm", "Warning" and "Error". You may specify
whether the instrument should react as if for an "Alarm" or "Warning" for "Error" messages.
→ See "Error type/NA 64" column and Section 8.2 "Response of outputs to errors".
In addition, the "Error type/NA 64" column classifies the messages in accordance with NAMUR
Recommendation NA 64:
• Break down: indicated with "B"
• Maintenance need: indicated with "C" (check request)
• Function check: indicated with "I" (in service)
Error message display on the on-site display:
• The measured value display shows the message with the highest priority. → See "Priority"
column.
• The ALARM STATUS parameter shows all the messages present in descending order of priority.
You can scroll through all the messages present with the S-key or O-key.
Message display via digial communication:
• The ALARM STATUS parameter shows the message with the highest priority. → See "Priority"
column.
! Note!
• If the device detects a defect in the on-site display during initialization, special error messages are
generated. → For the error messages, → ä 71, Section 8.1.1 "On-site display error messages".
• For support and further information, please contact Endress+Hauser Service.
• → See also Section 8.4 ff.
Code Error type/ Corresponds Message/description Cause Measure Prio

NA 64 NE 107 rity
101 (A101) Alarm Failure (F) B>Sensor electronic EEPROM – Electromagnetic effects are greater – Wait a few minutes. 17
B error than specifications in the – Restart the device. Perform reset
technical data. (→ See Section 9.) (Code 62).
This message normally only – Block off electromagnetic effects
appears briefly. or eliminate source of
disturbance.
– Sensor defect. – Replace sensor.
102 (W102) Warning Maintenance C>Checksum error in – Main electronics defect. Correct – Replace main electronics. 53
C request (M) EEPROM: peakhold segment measurement can continue as
long as you do not need the peak
hold indicator function.
106 (W106) Warning Funktion C>Downloading - please wait – Downloading. – Wait for download to complete. 52
C check (C)
110 (A110) Alarm Failure (F) B>Checksum error in – The supply voltage is – Reestablish supply voltage. 6
B EEPROM: configuration disconnected when writing. Perform reset (Code 7864) if
segment necessary. Carry out calibration
again.
– Electromagnetic effects are greater – Block off electromagnetic effects

than specifications in the or eliminate sources of
technical data. disturbance.
(→ See Section 9.)
– Main electronics defect. – Replace main electronics.
113 (A113) Alarm Failure (F) B>ROM failure in transmitter – Main electronics defect. – Replace main electronics. 1
B electronic
Endress+Hauser 63
Trouble-shooting Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART

NA 64 NE 107 rity
115 (E115) Error Out of B>Sensor overpressure – Overpressure present. – Reduce pressure until message 29
B specification disappears.
factory (S)
setting:
Warning C
116 (W116) Warning Maintenance C>Download error, repeat – The file is defect. – Use another file. 36
C request (M) download
– During the download, the data are – Check cable connection PC –
not correctly transmitted to the transmitter.
processor, e.g. because of open – Block off electromagnetic effects
cable connections, spikes (ripple) or eliminate sources of
on the supply voltage or disturbance.
electromagnetic effects. – Perform reset (Code 7864) and
carry out calibration again.
– Repeat download.
120 (E120) Error Out of B>Sensor low pressure – Pressure too low. – Increase pressure until message 30
B specification disappears.
factory (S)
setting:
Warning C
121 (A121) Alarm Failure (F) B>Checksum error in factory – Main electronics defect. – Replace main electronics. 5
B segment of EEPROM
122 (A122) Alarm Failure (F) B>Sensor not connected – Cable connection sensor –main – Check cable connection and 13
B electronics disconnected. repair if necessary.
– Electromagnetic effects are greater – Block off electromagnetic effects
than specifications in the or eliminate source of
(→ See Section 9.)

130 (A130) Alarm Failure (F) B>EEPROM is defect. – Main electronics defect. – Replace main electronics. 10
B
131 (A131) Alarm Failure (F) B>Checksum error in – Main electronics defect. – Replace main electronics. 9
B EEPROM: min/max segment
132 (A132) Alarm Failure (F) B>Checksum error in – Main electronics defect. – Replace main electronics. 7
B totalizer EEPROM
133 (A133) Alarm Failure (F) B>Checksum error in History – An error occurred when writing. – Perform reset (Code 7864) and 8
B EEPROM carry out calibration again.
– Main electronics defect. – Replace electronics.
602 (W602) Warning Funktion C>Linearisation curve not – The linearisation table is not – Add to linearisation table or 57
C check (C) monotone monotonic increasing or perform linearisation again.
decreasing.
64 Endress+Hauser

NA 64 NE 107 rity
604 (W604) Warning

C
Funktion
check (C)
C>Linearisation table not
valid. Less than 2 points or
! Note!
From software version "02.10.xx" onwards, there is no min. span for the Y-
58
points too close points.
– The linearisation table consists of – Add to linearisation table. If

less than 2 points. necessary, perform linearisation
again.
– At least 2 points in the – Correct linearisation table and

linearisation table are too close accept again.
together. A minimum gap of 0.5
% of the distance between two
points must be maintained.
Spans for the "Pressure linearized"
option: HYDR. PRESS MAX. –
HYDR. PRESS MIN.; TANK
CONTENT MAX. – TANK
CONTENT MIN.
Spans for the "Height linearized"
option: LEVEL MAX – LEVEL
MIN; TANK CONTENT MAX. –
TANK CONTENT MIN.
613 (W613) Warning Funktion I>Simulation is active – Simulation is switched on, i.e. the – Switch off simulation. 60
I check (C) device is not measuring at
present.
620 (E620) Error Out of C>Current output out of The current is outside the permitted – Check pressure applied, 49
C specification range range 3.8 to 20.5 mA. reconfigure measuring range if
Factory (S) – The pressure applied is outside necessary (→ See also Operating
setting: Instructions BA00274P or these
the set measuring range (but
Warning C Operating Instructions → ä 2.)
within the sensor range).
– Perform reset (Code 7864) and
carry out calibration again.
– Loose connection at sensor cable – Wait a short period of time and

tighten the connection, or avoid
loose connection.
700 (W700) Warning Maintenance C>Last configuration not – An error occurred when writing – Perform reset (Code 7864) and 54
C request (M) stored or reading configuration data or carry out calibration again.
the power supply was
disconnected.

701 (W701) Warning Funktion C>Measuring chain config. – The calibration carried out would – Carry out calibration again. 50
C check (C) exceeds sensor range result in the sensor nominal
operating range being undershot
or overshot.
702 (W702) Warning Maintenance C>HistoROM data not – Data were not written correctly to – Repeat upload. 55
C request (M) consistent. the HistoROM, e.g. if the – Perform reset (Code 7864) and
HistoROM was detached during carry out calibration again.
the writing process.
– HistoROM does not have any – Copy suitable data to the

data. HistoROM. (→ See also → ä 40,
Section 5.5.1 "Copying
configuration data".)
703 (A703) Alarm Failure (F) B>Measurement error – Fault in the main electronics. – Briefly disconnect device from the 22
B power supply.

704 (A704) Alarm Funktion B>Measurement error – Fault in the main electronics. – Briefly disconnect device from the 12
B check (C) power supply.
Endress+Hauser 65

NA 64 NE 107 rity
B power supply.
706 (W706) Warning Maintenance C>Configuration in – Configuration (parameters) in the – Copy data from the device to the 59
C request (M) HistoROM and device not HistoROM and in the device is HistoROM. (→ See also
identical not identical. → ä 40, Section 5.5.1 "Copying
configuration data".)
– Copy data from the HistoROM to
the device. (→ See also → ä 40,
Section 5.5.1 "Copying
configuration data".) The message
remains if the HistoROM and the
device have different software
versions. The message goes out if
you copy the data from the device
to the HistoROM.
– Device reset codes such as 7864
do not have any effect on the
HistoROM. That means that if you
do a reset, the configurations in
the HistoROM and in the device
may not be the same.
707 (A707) Alarm Funktion B>X-VAL. of lin. table out of – At least one X-VALUE in the – Carry out calibration again. (→ 38
B check (C) edit limits. linearisation table is either below See also Operating Instructions
the value for HYDR. PRESS MIN. BA00274P or these Operating
or MIN. LEVEL or above the Instructions → ä 2.)
value for HYDR. PRESS. MAX. or
LEVEL MAX.
710 (W710) Warning Funktion B>Set span too small. Not – Values for calibration (e.g. lower – Adjust calibration to suit sensor. 51
C check (C) allowed. range value and upper range (→ See also Operating
value) are too close together. Instructions BA00274P,
parameter description MINIMUM
SPAN or these Operating
Instructions → ä 2.)
– The sensor was replaced and the – Adjust calibration to suit sensor.
customer-specific configuration – Replace sensor with a suitable
does not suit the sensor. sensor.
– Unsuitable download carried out. – Check configuration and perform

download again.
711 (A711) Alarm Funktion B>LRV or URV out of edit – Lower range value and/or upper – Reconfigure lower range value 37
B check (C) limits range value undershoot or and/or upper range value to suit
overshoot the sensor range limits. the sensor. Pay attention to
position factor.
– The sensor was replaced and the – Reconfigure lower range value
customer-specific configuration and/or upper range value to suit
does not suit the sensor. the sensor. Pay attention to
position factor.
– Replace sensor with a suitable
sensor.

download again.
713 (A713) Alarm Funktion B>100% POINT level out of – The sensor was replaced. – Carry out calibration again. 39
B check (C) edit limits
66 Endress+Hauser

NA 64 NE 107 rity
715 (E715) Error Out of C>Sensor over temperature – The temperature measured in the – Reduce process temperature/ 32
C specification sensor is greater than the upper ambient temperature.
Factory (S) nominal temperature of the
setting: sensor. (→ See also Operating
Warning C Instructions BA00274P,
parameter description Tmax
SENSOR or these Operating

download again.
716 (E716) Error Failure (F) B>process isolating – Sensor defect. – Replace sensor. 24
B diaphragm broken – PMD70, FMD76: Overpressure is – Reduce pressure.
Factory present at minus or plus side of
setting: the device (on-sided overpressure)
Alarm B
717 (E717) Error Out of C>Transmitter over – The temperature measured in the – Reduce ambient temperature. 34
C specification temperature electronics is greater than the
Factory (S) upper nominal temperature of the
setting: electronics (+88 °C (+190 °F)).
Warning
download again.
718 (E718) Error Out of C>Transmitter under – The temperature measured in the – Increase ambient temperature. 35
C specification temperature electronics is smaller than the Insulate device if necessary.
Factory (S) lower nominal temperature of the
setting: electronics (–43 °C (-45 °F)).
Warning C
download again.
719 (A719) Alarm Funktion B>Y-VAL of lin. table out of – At least on Y-VALUE in the – Carry out calibration again. (→ 40
B check (C) edit limits linearisation table is below the See also Operating Instructions
MIN. TANK CONTANT or above BA00274P or these Operating
the MAX. TANK CONTENT. Instruction → ä 2.)
720 (E720) Error Out of C>Sensor under temperature – The temperature measured in the – Increase process temperature/ 33
C specification sensor is smaller than the lower ambient temperature.
Factory (S) nominal temperature of the
setting: sensor. (→ See also Operating
Warning C Instructions BA00274P,
parameter description Tmin
SENSOR or Operating

download again.
loose connection.
721 (A721) Alarm Funktion B>ZERO POSITION level out – LEVEL MIN or LEVEL MAX has – Perform reset (Code 2710) and 41
B check (C) of edit limits been changed. carry out calibration again.
722 (A722) Alarm Funktion B>EMPTY CALIB. or FULL – LEVEL MIN or LEVEL MAX has – Perform reset (Code 2710) and 42
B check (C) CALIB. out of edit limits been changed. carry out calibration again.
723 (A723) Alarm Funktion B>MAX. FLOW out of edit – FLOW-MEAS. TYPE has been – Carry out calibration again. 43
B check (C) limits changed.
Endress+Hauser 67

NA 64 NE 107 rity
725 (A725) Alarm Failure (F) B>Sensor connection error, – Electromagnetic effects are greater – Block off electromagnetic effects 25
B cycle disturbance than specifications in the or eliminate source of
technical data. (→ See Section 9.) disturbance.
– Setscrew loose.
– Retighten setscrew with 1 Nm
(0,74 lbf ft) (see Chap. 3.3.9).
– Sensor or main electronics defect. – Replace sensor or main

electronics.
726 (E726) Error Out of C>Sensor temperature error - – Electromagnetic effects are greater – Block off electromagnetic effects 31
C specification overrange than specifications in the or eliminate source of
Factory (S) technical data. disturbance.
setting: (→ See Section 9.)
Warning C
– Process temperature is outside – Check temperature present,
permitted range. reduce or increase if necessary.
– Sensor defect. – If the process temperature is

within the permitted range,
replace sensor.
727 (E727) Error Out of C>Sensor pressure error - – Electromagnetic effects are greater – Block off electromagnetic effects 28
C specification overrange than specifications in the or eliminate source of
Factory (S) technical data. disturbance.
setting: (→ See Section 9.)
Warning C
– Pressure is outside permitted – Check pressure present, reduce or
range. increase if necessary.
– Sensor defect. – If the pressure is within the

permitted range, replace sensor.
728 (A728) Alarm Failure (F) B>RAM error – Fault in the main electronics. – Briefly disconnect device from the 2
B power supply.
B power supply.
730 (E730) Error Out of C>LRV user limits exceeded – Pressure measured value has – Check system/pressure measured 46
C specification undershot the value specified for value.
Factory (S) the Pmin ALARM WINDOW – Change value for Pmin ALARM
setting: parameter. WINDOW if necessary. (→ See
Warning C also Operating Instructions
BA00274P, parameter description
Pmin ALARM WINDOW or these
Operating Instruction → ä 2.)

loose connection.
731 (E731) Error Out of C>URV user limits exceeded – Pressure measured value has – Check system/pressure measured 45
C specification overshot the value specified for value.
Factory (S) the Pmax ALARM WINDOW – Change value for Pmax ALARM
Pmax ALARM WINDOW or these
Operating Instructions → ä 2.)
68 Endress+Hauser

NA 64 NE 107 rity
732 (E732) Error Out of C>LRV Temp. User limits – Temperature measured value has – Check system/temperature 48
C specification exceeded undershot the value specified for measured value.
Factory (S) the Tmin ALARM WINDOW – Change value for Tmin ALARM
Tmin ALARM WINDOW or these

loose connection.
733 (E733) Error Out of C>URV Temp. User limits – Temperature measured value has – Check system/temperature 47
C specification exceeded overshot the value specified for measured value.
Factory (S) the Tmax ALARM WINDOW – Change value for Tmax ALARM
Tmax ALARM WINDOW or these
B power supply.
B power supply.
B power supply.
B power supply.
740 (E740) Error Maintenance C>Calculation overflow, bad – Level measuring mode: the – Check configuration and carry out 27
C request (M) configuration measured pressure has undershot calibration again if necessary.
Factory the value for HYDR. PRESS. MIN. – Select a device with a suitable
setting: or overshot the value for HYDR. measuring range.
Warning C PRESS MAX.
– Level measuring mode: The – Check configuration and carry out

measured level did not reach the calibration again if necessary.
LEVEL MIN value or exceeded (→ See also Operating
the LEVEL MAX value. Instructions BA00274P,
parameter description LEVEL
MIN. these Operating Instructions
→ ä 2.)
– Flow measuring mode: the – Check configuration and carry out

measured pressure has undershot calibration again if necessary.
the value for MAX. PRESS FLOW. – Select a device with a suitable
measuring range.
741 (A741) Alarm Funktion B>TANK HEIGHT out of edit – LEVEL MIN or LEVEL MAX has – Perform reset (Code 2710) and 44
B check (C) limits been changed. carry out calibration again.
742 (A742) Alarm Failure (F) B>Sensor connection error – Electromagnetic effects are greater – Wait a few minutes. 18
B (upload) than specifications in the – Perform reset (Code 7864) and
technical data. (→ See Section 9.) carry out calibration again.
This message normally only
appears briefly.
– Cable connection sensor –main – Check cable connection and

electronics disconnected. repair if necessary.
Endress+Hauser 69

NA 64 NE 107 rity
743 (E743) Alarm Failure (F) B>Electronic PCB error – This message normally only – Wait a few minutes. 14
B during initialisation appears briefly. – Restart the device. Perform reset
(Code 62).

744 (A744) Alarm Failure (F) B>Main electronic PCB error – Electromagnetic effects are greater – Restart the device. Perform reset 11
B than specifications in the (Code 62).
technical data. – Block off electromagnetic effects
(→ See Section 9.) or eliminate source of
disturbance.

745 (W745) Warning Maintenance C>Sensor data unknown – Sensor does not suit the device – Replace sensor with a suitable 56
C request (M) (electronic sensor nameplate). sensor.
Device continues measuring.
746 (W746) Warning Funktion C>Sensor connection error - – Electromagnetic effects are greater – Wait a few minutes. 26
C check (C) initialising than specifications in the – Restart the device. Perform reset
technical data. (→ See Section 9.) (Code 7864).
This message normally only – Block off electromagnetic effects
appears briefly. or eliminate source of
disturbance.
– Overpressure or low pressure – Reduce or increase pressure.
present.
747 (A747) Alarm Failure (F) B>Sensor software not – Sensor does not suit the device – Replace sensor with a suitable 16
B compatible to electronics (electronic sensor nameplate). sensor.
748 (A748) Alarm Failure (F) B>Memory failure in signal – Electromagnetic effects are greater – Block off electromagnetic effects 15
B processor than specifications in the or eliminate source of
(→See Section 9.)
70 Endress+Hauser
8.1.1 On-site display error messages

If the device detects a defect in the on-site display during initialization, the following error messages
can be displayed:
Message Measure
Initialization, VU Electr. Defect A110 Exchange on-site display.
Initialization, VU Electr. Defect A114
Initialization, VU Electr. Defect A281

Initialization, VU Checksum Err. A110
Endress+Hauser 71
8.2 Response of outputs to errors

The device differentiates between the error types Alarm, Warning and Error.
→ See the following table and → ä 63, Section 8.1 "Messages".
Output A (Alarm) W (Warning) E (Error: Alarm/Warning)
Current output Assumes the value specified via the Device continues measuring. For this error, you can enter whether the
OUTPUT FAIL MODE1), ALT. CURR. device should react as in the event of an
OUTPUT1 and SET MAX. ALARM1 alarm or as in the event of a warning. See
parameter. → See also the following section corresponding "Alarm" or "Warning"
"Configuring current output for an alarm". column. (→ See also Operating Instructions
BA00274P, parameter description SELECT
ALARM TYPE or these Operating
Bargraph The bargraph adopts the value defined by The bargraph adopts the value which → See this table, "Alarm" or "Warning"
(on-site display) the OUTPUT FAIL MODE 1 parameter. corresponds to the current value. column, depending on selection.
On-site display – The measured value and message are – The measured value and message are – The measured value and message are
displayed alternately displayed alternately displayed alternately
– Measured value display: -symbol is – Measured value display: -symbol – Measured value display: see
permanently displayed. flashes. corresponding "Alarm" or "Warning"
column
Message display Message display: Message display:

– 3-digit number such as A122 and – 3-digit number such as W613 and – 3-digit number such as E731 and
description description description
Remote operation In the case of an alarm, the In the case of a warning, the ALARM In the case of an error, the
(digital communication) ALARM STATUS2) parameter displays a 3- STATUS2 parameter displays a 3-digit ALARM STATUS2 parameter displays a 3-
digit number such as 122 for "Sensor not number such as 613 for "Simulation is digit number such as 731 for "URV user
connected". active". limits exceeded".
1) Menu path: (GROUP SELECTION →) OPERATING MENU → OUTPUT

2) Menu path: (GROUP SELECTION →) OPERATING MENU → MESSAGES
72 Endress+Hauser
8.2.1 Configuring current output for an alarm

You can configure the current output for the event of an alarm by means of the OUTPUT FAIL
MODE, ALT. CURR. OUTPUT and SET MAX. ALARM parameters. The parameters are displayed
in the OUTPUT group (menu path: (GROUP SELECTION →) OPERATING MENU → OUTPUT).
In the event of an alarm, the current and the bargraph assume the value entered with the OUTPUT
FAIL MODE parameter.
I
max.
➀ 21...23 mA
min.
➂ 3.6 mA
t
P01-xxxxxxxx-05
Fig. 43: Current output in the event of an alarm

Options:
1 Max. alarm (110%): can be set between 21...23 mA via the SET MAX. ALARM parameter
2 Hold meas. value: last measured value is kept
3 Min. alarm (–10%): 3.6 mA
Factory setting:
• OUTPUT FAIL MODE: Max. Alarm (110%)
• SET MAX. ALARM: 22 mA
Use the ALT. CURR. OUTPUT parameter to set the current output value for the error messages E
120 "Sensor low pressure" and E 115 "Sensor overpressure". You have the following options:
– Normal: the current output assumes the value set via the OUTPUT FAIL MODE and SET MAX.
ALARM parameters.
– NAMUR
– Lower sensor limit undershot (E 120 "Sensor low pressure"): 3.6 mA
– Upper sensor limit overshot (E 115 "Sensor overpressure") overshot: current output assumes
the value set via the SET MAX ALARM parameter.
Factory setting:
• ALT. CURR. OUTPUT: normal
Endress+Hauser 73
8.3 Confirming messages

Depending on the settings for the ALARM DISPL. TIME and ACK. ALARM MODE parameters, the
following measures should be taken to clear a message:
Settings 1) Measures
– ALARM DISPL. TIME = 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = off
– ALARM DISPL. TIME > 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = off – Wait for the alarm display time to elapse.
– ALARM DISPL. TIME = 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = on – Confirm message using ACK. ALARM parameter.
– ALARM DISPL. TIME > 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = on – Confirm message using ACK. ALARM parameter.
– Wait for the alarm display time to elapse. If a message appears and the alarm
display time elapses before the message has been acknowledged, the message
will be cleared once it has been acknowledged.
1) Menu path for ALARM DISPL. TIME and ACK. ALARM MODE: (GROUP SELECTION →) OPERATING MENU →
DIAGNOSTICS → MESSAGES
If the on-site display displays a message, you can suppress it with the F-key.
If there are several messages, the on-site display shows the message which has the highest priority
(see also Section 8.1). Once you have suppressed this message using the F-key, the message with
the next highest priority is displayed. You can use the F-key to suppress each message, one after
the other.
The ALARM STATUS parameter continues to display all the messages present.
74 Endress+Hauser
8.4 Repair
The Endress+Hauser repairs concept provides for measuring devices to have a modular design and
also the customer may carry out repairs (→ ä 76, Section 8.6 "Spare Parts").
! Note!
• For certified devices, please consult Chapter "Repair of Ex-certified devices".
• For more information on service and spare parts contact the Endress+Hauser Service. ( → See
www.endress.com/worldwide)
8.5 Repair of Ex-certified devices

# Warning!
When repairing Ex-certified devices, please note the following:
• Only specialist personnel or Endress+Hauser may undertake repairs of certified devices.
• Relevant standards, national hazardous area regulations and Safety Instructions and Certificates
must be observed.
• Only genuine Endress+Hauser spare parts may be used.
• When ordering spare parts, please check the device designation on the nameplate. Identical parts
may only be used as replacements.
• Electronic inserts or sensors already in use in a standard instrument may not be used as spare parts
for a certified device.
• Carry out repairs according to the instructions. After repairs, the device must fulfil the
requirements of the specified individual tests.
• A certified device may only be converted into another certified variant by Endress+Hauser.
• All repairs and modifications must be documented.
Endress+Hauser 75
8.6 Spare Parts

An overview of the spare parts for your device is available in the internet at www.endress.com.
To obtain information on the spare parts, proceed as follows:
1. Go to "www.endress.com" and select your country.
2. Click "Instruments".
3. Enter the product name into the "product name" field.
4. Select the device.

5. Click the "Accessories/Spare parts" tab.
6. Select the required spare parts (You may also use the overview drawing on the right side of the
screen.)
When ordering spare parts, always quote the serial number indicated on the nameplate. As far as
necessary, the spare parts also include replacement instructions.
76 Endress+Hauser
8.7 Return
The measuring device must be returned if repairs or a factory calibration are required, or if the
wrong measuring device has been ordered or delivered. According to legal regulations,
Endress+Hauser, as a ISO-certified company, is required to follow certain procedures when
handling returned products that are in contact with process fluids.
To ensure swift, safe and professional device returns, please read the return procedures and
conditions on the Endress+Hauser website at www.services.endress.com/return-material.
8.8 Disposal
When disposing, separate and recycle the device components based on the materials.
Endress+Hauser 77
8.9 Software history
Date Software version Changes software Documentation
Operating Instructions Description of

Instrument Functions
11.2003 01.00.zz Original software. BA270P/00/EN/10.03 —

52020515
Compatible with:
– ToF Tool Field Tool Package, version 1.04.00 or higher
– Commuwin II version 2.08.-1, Update G or higher
– HART Communicator DXR375 with Device Rev.: 10, DD
Rev.: 1
06.2004 02.00.zz – Number of parameters in the Quick Setup menus has been BA270P/00/EN/05.04 BA274P/00/EN/05.04
reduced. 52022793 52021469
– On-site operation: LANGUAGE and MEASURING MODE
parameters have been moved to the top level.
– New SAFETY CONFIRM. group implemented for SIL.
→ See also SD00189P Safety Manual Deltabar S.
– MEASURING MODE "Level", LEVEL MODE "Linear": AREA
UNIT and TANK SECTION parameters have been replaced
with the TANK VOLUME and TANK HEIGHT parameters.
– Function of the UNIT FLOW parameter has been split across
four parameters.
– Function of the SIMULATED VALUE parameter has been
split across six parameters.
– SENSOR TRIM and CURRENT TRIM groups have been
removed.
– Sensor adapt reset, code 1209 and sensor calibration reset,
code 2509 have been removed.
– Quick Setup menus are available via ToF Tool.
Compatible with:
– ToF Tool Field Tool Package version 2.00.00 or higher
– Commuwin II version 2.08.-1, Update > G
– HART Communicator DXR375 with Device Rev.: 20, DD
Rev.: 1
06.2005 02.01.zz – Operating keys also integrated on the optional on-site display. BA270P/00/EN/06.05 BA274P/00/EN/05.04
– Chinese and Japanese are available as the menu language on 71000109 52021469
request.
BA270P/00/EN/11.05 BA274P/00/EN/05.04
Compatible with: 71009586 52021469
– ToF Tool Field Tool Package version 3.00.00 or higher
– FieldCare version 2.01.00, DTM Library version 2.06.00,
DTM: Deltabar S/MD7x/V02.00 V 1.4.98.74*
– HART Communicator DXR375 with Device Rev.: 20,
DD Rev.: 1*
* Menu languages Chinese and Japanese not selectable
78 Endress+Hauser
Date Software version Changes software Documentation
Operating Instructions Description of

Instrument Functions
06.2006 02.10.zz – New "Level Easy Pressure" and "Level Easy Height" level BA270P/00/en/07.06 BA274P/00/en/07.06
modes implemented. New LEVEL SELECTION parameter 71027244 71027249
implemented.
– OPERATION group with DOWNLOAD SELECT parameter BA270P/00/en/08.06 BA274P/00/en/07.06
71027244 71027249
extended.
– SAFETY CONFIRM group extended for the "Level" operating BA270P/00/en/10.07 BA274P/00/en/07.07
mode in the "Level Easy Pressure" level selection. 71043294 71061021
→ See also SD00189P Safety Manual Deltabar S.
– Factory setting for the "Error" messages redefined. BA270P/00/en/12.07 BA274P/00/en/07.07
– Chinese and Japanese included as menu languages by 71043294 71061021
default.
BA270P/00/en/05.08 BA274P/00/en/05.08
Compatible with: 71071730 71071855
– ToF Tool Field Tool Package version 4.0
BA270P/00/en/08.08 BA274P/00/en/05.08
– FieldCare version 2.02.00
– HART Communicator DXR375 with Device Rev.: 21, DD 71077506 71071855
Rev.: 1 BA270P/00/EN/06.09 BA274P/00/EN/06.09
71095415 71095452
BA270P/00/EN/05.10 BA274P/00/EN/05.10
71114104 71118244
BA00270P/00/EN/13.11 BA00274P/00/EN/13.11
71139762 71139795
BA00270P/00/EN/14.12 BA00274P/00/EN/13.11
71161876 71139795
01.2013 02.11.zz "Russian" is included as a menu language by default. BA00270P/00/EN/15.13 BA00274P/00/EN/14.13

The menu language "Nederlands" is no longer supported. 71204581 71204628
Endress+Hauser 79
Technical data Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
9 Technical data
For technical data, please refer to the Technical Information TI00382P for Deltabar S.
10 Appendix
10.1 Operating menu for on-site display, FieldCare and

HART handheld terminal
! Note!
• The entire menu is depicted on the following pages.
• The menu has a different structure depending on the measuring mode selected. This means that
some function groups are only displayed for one measuring mode, e.g. "LINEARISATION"
function group for the Level measuring mode.
• In addition, there are also parameters that are only displayed if other parameters are appropriately
configured. For example the Customer Unit P parameter is only displayed if the "User unit" option
was selected for the PRESS. ENG. UNIT parameter. These parameters are indicated with a "*".
• For a description of the parameters, please refer to Operating Instructions BA00274P "Description
of device functions". The exact dependency of individual parameters on one another is explained
here. See also → ä 2, section "Overview documentation".
80 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Appendix
Measured value
1)
GROUP SELECTION
1) 1)
1)
Level measuring
LEVEL SELECTION mode only SETTINGS
POSITION ADJUSTMENT
2)
MEASURING MODE
Pressure Level Flow

2)
POS. ZERO ADJUST LEVEL SELECTION POS. ZERO ADJUST POS. ZERO ADJUST
SET LRV POS. ZERO ADJUST MAX. FLOW POS. INPUT VALUE
SET URV EMPTY CALIB.

* MAX PRESS. FLOW CALIB. OFFSET
DAMPING VALUE FULL CALIB.

* DAMPING VALUE
DAMPING VALUE

HART Handheld terminal only
* There are parameters that are only displayed if other parameters are
appropriately configured.
For example the CUSTOMER UNIT P parameter is only displayed
if the "User unit" option was selected for the PRESS. ENG. UNIT parameter.
These parameters are indicated with a "*".
Endress+Hauser 81
Appendix Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
BASIC SETUP
2)
MEASURING MODE
Pressure Level Flow

2)
PRESS. ENG. UNIT LEVEL SELECTION PRESS. ENG. UNIT
CUSTOMER UNIT P
* CUSTOMER UNIT P
*
Level Easy Pressure Level Easy Height Level Standard
CUST. UNIT FACT. P
* CUST. UNIT FACT. P
*
PRESS. ENG. UNIT PRESS. ENG. UNIT
X
SET LRV
CUSTOMER UNIT P
* CUSTOMER UNIT P
* Continuation,
see the following page
FLOW-MEAS. TYPE
SET URV
CUST. UNIT FACT. P
* CUST. UNIT FACT. P
* A
GET LRV B
OUTPUT UNIT OUTPUT UNIT
GET URV CUSTOMER UNIT F

*
CALIBRATION MODE HEIGHT UNIT
DAMPING VALUE
Dry
CUST. UNIT FACT. F
*
Wet CALIBRATION MODE
EMPTY CALIB. EMPTY CALIB. MAX. FLOW

Wet Dry
FULL CALIB. EMPTY PRESSUE DENSITY UNIT DENSITY UNIT MAX PRESS. FLOW
FULL CALIB. ADJUST DENSITY ADJUST DENSITY DAMPING VALUE
FULL PRESSURE EMPTY CALIB. EMPTY CALIB.
FULL CALIB. EMPTY HEIGHT

SET LRV
FULL CALIB.
SET URV
FULL HEIGHT
DAMPING VALUE
SET LRV
SET URV
DAMPING VALUE
Volume Gas Gas Mass

p. cond. norm cond. std. cond.
UNIT FLOW NORM FLOW UNIT STD. FLOW UNIT MASS FLOW UNIT
B B B B

HART Handheld terminal only
For example the CUSTOMER UNIT P parameter is only displayed
if the "User unit" option was selected for the PRESS. ENG. UNIT parameter.
82 Endress+Hauser
C
Continuation
BASIC SETUP "Level",
X see also the previous page Height Volume Mass %
LEVEL SELECTION = HEIGHT UNIT UNIT VOLUME MASS UNIT

Level Standard
PRESS. ENG. UNIT CUTOMER UNIT H * CUSTOMER UNIT V * CUSTOMER UNIT M *

CUSTOMER UNIT P CUST. UNIT FACT. H * CUST. UNIT FACT. V * CUST. UNIT FACT. M *
CUST. UNIT FACT. P D D D D
LEVEL MODE
Linear
Pressure Height E
Linearized Linearized
LIN. MEASURAND LINd MEASURAND COMB. MEASURAND
% Volume Mass
UNIT VOLUME MASS UNIT

C E G
D F H CUSTOMER UNIT V * CUSTOMER UNIT M *
CALIBRATION MODE HYDR. PRESS MIN.
E CUST. UNIT FACT. V * CUST. UNIT FACT. M *
HYDR. PRESS MAX. F
Wet Dry F F F
EMPTY CALIB. DENSITY UNIT DAMPING VALUE LEVEL MIN
EMPTY PRESSURE ADJUST DENSITY LEVEL MAX

G
FULL CALIB. VOLUME UNIT
* CALIBRATION MODE
Height+... %Height+...
FULL PRESSURE CUSTOMER UNIT V
*
Wet Dry HEIGHT UNIT
ADJUSTED DENSITY * CUST. UNIT FACT. V

* EMPTY CALIB. DENSITY UNIT
*
CUTOMER UNIT H
TANK VOLUME
* EMPTY PRESSURE ADJUST DENSITY
*
CUST. UNIT FACT. H
HEIGHT UNIT
* FULL CALIB. HEIGHT UNIT *
H H
CUSTOMER UNIT H FULL PRESSURE CUSTOMER UNIT H *
CUST. UNIT FACT. H
* ADJUSTED DENSITY * CUST. UNIT FACT. H *
TANK HEIGHT
* 100% POINT *
100% POINT
* ZERO POSITION
ZERO POSITION
DAMPING VALUE
SET LRV
SET URV
DAMPING VALUE * There are parameters that are only displayed if other parameters are
For example the CUST. UNIT FACT. H parameter is only displayed
if the "User unit" option was selected for the HEIGHT UNIT parameter.
Endress+Hauser 83
EXTENDED SETUP LINEARISATION LINEARISATION TOTALIZER SETUP

Level measuring Level measuring Flow measuring
mode only mode only mode only
Display via on-site Display via ToF Tool or

display only HART handheld terminal
only
Pressure Level Flow
TEMP. ENG UNIT TEMP. ENG UNIT TEMP. ENG UNIT TANK CONTENT MIN TANK CONTENT MIN TOTALIZER 1 UNIT
DENSITIY UNIT LOW FLOW CUT-OFF TANK CONTENT MAX TANK CONTENT MAX TOT. 1 USER UNIT
*
ADJUST DENSITIY SET L. FL. CUT-OFF
* TABLE SELECTION TABLE SELECTION FACT. U. U. TOTAL.1
*
PROCESS DENSITY SET LRV Measuring Measuring NEG. FLOW TOT. 1
Editor Table Editor Table
Table Table
SET LRV
* SET URV LIN. EDIT MODE MEASURING TABLE LIN. EDIT MODE LINE-NUMB RESET TOTALIZER 1
SET URV * EDITOR TABLE MEASURING TABLE EDITOR TABLE ACTIVE LIN. TAB. X TOTALIZER 2 UNIT
EDITOR TABLE LINE-NUMB ACTIVE LIN. TAB. Y TOT. 2 USER UNIT

*
EDITOR TABLE X-VAL. FACT. U. U. TOTAL. 2 *
Y-VAL. NEG. FLOW TOT. 2
TANK DESCRIPTION
EDITOR TABLE
TANK DESCRIPTION
For example the TOT. 1 USER UNIT parameter is only displayed
if the "User unit" option was selected for the TOTALIZER 1 UNIT parameter.
84 Endress+Hauser
SAFETY CONFIRM.
** DISPLAY OUTPUT
SAFETY LOCK MENU DESCRIPTOR OUTPUT CURRENT
SAFETY PASSWORD MAIN DATA FORMAT CURR. CHARACT.
DIGIT SETS ALTERNATE DATA OUTPUT FAIL MODE
2)
CURRENT OUTPUT LANGUAGE ALT. CURR. OUTPUT
ACK. ALARM MODE DISPLAY CONTRAST SET MAX. ALARM
CALIB. OFFSET DIGIT SETS SET MIN. CURRENT
3)
MEASURING MODE ASSIGN CURRENT
4)
Pressure Level Flow LINEAR/SQROOT
5)
SET LRV EMPTY PRESSURE MAX. FLOW
SET URV EMPTY CALIB. MAX PRESS FLOW
DAMPING VALUE FULL PRESSURE LOW FLOW CUT-OFF
CONF. PASSWORD FULL CALIB. SET L. FLOW CUT-OFF

*
SET LRV LINEAR/SQROOT
SET URV SET LRV
DAMPING VALUE SET URV
CONF. PASSWORD DAMPING VALUE
CONF. PASSWORD
2) Display via
HART handheld terminal only * There are parameters that are only displayed if other parameters are
3) Level measuring mode only These parameters are indicated with a "*".
4) Flow measuring mode only See Safety Manual SD189P
5) only LEVEL SELECTION = Level Easy Pressure
** for Deltabar S.
Endress+Hauser 85
TRANSMITTER INFO PROCESS INFO
HART DATA TRANSMITTER DATA PROCESS CONNECTION SENSOR DATA PROCESS VALUE PEAK HOLD INDICATOR
Pressure Level Flow
BUS ADDRESS DEVICE SERIAL No Pmax PROC. CONN. SENSOR SER. NO. MEASURED VALUE MEASURED VALUE MEASURED VALUE COUNTER:P > Pmax
DEVICE TYPE ELECTR. SERIAL No PROC. CONN. TYPE PRESS. SENS LOLIM PRESSURE PRESSURE PRESSURE MAX. MEAS. PRESS.
DEVICE REVISION CUST. TAG NUMBER MAT. PROC. CONN. + PRESS. SENS HILIM CORRECTED PRESS. CORRECTED PRESS. CORRECTED PRESS. COUNTER:P < Pmin
2)
BURST MODE LONG TAG NUMBER MAT. PROC. CONN. – MINIMUM SPAN SENSOR PRESSURE SENSOR PRESSURE SENSOR PRESSURE MIN. MEAS. PRESS.
2)
BURST OPTION ADDITIONAL INFO. SEAL TYPE SENSOR MEAS. TYPE SENSOR TEMP. SENSOR TEMP. SENSOR TEMP. COUNTER:T > Tmax
2)
PREAMBLE NUMBER DEVICE DESIGN. BOLTS MATERIAL Pmin SENS. DAMAGE MEAS. VAL. TREND MEAS. VAL. TREND MEAS. VAL. TREND MAX. MEAS. TEMP.
2)
MANUFACTOR ID HARDWARE REV. NUTS MATERIAL Pmax SENS. DAMAGE LEVEL BEFORE LIN
* SUPPRESSED FLOW COUNTER:T< Tmin
2)
HART MESSAGE SOFTWARE VERSION DRAIN VENT MAT. MAT. MEMBRANE TANK CONTENT
* TOTALIZER 1 MIN. MEAS. TEMP.
2)
HART DATE CONFIG RECORDER DRAIN VENT POS. FILLING FLUID TOTAL. 1 OVERFLOW PCB COUNT:T > Tmax
2) 2)
PRIMARY VALUE IS PCB TEMPERATURE THREAD Tmin SENSOR TOTALIZER 2 PCB MAX. TEMP.
2) 2)
PRIMARY VALUE ALLOWED MIN. TEMP MOUNTING THREAD Tmax SENSOR TOTAL. 2 OVERFLOW PCB COUNT: T< Tmin
2) 2)
SECONDARY VAL. IS ALLOWED MAX. TEMP REMOTE SEAL + SENSOR H/WARE REV. PCB MIN. TEMP.
2) 2)
SECONDARY VALUE DIP STATUS REMOTE SEAL – RESET PEAKHOLD
2) 2)
THIRD VALUE IS DIAPHRAGM MAT. +
2) 2)
THIRD VALUE DIAPHRAGM MAT. –
2) 2)
4TH VALUE IS NR OF REMOTE SEAL
2) 2)
4 TH VALUE FILL FLUID
2) Display via FieldCare

HART handheld terminal only
There are parameters that are only displayed if other parameters are
* appropriately configured.
86 Endress+Hauser
OPERATION DIAGNOSTICS SERVICE
SIMULATION MESSAGES USER LIMITS SYSTEM 2
ENTER RESET CODE SIMULATION MODE ALARM STATUS Pmin ALARM WINDOW CURR. TRIM 4mA
OPERATING HOURS LAST DIAG. CODE Pmax ALARM WINDOW CURR. TRIM 20mA
INSERT PIN NO ACK. ALARM MODE Tmin ALARM WINDOW OFFSET 4mA TRIM
HistoROM AVAIL. ACK. ALARM * Tmax ALARM WINDOW OFFSET 20mA TRIM
DOWNLOAD SELECT. * RESET ALL ALARMS
HistoROM CONTROL * ERROR NO.

Display via digital communication
SELECT ALARMTYPE
ALARM DELAY
ALARM DISPL. TIME
none Pressure Flow Level Tank content Current Alarm Warning

SIM. PRESSURE SIM. FLOW VALUE SIM. LEVEL SIM. TANK CONT. SIM. CURRENT SIM. ERROR NO.
There are parameters that are only displayed if other parameters are
* appropriately configured.
Endress+Hauser 87
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Index
Index
Numerics N
4...20 mA test signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A O
Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 On-site display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operating elements, function . . . . . . . . . . . . . . . . . . . 31–32
C Operating elements, position. . . . . . . . . . . . . . . . . . . . . . . 30
Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operating keys, on-site, Flow measuring mode . . . . . . . . . 36
Commubox FXA195 anschließen . . . . . . . . . . . . . . . . . . . 26 Operating keys, on-site, function. . . . . . . . . . . . . . . . . 31–32
Connecting Commubox FXA291 . . . . . . . . . . . . . . . . . . . 27 Operating keys, on-site, Level measuring mode . . . . . . . . . 34
Connecting ToF Adapter FXA291 . . . . . . . . . . . . . . . . . . . 27 Operating keys, on-site, Pressure measuring mode. . . . . . . 33
Operating keys, position . . . . . . . . . . . . . . . . . . . . . . . . . . 30
D Operating menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 80
Diaphragm seals, installation instructions . . . . . . . . . . . . . 17 Overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diaphragm seals, vacuum application . . . . . . . . . . . . . . . . 18
Differential pressure measurement . . . . . . . . . . . . . . . . . . 59 P
Differential pressure measurement, information . . . . . . . . 60 Pipe mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differential pressure measurement, installation . . . . . . . . . 16 Position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Differential pressure measurement, preparatory steps . . . . 59 Potential matching . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–27
Differential pressure measurement, Quick Setup menu . . . 60 Pressure measurement, Quick Setup menu . . . . . . . . . . . . 60
Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Q
E Quick Setup menu flow . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Quick Setup menu level . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Quick Setup menu pressure . . . . . . . . . . . . . . . . . . . . . . . 60
F R
Factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FieldCare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Repair of Ex-certified devices . . . . . . . . . . . . . . . . . . . . . . 75
Flow measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flow measurement, installation . . . . . . . . . . . . . . . . . . . . 11 Returning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Flow measurement, Ouick Setup menu . . . . . . . . . . . . . . 51 Rotating the housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Flow measurement, preparatory steps . . . . . . . . . . . . . . . . 49
S
H Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Heat insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Separate housing, assemble and mount . . . . . . . . . . . . . . . 21
HistoROM/M-Dat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Service Interface FXA291 . . . . . . . . . . . . . . . . . . . . . . . . . 27
SIL3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Language, selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Level measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 55–56 T
Level measurement, installation . . . . . . . . . . . . . . . . . . . . 12 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Level measurement, preparatory steps. . . . . . . . . . . . . . . . 52
Level measurement, Quick Setup menu . . . . . . . . . . . . . . 57 U
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Unlocking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Locking operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
W
M Wand mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Measuring layout for flow measurement . . . . . . . . . . . . . . 11 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Measuring layout for level measurement . . . . . . . . . . . . . . 12
Measuring layout for pressure measurement . . . . . . . . . . . 16
Measuring mode, selection . . . . . . . . . . . . . . . . . . . . . . . . 47
90 Endress+Hauser
INSTRUCTION MANUAL

TABLE OF CONTENTS
PAGE
1. TYPE --------------------------- 3
2. MATERIALS --------------------------- 4
3. CONSTRUCTION --------------------------- 5
4. WORKING AIR PRESSURE --------------------------- 7
5. NAME PLATE --------------------------- 7
6. AIR PIPING CONNECTION --------------------------- 8
METHOD OF INSTALLING
7. --------------------------- 9
CONTROL VALVE
8. MAINTENANCE --------------------------- 10
9. TROUBLE SHOOTING --------------------------- 14
10. GENERAL PRECAUTIONS --------------------------- 15
Method of Handling and Maintenance of

11. --------------------------- 17
Gland Packing
2
1. TYPE
The indication of type of cage type control valve is as shown below :
The following sample a full designation of type.
[Example]
K2C(3C) - DP 1 ( R )
┃ ┃ ┃ ┗━━━ Diaphragm Acting Mode
┃ ┃┃ D : Direct action
┃ ┃┃ R : Reverse action
┃ ┃┃ B : Double action
┃ ┃┃
┃ ┃ ┗ Indicates body configuration. (See Table b.)
┃ ┃
┃ ┗━ ACTUATOR TYPE ( DP : Pneumatic Diaphragm)
┃
┗ 2Way(3Way) Control valve series
Table a. STANDARD PRESSURE RATING

MARK 1 2 3 4 5 6
JIS
(kgf/cm 5ㆍ10 16ㆍ20 30ㆍ40 63 (100) ---
2)
ANSI
(125ㆍ150)250ㆍ300 400ㆍ600 900 1500 2500
(Class)
Table b. Body configuration

Symbol Meaning
1 Cage guided type body
2 Single seated and top guided type body
3 Cage guided and angle type body
4 Single seated and suitable flow type body
5 Special body (Other than those mentioned above)
3
2. MATERIALS
2.1 BODY
Optimum materials are selected, depending on type of fluid, pressures,
temperatures and other requirements. (flushing, cavitation, corrosion, etc.)
Cast iron (FC), gunmetal (BC) , ordinary cast steel (SC) and cast stainless steel
(SUS) conform to the requirements specified in JIS and special cast steel (WC,
S5, etc.) conform to the requirements specified in ASTM.
2.2 TRIM
Table shows typical standard trim materials among types herein. The trim
materials for cage type control valves are shown on pertinent drawing. Standard
trim materials for general purpose type control valve (Mark of materials : JIS)
Service temperature of
Lower Seat
Disc Seat Gland fluids such as water, oil,
Stem Ring
steam, air and gas (℃)
SUS
410 SCS SUS SUS SUS
220 AND UNDER
or 24 316 316 316
SCS 24
4
3. CONSTRUCTION
3.1 Body (See Attached Figs. 1～8.)
Control valves can be largely divided into single seat valve and double seat valve.
Normally single seat valve is used. How ever, for small n bore or where pressure is
relatively low and low leaking is desired single seat valve is used.
Balance piston valve combines the advantages of both single and double seat
valves. Its leaking is similar to that of single seat valve. It can be used up to the
differential pressure 5 - 6 times that of the single seat valve.
Operation Principle of the balance piston valve is
: When working pressure is applied on diaphragm, the stem is brought down.
This causes pilot valve to open first. Then the inlet pressure is applied on the
upper side of piston, Since the piston is almost the same in diameter with the main
valve, it balances with the back pressure of the main valve. Thus the unbalance of
the valve is reduced to a fraction.
3.2 Valve disc

a. Single seat : <FIG. 1>
b. Double seat : <FIG. 2>
See Figs. 1 and 2 for the shape of each disc.
<FIG. 1> <FIG. 2>
5
3.3 Bonnet
Standard Fin type bellows extension type

Fin type
type ( for cage seal type
( FOR GENERAL
type )
PURPOSE TYPE )
<Fig.
g 3> Type
yp of bonnet
3.4 Diaphragm Motor
Diaphragm motor includes D (direct action) Type and R (reverse action) Type.
The two types are used either as air to open air to close type considering from the
process condition in the event of interuption of working air.
Single Action
< Fig. 4> Diaphragm Motor

6
4. WORKING AIR PRESSURE

The range of standard working air pressure is 0.2 to 1.0 kg/cm2 or 0.4 to
2.0kg/cm2. However, in a special case when closing force is specially required, the
range is may be deviated to 0.4～1.2kg/cm2 or 0.6～2.2kg/cm2.
5. NAME PLATE
5.1 Name Plate for Specification
<Fig. 5>
7
5.2 Indicator Plate for Lift
<Fig. 6>
6. AIR PIPING CONNECTION
6.1 Direct Action Diaphragm
<Fig. 7>
8
6.2 Reverse Action diaphragm
<Fig. 8>
7. METHOD OF INSTALLING CONTROL VALVE

7.1 Selection of Location
a) Select the place convenient for maintenance and servicing.
(Consider the space to allow vertical disassembly of control valve.)
b) Avoid the place where vibration is produced.
c) Avoid the place of high ambient temperature. (Lese than 60℃)
d) Consider the distance air piping from controller.
(UP ti 50 meters with air operated type)
7.2 Control valve should essentially be installed in vertical position, to horizontal

piping, with the actuator positioned upward on the upper side.
However, if location compels to install the control valve in inclined position,
provide support to the control section.
7.3 Install the control valve with its flow direction conforming to the direction shown by
the arrow mark casted (or engraved) on the body.
9
8. MAINTENANCE
8.1 Disassembly, Assembly and Parts Replacement
8.1.1 Replacing the Diaphragm of direct action Diaphragm

a) Disconnect air piping from diaphragm casing.
b) Remove bolt and nut.
c) Remove diaphragm casing.
d) Replace diaphragm.
e) Reassemble in the reverse order of disassembly.
f) Perform adjustment and checking according to Paras. 8.2. and 8.3.
(Perform the following Paras end just the same procedure as paras 8.2. and 8.3)
Note.
1. If casing removal is difficult due to sticking of diaphragm, tap a screw
driver or the like into the clearance.
2. It is desirable to use a chain block for handing diaphragm casings of
520J and 645J because of their weight.
3. After replacing the diaphragm, correctly set the mounting holes.
4. Notes 1, 2 and 3 air also applied to each of the following paragraphs.
8.1.2 Replacing the diaphragm of reverse Action Diaphragm

a) Loosen adjusting screw to bring it down.
b) remove bolt and nut.
c) Remove diaphragm casing.
d) Slightly loosen bolt.
e) Turn the assembly diaphragm disc, diaphragm stem and diaphragm
counterclockwise and withdraw it upward.
f) Hold the head of diaphragm disc with a vise, apply a wrench on the square shaft
of
diaphragm stem and unscrew.
g) replace diaphragm.
h) Reassemble in the reverse order of disassembly.
10
8.1.3 Replacing the spring of direct Action Diaphragm

a) Perform the same operations up to a) - c) of para. 9.1.1.
b) Remove diaphragm.
c) Slightly loosen bolt, turn the top of diaphragm disc to left by hand
and draw out diaphragm stem.
d) Replace spring.
e) Reassemble in the reverse order of disassembly
Note.
1. Diaphragm stem must be screwed down completely to the step of.
2. Fasten firmly bolts after assembly at any occasion.
3. If the valve is fixed with positioner, keep the spring in positioner casing
free before disassembling, after finishing, keep it original performance.
8.1.4 Replacing the Spring of Reverse Action Diaphragm

a) Perform the same operations of a) - e) of para. 9.1.2.
b) Disconnect air piping from diaphragm casing.
c) Remove bolt and remove casing and piece.
d) Replace spring.
e) Reassemble in the reverse order of disassembly.
8.1.5 Valve with Handle

A. For paras. 9.1.1., and 9.1.3. (Direct Action Diaphragm Motor)
Operations are the same.
B. For paras. 9.1.2., 9.1.4.
a) First remove hand wheel and lock nut.
b) Remove bolts and nuts of diaphragm casing.
c) While bringing up the diaphragm casing, screw down the spindle
of the handwheel to let it protrude inward.
11
8.1.6 Valve disc

A. Reverse Valve
a) Loosen the bolt and disassemble in half.
b) Loosen nut and remove lower cover.
c) slightly bring down valve plug and remove indicator and nut.
Then completely draw out the plug downward.
d) Reassemble in the reverse order of disassembly.
Note.
Pay special attention in locking the nut in reassembly, taking care not to cause
uneven tightening. Move the valve stem vertically and see if it moves smoothly by
hand. While checking in this way, lock up the nut evenly.
B. Direct Valve
a) Disconnect air piping from diaphragm casing.
b) Remove bolt and disassemble into half.
c) Loosen round nut and remove it. For diaphragms larger than 410J
(nominal) yoke is bolted to upper cover. In this case, remove bolts nuts.
d) Bring up the assembly above yoke.
e) Remove nut and dismount cover.
f) Draw out the valve plug from cover.
g) Reassemble approximately in the reverse order to disassembly.
First insert the valve plug into body (valve seats). Then, put back bonnet.
Note.
1. Take the same care as that in the note of page. 9.1.6.A when locking
up the Bonnet.
2. When lifting the yoke and its related parts of a large size (diaphragms
larger then 410J) it is desirable to hook a wire rope to the arm of the yoke
or the head after slightly unscrewing the two bolts and then hoist the yoke
with a chain block.
3. While lifting the yoke, care not to bend valve stem or damage the
fitted parts by lifting the yoke diagonally.
4. The same care should be paid when handling the valve plug.
12
8.1.7 Gland Packing (Reference : para 12)

a) Screw down the nuts if tightening allowance is provided.
b) To place additional packing, insert packing only after confirming that
the pressure in the piping is perfectly zero. Remove the nuts, gland
flange bring up gland as high as possible and support them not to be
brought down.
Then, insert one ring of packing, push it by bringing down gland, raise
gland and gland flange and insert another ring and in the way put all
additional packing rings.
c) To replace the whole packing, reference para 12
d) When placing additional packing or replacing packing, do not lock up the
nut tightly from the beginning, but retighten little by little by checking
leakage, with internal pressure being kept applied.
13
9. TROUBLE SHOOTING
Problems and solutions for the cases when the lift of control valve is not correctly
changed against normal working air pressure.
Problems Solutions
Overhaul valve.
1) Sticking of valve guide, stem, etc. Remove engaged particles, scale etc, if
any and clearing
2) Defective diaphragm or leak out Replace with new one or lock

on connection face up the nut tightly
3) Leaking through O-ring seal of yoke,

in case of reverse action diaphragm Replace with new O-ring
motor
4) Leaking through handwheel

gland packing or O-ring in case Retighten or replace with new packing
of valve with handle
5) Sticking of pilot or lever, in case Remove scratches made after sticking

of valve with positioner with fine emery cloth or file.
6) Disconnection of diaphragm
Correct to normal.
stem from positioner
14
10. GENERAL PRECAUTIONS

(1) When disassembling a diaphragm control valve, put match marks to all joining
faces and reassemble according to these marks.
(2) Perfectly protect the removed parts.

(3) Never allow any foreign matter to enter the body and valve interior when
reassembling.
(4) Do not install valve unnaturally to piping.

(5) Periodical Inspection carry out static test for each individual valve or general
static test of each valve with controller periodically about twice a year
(disassemble and inspect the following) and check if operation is normal.
a) Inspect valve disc and seat in the body twice a year. Overhaul and inspect
the diaphragm, diaphragm sliding parts and o-rings (in case of reverse action type)
of control section once a year.
However, when no trouble is observed, overhaul period may be successively
prolonged, and overhaul and inspection must be carried out with proper intervals.
b) If oiler is provided with gland, properly feed oil by determining intervals

depending on the lubricating condition of valve stem.
However, oiler is not provided if teflon packing is used as these do not
require lubrication.
15
< FIG. 12 >
16
11. Instruction on Handling and Maintenance of Gland Packing

To assure high performance of the control valve, due care should be given
to handling and maintenance of gland packing since it is required to meet severe
conditions of sealing and low friction.
11.1 Preparation
11.1.1 Maintenance of Valve
Inner surface of the stuffing box:
Rusting or roughened surface will reduce the tightness. If it is the case, the
clamping force of the gland flange will not reach the bottom of the stuffing box,
resulting in inferior compaction. Clean and smooth the inner surface with a piece of
fine sandpaper. If it is permissible, coat the inner surface of the stuffing box with a
thin coat of grease.
11.1.2 Valve Stem

Check the sliding surface of the valve stem for any harmful scars, bend,
or misalignment against the stuffing box.
11.1.2 Make sure the material and size of the packing are as specified.
17
11.2 Fitting
11.2.1 Fit the formed ring without distorting the forming as much as practicable. When
putting the ring on the stem from the end of the stem, do not disturb the shape of
the ring. When putting the ring from the side of the stem, twist the ring to open as
shown in the diagram. In this way, deformation of the ring, which is formed to have
even density, can be minimized. It should be avoided to loosen a ring of
inappropriate size and repack it into the stuffing box.
< FIG. 13 >

11.2.2 Distribution of the cuts of the rings over the circumference of the stem should be
by 90 degrees.
< FIG. 14 >
18
The density of the portions near the cut tends to become low, resulting in leakage.
Arrange the rings so that the cuts overlap once every four rings.
11.2.3 Hammer in one ring at a time with a wood hammer or a plastic hammer and a
bush-shaped jig. (The bush is made of aluminium or brass to prevent damage to
the stem or stuffing box. As for the size of the bush, it is sufficient to have a small
clearance when it is inserted in the box.) If insertion of the first rings is not
appropriate, tightening of the gland nuts will not generate a clamping force which
reaches the bottom of the stuffing box; effective sealing can not be obtained.
It will also result in partial clamping of only one or two rings near the gland
flange. Such partial clamping has the following demerits;
a) Degrading of packing. Lubricant contained in the packing will ooze out.

b) Larger friction resistance and increased hysterics.
c) Valve stem tends to wear or receive damages.
d) Sealing lasts for a shorter time. Retightening of gland nuts has only
temporary effect. The conditions will get worse.
11.3 Tightening of Gland Nuts

The sliding surface of the packing will get to fit the stem through movement
of the stem, resulting in a smaller friction resistance. Accordingly. tighten the nuts
little by little and alternately while constantly moving the stem till leak stops.
19
11.4 Lubrication
If an oiler is provided on the side of the stuffing box, feed the specified grease
without fail.
11.5 Retightening
11.5.1 The objective of retightening is to recover the initial clamping pressure. The
procedure is the same with 3.
11.5.2 When exposed to high temperature, packing will experience thermal creep and
loss. Retightening the packing after it has been exposed to the possible to bring
the packing back to the normal temperature, it is necessary to retighten the
packing at the service temperature.
11.5.3 Should a leak be detected when the valve is in service, retighten the packing
immediately to prevent the leak from increasing.
11.5.4 If retightening to stop leakage is frequent and the clamping torque is excessive,
degrading of the packing may be suspected. As it affects the performance of the
control valve, replace the packing with new one.
11.6 Addition of packing rings

Under normal service conditions, it is hardly required to add extra packing rings.
However, if the packing loose capacity for clamping, add one or two rings. Before
starting work, always make sure that the fluid pressure has been released to
atmosphere and the valve is safe to work on it.
11.7 Replacement with new packing

As explained in 2～3, should the packing be degraded due to improper fitting,
oozing of lubricant, etc., replace it with a new one in accordance with the
procedure described in this manual.
20
INSTRUCTION MANUAL

TABLE OF CONTENTS
PAGE
1. Notice for Safety --------------------------- 3
2. Confirmation of Product --------------------------- 4
3. General --------------------------- 5
4. Model Code --------------------------- 5
5. Specifications --------------------------- 6
6. Standard Liquid End Materials --------------------------- 6
7. Performance Curves --------------------------- 7
8. Principle of Operation & Structure --------------------------- 9
9. Installation --------------------------- 13
10. Operation --------------------------- 21
11. Repair and Maintenance --------------------------- 22
12. Cause of Trouble and Troubleshooting --------------------------- 24
13. Replacement of Parts --------------------------- 25
14. Consumable Parts and Spare Parts --------------------------- 27
15. Warranty --------------------------- 28
16. Repair Service --------------------------- 28
17. Structure and Name of Each Parts --------------------------- 29
2
1. Notice for Safety

1.1 Introduction
• To use the products safely, the signs are showed on the manual as below.
• As it is a matter of safety, please be sure to keep the directions in manual.
• The sign and indications are as follows.
※WARNING
Person death or serious injury will be occurred, if warning is not kept by wrong
handling.
※CAUTION
Person injury or property damage will be occurred, if cautions is not kept by wrong
handling.
1.2 Cautions for Operating Condition
※CAUTION
• Do not use this pump for other purposes except liquid injection. Otherwise it may
cause trouble.
• Please keep the followings, otherwise it may cause trouble.
Ambient temperature : 0~40℃
Temperature of the handling liquid : Head material of PP & PVDF 0 0~50℃
50℃
Piping pressure : Below the max. discharge pressure indicated on the
specifications.
Do not use this pump to transfer the liquids containing slurry.
1.3 Cautions for Handling Condition

※WARNING
• Install this pump beyond the reach of children and/or unauthorized person.
• Turn off the power and stop the pump & other equipments when repairing or
disassembling pumps.
If power is on during work, it may cause electric shock.
• Do not operate when the discharge valve is closed or do not close the valve
during operation. Pump and piping may be damaged with excessive pressure
rising and liquid may spout when operation under valve closing.
• Do not touch with wetted hand. Electric shock may be occurred.
• Use only designated parts. If undesignated parts are used to the pump, it may
cause accident & trouble.
• Do not arbitrarily reconstruct the pump. If the pump is arbitrarily reconstructed, it
may cause accident & trouble.
3
※CAUTION
• Do not use damaged pump. It may cause accident.
• Do not install pump in the heavy moist or dusty place. It may cause electric shock
and trouble.
•Wear suitable protective clothing(gloves, mask, goggles, working clothes, & etc.)
during assemble and disassemble work when pumping hazardous liquids or
uncertain liquids.
• Do not use power other than that specified in the motor nameplate. Otherwise, it
may cause malfunction or fire.
• Pump should be properly grounded. If pump is not grounded, it may cause
electric shock.
•Work after releasing pressure from discharge piping and remove liquid from
Liquid End Part prior to repair or maintenance of pump.
•Pump may be damaged when ambient temperature go down below freezing point
of liquid. Be sure to remove the liquid in the pump and piping after operation stop.
• Make proper protection in consideration of indeliberate leakage from damage of
pump & Piping.
• Dispose of waste pump in accordance with related national law.
2. Confirmation of Product
2.1 Cautions for Operating Condition
Please check following points immediately after receiving the pump.
If the defect is found from pump, please request it to local agent.
1) Is specification correct as ordered?
2) Is there any missing parts?
3) Is there any visible damage caused by vibration or shock during transport?
4) Is there any loosened bolt or nut?
2.2 Standard Accessories
4
3. General
Solenoid Metering Pump SP-A Series is reciprocating diaphragm metering pump
which have a solid & compact structure and liquid end part of strong chemical
resistance.
It can be used for injection of Boiler Chemical, Chlorine Disinfectants, & Food
Additives, and used for dosing chemicals in various industrial fields including
physico-chemical fields, semiconductor device, water treatment, waste water
treatment filed, & etc.
4. Model Code
① Series Name SP: SP Series

② Control Panel Type A: Automatic or Advanced
③ Nominal Capacity 20 : 20 mL/min
④ Liquid End Material (a) Head P:PP F:PVDF
(b) Ball Seat F:FKM E:EPDM V:FKM(ETP)
((c)) Check Ball C:CERAMIC S:SS316
⑤ Hose Standard 1 : Ø4×Ø6 2 : Ø4×Ø9(Braided PVC)
3 : Ø6×Ø8 4:Ø6×Ø×11(Braided PVC)
⑥ Valve Structure W:Standard(0~100mPa s)
V:High Viscosity(100~1000mPa s)
※ In case of high viscosity, spring is installed in the valve.
⑦ General Specification S:Standard B:Boiler F:Relief Valve
G:Boiler + Relief Valve
※ In case of Boiler type, discharge hose is nylon and the body of Anti-siphon
Check Valve is PPS.
⑧ Control Specification 1 : Manual 2 : Manual +Add. Func. 3 : PULSE(1:1)
4 : PULSE(1:1)+Add. Func. 5 : 4~20mA
6:4~20mA+Add.
Func. 7:PULSE(DIV/MUL)+4~20mA+Add. Func.
※ Additional Function is Input of Level Switch, Output of Alarm, &
RemoteRUN/STOP.
⑨ Power Supply 1: AC220V(198~242V) 2:AC240V(216~264V)
※ Common:1 Phase 50/60Hz
⑩ Power Cord 0 : 2m of Power Cord without Plug
1 : 2m of Power Cord & Plug
5
5. Specifications
Note.
1. Max. capacity is the volume at max. discharge pressure.
2. Repeatability is 2%F.S.(Full Scale) and noise is within 70dB.
3. Setting pressure of Relief Valve is 10% of max. discharge pressure.
4. Specification can be changed for improvement without prior notice.
6. Standard Liquid End Ma

6.1 Standard Liquid End Materials
Note. In case of Boiler type, discharge hose is nylon.

6
6.2 Strainer Food Valve
6.3 Anti-siphon Check Valve
7. Performance Curves
※ Condition : Clean water, Room temperature, Suction head - 1m
St k L th(%)
SP-A20 SP-A40
7
SP-A60 SP-A100
SP-A200 Note.
1. Above performance curves were
tested at our testing equipment under the
fixed condition(Clean water, Room
temperature, Suction head - 1m).
Therefore, performance curves can be
somewhat different in accordance with
condition of job site.
2. Way to understand performance
curves Ex.) In case of SP-A200, Capacity
Rate is 150mL/min at 80% of Stroke
Length & 120SPM of Stroke Number. If
discharge pressure is 1bar, correction
factor will be 1.1 and expected capacity
rate will be 65mL/min (1.1 150mL/min =
165mL/min)
8
3. Capacity rate can be changed according to piping condition of suction &

discharge. For effective use, measure the discharge rate(make out performance
curve) when trial operation, after installation.
4. if test of capacity rate is regularly operated, operator can know exchange cycle
for the consumable parts in Liquid End part.
8. Principle of Operation & Structure

8.1 Principle of Operation
8.1.1
If electric power is supplied to the Solenoid Coil, magnetic field is generated in the
Solenoid and Plunger moves forward by magnetic force, and, if electric power is
shout down, magnetic field disappears in the Solenoid and Plunger moves
backward by spring force.
8.1.2
Reciprocating motion of Solenoid Plunger is transferred to the Diaphragm
connected with the end of Slider Shaft and Diaphragm can be reciprocated.
Volumetric change occurs in the pump head by this reciprocating motor of
Diaphragm.
8.1.3
When diaphragm moves backward, minus(-) pressure is generated in pump head.
At this time, check ball of discharge side is closed in order to prevent flowing
backward of liquid from piping of discharge side to pump head. On the contrary,
check ball of suction side is opened so that liquid can be flowed into the pump
head.
8.1.4
When diaphragm moves forward, plus(+) pressure is generated in pump head. At
this time check ball of suction side is closed and check ball of discharge side is
opened so that liquid can be discharged.
8.1.5
Capacity rate can be accurately controlled by adjustment of stroke length or
stroke number.
9
8.2 Structure
The pump consists of Liquid End Part, Driving Part, Control Part as follows.
8.3 Control Panel

Manual Control PULSE(1:1) Control
10
DC4~20mA Control PULSE(DIV/MUL) & DC4~20mA Control
1: Status Lamp(LED) 2: Control Knob for Stroke Length

3: Control Knob for Stroke Number 4: Toggle Switch of 2 Stages
5: Toggle Switch of 3 Stages 6: Rotary Switch
7: Cable Socket for Power 8: Cable Socket for Input Signal
9: Cable Socket for Level Switch &Output Signal
8.3.1 Status Lamp(LED)

a. Stand by : Green Lamp is lighted
b. Operation : Green Lamp is flickered
c. Faulty Input Signal of DC 4~20mA :
Yellow Lamp is lighted and Pump is stopped
d. Low level of Tank : Red Lamp is lighted and Pump is stopped
8.3.2
Operation by manual control according to Stroke Length and Stroke Number
8.3.3
Operation by automatic control according to external Input Signal
a. Proportionally Automatic control of Stroke Number according to Analog Input
Signal(DC4~20mA)
11
b. PULSE :
1/2, 1/4, 1/8, 1/16, 1/32, 1/64 Division selection
1:1 selection
1×2, 1×4, 1×8, 1×16, 1×32, 1×64 Multiplication selection
Pump perform the calculated stroke number(SPM) according to the selection
Ex.1) When Rotary Switch is located at "1/4"
Ex.2) When Toggle Switch of 3 Stages is located at "PULSE" or

Rotary Switch is located at "1"
Ex.3) When Rotary switch is located at "x4"
Note.
Even if a lot of PULSE is inputted, pump's Stroke Number can't exceed 150SPM.
8.3.4
When Tank is LOW Level according to Input Signal of Level Switch or Analog
Input Signal is ERROR, Pump is stopped and Alarm Signal is outputted.
8.3.5
Pump can be remotely stopped or operated during Manual operation or Automatic
operation by Input Signal.
12
9. Installation
※CAUTION
Do not install pump at the place where ambient temperature is higher than 40℃ or
lower than freezing point. If the pump is installed at the place, internals of the
pump may be damaged.
9.1 Installation Place

Please take into consideration of those conditions listed below.
9.1.1
Place where is out of the direct rays of light, rain, & wind. Temperature rise of
metal part, Heat deterioration of plastic part by direct rays of light and Damage &
rust by sand, dust and rain may occur. If the pump should be installed at outdoor,
the pump should be protected by roof or cover in order to prolong the life time.
9.1.2
Place where is well ventilated in summer and not frozen in winter. If pump is used
in the closed room where is high temperature & humidity, solenoid will be
overheated and rust of metal part will be accelerated
accelerated. If pump is used for the liquid
which may freeze in winter, install warming or heating device.
9.1.3
Take sufficient space around the pump to facilitate maintenance or repair. Several
tools are used for disassembly of pump, therefore, fully consider enough space for
using tools and work space when installing pump.
13
9.2 Dimension
9.3 Piping
9-3-1 Pulsation
Pulsation which is the characteristic of metering pump occurs since the pump is
reciprocating type.
➞ Can reduce pulsation by using Air Chamber.
Note.
Possible piping length is changed according to Liquid Viscosity or piping diameter.
When changing piping diameter, be fully careful.
14
9-3-2 Installation of Piping

a. When bending the hose, be careful
not to be folded.
b. Before inserting Hose to Hose
Adaptor, insert Hose Nut & Clamp Ring,
then be careful that Hose is not twisted,
and connect Joint & Hose Nut.
c. Hose is vibrated because
reciprocating metering pump makes
pulsation. Support Hose in order not to
be vibrated. (It is enough to support
hose with string)
d. Install Hose in consideration of
temperature condition. Specially, keep
out of the direct rays of light in summer,
consider freeze protection in winter.
(Roof, cover, winterization, & etc.)
e. When re-connecting Hose after
maintenance, re-connect after cut the
end of Hose about min. 10mm.
※Anti-siphon Check Valve

a. In case that injection port is open to atmosphere and its location is lower than
liquid level in the tank.
➞ Siphon Phenomenon: although pump is stopped, liquid may continuously flow
because location of discharge port is lower than liquid level in suction tank.
➞ If there is constant pressure at injection port, it may be used as Check Valve.
b. When injecting to suction piping of centrifugal pump
c. When flow is much larger than rated capacity
(In spite of upward piping, if piping length is too long, Overfeeding can be
generated.)
➞ Overfeeding : Overfeeding stands for the excessive discharge flow due to
abnormal function of the Check Valve caused by pulsation of the liquid in piping.
Check carefully differential pressure if the differential pressure between suction
side and discharge side is lower than 0.5~1 bar and discharge piping is too long.
15
※Mounting of Anti-siphon
Ch k V Rc3/8
a. Install l or Rc1/2 of Female Thread at the injection point. Fits both sizes
because Anti-siphon Check Valve has both R3/8 and R1/2 of Male Thread.
b. Anti-siphon Check Valve is fragile against impacts since it is made by plastics
such as PP, PVDF, & PPS, therefore, install it in a place sheltered from impacts
and free from obstacles.
c. Cut off the end of the injection nozzle properly. It is suitable that the end of
injection nozzle is positioned in the middle of water pipe.
※Installation on Liquid Tank

a. Fix the pump to the bracket on the
tank, by using the Mounting Bolts
supplied as standard accessories.
b. Pass the Hose Nut into the suction
side hose and connect it to the Strainer
Foot Valve.
c. Place the Strainer Foot Valve into the
tank.
d. Pass the Hose Nut into the discharge
side hose and connect it to discharge
side Joint of pump. Drive the Anti-
siphon Check Valve into the injection
point and connect the hose.
16
9.4 Electrical Wiring

※WARNING
•Do not touch with wetted hand. Electric shock may be occurred.
•Before wiring, check voltage, phase, & frequency and connect the pump with
correct power.
It may cause trouble and fire, if connecting with incorrect power.
•Pump should be properly grounded in order to prevent electric shock.
•Entrust the wiring to electrical engineer.
•Install regulated Magnet Switch and Thermal Relay for the adjustment and
maintenance of the pump.
•Use standardized parts in wiring and fully pay attention to safety in accordance
with the technical
standard & wiring regulation of the electrical equipment.
9.4.1
Disassemble Terminal Cover after loosening tapping screw from Control Panel by
(+) screwdriver.
9.4.2. Connector inserted to Terminal Block

Separate the Terminal Connector connected to Terminal Block by Long Nose Plier
and after passing the wire into the Cable Socket and inserting the wire to the
Terminal Connector. Fix it by (-) screwdriver.
Terminal Block for external contacts such as Level Switch is connected with
jumper wire. Before wiring, remove it.
17
9.4.3. Allowable wire standard for Terminal Block & Cable Socket is as follows.
a. Terminal Block for Flow Control & Additional Function : AWG16~30
b. Terminal Block for Power : AWG18~26
c. Cable Socket: External dia. Ø4~Ø8
9.4.4.
Put the Terminal Connector connected with wire into the Socket of Terminal Block
and assemble the Terminal Cover. Tighten the Cable Socket so that wire don't be
fall out, after adjusting wire length.
9.4.5
Power wires are 3 wires including ground. be careful not to confuse since Green &
Yellow color are used for ground wire.
18
9.4.6
Diagram of Electric Circuit (Example)
a. PULSE Input Signal: Min. PULSE Duration Time is 4ms
• DI1 Selection: VOLTAGE WITH OPEN CONTACT
• DI2 Selection: NO VOLTAGE WITH OPEN CONTACT
b. DC4~20mA: Input Resistance 250Ω
19
c. LEVEL SWITCH Input Signal : NO VOLTAGE WITH OPEN CONTACT

OPEN : LOW LEVEL CLOSE: NORMAL LEVEL
d. ALARM Output: DRY CONTACT (SPST)

Contact Capacity: 3A 250VAC (5A 30VDC)
e. REMOTE RUN/STOP Input Signal : NO VOLTAGE WITH OPEN

CONTACT. OPEN : PUMP STOP CLOSE: PUMP RUN
20
10. Operation
10.1 Start
※WARNING
Do not operate when the discharge valve is closed or do not close the valve during
operation. Pump and piping may be damaged with excessive pressure rising and
liquid may spout when operation under valve closing.
※CAUTION
• When discharge valve of pump is clogged with foreign substance, pressure is
raised and liquid is spouted and it cause damage of piping.
•Wear suitable protective clothing(gloves, mask, goggles, working clothes, & etc.)
when pumping hazardous liquids.
•Some water may be remained in the pump after final performance test.
In case of use for some liquids reacted to water, remove water in the pump and
dry the pump necessarily.
10.1.1
Check if suction side and discharge side hose is tightly connected, and Hose of
Air Vent is connected with Liquid Tank or other container.
10.1.2
Set each Control Knob to 100% and operate the pump after turning the Air Vent
Cock counterclockwise about 1~ 1½ revolutions. Confirm that liquid is flowed
through Air Vent and start normal operation after closing the Air Vent Cock by
turning it clockwise.
10.1.3
In case of the pump attaching Relief Valve, if the Knob of Relief Valve is clockwise
turned about 90°, Air Vent Valve is opened. On the other hand, if the Knob of
Relief Valve is clockwise turned about 90° again, Air Vent Valve is automatically
closed by spring force.
21
10.2 Adjustment of Capacity Rate

※WARNING
Do not turn the Control Knob of Stroke Length & Stroke Number below 0% or over
100%.
Since capacity Rate is controlled by both the Control Knob of Stroke Length and
the Control Knob of Stroke Number, fine control of capacity rate is possible.
11. Repair and Maintenance

※WARNING
• Turn off the power and stop pump & other equipments before repair &
maintenance, otherwise it may cause electric shock.
※CAUTION
•Wear suitable protective clothing during assemble and disassemble work.
Liquid End Part prior to repair or maintenance of pump..
11.1 Check before Operation
a. Check the level of liquid tank and, if it is insufficient, supplement the liquid.
b. Check if the valves on the suction & discharge piping are opened.
c. Check if piping is loosened or damaged.
d. Check electrical wiring if there are no electrical short & disconnection.
11.2 Check during Operation

a. Check the level of liquid tank and, if it is insufficient, supplement the liquid.
b Specially, be areful for the
process or chemical influenced by Air
b. Check if liquid is leaked out the Joint or other parts. If necessary, fasten it again.
If leakage doesn’t stop, check O-ring and/or Packing of each parts and replace the
damaged O-ring and/or Packing with new one.
c. Check if noise sounds from the pump.

d. Check if the needle of pressure gauge is located at normal range.
22
11.3 Maintenance prior to long shutdown

a. Wash inside Pump Head by drawing & discharging clean water
for 30 minutes.
b. Put the cover on the pump to protect it from dust and/or corrosion.
c. Set the Control Knob of Stroke Length at 100% in order to prevent the deformation
of diaphragm.
b. Check foreign substances lay on the Check Ball and/or Ball Seat before restarting
the pump.
11.4 Maintenance prior to long shutdown
※WARNING
• Turn off the power and stop pump & other equipments before repair &
maintenance, otherwise it may cause electric shock.
※CAUTION
•Wear suitable protective clothing during assemble and disassemble work.
Liquid End Part prior to repair or maintenance of pump..
11.1 Other maintenance

a. When diluted liquid or high viscosity liquid is used at freezing place in the winter,
install HEAT TRACING to prevent the pump from freezing because it causes the
damage of the pump & other devices with freezing on the liquid end part of pump
and inside piping.
b. Clean the inside of Tank and Joint every 3 months at least.
23
12. Cause of Trouble and Troubleshooting

Trouble Cause Troubleshooting
Leaks from joint or sealing part Check o-ring & tighten

Air is drawn
Empty tank Fill up and expel air
Pump is Strainer is clogged Clean strainer & tank
running
but Pump head is filled with gas Purge the gas by air vent cock
liquid is
not Suction is Assembly direction of valve is
Re-assemble the valve
discharged not wrong
. sufficient. Ball Seat is worn out Replace
Set stroke length at 100% and
Short stroke length control discharge capacity by
stroke number
Check ball & ball seat are

Replace
damaged
Spring is broken Replace
Insufficient discharge rate Diaphragm is aged or broken Replace
Setting of knob is wrong Readjust

Liquid being treated is Recheck the pump
changed specifications
Pressure is increased by
Disassemble and clean
foreign substance or clogging
Hose or diaphragm broken

Leakage of liquid Replace
due to fatigue
Head and joint are loosened Tighten
There is no o-ring Insert o-ring
24
Trouble Cause Troubleshooting

Wrong voltage Check voltage & correct
Wrong wiring Check the wiring & correct
Status Disconnection of cable Modify or replace
Lamp(LED) Switch is cut off Turn on switch
is off
Pump Check the cause and replace
Fuse is burnt out
dose fuse
not run Defective magnetic switch Replace
Unsuitable voltage Connect suitable voltage
Solenoid Spring is broken Replace
does not run Check the resistance &
Defective solenoid
insulation
13. Replacement of Parts

※CAUTION
Wear suitable protective clothing during assembly and disassembly work.
13.1 Replacement of Ball Seat and Check Ball
a. Disconnect the hose of suction &
discharge from the pump.
b. Loosen the joint of suction & discharge side and
take out valve parts(check ball, ball guide, & ball
seat)
c. Check the damage & sticking of foreign

substances on the valve parts and replace or wash
if necessary.
d. When reassembling joints, be careful not to

change assembly direction of the parts in upper
joint & lower joint.
e. Specially, be careful not to forget assembly of o-

ring, ball guide, & check.
25
※CAUTION
Be careful to assemble valve parts correctly according to sequence (top : ball guide,
middle : check ball, bottom : ball seat). If the sequence is wrong, liquid flow backward
and pump may be damaged.
13.2 Replacement of Pump Head

a. Disconnect the hose from the joint of suction and discharge side.
b. Loosen the head fixing bolts with hex. wrench.
Head is disassembled by pulling the head forward.
c. Assembly should be done with inverse sequence of disassembly.
※ CAUTION
• When assemble the head with head bolt, tighten
the head bolt in the order of right diagram.
For example, if tighten the bolts in order of
1→3→2→4, leakage from the pump head may be
caused by unequal tightening
tightening.
• Suitable tightening force(torque) is 3N m(30.4kgf
cm).
13.3 Replacement of Diaphragm

a. Disassemble pump head according to the procedure detailed in 13-2.
b. Set stroke length at 0%.
Diaphragm is screwed into the slider shaft and diaphragm can be easily
disassembled by turning it counterclockwise.
c. After replacing diaphragm with new one, fix it to the slider shaft by turning it
clockwise.
26
d. Set stroke length at 100% and assemble the pump head with head bolts.
14. Consumable Parts and Spare Parts

14.1 Consumable Parts
Part Name Q'ty
Diaphragm 1
Ball Seat 4
Check Ball 4
O-ring 2
Spring(High Viscosity) 2
14.2 Spare Parts
•Hose Nut •Joint •Hose Adaptor •Clamp Ring • Ball Guide
27
15. Warranty
15.1 Warranty period is one year from purchase date.
15.2 During warranty period, repair or change of pump is free of charge, if trouble or
damage of pump due to design or manufacturing.
※ Consumable parts are excluded.
15.3 Repair or change product due to following reasons will be charged regardless the
warranty period.
a. Trouble or damage of pump expired warranty period.
b. Trouble of using by careless handling.
c. Trouble or damage due to using non-designated part & reconstructing the pump
arbitrarily.
d. Trouble by fire or natural disaster.
16. Repair Service
※ CAUTION
• When the pump is sent to factory for repair service, clean out inside of pump.
• Do not send the p
pump
p back,, if the p
pumpp has been used for harmful & fatal liquid
q
to health.
a. Contact to CHEONSEI or local distributor as shown on back of the manual, if you

have any problem or questions.
b. If you want to repair, please inform the following.
• Model Name & manufacture number written in name plate
• Used period, using condition, state, and transfer liquid
c. If warranty period is over, it may charge according to repair part. Please contact
with sales agent for more information.
d.
Minimum retention period of parts for repair is 5 years from the date of production.
28
17. Structure and Name of Each Parts

17.1 Liquid End Parts
Note.
(1) Only for High Viscosity Type
(2) Only for Relief Valve Type
29
17.2 Accessories Parts

a. Anti-siphon Check Valve
b. Strainer Foot Valve
c. Relief Valve
Note. (1) Quantity is changed according tomodel.

30
FUE SALINITY INDICATOR
INSTRUCTION MANUAL
SALINITY INDICATOR

TABLE OF CONTENTS
PAGE
1. THE GENERAL OF SYSTEM ---------- 2
1.1 INSTRUCTION
1.2 MEASURING PRINCIPAL
2. INSTALLATION OF SALINITY METER ---------- 3

2.1 CONTROLLER INSTALLATION
2.2 THE SENSOR INSTALLATION
3. OPERATING THE SALINITY METER ---------- 5
4. TECHNICAL SPECIFICATIONS OF SYSTEM 6
5. DRWAING INSPECTION ---------- 7
2
1. THE GENERAL OF SYSTEM
1.1 INSTRUCTION
Salinity Meter is an instrument, which measures the content of
natrium chloride in the evaporated water from a fresh water
generator displayed in PPM (parts per million), and ensures
that water containing a higher level of PPM, than what has been
keyed in at the salinity meter, is rerouted back to the fresh wate
generator.
1.2 MEASURING PRINCIPAL

Measuring principle is that calculating the conductivity between
two electrodes submerged in evaporated water as means of
quantity of current on condition that constant voltage is
supplied.
Furthermore, measured value, that is substantially affected by
ambient temperature,is to be calibrated by additional temperatu
compensation circuit to acquire reliable r
2. INSTALLATION OF SALINITY METER
2.1 CONTROLLER INSTALLATION

The Salinity Meter is consist of two parts :
A display part where from the connected sensors is shown as w
installation part whitch is delivered in a plastic module in which
power supply and connection clips are mounted.
The display part is delivered in a cabinet for front installation in
control cabinet and enclosed shape can be used for the installa
The installation part is fastened. The cab
through receptable & plug to the sensor and the sensor must be
connected to the terminal block, as described Fig 1.
3
1) The white color cable of the sensor is connected to the terminal 4 (' Sensor + ')
2) The white color cable of the sensor is connected to the terminal 5 (' Sensor - ')
3) The red color cabe of the sensor is connected to the terminal 6 (' Temp +')
4) The red color cabe of the sensor is connected to the terminal 7 (' TEMP.- ')
4
2.2 THE SENSOR INSTALLATION
INSTALLATION & DISASSEMBLY METHOD
5
3. OPERATING THE SALINTIY METER

▶ On the front plate of the display part there are 4 keys
( MENU/ACK ,Increase(▲) ,Decrease(▼) ,ENTER ON/OFF ).
▶ When press ENTER ON/OFF' key once for '3 second'

After the power on ( AC 220V )
The PPM and TEMP. value will be displayed on the board.
▶ If you want to alter the alarm setting value, press the '▲' + key or
▼' - key at the same time then the current value will be displayed
while the ALARM lamp is turned on
after that set the alarm setting value as much as you want.
▶ After adjusting, Please make sure of saving the altered value

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

then the alarming will be stopped
but the solenoid valve will be still on working.
▶ The Power Fail ,Alarm and Sol'valve output function is free contact
(NO / COM / NC).
6
4. SPECIFICATION SHEET
7
5. DRWAING INSPECTION
8
TORUBLE SHOOTING GUIDE
9
OIL DETECTOR
INSTRUCTION MANUAL
OIL DETECTOR

OIL DETECTOR
TABLE OF CONTENTS
PAGE
1. INFORMATION --------------------------- 3
2. Features --------------------------- 3
3. Principle of Operationon --------------------------- 3
4. Application --------------------------- 3
5. Specifications --------------------------- 4
6. Adjustment Elements --------------------------- 5
7. Simulation --------------------------- 6
8. Functional Table --------------------------- 6
9. Maintenance --------------------------- 7
10. Repair --------------------------- 7
11. Exchange ofelectronics --------------------------- 7
2
OIL DETECTOR
1. INFORMATION
The Model CLS-113 is the versatile Capacitance Type Level switch that can detect
the level of sediments in liquid, interface between two different liquids as well as
the level of high- insulating powders / granules, conductive liquids / viscous liquids
and others. It is one of the highly efficient detectors whitch company has
developed to ensure a correct level detection under such conditions requiring the
high technology as varied measuring materials, complex / harsh products and so
on. Through our long-term experiencrs and achievements, use of quality materials
and strict quality control, we have here provided you with more stable and reliable
products.
2. Features
ㆍChemically highly resistant materials.
ㆍHighly sensitive and stable meter .
ㆍMaintenceance - free.
ㆍCan easily detect highly corrosive substance .
ㆍRugged construction.
ㆍInsensitive to buildup.
ㆍCan easily install and adjust .
3. Principle of Operationon
This measures the impedance variation coming out between a main electrode and
a tank-wall or between the main electrode and an earth electrode.
As the level rises, the capacitance value goes up, and it provides a contact output
when the level exceeds the set value.
4. Application
ㆍINTERFACE : Oil and Water mercury in the Water alcohol and Acid, Sediment
in the water liquid and foam.
ㆍPOWDER : Plastic power, Slaked lime, Carbon, Iron oxide, Dust, Soil and Sand,
Surgar, Flour and others.
3
OIL DETECTOR
5. Specifications
▶ Installation Method : Top Mounting , Side Mounting.
▶ Conn. Size : PF 1" Thread , JIS 10K 50A FF Flange Type.
▶ Cable Gland : GMS13.5 * 2 or GMS16 * 2 (Brass)
▶ Power Supply : DC 20 ~ 72V , AC 20 ~ 250V / 60HZ FREE
▶ Output : Relay(SPDT) Contact , 250VAC 5A
▶ Material : Housing ~ ADC12
Connector ~ SUS 304
Probe ~ C.S + PTFE
▶ Max. Pressure : 10 Kg/Cm2
▶ Max. Temperature : -40 ~+80℃
▶ Frequency : 400KHz
▶ Range 1 / 2 / 3 : 0 ~ 20 / 0 ~ 80 / 0 ~ 450 pF
▶ Power Consumption : Max. 1.5W
▶ Protection : IP66
①POWER LAMP
②INDICATOR ALARM LAMP
③TIME DELAY RANGE
④SENSITIVITY ADJUST RANGE
⑤COARSE RANGE
⑥SENSITIVITY CONTROL S/W(Potentiometer)
4
OIL DETECTOR
6. Adjustment Elements
① POWER LAMP
Diode for indication of the switching status (DC or AC power supply).
② ALARM LAMP
Diode for indication of the switching status (when any of substances are contacted
on the probe).
③ TEST PUSH BUTTON S/W
By pushing the test switch an additional capacitance(20pf) is provided. Hence the
function of the oscillator and the connected in instruments are tested.
④ RANGE (CHANGEOVER S/W) : 1,2,3
Select the capacitance range of the probe with the mode switch. With the
potentiometer ⑥ and the mode switch ⑤ you can change the switching point
of the probe or adapt the sensitivity of the probe to the electrical properties of the
product and the conditions in the vessel.
This is required to enable the level switch to reliably detect products with very low
or very high dielectric value reliably (DK = dielectric value).
- Examples of dielectric values (DK) : air = 1 , oil = 2 , acetone = 20 , water = 81 ,
etc .
- Capacitance range : Range 1 : 0 ~ 20pF / Range 2 : 0 ~ 80pF / Range 3 : 0 ~
450pF .
Turn the potentiometer ⑥ anticlockwise to make the probe more sensitive.
⑤ MODE SELECT S/W : A,B
With the mode adjustment (A/B) you can change the switching condition of the
output. You can set the required mode (A- min. detection or protection against dry
running of pump, B-max. detection or overfill protection). With two-wire electronics
the mode is selected on the signal conditioning instrument. For that reason there is
mode switch.
⑥ SENSITIVITY CONTROL S/W(Potentiometer) : 1,2,3,~….10
By using the potentiometer(SENSITIVITY), you can adjust the switching point .
5
OIL DETECTOR
7. Simulation
Mode A (detecting oil on water)
1) Set the A/B-switch (2) to mode A ( min. detection)
2) Set the Changeover switch (4) to position 1.
3) Turn the potentiometer very slowly to the anti-clockwise from 10 to 0 until the
alarm lamp ② working (lights).
4) If the alarm lamp dose not work, set the Changeover switch ④ to the next higher
stage(position 2.) and repeat the adjustment with the potentiometer from 10 to 0
until the alarm lamp ② lights.
5) When the alarm lamp lights during the above steps, turn the potentiometer s/w
1step to the anti-clockwise ,Then the setting can be done properly.
※If you cannot find the full switching point in one of the ranges, we recommend
setting the changeover switch ④ to the lowest range in whitch you have found the
empty switching point. Set the potentiometer ⑥ to the average value between
empty switching point and 10. The measuring system is ready for operation.
8. Functional Table
6
OIL DETECTOR
8. Maintenance
The instrument is maintenance free.
9. Repair
For safety and warranty reasons, any internal work on the instrument,
apart from installation and wiring, must be carried out only by us.
10. Exchange of electronics

Remove the old electronics and plug in the new oscillator. Carry out an
adjustment. The instruction is given upper “Simulation"(Switch point adjustment).
7
BURNER
INSTRUCTION MANUAL
BURNER

『 INDEX 』
1. Burner general specification ・・・・・・・・・・・・・・・・・・・・・・・・・ (3)
2. Outlines ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・(4 - 5)
Preparation for operation・・・・・・・・・・・・・・・・・・・・・・・・・・(6 - 7)
Operation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・(8 - 9)
Weste Oil combustion・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・(10)
Fuel Change Procedure・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・(11)
Rotary Cup Burner Unit, Sectional drawing of part ・・・・・・・・・・・・・・・・ (12)
Rotary Cup Burner Unit, Disassembling drawing ・・・・・・・・・・・・・・(13 - 14)
3. Replacement procedure of main shaft bearing・・・・・・・・・・・・・・・ (15 – 22)
Direct Drive Rotary Cup Burner, Sectional drawing ・・・・・・・・・・・・・・ (23)
4. Accessories Drawings of Burner ・・・・・・・・・・・・・・・・・・・・ (24– 32)
5. Maintenance and Cleaning of Burner・・・・・・・・・・・・・・・・・・・・・・ (33)
List of Maintenance & Inspection ・・・・・・・・・・・・・・・・・・・・・・ (34)
Please read sections of W.O.combustion and Fuel change procedure (2-(7), (8)) only when the burner
has these functions. (Standard burner is for only F.O. combustion.)
2
DATE CHARGE
TYPE : SDR-350～700 SUNFLAME BURNING APAPARATUS
1. Burner general specification
1 – 1. Burner type Direct drive Rotary Cup Burner
1 – 2. Capacity 6000－60,000 MJ/H

(50 ～ 700 Kg/H, H.F.O.) (Note 1)
10,000－60,000 MJ/H
(80 ～ 700 Kg/H, H.F.O.) (Note 2)
(Note 1 : with Primary air control)

(Note 2 : Primary air fixed)
1 – 3. Fuel ・Marine A-Oil（at cold start）

・Marine C-Oil (normal) (～500cSt) MAX 135Deg. C.
・Emulsified Fuel MAX 100Deg. C.
1 – 4. Primary Air 11 KPa ～ 1100 Nm3/H
1 – 5. Secondary air 3.5 KPa ～ 22000 Nm3/H
1 – 6. Calorific value 40.9 MJ/Kg fuel
1 – 7. Cup revolutions 3500 mim-1 ～ 8000 mim-1
1 – 8. Vibration Our internal standard：

15μｍ(full vibration range）TYP.
3
2. Outlines Sunflame Rotary Cup Burner (Fig.1)
This burner consists of Rotary Cup, Wind Box, and devices for ignition and safety combustion.
The fuel oil is led to Rotary Cup and goes into Cup inside which is rotated with high speed.
And fuel oil is spread evenly in Cup inside by centrifugal force and thin oil film is formed at
Cup outer end.
The oil film is collided with the high speed air of normal and reverse directions from
Primary Air Nozzle at Cup outer end. Thus fuel oil is atomized and the spray angle is made.
Secondary air (combustion air) is distributed evenly in Wind Box and circulated from the
outer circle of Primary Air Nozzle for easy mixing with the oil particles.
As above, the atomizing of this burner is done in the Rotary Cup, and then the pressure of
fuel oil can be low and the atomized particles are even. This makes complete combustion
and combustion to low load with low excess air ratio
Also ignition is ensures with Ignition Burner using A-Oil.
4
Rotary Cup Burner Unit is fitted with the hinges, and can be opened without removing the air
or oil pipes and electric cables.
In the opened position, all parts can be observed for inspection and maintenance.
Burner can be applied for both horizontal use and vertical use.
The oil film is atomized by the primary air of 600～1,500mmAq.
In case the pressure of furnace is positive pressure, it is required to increase primary air
pressure depending on the furnace pressure.
The volume of primary air will be approx. 7% of necessary combustion air volume.
Regarding atomizing viscosity of the fuel oil ,24cSt is standard, but

combustion can be done at 100cSt.
For better ignition performance, lagging for oil pipe is provided and fuel oil
return- line is provided for oil circulation in order to keep the fuel oil temperature.
Also following improvements for better ignition are applied :

1) Lagging is provided on the piping (from Main Sol. Valve outlet to Flexible connection).
2) Circulation line is provided near to Main Sol. Valve.
3) Also, the start/stop control of F. O. Circulating Pump due to the changing of oil temp.
is done by Temperature Switch located near to Main Sol. Valve.
Above 3 improvements prevent from lowering of fuel oil temperature which is supplied at the
ignition and make ignition performance better.
5
ＰREPARATION FOR OPERATION
Ａ Check the followings before operating the burner.
1. Piping and valve operation of the feed water system.
2. Power source of the feed water control and control air
3. Water level in the boiler
4. Oil level in the service tank
5. Valve operation and no leakage from fuel oil piping (check the ignition burner suction line especially
for air release and oil leakage.)
6. Fuel oil piping according to the flowchart (before commissioning in the yard)
a) Position of the flow meter (to measure the flow rate correctly)
b) Position of the relief valve (for proper oil circulation near the burner)
c) Connecting position of the return line (for sufficient air release)
d) Complete steam heat tracing and insulation (The air blown from the engine room should not cool
the oil piping line.)
Ｂ Initial operation(including operation resumed after a long time shut down)
1. When the service tank cannot be heated, use marine diesel oil.
(Whenever boiler steam is blown at docking, oil piping line is changed to marine diesel oil.)
2. Release air in oil piping completely.

(Especially at commissioning, release air completely after hydraulic test; confirm if oil reaches to
pump suction.)
3. Check wiring of the control panel, external terminals on the junction box, the pressure switches and
the temperature switches
4. Check the rotating direction of each motor.
5. When the boiler is cool, start the operation with low combustion. After the boiler is heated (boiler
pressure is over 0.1MPa), change to high combustion.
6
Ｃ Operation procedure and Notes
1. The burner operation is basically automatic. Manual operation is available in an emergency. There
are safety devices against burner cut for low water level, flame –off or stop of the FD fan overload.
However, burner cut because of the rise if boiler steam pressure is not performed and therefore the
boiler pressure needs monitoring.
In ignition, check the flame of ignition burner first before turning on the fuel oil main solenoid valve.
2. In case of using 2 F.O.Pump, select No.1 pump or No.2 pump at the control panel. Confirm the
valve operation in the piping system as well.
3. Confirm if each switch on the control panel is off before power is turned on.
4. Open or close valves on the piping system and select the position of F.O.TEMP DETECT SWITCH
on control panel according to the fuel oil used for combustion.( For Marine diesel oil ,turn the
thermostat bypass on.)
7
OPERATION
A－MANUAL OPERATION
1. After confirmation of each points in preparation for operation, turn on main power source.
2. According to used fuel, confirm if each valve in oil piping line is open or close.
3. When Marine A-oil is used, set oil heater switch to “OFF”, and also set temperature detect switch
to “CANCEL(D.O.)”.
4. Set ACC switch (switch for auto combustion control ) to “AUTO.”In case PLC is defective, set
ACC switch to “MANU.”.
“AUTO.”： F.O.Flow and damper adjustment are controlled automatically in “AUTO.”mode .
“MANU.” ：F.O.Flow and damper adjustment are controlled manually in “MANU.” mode.
Manual adjustment is carried out by pushing each “INC.”and,“DEC.”switches
of MANU. AIR FLOW and MANU. F.O. FLOW.
＊Please change ACC switch during the burner stops.
5. Set the burner operation switch (OPERATION) to “MANU.” position and start the burner operation.
5.1 In case of ACC“AUTO.”
Prepurge is carried out for 30seconds automatically.
After prepurge finishes, lamp for “IGNITION READY” on the junction box lights up.
5.2 In case of ACC “MANU.”
Carry out prepurge manually.
Open air damper fully for 30 seconds by switch of MANU. AIR FLOW.
After that, set the damper to ignition position (where lamp for “IGNITION READY”lights up.)
Next confirm FO Flow and adjust FO Flow by switch for MANU. F.O. FLOW not to generate
smoke.
6. After confirm lamp for “IGNITION READY” lights up, start ignition.
After pushing switch for “IGNITION MANU” start, ignition starts within 3 seconds.
If ignition does not start within 5seconds, switch off and investigate the cause.
7. After confirmation of ignition burner firing, remain pushing “IGNITION MANU”switch and turn
on “SOLENOID V. MANU” switch. Then combustion starts.
8. In case ACC switch is in “AUTO.”mode, proportional control is carried out in response to steam
pressure.
“In case ACC switch is in MANU. mode, adjust combustion capacity by each switch for MANU. AIR
FLOW and MANU. F.O. FLOW.
8
9. When combustion is stopped, set the burner operation switch (OPERATION)to “STOP”position.
D.O.MIX (cleaning in burner combustion line) is carried out and combustion stops.
Then postpurge is carried out and burner stops completely.
B－AUTOMATIC OPERATION
1. Initial operation is same as 1-3 sections in MANUAL OPERATION.
After setting each switch to Auto position, set the burner operation switch to “AUTO” side.(If steam
pressure is high, burner enters STAND-BY mode )
When the condition is right, burner is operated automatically based on program control.
2. When combustion is stopped, set burner operation switch to “STOP”.

After postpurge finishes, burner stops completely.
Do not turn off main power source until postpurge finishes.
3. For time table of auto operation, refer to the attached flow chart.
9
＊ Waste Oil Combustion （Waste Oil Combustion Only）
(a) Preparation for operation

1. Water and solid materials in the waste oil cause failure of the pumps and valves. And they also cause
clogging of the strainer. Therefore, the tank needs proper drainage and the strainer must be cleaned
before operation.
2. At low temperature, waste oil does not flow smoothly and atomized particles become rough.
Because combustion cannot be carried out at lower than ignition point, waste oil must be heated
before combustion. Though heating temperature is normally from 80°to 100°,heating temperature is
changeable depending on waste oil condition. Please adjust according to the combustion condition.
Water in waste oil can be evaporated by heating. (If a lot of water is contained in case water is
evaporated by heating, the temperature in the tank rises up to 100 .(maximum is 100 ))
3. Stir waste oil before feeding to the burner to equalize waste oil including microscopic water particles
after drainage and stratifying by difference in specific gravity and temperature in tank. This can also
facilitate evaporation of the water.
(b) Operation
After above mentioned preparation, stop the burner once. Changes the 3-way valve to waste oil
usage and operate W.O.Pump.Then apply the same operations as those for heavy fuel oil. Depend
on the waste oil condition, oil pressure must be adjusted. Increase oil pressure for the oil with low
heat generation to increase oil flow and prevent from blow –off. Decrease oil pressure for the oil
with high heat generation to decrease oil flow and prevent from generation of black smoke.
(c) Stop
Stop the burner and W.O.PUMP once. Replace suction line of W.O.PUMP to marine diesel oil.
Operate W.O.PUMP for 2 or 3minutes to replace W.O.line to marine diesel oil and then change the
3-way valve to heavy fuel oil usage
10
＊ Fuel Change Procedure
(a) Change to D.O./M.G.O from H.F.O.

1. Measure and record the present temperature of thermometer at the burner side. Change the fuel
during burner combustion.
2. Stop the F.O.Heater by control panel.
3. Set F.O.TEMP.DETECT on the control panel to ”CANCEL”.
4. Stop steam supply to F.O.line.
5. Wait until temperature become less than100℃from the temperature recorded in 1.
6. Change combustion valve to D.O. /M.G.O. from H.F.O.
7. If black smoke is generated due to increase of combustion capacity, decrease the pressure by oil
pressure adjusting valve.
(b) Change to H.F.O from. D.O. /M.G.O
1. Measure and record the present temperature of thermometer at the burner side.
2. Change combustion valve to H.F.O. from D.O. /M.G.O.
3. Wait until the temperature starts increasing.
4. Start steam supply to F.O.line.
5. Start operation of F.O.Heater by control panel.
6. Wait until the temperature increases more than the setting temperature for F.O. temperature low
alarm.
7. Turn off the F.O.TEMP.DETECT SWITCH on control panel.
11
Rotary Cup Burner Unit, Sectional drawing of part
25
Spare parts list of the burner unit

No. Q'ty NAME OF PARTS REMARKE No. Q'ty NAME OF PARTS REMARKE
1 1 Primary Air Tube 20 8 Cap Screw M5x12
3 EACH1 Primary Air Tube-parts 21 9 Cap Screw with S.W. M5x15
4 1 Primary Air Nozzle 22 1 Coupling AL-70
5 1 Main Shaft 23 6 Cap Screw M5x15
6 1 Rotary Cup & Cup Holder 24 6 Cap Screw with S.W. M5x20
7 1 Cup Nut 25 8 Cap Screw with S.W. M3x10
8 1 Bearing Cover 26 1 Key at S. Cup (both round) 5x5x17
9 1 Oil Pipe Connection Part 27 2 O-ring (viton) 特 13.3x2.4
10 1 Distributor Oil Guide (inner) 28 3 Spring Washer φ16
11 1 Distributor Oil Guide (outer) 29 1 Key at S. Motor(both corner) 5x5x20
13 1 Bearing Holder 30 1 Oil Seal 25457
14 1 Motor Base 31 5 Cap Screw M5x60
15 1 Fuel Oil Pipe 32 1 O-ring (viton) S65
16 1 Fuel Oil Pipe Cover 33 1 O-ring (viton) G55
17 1 Burner Motor 250W 48V 34 1 Packing 8x8
18 1 O-ring (viton) S24
19 1 Bearing 6006LLB 36 3 Hexagon Socket M5
Countersunk Screw
37 1 Snap Ring S-30
12
Rotary Cup Burner Unit, Disassembling drawing (1)
25
Disassembling drawing (2)
No. Q'ty NAME OF PARTS REMARK

1 1 Primary Air Tube
3 Each 1 Primary Air Tube-parts
4 1 Primary Air Nozzle(Clockwise direction)
6 1 Rotary Cup & Cup Holder
7 1 Cup Nut
14 1 Motor Base
15 1 Fuel Oil Pipe
16 1 Fuel Oil Pipe Cover
17 1 Burner Motor 250W 48V:amplifier DCE70/10
20 8 Cap Screw M5x12
21 9 Cap Screw with S.W. M5x15
22 1 Coupling AL-70
23 6 Cap Screw M5x15
27 2 O-ring (viton) 特 13.3x2.4
28 3 Spring Washer φ16
34 1 Packing 8x8
36 3 Hexagon Socket Countersunk Screw M5x12(2), M5x20(1)
13
Rotary Cup Burner Unit, Disassembling drawing (2)
No. Q'ty NAME OF PARTS REMARK

5 1 Main Shaft
8 1 Bearing Cover
9 1 Oil Pipe Connection Part
10 1 Distributor Oil Guide (inner)
11 1 Distributor Oil Guide (outer)
13 1 Bearing Holder
19 2 Bearing 6006LLB
26 1 Key at S. Cup (one round) 5x5x17
29 1 Key at Shaft Motor 5x5x20
30 1 Oil Seal 25457
31 5 Cap Screw M5x60, P=0.8
33 1 O-ring (viton) G55
37 1 Snap Ring S-30
14
Ｒeplacement procedure of main shaft bearing
＊ Maker sure no debris nor foreign particle are involved on the part surface at replacing
bearing.
＊ O-ring shall be renewed after disassembling and re-assembling.
＊ The equivalent type of the grease for the main shaft should be, Grease heavy (CHEVRON),
or Unirex N3 (ESSO).
1-1. Remove Primary air nozzle ④.
1）Remove 3pcs of Cap screws ㉑.
2）Take out Primary air nozzle ④ from Primary air tube ①.
㉑ Cap screw 3 pcs.
(M5x15spring/flat washer）
① Primary air tube

Note: When taking out Primary air nozzle ④,
pay good attention not to give any damange
④ Primary air nozzle
to the rotary cup.
1-2. Detach the rotary cup ⑥ and cup nut ⑦.
Note: When removing Cup nut, stopper & cap

screw M8×45 in spare parts box should be
used to the coupling to avoid rotation of & Stopper
fixing the cup shaft. (As per photo on the
right-hand side.)
Note: Do not give an impact to the “T”shape Hex.

Wrench to rotate cup nut. Never use hammer for
Cap screw （M8×45）
this action.
1）Using 24mm “T”shape Hex. Box wrench, loosen the Cup nut ⑦ and removecup nut, 3pcs of
conical spring washer ㉘.
※Pay attention on combination of the ※Cup-nut is un-screwable
conical spring washers.
Counter-clockwise.
㉘ springs washer
⑦ Cup nut
15
2）Take out the rotary cup ⑥ ＆ holder.
※ Caution when removing rotary cup.
Due to rather soft material, Alminum for the rotary cup and its holder, never give impacts by
hitting the hammer. Use tools (cup remover) supplied by us.
＊Prepare tool as per above sketch.

Item ② , puller can screw and the part ① will
① Tool for removing nut F.B. t9x25
come out for removal of the cup.
② Cap screw M12x150
③ Cap screw 2-M6x30
⑥ Rotary up & its holder
3）Remove Cup key ㉖ of the main shaft from the groove.
㉖ Cup key
※For refixting the rotary cup, never ＊Showing after removal of rotary cup &
use pipe wrench. nut.
16
1-3. Take out Primary air nozzle.
1）Remove Hex. bolts（M6×20 S/F Ｗasher 6pcs.）
Primary air housing Hexagonal bolt
1-4. Please pull up ⑮ Fuel Oil Pipe from a Burner backplate.
㉑ Cap screw with S.W.
(M5×15)
※ Attention : Leakage of the oil.
※ Always replace with new O-ring.

(always apply grease to the O-ring. 13.3×2.4)
1-5. Remove bearing holder ⑬.
1）Take out Cap screw ㉓
㉓ Cap screw ※For assembling, use anti-baking agent.
（M5×15 ６ pcs.）
17
1-6. Disassemble the burner unit（referring Disassembling fig. 2）
1-7. Loosen the screws of shaft side coupling ㉒.
Hallow set screw
(M5×6)
1-8. Remove cup key ㉙ from shaft key groove.
1-9. Detouch the bearing cover ⑧.

1）Remove the Cap screw ㉔（M5×20 S. Washer 6 pcs.）
⑧Bearing cover
㉔ Cap screw
（M5×20 S. Washer 6cps.）
18
1-10. Take out the outside oil guide ⑪.
1）Remove Cap screw ㉛（M5×60 5pcs.）
㉔ Cap scrwe
（M5×60 5pcs.）
⑪ Outside oil guide
⑩ Inner oil guide ⑪ Outer oil guide
1-11. ⑤ Remove main shaft.

1）Softly hit the motor side main shaft by soft hammer.
2） Remove the main shaft & bearing ⑲ on the cup side from the motor side bearing.
⑤ Main shaft
⑲ Bearing
1-12. Remove the motor side bearing ⑲ from bearing holder ⑬, using pipe for even force.
⑬ Bearing holder
⑲ Bearing
19
1-13. Remove the snap ring ㊲ from Main shaft ⑤.
⑲ Bearing
Cup side
㊲ Snap ring
1-14. Using Puller, remove Cup side bearing ⑲ from main shaft ⑤.
⑤ Main shaft
㊲ Snap ring
⑲ Bearing
After dis-assembling
1-15. Replace with new bearing.

1）Insert the cup side Bearing ⑲ to Main shaft ⑤.
2）Up-right the main shaft and insert the bearing down to the installation
position carefully.
※ Apply the even power when insert the bearing, such as
using pipe.
Note at installing bearing！！

Possible to damage bearing performance if hitting the bearing
face by hammer.
We do recommend the way or tools to give even force to bearing
face, and insert to the correct position.
20
1-16. Apply Snap ring ㊲ to the groove on the main shaft ⑤.
⑲ Bearing
(Cup side)
I fit a snap ring and am located.
1-17. Re-install main shaft ⑤ to the bearing holder ⑬.

1）Set the O-ring ㉝ to the groove of Bearing holder ⑬.
※ Make sure before installation, if there is no

debris adhere on the groove of O-ring
installation on the bearing holder.
⑬ Bearing holder
※ Always replace with new O-ring.

（always apply grease to the O-ring.）
㉝ O ring
2）Insert the main shaft with bearing ⑲ for cup side into the bearing holder ⑬ to the face
of bearing seat.
21
1-18. Insert the bearing ⑲ for motor side to the main shaft ⑤ in the position of upright the main shaft.
1）Keeping the bearing holder ⑬ in upright position, using pipe to share the even power to
bearing’s inner/outer circumferences, insert the bearing⑲ down to the bearing seat of the
main shaft.
⑲ Bearing
※Be careful not to damage thread of screw at main shaft.

Be Careful threads
※Confirm after installation if bearing smoothly rotate.
※After completion of assembling the bearing holder and the
main shaft, implement assembling in the order of totally
opposite way of dis-assembling.
22
Direct Drive Rotary Cup Burner, Sectional drawing
(38) Hinge Arm (37) Burner Front Door
(20) Fixation Hinge (35) Burner Unit Stopper
Burner Hinge Stopper：FA841-W
How to open
Take out Burner Stopper (35), pull out the
burner unit about 90mm.（Pull out it to be
locked by Stopper again. ）
Pin
Next turn the lock lever for burner hinge
counterclockwise. And open the burner
hinge at 90 degree. Fix it with pin attached
to the fixation hinge.
(27) Primary Air Housing

(33) Spoked Bracket
(28) Burner Unit・Eccentric Roller
Limit Switch：RS-604
Burner Motor amplifier : DCE70/10
A drawer 90mm
(30) Secondary Air Nozzle

Burner Unit
(17) Wind box
(29) Secondary Air Damper 23

4. Accessories drawing of Burner
4-1. Fitting of Burner Front Door (37)

Burner Unit is fitted to Spoked Bracket (33) and supported by Eccentric Shaft with Rollers (Bearing)
in order to maintain the centering.
Adjustment is done with rotating Eccentric Shaft for smooth movement.
Burner cannot be opened or closed if front part or rear part of burner is not locked by Burner Unit
Stopper (35).
4-2 Burner Wind Box (17)

Burner Wind Box (17) takes primary and secondary air in from the fan separately located
and distribute or adjust the combustion air evenly through Secondary Air Nozzle (30).
4-3 Secondary Air Nozzle (30)

Secondary Air Nozzle is composed in two parts. (Please refer to below drawing)
Secondary Air Register Vane inside and Secondary Air Vane outside control the secondary air
flow to the flame and maintain the stable combustion.
By the angle adjusting of Secondary Air Vane, the flame shape can make suitable for the
furnace shape.
(30) Secondary Air Nozzle

Hexagon head bolt M6 with plain washer
Secondary Air Register Vane
Secondary Air Vane
24
4-4. Assembling with Spoked Bracket (33) and Eccentric Roller
Assemble Eccentric Roller (Bearing) as described below.
(33) Spoked Bracket
Pay attention to the

direction of eccentric roller
attachment.
Assemble to make
touching surface of all
bearings face to center.
Spoked Bracket Eccentric Roller
No. Q' ty Name of part Remarks
1 1 Eccentric Shaft for Roller
2 1 Bearing 6302ZZ
3 1 Hexagon Nut M16
4 1 Spring Washer
5 1 Snap Ring S-15
（Above quantity shows for 1 set of Roller / 6 sets are used for 1 Burner.）
25
4-5. Assembling procedure for Primary Air Damper &Secondary Air Damper
＊Primary Air Damper
Set Shaft of Primary Air Damper(size:10φ)(24) into Hinge Pin 80A(23).
Fix Blade to Hinge Pin80A(23) by Cap Screw M5×12 with S.W.
(23) Hinge Pin 80A
(24) Shaft of Primary Air Damper
(24) Blade of Primary Air Damper
Cap Screw M5x12 with S.W.for Blade attachment

Make Blade surface parallel to cutout of Shaft.
Set cutout of Shaft to Name Plate side.
＊Secondary Air Damper

Set Shaft(φ１６) of Secondary Air Damper into Window box.
こ
Put the grease on Shaft collar.
(29) Shaft of Secondary Air Damper

Set cutout of Shaft to Primary Air Damper side.
Put the grease on.
26
Fix Blade of Secondary Air Damper by Cap Screw M8×15 with S.W..
Put Plain Washer （outside diameterφ25, inside diameterφ16.5, thickness:2）between
Blade and Wind Box. Adjust to equalize the position of Blade and fix with Screws.
Cap Screw (M8x15with S.W.)
Plain Washer Plain Washer
Linkage parts between Linkage parts between

Primary &Secondary Air Damper Control Motor and Secondary Air Damper.
Spare parts list of Damper Linkage

No. Q'ty NAME OF PARTS REMARK No. Q'ty NAME OF PARTS REMARK
48 12 Spring Washer For M8 68 4 THK Ring Ball BL8
52 1 Scale Plate of Secondary Air Damper 69 1 Flush Cut Bolt M8
58 1 Scale Plate of Primary Air Damper 70 6 Hexagon Bolt M8
61 2 Secondary Air Damper Lever 71 1 Stud bolt M8x65L
62 1 Secondary Air Damper Lever 72 1 Flush cut bolt M8x50L
64 1 Indicator Needle for Primary Air 73 1 Turnbuckle M8x55
Damper
27
4-6．Ignition Burner (Pilot Burner) assembling drawing
This is the pilot burner which is ignited by A oil.
The atomized oil (0.7MPa of A oil pressure) is ignited by the electric spark of 10,000V between two Electrodes
＊Use hex.wrench in vertical direction for easy assembling when you assemble the atomizer.
＊Pay attention to the direction of 2) disc in case of assembling
28
4-7. Flame Eye (detecting of the combustion) (R407)
This detects flame and composes the safety circuit by amplification circuit of semi-conductor.
4-7-2. Flame Eye Relay
29
30
31
－３５－
32
5. Maintenance and Cleaning of Burner
＊Daily inspection and maintenance
1. Inspection of oil strainer.
2. Inspection of oil pressure & oil volume.
3. Inspection of furnace pressure and exhaust gas temperature.
4. Open the burner and clean the rotary cup if necessary.
It is possible to clean Rotary Cup without removing Main Shaft.
But after long time operation, it is necessary to clean it with removing Cup, Primary Nozzle
and Distributor from Main Shaft.
In case of reinstallation of these parts, please coat the grease oil on Main Shaft slightly for easy
disassembling at next time.
＊Weekly inspection and maintenance

1. Inspection and maintenance of Ignition Burner.
2. Inspection of Flame Eye function.
3. Inspection and greasing at each linkage.
＊Other notes
Do not heat up Rotary Cup over 150 ℃
Also do not use hard tool such as steel made without fail for the cleaning of Cup.
If Cup inside is hurt, the combustion become abnormal due to the insufficient atomizing.
In case of cup removal, please use the special tool for removal of rotary cup.
（refer to 1-2 for Ｒeplacement procedure of main shaft bearing）
When Primary Air Nozzle is refitted after the cleaning, please check the distance
between both outer ends of Nozzle and Cup as shown in below sketch.
Table for Cup motor controller setting Primary air nozzle and atomizing cup
A ・Standard value : 0.5

・Minimum value : 0
・Maximum value : 1.5
33
List of Maintenance /Inspection
ITEM JOB ITEM INTERVAL RAMARKS
No.
項目内容周期備考
F.O. PRESSURE VISUAL CHECK ALL TIMES SET-PRESS. FOR SHIP:0.6MPa

1
燃焼油圧目視点検常時本船の油圧は Nor. 0.6MPa です
CLEANING & WEEKLY CLEANING OF INSIDE &

ROTARY-CUP INSIDE
CHECK AFTER WO COM. CONFIRMATIO OF MOUNTING POSITION
2
1 回／1 週間
ロータリ・カップ内面掃除＆確認内面の掃除及び一次ｴｱﾉｽﾞﾙのｾｯﾄ位置の確認
廃油燃焼後
ROTARY-CUP & DISASSEMBLING DEPENDING ON THE DIRTYCON, THE INTERVAL

MONTHLY
DISERIBUTOR & CLEANING TO BE CHANGED.
3
ロータリ・カップ及び
分解掃除 1 回／1 か月汚れ具合によってその都度変更して下さい
ディストリビューター
CLEANING & CONFIRMATION OF ELECTRODE

WEEK / TWICE OR
IGNITION BURNER CHECK MOUNTING POSTION.
MORE
4 VISUAL CHECK OF ELE. CHECK
ｴﾚｸﾄ・ﾛｯﾄﾞのｾｯﾄ位置確認
点火バーナ掃除＆確認 2 回以上／1 週間
ｴﾚｸﾄ・ﾛｯﾄﾞのひび割れの有無確認
CLEANING & CONFIRMATION OF ELECTRIC

FLAME-EYE GLASS WEEKLY
5 CHECK RESISTANCE(600～20KΩ)
フレーム・アイ前面掃除＆確認 1 回／1 週間電気抵抗値の確認(600～20kΩ)
DEPENDING ON THE DIRTINESS, THE INTERVAL.

STRAINER SCREEN CLEANING WEEKLY
6 / TO BE CHANGED.
ストレーナ網掃除 1 回／1 週間汚れ具合によってその都度変更して下さい
AIR / OIL LINKAGE VISUAL CHECK MONTHLY CHECK OF EACH BOLT & SCREW
7
油／空気量調節リンゲージ目視点検 1 回／1 か月各部セットネジの緩みの有無
CHECK OF ABNORMAL SOUND OF BEARING FOR

BEARING AUDIBLE CHECK MONTHLY
BURNER MAIN SHAFT & EACH MOTOR
8
バーナ主軸／電動機用ベアリングの異常音の有無
ベアリング異音点検 1 回／1 か月
CLEANING & CLEANING OF HEATING SURFACE.
HEATER ELEMENT YEARLY ELECTRIC TYPE : CHECK OF TERMINAL

CHECK
9 WIRING CONNECTION
加熱部表面の掃除 / 断線の有無
加熱器エレメント掃除＆確認 1 回／1 年
電気式：各部端子台等配線ネジの緩み
CHECK OF TERMINAL WIRING

ELECTRIC PARTS VISUAL CHECK MONTHLY
10 CONNECTION.
電気部品目視点検 1 回／1 か月各端子台等配線ネジの緩みの有無
34
3 9 4 6 2 6 5
8 1 7
9 PUMP BASE 1
ポンプベース
4 COMPOUND GAUGE 1 8 INLET FLANG 1
コンパウンド・ゲージ E IN側フランジ
3 MOTOR 1 7 OUTLET FLANGE 1
電動機 OUT側フランジ
2 COUPLING 1 6 BALL VALVE 2
カップリングボールバルブ
1 OIL PUMP 1 5 PRESSURE GAUGE 1
油ポンプ圧力・ゲージ
項目部品番号数量項目部品番号数量
CHECKED BY
DRAWING HISTORY 図面来歴 DRAWING NAME
承認印
図面名称 OIL PUMP ASSEMBLY
DRAWN BY
製図オイル・ポンプ組立図
SCALE 図番 Mp-10097
尺度
NO
日付
2012/01/16
3 5 6 7 8 9 10
4 11 2 1
6 BALL VALVE 1
ボールバルブ
5 CHECK VALVE 1 11 OUTLET FLANGE 1
チャッキ弁 OUT側フランジ
4 MOTOR 1 10 INLET FLANGE 1
電動機 IN側フランジ
3 COUPLING 1 9 PIPE φ6 1
カップリング逃がし配管 φ6
2 PUMP FLANGE 1 8 RELIEF VALVE 1
ポンプフランジリリーフ弁
1 OIL PUMP 1 7 PRESSURE GAUGE 1
油ポンプ圧力・ゲージ
NO. NAME OF PARTS Q'TY NO. NAME OF PARTS Q'TY
DRAWING HISTORY 図面来歴
CHECKED BY
承認印
DRAWING NAME OIL PUMP ASSEMBLY
図面名称 (IG BRN. PUMP)
DRAWN BY
製図
オイル・ポンプ(IGバーニング・ポンプ)組立図
SCALE 図番 Mp-10098
尺度
NO
日付
2012/01/16
FUEL SUPPLY UNIT OF BURNER SIDE
（F.O. Exclusive）
ＴＹＰＥ： SDR-350 / 500 / 700
INSTRUCTION MANUAL
1-30, Nishinohata, Okubo-Cho, Uji, Kyoto, 611-0033, Japan

TEL : 0774-41-3310 / FAX : 0774-41-3331
1
『CONTENT』
1. Block piping
1-1. Unit overall view・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3
1-2. Block Piping・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 4
1-2-1. Exploded diagram of Block piping・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 4
1-2-2. Assembly of block piping and part drawing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 5
1-3. Flow diagram
1-3-1. Bunker C flow in combustion・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6
1-3-2. Bunker C flow in circulation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 7
1-3-3. Bunker A flow in D.O.mix・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 8
1-4. Maintenance
1-4-1. Disassembly・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 9
1-4-2. Caution in case of disassembly・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・9
2. Each unit
2-1.Flow control valve unit
2-1-1. Cross section diagram and parts list・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・10
2-1-2. Structure ・Disassembly ・Maintenance・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 11

2-2.Flow checker unit
2-2-2. Disassembly ・Maintenance・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 13

2-3. Main valve unit

2-4. Main valve unit (2)
2-5. Return valve unit
2-5-1. Cross section diagram and parts list・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 17
3. Caution when O-RING is replaced and installed・・・・・・・・・・・・・・・・・・・・・・・・・・・・18
4. Assembly of F.O. line unit and part drawing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・19
5. Assembly of D.O. line unit and part drawing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・20
6. Assembly of Pressure sw. unit and part drawing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・21
2
1. Block piping
1-1. Unit overall view
IN
BLOCK PIPING
TO BURNER
RETURN
F.O. RETURN F.O. IN

3
1-2. Block piping
1-2-1. Exploded diagram of Block piping
Parts List
ITEM Q'TY NAME OF PART REMARK ITEM Q'TY NAME OF PART REMARK
2 1 CONTROL VALVE 14 4 CAP SCREW M6x180mm
4 1 CONNECTING BLOCK TO CONTROL VALVE 15 6 CAP SCREW M6x30mm
5 1 FLOW CHECKER 16 2 CAP SCREW M6x145mm
6 1 RETURN VALVE UNIT 17 1 BASE・BLOCK (F.O.)
7 1 MAIN VALVE UNIT (1) 19 2 SUNK HEAD PLUG 10A
8 1 ARBORIZATION BLOCK TO 18 1 CONNECTING BLOCK TO
CIRCULATION CIRCULATION
9 7 O-RING P20 21 4 CAP SCREW M6x137mm
11 4 CAP SCREW M6x45mm 23 4 CAP SCREW M6x20mm
13 2 CAP SCREW M6x105mm 26 2 CAP SCREW WITH S.W. M6x35mm
4
1-2-2. Assembly of block piping and part drawing
Sizes of CONTROL VALVE are different

depending on type of the burner.
Please look and distinguish number
of cutout
SDR-350...0.8
SDR-500...0.8
SDR-700...1
Parts List
ITEM Q'TY NAME OF PART REMARK ITEM Q'TY NAME OF PART REMARK
2 1 CONTROL VALVE 14 4 CAP SCREW M6x180mm
4 1 CONNECTING BLOCK TO CONTROL VALVE 15 6 CAP SCREW M6x30mm
5 1 FLOW CHECKER 16 2 CAP SCREW M6x145mm
6 1 RETURN VALVE UNIT 17 1 BASE・BLOCK (F.O.)
8 1 ARBORIZATION BLOCK TO 18 1 CONNECTING BLOCK TO
CIRCULATION CIRCULATION
21 4 CAP SCREW M6x137mm
13 2 CAP SCREW M6x105mm 26 2 CAP SCREW WITH S.W. M6x35mm
5
1-3. Flow Diagram
1-3-1. Bunker C FLOW in combustion
F.O.IN
リターンバルブ閉
RETURN VALVE CLOSE
TO BURNER
メインバルブ開
MAIN VALVE OPEN
1）Bunker C from connection block to flow control valve is installed from behind of flow control valve.
2）Flow control valve has two exits, one is connected to flow checker block and the other is connected to
connection block to circulation.
3）Bunker C installed to flow control valve is distributed to the exits described above depending on angle of
rotary valve.
4）In combustion, fuel from flow control valve to flow checker is supplied to burner through two main valves.
6
1-3-2. Bunker C Flow in circulation
F.O. RETURN
リターンバルブ開
RETURN VALVE OPEN
TO BURNER
メインバルブ閉
MAIN VALVE CLOSE
5）As above drawing, fuel from flow control valve to flow checker is set back to return line (Bf) from
connection block to circulation through return valve unit when combustion is stopped (F.O. PUMP is
rotating)
7
1-3-3. Bunker A FLOW in D.O.MIX
D.O. IN
（BUNKER A）
BASEBLOCK
TO BURNER
INTERFLOW WITH BUNKER C
6）In BASE BLOCK, port for D.O.MIX is connected in between two main valves.
8
1-4. Maintenance
1-4-1. Disassembly
①Procedure
Stop oil flow
Stop air flow
Stop control motor for air cylinder
NOTE）Floor may get dirty when oil is

Remove oil
removed. (Cover the floor by the sheet.）
Disassemble block piping
②Caution
・Be careful about fire and injury when you disassemble block piping.
・Block made of metal has good heat conductivity and its temperature increases to 110℃ when oil flows.
Wait until temperature decreases before disassembly. If necessary, stop steam flow.
1-4-2. Caution in case of assembly

(1) Assemble block piping based on BASEBLOCK
(2)After assembly and oil flow, confirm the following points.

・Do blocks heat up?
・Does the flow checker work?
・Doesn’t oil leak in all parts?
9
2. Each unit
2-1. Flow control valve unit
2-1-1. Cross-section diagram
and parts list
Parts list
ITEM QUANTITY NAME OF PART REMARK
1 1 O-RING JASO-1017
2 1 CAP SCREW M3x10mm
3 1 FLOW CONTROL VALVE CASE
4 1 FLOW CONTROL OUTER VALVE
5 1 FLOW CONTROL INNER VALVE
6 1 FLOW CONTROL VALVE HOLDER
8 2 O-RING P24
9 2 O-RING P20
10
2-1-2. Structure ・Disassembly ・Maintenance
・After assembly, check over

if inner valve rotates well
manually.
OUTER VALVE
INNER VALVE
SLIT
FLOW CONTROL VALVE HOLDER
Caution! FLOW CONTROL BY CHANGING
Width of slit is different depending SLIT SIZE
on the burner type .
＊Structure
Rotation of inner valve by control motor changes slit space where oil flows and
controls oil flow.
1) When the slit of main valve side is fully -opened, the slit of return side is fully-closed. When the slit of
return side is fully-opened, the slit of main valve side is fully-closed. And in response to inner valve
angle, aperture size of each slit keeps inverse relationship.
2) Total quantity of F.O. supply to control valve is constant. So quantity of flow is switched to main valve
side and to return side by this valve.
＊Disassemble ・Maintenance
①Unclasp cap screw (M6×20mm) described above, and control valve holder comes off and inner valve
can be taken off.
②Unclasp outer valve after control valve is taken off from BASEBLOCK.(Treat O-RING with caution.)
・If O-RINGs swell, get damage, or distort, replace all O-RINGs to new parts. We recommend VITON
O-RING.
・After make sure if there is no dirt dust in slit, assemble inner valve not to get damage.
11
2-2. Flow checker unit
2-2-1. Cross-section diagram and parts list
フローチェッカー
FLOW CHECKER
φ5
(Pulse rate 100)
Parts list
1 1 FLOW CHECKER CASE(BASE PROTECTION COVER)
2 1 FLOW CHECKER CASE
3 1 FLOW CHECKER SHAFT
4 1 FLOW CHECKER VANE (TURBIN)
5 1 FLOW CHECKER BEARING
6 2 MAGNET
7 1 FLOW CHECKER CASE(2)
8 1 FLOW CHECKER SENSOR HOLDER
12
2-2-2. Disassembly and Maintenance of FLOW CHECKER
CAUTION!
Don’t take apart these parts.
CAUTION！
BASE BONDING SIDE
MAGNET
Don’t mistake North Pole for South Pole.
SENSOR HOLDER
NORTH POLE SOUTH POLE
Treat with caution because
sensor holder is made of resin.
BASE PROTECTION COVER
Structure and Maintenance

＊Flow：Water flows to turbines directly, and FLOW METER sensor detects rotation number.
＊Maintenance
1. Loosen the cap screw ⑰ (M5×35) and Remove the sensor cover ②.
2. Remove the Pulse transmitter ③ .
＊ Treat the wires with caution when disassembling, because it is directly connect to the Pulse
transmitter.
＊ Tightening torque for wiring screw : Screw M3 ／torque 0.3Nm
3. Remove the Flow checker case ⑥.
4. Remove the scale on the turbine ⑨ and the inner side of the Flow checker block
① by a soft brush or something equivalent.
＊ O-rings ⑱ shall be renewed after disassembling and re-assembling.
Grease is to be put on the O rings before fitting.
Treat with caution because flow checker causes trouble if it has disassembled or has damage once.
13
2-3. Main valve unit
Caution !! (During Assembly)

Fixed valve of Main valve unit is
oppositely oriented to Return valve
unit. When Main valve unit
is assembled, first set fixed valve in
and then set movable valve in.
Assembling Caution !!
Parts list
1 2 O-RING P6
3 1 O-RING P30
5 1 MOVABLE VALVE OF MAIN VALVE
6 1 FIXED VALVE OF MAIN VALVE
7 1 MAIN VALVE SPRING
8 2 MAIN VALVE SPRING WASHER
9 1 MAIN VALVE SEAL GUIDE
10 1 MAIN VALVE CASE
11 4 SPECER FOR MAIN VALVE
12 1 AIR CYLINDER CQ2Z40
13 1 O-RING P20
14 1 HEXAGON NUT M6
15 1 SPRING WASHER M6 use
14
2-3-2. Structure ・Disassembly ・Maintenance
＊Structure
When air cylinder pushes movable valve as described below, movable valve departs from fixed valve and
main valve is open. (-In case of return valve, return valve is closed when air cylinder pushes movable valve)
Movable valve
Fixed valve
Close
Push by air cylinder
Open
＊Disassembly ・Maintenance
①Unclasp cap screws of four corners in air cylinder, and return valve unit can be taken off.
②Unclasp hexagon nut of movable valve end, and
movable valve can be taken off. Be careful not to
lose spring and spring washer.
③Take off fixed valve and movable valve.
③ DISASSEMBLE MOVABLE VALVE
① Unclasp Cap Screw

② Unclasp Hexagon nut
・Don’t damage on fixed valve and movable valve during assembly.

・Before setting air cylinder, push movable valve and confirm operating condition. Normally movable valve
moves when it is pushed by finger.
15
2-4. Main valve unit (2)
Fixed valve of Main valve unit is
oppositely oriented to return valve unit.
When main valve unit (2) is assembled,
first set fixed valve in and then set
movable valve in.
＊Structure・Disassembly・
Maintenance is same as
chapter 2-3-2.main valve
unit above.
Caution about Assembling!!
Parts list
1 2 O-RING P6
3 1 O-RING P30
9 1 MAIN VALVE CASE
10 4 MAIN VALVE SPACER
12 1 CONNECTION BLOCK TO MAIN VALVE
13 1 O-RING P20
14 1 HEXAGON NUT M6
16
2-5. Return valve unit
Fixed valve of return valve unit is

oppositely oriented to main valve
unit. When return valve unit is
assembled, first set movable valve
in and then set fixed valve in.
Assembling Caution !!
Parts list
1 2 O-RING P6
3 1 O-RING P30
4 1 MAIN VALVE CASE
10 4 SPECER FOR RETURN VALVE
12 1 O-RING P20
14 1 HEXAGON NUT M6
17
2-5-2. Structure・Disassembly・Maintenance
＊Structure
When air cylinder pushes movable valve as described below,
movable valve pushes fixed valve and return valve closes.
Fixed valve
Movable valve
＊Disassembly・Maintenance
is same as chapter 2-3-2Main
Open
valve unit
b
Push by air cylinder

Close
＊Disassembly ・Maintenance
Disassembly ・Maintenance is same as chapter 2-3-2 main valve unit above.
3. Caution when O-RING is replaced and installed.

・Be careful of missing and loss.
・In case of maintenance, we recommend O-RING is replaced to new one. Especially, don’t use O-RING
which swells, gets damage, or distorts.
・Make sure if there is no dirt and dust in groove of O-RING.
・Put grease on O-RING and install.
・Be careful not to install wrong size of O-RING. Refer to drawings about size of O-RING.
・Be careful not to get damage.
 We recommend VITON O-RING.(Fluoro -rubber type)
18
4. Assembly of F.O. line unit and part drawing
部品表
項目数量部品名称備考
1 2 THERMOSTAT MBC-8100
2 1 THERMO METER 0-150℃
3 1 Y-TYPE STRAINER 25A #60
4 1 PRESSURE GAUGE 8A
5 2 BALL VALVE 8A
6 1 GLOBE VALVE 20A
7 1 GATE VALVE 15A
8 2 FLANGE JIS10K 25A
19
5. Assembly of D.O. line unit and part drawing
部品表
1 1 SOLENOID VALVE BASE
2 1 BALL VALVE 8A
3 1 PRESSURE GAUGE 8A
4 2 D.O. SOLENOID VALVE EV210B4.5B
5 1 D.O. FLOW REGULATOR HT-728N03 10A
6 1 Y-TYPE STRAINER 15A #100
7 1 FLANGE JIS10K 15A
8 1 DO LINE STEEL TUBE φ6
20
6. Assembly of Pressure sw. unit and part drawing
部品表
1 1 PRESSURE SWITCH・BOARD
2 1 NAME PLATE (ALARM)
3 1 NAME PLATE (BNR. TRIP)
4 1 PRESSURE SWITCH MBC-5100
5 1 BALL VALVE 8A
6 1 STEEL TUBE φ10
END
21
OPERATION SEQUENCE
1. START COMBUSTION
START
ORDER
FD. FAN RUN
CUP MOTOR RUN
F.O. PUMP RUN
PRE-PURGE TIME
OPEN
AIR DAMPER START POSITION
CLOSE D.O. PUMP RUN
IGNITION
FLAME-EYE ON
FLAME-EYE ABNORMAL
MONITOR MAIN VALVE ON
DELAY FOR ACC FREE
MIS-IGNITION
MONITOR ACC FREE
FLAME FAILURE MONITOR
When the signal of start order enters, the control system begins the start sequence in the following
■ Primary air fan (1st-AIR FAN) is started.
■ The F.O. pump and set time (2nd-AIR FAN START DELAY) are started from primary
air fan's driving signal. After the set time is over, the second air fan is started.
■ Pre-purge (PRE-PURGE) is begun when the driving signal of the second air fan
enters, and the burner motor is started.
■ When the pre-purge ends, and the second air damper returns to ignition position
(START POSITION), D.O. pump is started and the ignition of the pilot burner begins.
■ Main solenoid valve (MAIN VALVE) is open when flame eye (FLAME-EYE) detects the
flame of the pilot burner.
And the combustion of the main burner begins.
■ After set time (normal 10 second) from time when a main burner was ignited, the
automatic combustion control ( ACC –FREE ) is begun.
■ End of start combustion sequence.
Note）FLAME EYE ABNORMAL MONITOR； The ember in the furnace and abnormal of the
flame eye (short-circuit) are detected while combustion is stopping.
1/3
2. STOP COMBUSTION
STOP
ORDER
STOP SEQUENCE
FD. FAN RUN
BNR. MOTOR RUN

＊1：At D.O. use
F.O. PUMP RUN ＊1 ＊2

＊2：At H.F.O. use
POST PURGE TIME
-
OPEN
AIR DAMPER
CLOSE
Note 2) D.O. PUMP RUN

DELAY FOR
Note 2) FLAME - EYE
D.O. MIX. V. ON
ABNORMAL
FLAME -EYE ON FLAME -EYE ABNORMAL MONITOR
MAIN VALVE ON
Note 1) 2 nd-AIR FAN STOP DELAY
ACC FREE
When the stop order enters while burning, the control system begins the stop sequence.
■ ACC FREE is ended.
■ The DO pump is started. The DO mixing valve is opened.
D.O. is mixed with H.F.O..
When the fuel is D.O., this operation is skipped.
■ A main solenoid valve is shut when the D.O. mixing ends, and combustion ends.
■ The second air damper is opened, and post purge (POST-PURGE) is begun.
■ The primary air fan, the second air fan, the burner motor, and the F.O. pump are
stopped after set time (POST-PURGE TIME) , and the stop sequence is ended.
Note1) The D.O. mixing is not done when “F.O. TEMP. DETECT switch” selects
“CANCEL (D.O.)” ( on the D.O. combustion ).
2/3
3. SETTING TIME
No. Item Setting time Remark
1 PRE-PURGE TIME 30 sec.
2 IGNITION TIME 15 sec.
3 DELAY FOR ACC FREE 10 sec.
4 D.O. MIX. TIME 10 sec.
5 POST-PURGE TIME 30 sec.
6 DELAY FOR FLAME-EYE ABNORMAL 15 sec
3/3
INSTRUCTION MANUAL

BM-09
User’s Manual
TYPE ； R-9 , R-15 , R-25 , R-40

SDR-350-700, SDR-1000, SDR-1500
Name ； Boiler Burner Control System
Revision history
27 JUL.2009 Make doc. Maenishi
5 APR. 2010 Addition of W.O.control manual. Morii
6 APR. 2011 Addition of Note about ACC switch on page 56. Oota
２７JUN.2011 Vocabulary and grammer check Kagawa
1 ／ 80 株式会社サンフレム
BM-09
Content
Preface・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・4 page
About special components・・・・・・・・・・・・・・・・・・・・5 page
New technology of this system・・・・・・・・・・・・・・・・・・6 page
Structure of system・・・・・・・・・・・・・・・・・・・・・・・・7page
About safety system・・・・・・・・・・・・・・・・・・・・・・・14 page

1. Safety system （14 page）
2. Performance of safety system （15 page）
3. Function of safety system in MANU. Operation （19 page）
4. Wired sequence circuit
（Error control relay board）（20 page）
5. Wired sequence circuit
（emergency operation relay board）（24page）
Summary of operating sequence・・・・・・・・・・・・・・・・・27page

1. Combustion sequence in AUTO. Operation （27 page）
2. Sequence in emergency operation （31 page）
3. Steam up condition （32 page）
4. IGS mode （32 page）
5. Master slave mode （33 page）
Numeric control・・・・・・・・・・・・・・・・・・・・・・・・・38 page

1. Rated burning capacity ,CV and MV （38 page）
2. Water level control （40page）
3. Combustion capacity control （44 page）
4 Control for combustion air capacity （47 page）
5. TABLE setting methods （48 page）
6. Automatic setting （50 page）
Protection of control data・・・・・・・・・・・・・・・・・・・52 page
Function of each devices・・・・・・・・・・・・・・・・・・・ 56 page

1. Operation switch （56 page）
2. Control devices （60 page）
Confirmation after installation・・・・・・・・・・・・・・・・・・61 page
Confirmation by operation・・・・・・・・・・・・・・・・・・・・64page
BM-09
Steam supply・・・・・・・・・・・・・・・・・・・・・・・・・・67 page
Change to H.F.O. and change to D.O./MGO・・・・・・・・・・・・69 page
Trouble of devices・・・・・・・・・・・・・・・・・・・・・・・・ 70 page
BM-09
Preface
This document describes what engineers of this vessel should understand when they use the
system.
For also boiler makers and engineers of shipyards, we hope that this book will give useful
information.
This user’s manual includes optional functions.

For some ships, this book may give information that is not
relevant.
Confirm your specification for information of your
optional function.
About Icons
This indication gives you a warning when mishandling

WARNING the product, it will lead to serious injuries or result to
death for the user. It also may result to serious damage
for the product as well.
This indication gives you a warning when mishandling

CAUTION the product, it may lead to minor injuries to the users, or
physical damage to the product.
BM-09
About special components
１． Special Components
1.1. Battery
The programmable terminal (the NS8 series or the NS12 series), which is installed in
the front part of the control panel, is built- in a lithium battery for the backup of the
calendar clock.
 battery life； About 5 years in room temperature
 battery exhaustion；The LED , which is in front of the programmable
terminal turns from green to orange.
When this LED black-outs for over 5 minutes, the built –in calendar
clock will be reseted.
Battery exhaustion does not affect the other performances.
Note: The Control panel that does not contain the programmable terminal does not
have a battery built-in.
1.2. Fluorescent lamp

The programmable terminal (theNS8 series or the NS12 series), which is installed in
the front part of the control panel, contains a fluorescent lamp for the back-light of
the liquid -crystal display.
 The life of the fluorescent lamp；the total lighting time in a room
temperature will be over 50000 hours.
The assuming average life of the battery is over 10 years
Note: The Control panel without the programmable terminal does not have a
fluorescent lamp builted-in.
1.3. Aluminum Electrolysis Capasitor

Almost all the electronic devices use the aluminum electrolysis capasitors.
The life of each device by deterioration of the aluminum electrolysis capasitors is
listed bellow,
 AC/DC converter；５～１０ years
 PLC（BPC）and other units；１０～１５ years
 programmable terminal；１０～１５ years
 electronic timer；１5～20 years
 SDC series controller；１5～20 years
Note: the numbers described above are not guaranteed.

The major reason for the aluminum electrolysis condenser’s breakdown is
heat deterioration.
When the temperature drops 10℃ lower, the life of the battery becomes
twice longer.
BM-09
New technology of this system
The concept for this system’s development is to be “natural”. We did not choose a control
system that controls the boiler, but a control system which helps the boiler operate in stable
condition.
We will introduce the main technology development for the system.
■ Generalization
The three elements “ burning capacity ” , “ water supply ” , and “ steam

consumption”, decides the steam pressure and the water level of the boiler.
By controlling the burning capacity by steam pressure, and by controlling the
water supply by the water level, the conventional technology had destabilizing
factors by controlling each system independently,
Our new technology estimates the steam consumption by the steam pressure,
water level, burning capacity of the burner and the water supply to the boiler, and
controls the burning capacity of the burner, the combustion air capacity and the
water supply to the boiler comprehensively.
This moves the boiler to a stable condition depending on the steam consumption,
and will also eliminate the hunting of the water level control for the single boiler
and the double boiler systems.
■ Presumption
This technology is the core of our system.

The system presumes the steam consumption according to the varying burning
capacity, water supply, steam pressure and water level.
This presumption is done over the entire period ether when the burner is
working or stopping (the economizer working), and is calculated every 1
second, and will be send to the S-P-Ia control.
To enhance the robustness of the control, this presumption uses the fuzzy
inference.
■ Shifter Proportion
Advanced Integrator
The shift function, the advanced integral and the proportional control (S-P-Ia)
calculates the controlled amount quickly, and offers a smooth result of the
calculation.
The shifter adjusts the table of the proportional control, and calculates the
proportional control value with the least delay.
The advanced integral control takes the integral action in accordance with the
position of the present process value (PV) to the setting value (SV).
Thus, the hunting caused by the integrator’s poor response in conventional
technology is improved.
BM-09
Structure of system
The explanation below includes functions which may not be installed in this vessel.
Example of system structure
The main structures of the system is described below

・This system describes the two boiler system and the system to control the peripheral
equipments
・The main structures of this system are written below
 No.1 LOCAL CONTROL PANEL； Controls the No.1boiler, burner, and the
peripheral equipments.
Controls the STEAM DUMP.
 No.2 LOCAL CONTROL PANRL ； Controls the No.2boiler, burner, and the
peripheral equipments.
Controls the STEAM DUMP.
 CONSOLE CONTROL PANEL ； Share information between two LOCAL
CONTROL PANELs through the communication channels, and enable an
operation from the CONSOLE room. It also communicates with the ECC.
 CONSOLE OPERATION PANEL ； A switchboard for operation from the
CONSOLE room.
 CONSOLE MAMAGEMENT PANEL ； A board equipped with graphics
screen(programmable terminal) which indicates conditions of the boiler, the
burner and the peripheral equipments
CONSOLE CONSOLE
ECC OPERATION MANAGEMENT
PANEL PANEL
CONSOLE
CONTROL
PANEL
DRM. LEVEL DRM. LEVEL
DRM. PRESS. DRM. PRESS.
No.1 Feed-water Feed-water No.2

BLR. flow control No.1 No.2 flow control BLR.
LOCAL LOCAL
Combustion CONTROL CONTROL Combustion
control PANEL PANEL control
F.O. TEMP. / PRESS. control

STEAM DUMP control
BM-09
■ Main Function of LOCAL CONTROL PANEL
The LOCAL CONTROL PANEL has functions written below.
 DRM. LEVEL CONTROL ； control the opening and the closing of the
FEED-WATER FLOW CONTROL VALVE for the water level control.
 DRM. PRESS. CONTROL；For PRESS. CONTROL

1) Starts and stops the control of the burner combustion.
2) Output of F.O. FLOW CONTROL SINGA
3) Output of AIR FLOW CONTROL SIGNAL
4) Output of STEAM DUMP VALVE CONTROL SIGNAL
5) Output of F.O. TEMP and F.O.PRESS. CONTROL SIGNAL
 MANU. SETTING；The following output setting can be done at the MANU. mode
1) FEED WATER FLOW CONTROL SIGNAL
2) F.O. FLOW CONTROL SINGAL
3) AIR FLOW CONTROL SIGNAL
4) STEAM DUMP VALVE CONTROL SIGNAL
5) STEAM DUMP PRESS. SET POINT VALUE (SP)
6) PARAMETER OF EACH COTROL（password is necessary）
 COMMUNICATION TO CONSOLE
1) CONTROLLER LINK（COMMUNICATION USING
COMMUNICATION CHANNEL）
2) CURRENT LINK（COMMUNICATION USING
INSTRUMENTATION SIGNAL）
3) BIT LINK（COMMUNICATION USING RELAY CONTACT）
 ERROR,WARNING PROCESSING
 INDICATOR
 EMERGENCY OPERATION；
BM-09
■ Main function of COSOLE COTROL PANEL
The CONSOLE CONTROL PANEL has functions written below
 Communication to the LOCAL CONTROL PANEL；
 The remote control of the burner；Instruct the LOCAL CONTROL PANEL to start
or to stop the burner combustion via communication
 MANU. SETTING；The following output setting can be done at the MANU. mode
1) FEED WATER FLOW CONTROL SIGNAL
2) F.O. FLOW CONTROL SINGAL
3) AIR FLOW CONTROL SIGNAL
4) STEAM DUMP VALVE CONTROL SIGNAL
5) STEAM DUMP PRESS. SET POINT VALUE (SP)
6) control parameters of some parts
 Output of the ECC；Output the following information

1) TRIP SIGNAL
2) ALARM SIGNAL
3) Instrumentation signal for CONSOLE INDICATOR
 Input from the ECC；Receive the following information

1) Each command value
 The control of the CONSOLE OPERATION PANEL；

1) Observe the position of operation switch for CONSOLE OPERATION
PANEL and CONTROL INDICATOR
 Communication with the PROGRAMABLE TERMINAL equipped with the

CONSOLE MANAGEMENT PANEL
NOTE) Systems without the CONSOLE CONTROL PANEL, the LOCAL CONTROL
PANEL outputs at the ECC.
BM-09
Computing part for control output（LOCAL CONTROL PANEL）
The main configuration diagram of the computing parts which are the core parts of
this system is described below.
 Signals of the DRM. LEVEL transmitter and the DRM. PRESS transmitters, and
each signal of the FEED-WWTER FLOW Control value and the F.O. FLOW
Control value, which are the output from the computing parts, are led to the fuzzy
reasoning unit.
 The fuzzy reasoning unit presumes the steam consumption based on each input
signals.
 Outputs from the fuzzy reasoning unit are inputted into the shifter, the first S-P-Ia
and the second S-P-Ia.
 The shifter calculates the SP value based on the presumed steam consumption for
the FEED-W. FLOW Control, and then inform the calculation result to the first
S-P-Ia.
(Note) The SP value is calculated by the primary expression depending on the
input steam consumption (%), for example, SP-O is in the case of the steam
consumption 0%, the SP-100 is in the case of the steam consumption 100%.
 The first S-P-Ia for the FEED-Water Control value calculates the output value
based on the SP value from the shifter and the steam consumption from the fuzzy
reason unit.
It is necessary to increase the water supply as the steam consumption increases.
However, when the steam consumption increases, the DRM. LEVEL will increase
as well, and the normal integrate action will react in the opposite way, and this will
cause hunting. This system improved the hunting by introduceing the S-P-Ia
control.
 The second S-P-Ia for the F.O. FLOW Control value calculates the output value
based on the steam consumption from the fuzzy reason unit and the SP value for
the integral time. The integrate action (Ia) is taken against the PV position to the
SP. This contributes significantly to the stability of the DRM. PRESS
S-P-Ia
DRM. LEVEL
PV
SP-0 SP-100
Set Point
Shifter SP F.W. Control value
DRM. LEVEL
DRM. PRESS Fuzzy Shifter

reasoning Integration Time
F.W. Cont. IT
F.O. Cont.
STEAM
Consumption
S-P-Ia
DRM. PRESS
PV
Set Point
SP F.O. Control value
Shifter
Integration Time
IT
BM-09
■ Output part（LOCAL CONTROL PANEL）
The output parts are shown below.

 The output of the S-P-Ia is sended to the MANU. SET composed by the UP/DOWN
counter with a preset function. In a normal condition (ACC free), the UP/DOWN
counter with a preset function reads out the S-P-Ia output value by the preset
action.The preset function will be stopped when operating the MANU. The
UP/DOWN counter adjusts to the output depending on the switch input from the
preset value at the time.
（At this time the S-P-Ia will stop the integral action, and will prevent the
integrator from saturation. ）
 The TABLE Selector converts the input signal from the MANU. SET into the
output signal.
Especially, functions to adjust to the D.O. and the H.F.O. burning capacity are
included in the TABLE Selector for the F.O. Control value
 To enable an operation when the PLC (programmable logic computer) breaksdown,

the Emy’s SETTER is equipped as well.
Em’y
S-P-Ia SETTER
MANU. TABLE
F.W. Control value FEED-W FLOW Control value
SET Selector
4 – 20 mA
MANU. ▲ ▼
Em’y
S-P-Ia SETTER
MANU. TABLE
F.O. Control value F.O. Control value
SET Selector
MANU. ▲ ▼
D.O.
M.G.O. H.F.O.
Em’y
SETTER
TABLE
1st-AIR FLOW Control value
Selector
D.O.
Em’y Em’y
M.G.O. H.F.O.
SETTER SETTER
BNR. MOTOR
SPEED Control value TABLE AIR TABLE 2nd-AIR FLOW
Control value
Selector RATIO Selector
D.O. LOW
M.G.O. H.F.O. HIGH
BM-09
■ Configuration of output device
This system uses the following devices depending on requested specification
Input and
Device Feature Main usages
output signal
FEED FLOW CONTROL
Positioner
 Quick response VALVE
4-20mA  High resolution F.O. PRESS. CONTROL
(Pneumatic
(I/P converter)  Large-scale SUCTION DAMPER
drive)
 Expensive （Secondary-AIR）
 Slow response
 Resolution; 1～2%
4-20mA F.O. FLOW CONTROL
 Small-scale
Control Secondary-AIR DAMPER
 Relatively cheap
motor CONTROL
 Slow response
Forward reverse Primary-AIR DAMPER
 Resolution;0.2～0.5%。
control CONTROL
 Small-scale
(with feedback)
 Relatively cheap
■ Duplexing
This system increases confidence in operation by drive duplexing.
Main control Auxiliary control Remark

Item
Device Set-up Device Set-up
Error
Continuous
Safety control
――― PLC ――― parallel
device relay
processing
board
Water level Set “ACC”switch Set “ACC”switch
PLC SDC
control to AUTO " Em’y "
Emergency
Combustion Set“OPERATION”switch operation Set“OPERATION”switch
PLC
sequence to"AUTO" relay to " Em’y "
board
Combustion
Set “ACC”switch Set “ACC”switch
capacity PLC SDC
to”AUTO.” to"Em’y.”
control
BM-09
■ Interface between man and machine
This system adds the following innovation for effective usage on this vessel.
1) Programmable terminal
This system is equipped with the standard programmable terminal (touch
panel) to inform the condition correctly.
The programmable terminal has the following functions.
Item Explanation of function Remark

Condition display Indicate operating condition of burner
peripheral device visually.
Abnormal display Indicate details of BNR. TRIP and
ALARM, and help engineer’s decision
Trend Graphs out the operating condition.
Easy to understand the level and the
combustion control working correctly.
Operation record Records the BNR.TRIP, the ALARMs and
the operating condition.
Utility Record the integrated values of the
combustion capacity and the F.D.FAN
operational time. Effective to set-up the
time of maintenance.
Setting This system is operated by many
modification of controled data. About 2000 controled
control data datas setting and changing are able to be
done.
Input and output of The Input and the output conditions of
PLC the PLC are able to be confirmed by the
PT
2) Input and output conditions of the control panel are confirmed by the LED
equipped in each device.
BM-09
About safety system
１．Safety system
1.1. Classification of safety system

The safety system is classified as below.
 Limiter
 Safety devices
 Preventive devices
 Control devices
1.2. Limiter
1) In response to the following signals (the open-circuit condition), the control
system will stop the fuel supply immediately, and will send an alert signal to the
engine room. (burner trip)
 Em’y stop signal from engine room
 DRM. LEVEL LOW TRIP
 DRM. PRESS. HIGH TRIP
2) This system does not adopt the automatic restoration. The burner trip will be
canceled when an engineer pushes the reset switch on the control panel.
1.3. Safety devices

1) In response to the following signal (the open-circuit condition), the control
system will stop the fuel supply immediately, and will stop the actuation of
each devices and will send an alert signal to the engine room. (Burner trip)
 BNR. HINGE OPEN

 AIR PRESS. LOW TRIP or PRIMARY-AIR PRESS. LOW TRIP
 SECONDARY-AIR PRESS. LOW TRIP
 WIND-BOX TEMP. HIGH TRIP
 FLAME EYE ABNORMAL
 MIS-IGNITION
 FLAME FAILURE
 F.O. PPRESS. LOW
 F.O. TEMP. LOW
 BNR. MOTOR TRIP
 PRIMARY-AIR FAN TRIP
 SECODARY-AIR FAN TRIP
 D.O. PUMP TRIP
 F.O. PUMP TRIP
 START POSITION ABNORMAL
 DRM. LEVEL TRANSMITTER ABNORMAL
 DRM. PRESS. TRANSMITTER ABNORMAL
 SOURCE FAILURE
 CPU ABNORMAL
2) This system does not adopt an automatic restoration. A burner trip will be
BM-09
1.4. Preventive devices
1) In response to the following signals (open-circuit condition), the control system
will send an alert signal to the engine room. (Alarm)
 DRM. LEVEL LOW ALARM
 DRM. LEVEL HIGH ALARM
 DRM. PRESS. LOW ALARM
 F.O. PRESS. LOW ALARM
 F.O. TEMP. LOW ALARM
 F.O. TEMP. HIGH ALARM
 O2 CONCENTRATION HIGH
 SMOKE HIGH
 EACH TRANSMITTER ABNORMAL
3) This system does not adopt an automatic restoration. A burner trip will be
1.5. Control signal

1) In response to the signal from the device to decrease troubles for the boiler
burner shutting down, the control system needs to order the setting
operation.
 F.O. TEMP. LOW P/P CONT.
 ST-BY F.O. PUMP START
 FAN STOP DELAY
 SECONDARY-AIR FAN START DELAY
2) In response to the signal from the device to operate the boiler and the burner
normally, the control system will order the setting operation.
２． Performance of safety system
2.1. Limiter
1) Signals from the Emergency stop switch in the engine room
・ When the emergency stop switch in the engine room is pushed, the hard
and the soft ware will order burner trip.
2) DRM. LEVEL LOW TRIP

・ When the off -delay timer is turned off by the float less switch, or the
differential pressure transmitter (standard setting 15seconds) that is
from the dram level low signal, the hard and the soft ware will order
burner trip.
3) DRM. PRESS. HIGH TRIP

・ During the burner combustion, the hard and the soft ware will order
burner trip by the dram level high signal from the pressure switch, or the
differential pressure transmitter. （HIGH to OFF）
・ This function is optional.
2.2. Safety Device

1) Burner hinge open (BNR.HINGE OPEN)
・ When the burner hinge is opened during the combustion, the hard and
the soft ware will order burner trip.
・ The limit switch will detect when the burner hinge is opened.
（OPEN to OFF）
BM-09
2) AIR PRESS. LOW TRIP, PRIMARY-AIR PRESS. LOW TRIP or SECONDARY-AIR
PRESS. LOW TRIP
・ When the air pressure is lower than the setting value during the
combustion, the hard and the soft ware will order burner trip.
・ The air pressure will be detected by all range between the minimum and
the rated burning capacity except for the suction damper’s burner. This
burner will detect a higher air pressure than the setting combustion
capacity.
・ The primary air pressure and the secondary air pressure are detected
separately or totally according to the situation.
3) WIND-BOX TEMP. HIGH TRIP

・ When the thermostat in the wind-box detects a high temperature
regardless to combustion, the hard and the soft ware will order burner
trip.
4) FLAME EYE ABNORMAL

・ The condition of the flame eye is monitored, except during the
combustion and for a certain time after the combustion finishes
(separate setting) in the pilot burner or the main burner,.
・ When an ember in furnaces or a short –circuit of the flame eye has
occured, the hard and the soft ware will order burner trip.
5) MIS-IGNITION
・ When the flame eye does not detect flames by ignition over the setting
time (15 seconds), the hard and the soft ware will order burner trip.
6) FLAME FAILURE
・ When the main solenoid valve is opened during the combustion, if the
flame eye is turned off, the hard and the soft ware will order burner trip.
7) F.O. PPRESS. LOW

・ When the F.O. PRESSURE becomes lower than the setting value during
the burner combustion, the hard and the soft ware will order burner trip.
8) F.O. TEMP. LOW

・ When the F.O.TEMPERATURE becomes lower than the setting value
during the burner combustion, the hard and the soft ware will order
burner trip.
・ During the combustion using the D.O., this function must be canceled by
turning the thermostat by-pass switch on.
9) W.O. TEMP. LOW

・ When the F.O.TEMPERATURE becomes lower than the setting value
during the burner combustion, the hard and the soft ware will order
burner trip.
・ During the combustion using the D.O., this function must be canceled by
turning the thermostat by-pass switch on.
10) PRIMARY-AIR FAN TRIP

・ The primary air fan will be stopped by detecting the low primary air
pressure. Although in some cases, the primary air fan trip will also be
adopted.
BM-09
・ When the starter of the primary air fan is turned off during the burner
combustion, the software orders to burner trip.
・ With a system that has a switch gear (NFB) for the primary air fan, when
the switch gear (NFB) is turned off during the combustion, the soft ware
orders to burner trip.
11) SECONDARY-AIR FAN TRIP

・ The secondary air fan will be stopped by detecting low secondary air
pressure. Although in some cases, the secondary air fan trip will be also
adopted.
・ When the starter of the secondary air fan is turned off during the
burner combustion, the software orders burner trip.
・ For secondary air fans that are equipped with a speed selector, the LS
mode trip or the HS mode trip may be identified.
・ With a system that has a switch gear (NFB) for the secondary air fan,
when the switch gear (NFB) is turned off, the soft ware orders burner
trip.
12) BNR. MOTOR TRIP

・ When the starter of the burner motor is turned off, the hard and the soft
ware will order burner trip.
13) D.O. PUMP TRIP

・ When the starter of the D.O.PUMP is turned off under an operation
command from the control system, the soft ware orders burner trip.
14) F.O. PUMP TRIP

・ When the starter of the F.O.PUMP is turned off under an operation
command from the control system, the soft ware orders a burner trip.
・ However, when the system is equipped with the ST-BY F.O.PUMP, the
ST-BY F.O.PUMP will start working, and an alarm of the ST-BY F.O.
PUMP START will occur.
・ When the F.O.PUMP and the Stand-by pump both trips, the burner trip
will occur.
15) START POSITION ABNORMAL

・ When the secondary air damper does not come back to the ignition point
after setting time for prepurge (standard setting time: 30seconds), the
software will order a burner trip.
・ There are some cases when the position of the F.O FLOW CONT.MOTOR
is detected.
16) DRM. LEVEL TRANSMITTER ABNORMAL

・ When the level control adopts the differential pressure transmitter, and
when signals from the two are loaded in to the PLC, and when the input
current becomes under 3.2mA or over20.8mA, the software will order a
burner trip
・ In this case, the input current in the PLC will be calculated as 4mA.
17) DRM. PRESS. TRANSMITTER ABNORMAL

・ In case the DRUM PRESSURE CONTROL adopts the pressure
transmitter, signals from them are loaded on PLC, and input current is
under 3.2mA or over20.8mA, software orders burner trip
BM-09
・ At this time the input current in PLC is calculated 20mA.
18) SOURCE FAILURE

・ When the control source stops supplying, the hard ware orders a burner
trip.
19) CPU ABNORMAL

・ When each input and output units connected to CPU is out of order,
software orders burner trip.
・ This function detects mistakes of setting in unit replacement on this
vessel.
2.3. Preventive devices

1) DRM. LEVEL LOW ALARM
・ When the off delay timer (standard setting time 15seconds) is turned off
by a low drum level alarm from the floatless switch, or the differential
pressure transmitter, the control system sends out an alarm signal to the
engine room.
・
2) DRM. LEVEL HIGH ALARM
・ When the off delay timer (standard setting time 15seconds) is turned off
by a high drum level alarm from the floatless switch, or the differential
pressure transmitter, the control system sends out an alarm signal to the
engine room.
3) DRUM PRESSURE LOW ALARM

・ When the drum pressure signal from the pressure switch or the pressure
transmitter is turned off, the control system sends out an alarm signal to
the engine room.
4) F.O.PRESSURE LOW ALARM

・ When the F.O.pressure switch is turned off, the control system sends out
an alarm signal to the engine room.
5) F.O.TEMPERATURE LOW ALARM

・ If the thermostat for the low F.O.temperature is turned off when
thermostat bypass switch is turned off, the control system sends out an
alarm signal to the engine room.
6) F.O.TEMP HIGH ALARM

・ When the thermostat for high F.O.temperature is turned off, the control
system stops the heater and sends out an alarm signal to the engine
room.
7) O2 CONCENTRATION HIGH ALARM

・ When the O2 concentration signal sent from the IGS system excesses the
maximum of the setting value, the control system sends out an alarm
signal to the engine room.
8) SMOKE HIGH ALARM
・ When the system is equipped with a smoke concentration meter, if the
smokeing concentration meter excess the maximum of the setting value,
an alarm will be signaled out to the engine room
9) EACH TRANSMITTER ABNORMAL
BM-09
・ When signals from other transmitters are under 3.2mA or over 20.8mA,
the control system sends an alarm signal to the engine room.
2.4. Control Signal
1) F.O. TEMP. LOW P/P CONT.

・ The system equipped with a thermostat for the F.O.TEMP LOW PUMP
CONTROL, turns on the signal when the F.O.PUMP starts, and the
heater will be controlled.
・ When the thermostat bypass switch is on, this function is canceled.
2) STAND-BY F.O.PUMP START

・ When setting up the F.O.PUMP, if a burner trip occurs, or if the pressure
switch of the F.O.pressure low pumps start is turned off, the control
system switches to the stand-by pump operation.
3) FAN STOP DELAY

・ The Fan driven by the motor for over 30KW gets a higher rate of burn
out by repeating a brief start-stop operation.
・ When the combustion is stopped by a signal of a high drum pressure in
an auto mode, the fan continues to drive until the setting time passes.
4) SECONDARY AIR FAN START DELAY

・ With a system having both the primary and the secondary air fans
separately, the secondary air fan will start driving after setting up the
running signal of the primary air fan,.
・ Burden to the power system by starting current will be decreased.
３． Function of safety system in case of manual operation (emergency operation)
In a manual mode, only some of the safety devices will be operated.

Please operate under the supervision of an engineer.
3.1. CONTROL SYSTEM HAVING WIRED SEQUENCE CIRCUIT BUILT-IN
1) When the CPU unit is broken, only the following safety devices will be
workable.
 EMERGENCY STOP
 DRM. LEVEL LOW TRIP
 BNR. HINGE OPEN ）
 AIR PRESS. LOW TRIP
or PRIMARY-AIR PRESS. LOW TRIP
SECONDARY-AIR PRESS. LOW TRIP
 WIND-BOX TEMP. HIGH TRIP
 FLAME EYE ABNORMAL
 MIS-IGNITION
 FLAME FAILURE
 F.O. PPRESS. LOW
 F.O. TEMP. LOW
 SOURCE FAILURE
2) When the CPU unit is in a normal condition, all of the safety devices described
above are workable.
BM-09
４． Wired sequence circuit (error control relay board)
4.1. Aspect of error control relay board
LED1 LED2
BM-09
4.2. Performance of error control relay board
1) The error control relay board includs 29 LED and 25 small relays.
12pairs of the LED and thr relay detects errors.
2) The detecting circuit done by the K101and the K102 relay is shown bellow.
3) The relays of odd numbers (K101 in this example) are receiving signals. A signal
for closed circuit (abnormal to open) normally inputs a Terminal between the
N-EM. Therefore, the relay K101 normally works. The LED1connected to relay
K101 will light up and will inform the signal at that time. One side (not shown in
FIG.) of the relay K101 is connected to the PLC (programmable logic controller),
and is used for a burner trip caused by the software.
4) When pressing the reset switch, the relay K102 will work and continues to work
by its holding contacts.
At this time the LED 2 connected to the relay K102 will light up.
5) When the emergency switch is pressed, the relay K101 will be released, and the
contact of the K101 will be opened, and the relay K102 will immediately be
released to shut off its holding contacts.
At this time, the LED 2 connected to the relay K102 will light up and will inform
the abnormality.
6) The relay K102 does not work untill the reset switch is pressed.
7) Different contacts to the relay K102 that are not showen in the FIG (Normally
Open Contact）activates a burner trip. （OPEN to TRIP）
8) The error control relay board is equipped with 12 pairs of circuits, which
observes the condition of the limiters and the safety devices that are connected,
and starts a burner trip in an emergency.
9) The relay K125 interfaces to the open order signal of the MAIN VALVE. For
example, like the FLAME FAILURE, the relay K125 has an interlock function to
detect the MAIN VALVE when it is working.
Note1) When the power source is supplied, 12 relays of the even numbers are
released, and all the LED of even numbers light are off.
When checking the functions, make sure that all of the LED of even numbers
lights are off.
BM-09
Note2) When the reset switch is pushed, 12 relays of the even numbers will work,
and all the LED of the even numbers will light up.
When checking the functions, make sure all the LED of even numbers lights
are up.
4.3. Conditions of error control relay board
Input Condition of relay

Name of input Condition of relay release and LED
working and LED
RELAY LED signal lighting out
lighting up
Emergency stop switch is pushed.
K101 LED1 Em’y STOP Normal
Wire is disconnected.
DRM. LEVEL DRM.LEVEL is TheDRM LEVEL decreases lower than
K103 LED3
LOW normal the LOW TRIP, and 15 seconds passed.
DRM. PRESS. DRM.PRESS is The DRM .PRESS. rises higher than
K105 LED5
HIGH normal the High TRIP.
BNR. HINGE Burner hinge is
K107 LED7 The BURNER HINGE is open
OPEN closed
COMB. AIR Combustion air The fan for combustion air has stoped.
K109 LED9
PRESS. LOW pressure is normal The combustion air pressure is low
Temperature in
WIND-BOX Thetemperature in the WIND-BOX is
K111 LED11 WIND-BOX is
TEMP. HIGH over the setting value.
normal.
FLAME EYE Both of FLAME
K113 LED13 At least one FLAME EYE is on.
ABNORMAL EYE are off.
When the ignition continues for 15
K115 LED15 MIS-IGNITION Normal
seconds, it will be Off for that moment.
FLAME Both of FLAME
K117 LED17 At least one FLAME EYE is off.
FAILURE EYE are on.
The F.O.PUMP stops
F.O. PRESS. F.O.PRESS. is
K119 LED19 The F.O. PRESS. is lower than the
LOW normal
burner’s low trip.
F.O.TEMP is
The F.O. TEMP. becomes lower than
F.O. TEMP. normal.
K121 LED21 the LOW TRIP when the
LOW THERMOSTAT
THERMOSTAT BY-PASS is off.
BY-PASS is on.
The burner motor stops.
BNR. MOTOR Burner motor is
K123 LED23 An overload relay of a burner motor
STOP driving.
begins to work.
BM-09
Trip detection Condition of trip(relay release and LED

Name of trip Detecting point
Relay LED light out)
Emergency stop switch is pushed.
K102 LED2 Em’y STOP Always
Wire is disconnected.
DRM. LEVEL TheDRM LEVEL decreases lower than
K104 LED4 Always
LOW the LOW TRIP, and 15 seconds passed.
DRM. PRESS. The DRM .PRESS. rises higher than the
K106 LED6 Always
HIGH High TRIP.
BNR. HINGE MAIN VALVE is The BURNER HINGE is open during
K108 LED8
OPEN on combustion
COMB. AIR The combustion air pressure is low
K110 LED10 MAIN VALVE is on
PRESS. LOW during combustion.
WIND-BOX Thetemperature in the WIND-BOX is
K112 LED12 Always
TEMP. HIGH over the setting value.
Before IGN.starts,
FLAME EYE At least one FLAME EYE is on during
K114 LED14 after MAIN VALVE
ABNORMAL combustion.
is off.
When the ignition continues for 15
K116 LED16 MIS-IGNITION Always
seconds.
FLAME At least one FLAME EYE is off during
FAILURE combustion.
F.O. PRESS. The F.O. PRESS. is lower than the
LOW burner’s low trip during combustion.
The F.O. TEMP. becomes lower than the
F.O. TEMP.
K122 LED22 MAIN VALVE is on LOW TRIP when the THERMOSTAT
LOW
BY-PASS is off during combustion.
The burner motor stops during
BNR. MOTOR combustion.
STOP An overload relay of a burner motor
begins to work.
BM-09
5. Wired sequence circuit (emergency operation relay board)
5.1 aspect of emergency operation relay board
LED4
BM-09
5.2. Performances of emergency operation relay board
1) The emergency operation relay board includs 15 small relays, 5 timers, and
12LED.
2) When the OPERATIO switch that is on the control panel is turned to the
“Em’y”position, this board will start the semiautomatic operation without a
programmable logic controller
3) The operating sequence is similar to the PLC operation, but the following
actions are different.
 Auto ignition will not be performed. The Ignition will be started by the
following procedure.
① Turn the OPERATIO switch on the control panel to the ”Em’y”

position.
② The primary air fan will start automatically.
③ The secondary air fan will start automatically when the setting time of
the timer K251 passes after the operating signal of the primary air fan
returns.
④ The burner motor will start automatically after the operating signal of
the secondary air fan returns.
⑤ The Prepurge will start after the operating signal returns.
⑥ After the prepurge time set by the timer K-252passes, the secondary
air damper will go back to the position of the ignition, and the
illuminated push button switch on junction box of the burner lights up
automatically.
⑦ When the engineers can observe flame of the pilot burner through the
sight glass, the engineer pushes this illuminated push button switch（”
IGNITION”switch）
⑧ After confirming the flame from the sight glass, turn the main valve
switch that is next to the IGNITION switch “on”.
⑨ After confirmation the main burner being ignited, the main valve
switch will be returned to the original position.
⑩ After several seconds, return the ignition switch to the original
position.
⑪ The normal combustion will start when the setting time of the K254
timer passes after the main valve is turned on,.
 DRM PRESS .HIGH STOP is not carried out.

An operation should be carried out under continuous supervision from
the engineer.
An engineer’s continuous supervision is recommended, even though it is
possible to continue operating by the setting steam dump valve.
The Combustion will be stopped in the following two ways
① Turn the”OPERATION”switch on the control panel is turned back to
the ”STOP”position.
This operation is needed when using the H.F.O. fuel, because the D.O.
MIX will be done automatically.
② Turn the main valve switch, which is on the junction box of the burner,
“off” , and then turn the ”OPERATION”switch on control panel to
the ”STOP”position. In this operation, the D.O. MIX. is not done.
Note) If there is something abnormal during the ignition, turn off the main valve
switch on the junction box of the burner, and stop the combustion.
BM-09
5.3. Condition of emergency operation relay board
Input Condition of relay

Name of input Condition of relay release and
working and LED
Relay LED signal LED lighting out
lighting up
PRIMARY-AIR
K201 ――― ――― ―――
FAN RUNNING
SECONDARY-AIR
K202 ――― ――― ―――
FAN RUNNING
BNR. MOTOR
K203 ――― ――― ―――
RUNNING
Operation switch is set
K204 LED4 Em’y MODE Operation switch is set to stop.
to Em’y
PRIMARY-AIR
Operation switch is set Operation switch is set to stop
K205 LED5 FAN RUN
to Em’y and purge finishes
ORDER
SECONDARY-AIR Running signal of
Operation switch is set to stop
K206 LED6 FAN RUN primary air fan is sent
and post-purge finishes.
ORDER and K251time is up.
BNR. MOTOR Running signal of Operation switch is set to stop
K207 LED7
RUN ORDER secondary air fan is sent. and post-purge finishes.
Running signal of
OFF until finishing purge
K208 LED8 PURGE TIME-UP Burner motor is sent and
OFF after starting ignition
K252 time is up
K209 LED9 PURGE ORDER On during purge Purge is finished.
K210 LED10 PURGE END On after prepurge OFF when main valve is closed.
IGN.switch is pushed at The Ignition switch is returned
K211 LED11 IGN. ORDER
the start position to the original position.
When the Flame eye is off.
K212 LED12 The Main valve switch on the
IGN. flame is detected
MAIN VALVE junction box of the burner is
and main valve on
OPEN ORDER turned off.
K213 LED13 switch is pushed.
Operating switch is stopped,
and D.O. MIX. finishes
D.O. MIX. Operation switch is set
K214 LED14 K253 time is up
ORDER to the stop position.
Only when the Main valves
MAIN VALVE switch on the junction box of the
K215 LED15 Normally always on
CLOSE ORDER burner is turned off.
Standard setting Adjustable Setting value of

Timer Name of trip
time (second) range(second) vessel
SECONDARY-AIR
K201 FAN START 6 0.6 ～6
DELAY
PURGE TIME
K202 （30）**1) 6 ～60
D.O. MIX. TIME
K203 6 0.6 ～6
ON-DELAY for
K204 6 6 ～60
ACC-FREE
MIS-IGNITION
K205 20 6 ～60
DETECT
**1) Purge time is different depending on boiler volume.
BM-09
Summary of operating sequence
１． Combustion sequence in automatic operation
1.1. In automatic operation burner starts or stops by the following sequence.

1) START／STOP by drum pressure
HIGH STOP
DRM. PRESS.
LOW START
START SEQUENCE
NORMAL COMBUSTION
STOP SEQUENCE
 When the drum pressure becomes lower than the DRM.PRESS.LOW

COMBUSTION START from steam consumption, the control system will
initiate the START SEQUENCE.
 This system has functions for pre-ignition.
<Pre-ignition>
It takes more than 1 minute for the ignition of the burner to start
the main burner combustion. In pre-ignition when DRUM PRESSURE
decreases to DRUM PRESSURE calculated by DRUM PRESSURE rate
of decline, ignition starts. Therefore ignition starts at around DRM.
PRESS. LOW CONBASTION START PRESS.
DRM.
Combustion
sequence
SP
Combustion
sequence
Combustio
Combustio
P-star
60sec 60sec
Secon
 START SEQUENCE refers to page 29.
 After START SEQUENCE, normal combustion starts.
 Main burner starts combustion, then after setting time passes control
system becomes ACC free, and starts control combustion.
 When steam consumption is over minimum combustion capacity,
combustion capacity is adjusted to the setting point of steam pressure.
 When steam consumption is lower than minimum combustion capacity,
steam pressure increases and starts STOP SEQUENCE.
 START SEQUENCE refers to page 30.
BM-09
2) START/STOP by operation switch
 The following action is carried out depend on condition of DRM. PRESS.
 Operation in auto-mode
Action when “OPERATION “switch is turned from "STOP" position to
“AUTO”position.
DRM. PRESS. Burner operation
Combustion sequence is started in
PV ＜ P-start
auto-mode.
P-start ＜ PV ＜ P-stop
Burner is standby in auto-mode.
P-stop ＜ PV
PV ; Present value of DRM. PRESS.
P-start; DRM. PRESS. LOW COMPUSTION START PRESS.
P-stop; DRM. PRESS. HIGH COMPUSTION STOP PRESS.
Action when “OPERATION”switch is turned from”AUTO” position

to” ”AUTO. ON” position.
PV ＜ P-start Combustion sequence is started in
P-start ＜ PV ＜ P-stop auto-mode.
P-stop ＜ PV Burner is standby in auto-mode.
In case of BNR. TRIP, auto-mode doesn’t release only by operation of

the reset switch.
Auto mode releases in the following two ways.
■ “Operation switch is turned back to“STOP”position, and then
turned back to ”AUTO” position” again.

PV ＜ P-start
auto-mode.
P-start ＜ PV ＜ P-stop
Burner is standby in auto-mode.
P-stop ＜ PV
■ Operation switch is turned to “AUTO. ON” position.

PV ＜ P-start
P-start ＜ PV ＜
auto-mode.
P-stop
P-stop ＜ PV Burner is standby in auto-mode.
 Stop operation(auto mode and emergency mode)

When Operation switch is turned back to “STOP” position,
burner stops operation after the following actions
Condition Burner operation
Before ignition Stop immediately
Stop ignition, operate post-purge, and
During ignition
stop
Operate D.O. MIX. and post-purge
During combustion
and stop
During post- purge Operate post-purge and stop
During standby in auto-
Stop immediately
mode
BM-09
1.2. Start sequence
START
ORDER
1st-AIR FAN RUN
2nd-AIR FAN START DELAY
2nd-AIR FAN RUN
BNR. MOTOR RUN
F.O. PUMP RUN
PRE-PURGE TIME
OPEN
AIR DAMPER START POSITION
CLOSE
D.O. PUMP RUN
IGNITION
FLAME-EYE ON
FLAME-EYE ABNORMAL
MONITOR MAIN VALVE ON
DELEY FOR ACC FREE
MIS-IGNITION
ACC FREE
MONITOR
When signal of start order is received, control system initiates START

SEQUENCE in the following procedure.
 Primary air fan starts.
 When signal of primary air fan is received, secondary-air fan starts
after the setting time (SECONDARY-AIR FAN START DELAY）
 When signal of secondary air fan is received, prepurge starts, then
burner motor and F.O.PUMP starts
 When secondary air damper is turned back to the start position after
prepurge, D.O.pump starts and ignition of pilot burner starts, too.
 When flame eye detects flame of the pilot burner, main valve is opened
and combustion of the main burner starts.
 After setting time (normally 10seconds) since main burner starts
ignition, the burner becomes ACC free and controls combustion
capacity.
 Normal combustion continues until stop order is received or burner
trip occurs.
BM-09
1.3. Stop sequence
STOP
ORDER
STOP SEQUENCE
1st-AIR FAN RUN
2nd-AIR FAN RUN Note 1)
BNR. MOTOR RUN
F.O. PUMP RUN
PRE-PURGE TIME
OPEN
AIR DAMPER
CLOSE
D.O. PUMP RUN

DELEY FOR
FLAME-EYE
D.O. MIX. V. ON ABNORMAL
FLAME-EYE ABNORMAL
FLAME-EYE ON
MONITOR
MAIN VALVE ON
Note 1)
FAN STOP DELAY (OPTION)
ACC FREE
When stop order is received during combustion, control system initiates STOP
SEQUENCE.
When thermostat by-pass switch is off (H.F.O. combustion), STOP SEQUENCE. is
proceeded as described below.
 ACC free finishes.
 D.O.PUMP starts, D.O.MIX valve is opened and H.F.O. is mixed with D.O.
 After setting D.O.MIX time, D.O.PUMP stops, mix valve and main valve
are closed, and combustion stops. When thermostat by-pass is off
(H.F.O. combustion), this procedure is skipped.
 After finishing combustion, secondary air damper is opened and
post-purge starts.
 After setting time of post-purge primary and secondary air fan, burner
motor and F.O.PUMP stops and terminates STOP SEQUENCE.
 In control system with secondary air fan stop delay function, when
system stops automatically by high drum pressure, secondary air fan
stops after setting time (normally 30minutes).
BM-09
２．Sequence in emergency operation
1) When ”OPERATIO”switch on control panel is set to ”Em’y”position ,

Burner is operated semi –automatically by emergency operation relay board
without PLC (programmable logic controller)
2) Operating sequence is similar to PLC operation, the following actions are

different.
 Auto ignition is not carried out. Ignition is started in the following procedure.
① OPERATIO switch on control panel is turned to ”Em’y”position.
② Primary air fan starts automatically.
③Secondary air fan starts automatically after setting time of timer
K251 since operating signal of primary air fan returns.
③ Burner motor starts automatically after operating signal of secondary air
fan returns.
④ Prepurge starts after operating signal returns.
⑤ When secondary air damper is put back to the position of ignition after
setting prepurge time of timer K-252, illuminated push button switch on
junction box of burner lights up automatically.
⑥ In condition the engineer can observe flame of the pilot burner through
sight glass, the engineer pushes this illuminated push button switch(”
IGNITION”switch)
⑦ After the engineer confirms flame from the sight glass, main valve
switch right next to illuminated push button switch is turned on.
⑧ After confirmation of main burner ignition, main valve switch is turned
off.
⑨ After several seconds, ignition switch is turned off.
⑩ After setting time of K254 timer since main valve is turned on, normal
combustion is carried out.
 DRM PRESS .HIGH STOP is not carried out.

Operation has to be carried out under continuous engineer’s supervision.
We recommend continuous engineer’s supervision even though
continuous operation is possible with setting steam dump valve.
Combustion is stopped in the following two ways.
① ”OPERATION”switch on control panel is turned back to ”STOP
position.
In this operation D.O. MIX is carried out automatically. In burner using
H.F.O. fuel, stop combustion in this way.
② After main valve switch on junction box of the burner is turned off, ”
OPERATION”switch on control panel is turned back to ”STOP”position.
In this operation D.O. MIX. is not carried out.
BM-09
３． Steam up condition
3.1. Steam up condition
1) When drum pressure decreases and combustion starts by automatically, if

control starts based on SP (setting point), combustion capacity increases
rapidly. Rapid change of combustion capacity have bad effect on some parts
of boiler components
2) Therefore when combustion starts and the burner becomes ACC-FREE,

DRM.PRESS is set as a tentative setting point and this tentative setting point is
raised at 0.1[MPa] per 3 minutes
3) Features of this method are

 To keep combustion capacity according to steam consumption.
(This prevents rapid increase of combustion capacity, and if steam
consumption increases, combustion capacity increases, too.)
 Simple operation without special engineer’s work
3.2 Start and STOP of Steam up mode
1) Steam up mode starts in the following case.

 After combustion starts and setting time passes, burner becomes
ACC-FREE. At this time steam up mode starts.
 In system having 2 modes of pressure setting value, LP mode (ECO
mode) and HP mode (Boiler mode), when system changes from LP
mode to HP mode during combustion, steam up mode starts
2) Steam up mode stop in the following case.
 Tentative setting point reaches SP (setting point).
 DRUM.PRESS reaches SP (setting point).
４． IGS mode
This mode is special for tanker.

A function to change combustion gas to inert gas is added.
4.1. Function of IGS mode

1) Function of “ DRM. PRESS. HIGH COMBUSTION STOP ” is stopped,
combustion continues regardless of DRM.PRESSURE.
2) IGS mode uses exhaust gas having low O2 concentration. (normally less than
5%). MIN. COMBUS. WITH IGS-MODE”that minimum combustion capacity can
get less than 5% O2 concentration becomes functional.
Note) Surplus steam dump to condenser
4.2. Action of IGS mode
1) When ISG mode is requested from CCR (cargo control room), it is indicated on
indication lamp or programmable terminal.
2) After the engineer confirms setting of boiler burner and dump valve and
conditions of each device like condenser, push IGS switch on control panel or
programmable terminal and start IGS mode.
3) When IGS mode request is released or IGS mode on control panel is released,
normal combustion mode is turned back.
BM-09
5. Master slave mode
This is the system that 2 burners operate to generate steam. In this system one is
master, another is slave, and they work together.
5.1. Cooperation with master and slave
5.1.1 Cooperation with master and slave occurs in the following condition.
 Both of burners are in AUTO MODE. This means as described below.
1) During combustion in AUTO mode
”AUTO”indicator lamp on control panel lights up. (or flash)And ”
Normal combustion”on programmable terminal(center of the first line)
is indicated.
2) During standby in AUTO MODE
”AUTO”indicator lamp on control panel lights up. And” Waiting with
AUTO. MODE” on programmable terminal (center of the first line)is
indicated.
 One of burner is set as master by master switch. ”MASTER BOILER”
indicator lamp on control panel lights up. And ”MASTER”or“Slave” on
each programmable terminal(left of the first line) is indicated.
5.1.2. Cooperation with master and slave (combustion control) is stopped in the
following condition. Other functions continue.
And when the following condition is released, cooperation with master and
slave occurs again.
 ACC switch on master or slave is turned from AUTO to MANU.
 Combustion capacity of master or slave burner is set in MANU MODE. This
setting is carried out by programmable terminal.
5.1.3. Cooperation with master and slave is released in the following condition.
 Operation switch on one of burners is turned off.
 One of burners occurs burner trip.
5.2. Function
5.2.1. Function of master

 Master sends commands to start or stop combustion to slave.
1) Combustion capacity (CV) of master boiler becomes setting value, master
order slave to start combustion.
2) Combustion capacity (CV) of master boiler decreases lower than setting
value, master order slave to stop combustion.
Note) This setting value is carried out by programmable terminal.
 Master controls combustion capacity based on higher pressure of master
and slave DRM.PRESS since slave starts combustion.
 Master informs combustion capacity to slave.
5.2.2. Function of slave

 Slave starts combustion to follow master’s order.
 Slave increases combustion capacity slowly, since "NORMAL
COMBUSTION” starts.
 Since combustion capacity of slave and master become same value, slave
control combustion capacity to follow master’s combustion capacity.
 When slave receives stop combustion order from master, slave stops
BM-09
combustion.
 Slave in standby condition (master order slave to stop) starts combustion
when its DRM PRESS decreases to setting pressure of slave (DRM. PRESS.
LOW START for WARM UP）.
And also slave stops combustion when its DRM PRESS increases to setting
pressure of slave（DRM. PRESS. HIGH START for WARM UP）
5.3. Action of interrupted cooperation
This system takes the following actions when cooperation as described in section
5.1.2. is interrupted.
5.3.1. In case master interrupts cooperation

 Slave stops action following master combustion capacity, and continues
combustion by its control value based on its DRM. PRESS.
 Other functions (order to start and stop combustion from master and e.t.c.)
continue.
 Master stops observing slave’s DRM. PRESS.
5.3.2. In case slave interrupts cooperation
 Slave stops action following master combustion capacity, and continues
combustion by its control value based on its DRM. PRESS.
 Other functions (order to start and stop combustion from master and e.t.c.)
continue.
 Master stops observing slave’s DRM. PRESS.
5.4. Action of release cooperation
This system changes to independent mode when cooperation as described in

section 5.1.3. is released.
5.5. Start and stop combustion command (Master’s action)
Combustion
rate
④
①
②
Combustion command
① Combustion is started by start order.
② Steam up mode is started and system becomes ACC- FREE. after
BM-09
setting time (standard 10 seconds) passes since combustion starts
Steam up mode is finished when steam pressure reaches setting point.
③ Combustion capacity increases according to increase of steam
consumption. Master sends COMBUSTION COMMAND after
combustion capacity reaches to setting value （ START ORDER for
SLAVE BLR.）
④ Combustion capacity decreases according to decrease of steam
consumption.
Master releases COMBUSTION COMMAND after combustion capacity
decreases to setting value（STOP ORDER for SLAVE BLR.）
5.5. Slave’s compliance (slave’s action)
Combustion command
Combustion
rate
Combustion rate of master
Combustion rate of slave
①
② ⑤
③
① Slave starts combustion by start order from master.
② Slave starts steam up mode after setting time (standard 10 seconds)

passes since combustion starts and system becomes ACC- FREE.
③ When slave’s DRUM PRESS increases close to DRM. PRESS, steam in
slave is consumed and increases combustion capacity.
If steam pressure reaches to setting point or combustion capacity of slave
and master become same value, slave finishes steam up mode.
④ When combustion capacity of slave and master become same value,

slave follows combustion capacity of master.
⑤ Combustion command is released from master, slave stops combustion
and becomes standby condition.
BM-09
5.6. IGS mode and master slave
5.6.1. System takes different action in the following two cases.

Pay attention to setting in case of inert gas usage
Case 1
Case 2
Two cases
Case1; Setting value of MIN. COMBUS. WITH IGS-MODE”is smaller than setting
value of “STOP ORDER for SLAVE BLR.”
Case2; Setting value of MIN. COMBUS. WITH IGS-MODE”is greater than
setting value of “STOP ORDER for SLAVE BLR.”
5.6.2 Action in case1
IGS-MODE
Combustion
command
Combustion
rate Combustion rate of master

①
② ③
① Combustion command from master is released when steam

consumption decreases and combustion capacity is smaller than
setting value of “STOP ORDER for SLAVE BLR.”
BM-09
② But by function of IGS mode, combustion continues at“MIN. COMBUS.
WITH IGS-MODE”.
③ When IGS mode is released, stop combustion commands from master
becomes effective, combustion stops and system becomes standby
condition.
5.6.3 Action in case 2
IGS-MODE
Combustion
command
Combustion
rate Combustion rate of master
②
① ③
① When steam consumption decreases and combustion capacity

decreases to MIN. COMBUS. WITH IGS-MODE”,function of IGS mode
prevents combustion capacity from decreasing lower than “ MIN.
COMBUS. WITH IGS-MODE”.
Note) Surplus steam is dumped to condenser by dump valve.
② When IGS mode is released, combustion capacity decreases.
Release method of IGS-MODE
 Signal of “IGS MODE”from CCR is released.
 Switch of“IGS MODE”from control panel is canceled.
③ Combustion capacity decreases to “ STOP ORDER for SLAVE
BLR.”,combustion command from master is released.
④ Slave starts STOP COMBUSTION SEQUENCE, stops combustion and
becomes standby condition.
BM-09
Numeric control
１． Rated burning capacity, CV and MV
1.1. Rated burning capacity（ Kg-fuel／ｈ）

1) Rated burning capacity is set by rated evaporation of boiler.
2) Rated burning capacity of vessel is described in the first page of specification
1.2. Rated burning capacity using for control（ Liter-fuel／ｈ）

1) About H.F.O., D.O, and M.G.O, operating temperature, density and calorific value
are different greatly..
2) In convenience, at average of each operating temperature, calorific values per 1

litter are almost same. (Their differences are less than 1%)
3) Therefore when fuel is changed, if flow rate (liter-fuel/h) is same, it is not

necessary to change amount of combustion air.
4) So this control system is based on flow rate (liter-fuel/h)
5) Rated burning capacity of vessel is described in the first page of specification.
1.3. CV (Control value)

1) Control value (value for calculation in PLC) is described in percentage terms
2) Rated burning capacity of vessel is used as CV 100% of burning capacity for

each control
Rated evaporation capacity of boiler
Rated burning capacity (Kg-fuel／h)
Rated burning capacity (Liter-fuel／h)
CV of F.O.Flow＝ 100%
3) CV used in control is described in the following table

CV Explanation
F.O. Flow Refer to 2)
FEED WATER Flow Same as evaporation of boiler
2nd-AIR Flow CV of F.O. Flow multiply AIR RATIO
1st-AIR Flow Same as CV
BNR. MOTOR SPEED Same as CV
1.4. TABLE and MV

1) MV is output value on each control devices. (For example, F.O. FLOW
CONTROL MOTOR e.t.c.)
BM-09
2) Angle of F.O. FLOW CONTROL VALVE, F.O.FLOW RATE, angle of AIR

DAMPER and combustion air capacity are not direct proportional relationship
each other.
For example, when CV of F.O. Flow is 50%, the position of control motor where
F.O. flow rate become 50% is written in the table. As well the position of
control motor depending on CV (0～100％ per 1%) is written in table. When
output of control, CV,is 0%,0th data of this table output as MV.When CV is
50%, 50th data of this table output as MV.
3) Control using TABLE has the following benefits.

■ Control without delay.(little hunting)
■ Not necessary for Special operation to change fuel. (Easy operation)
■ Easy setting of air ratio((Easy operation) and e.t.c.
4) This system has tables as described below.

Name of Number of
Classification
TABLE TABLE
FEED WATER Flow FEED WATER ０～100
H.F.O. ０～100
F.O. D.O. ０～100
M.G.O. ０～100
LS ０～140
2nd-AIR Flow
HS ０～140 LOW/HIGH speed switch
H.F.O. ０～100
1st-AIR Flow D.O. ０～100
M.G.O. ０～100
H.F.O. ０～100
BNR. SPEED D.O. ０～100
M.G.O. ０～100
Note) Table for 2-nd AIR FLOW is range adjustable from 100% to140%,so
table shows to140%.
CV Em’y
S-P-Ia SETTER
MANU. TABLE
F.W. Control value FEED-W FLOW Control value
SET Selector
4 – 20 mA
MANU. ▲ ▼
Em’y MV 値
S-P-Ia SETTER
MANU. TABLE
SET Selector
MANU. ▲ ▼
D.O.
M.G.O. H.F.O.
BM-09
2． Water level control
2.1. Devices for water level control

The following devices are equipped for water level control.
1) PLC (PROGRAMABLE LOGIC CONTROLLER)
2) SDC（DIGITAL PROCESS CONTROLLER）
2.2. Device switching

Device switching is carried out by“ACC”switch.
Position
Conformation
Devices of ACC Feature
of control
switch
■ Control based on steam consumption.
■ Control with little hunting
PLC ■ Operate automatically without mutual
AUTO. S-P-Ia
(BPC) interference of 2boiler system
■ Resistance to alarm
■ Control water level separately

■ Simple composition and easy to
understand
SDC Em’y P—I ■ Hunting by mutual interference of 2
boiler system
■ Wide extent of fluctuation, occurrence
of alarm
2.3. Control power and water level control

1) When power source supply is stopped, water level control is not carried out.
(Output current (MV) is 0mA)
Pay attention to rapid rise of water level because of power discontinuity
when FEED CONTROL VALVE uses air motor (positioner) specified AIRLESS
OPEN.
2) When power source is supplied, and NFB of OPERATION SOURCE is turned

on, in about 2 seconds water level control starts. Even If 8×(or 88×) is
not operated, the following function becomes effective.
８X
Effective functions Remarks
or８８X
ERROR CONTROL Indicate Source failure trip
OFF About 2 seconds lag after power
Water level control
supply
ON All of functions
2.4. SP value (set point value) of water level control by PLC

1) In steam boiler water level increases and decreases according to
increase and decrease of steam consumption. So in this system SP
value is shifted according to steam consumption.
BM-09
2) SP shift is calculated by first-order approximation based on SP0 and
SP100.
LEVEL
SP0； Steam consumption 0%

SP100
SP100； Steam consumption 100%
SP0
STEAM CONSUMPTION
0% 100%
3) ALARM occurs less frequently because SP value changes according to

steam consumption.
HIGH ALARM HIGH ALARM
DRM. LEVEL TREND DRM. LEVEL TREND
SP-100
0mm 0mm
SP-0
LOW ALARM LOW ALARM
Fig-1 OLD SYSTEM（With constant SP) Fig-2 THIS SYSTEM（With SP SHIFTER）
4) Control parameter is set by programmable terminal.
5) The example of back-up operation in this boiler system is shown below,

when1 boiler is forced into burner trip by main force during 2 boiler
parallel operations in 3 boilers system.
BM-09
Water level increases about 250mm since combustion starts according to
rapid increase of steam consumption. Then water level converges into SP
value uniformly.
（09 JUN.2009 measured in vessel、burner；R-40、boiler；40t/h SANROD）
2,000 250
100
Press
F .O . F lo w ／ F W F lo w [% ]
DRM. PRESS. [KPa]
DRM. LEVEL [mm]

1,000 0
Level
PRESS
FO_Flow
FW_Flow
LEVEL
0 -250 0
1800 3600 5400 7200
2.5. S-P-Ia (shifter, proportion, advanced integrator control
1) Stop S-P-la control

This system has a function that for CV of FEED WATER FLOW is reset
to zero for a certain time after combustion stops. For example in case
of cargo pump turbine trip, when evaporation rapidly decreases, this
system prevents LEVEL HIGH ALARM by rapid rise of water level.
2,000 250
100
PRESS
FO_Flow
FW_Flow
Press
LEVEL
F.O. Flow／ FW Flow [% ]

DRM. PRESS. [KPa]
DRM. LEVEL [mm]
Level
1,000 0
0 -250 0
6300 6360 6420 6480 6540 6600
2) Economizer control
When burner stops and economizer is operated, steam consumption is
presumed by water level and S-P-Ia control is operated by this
presumption.
3) During burner combustion, steam consumption is presumed by fuzzy

inference. S-P-Ia control is operated by this presumption.
BM-09
S-P-Ia
DRM. LEVEL
PV
SP-0 SP-100
Set Point
Shifter SP F.W. Control value
DRM. LEVEL
DRM. PRESS Fuzzy Shifter

reasoning Integration Time
F.W. Cont. IT
F.O. Cont.
STEAM
Consumption
S-P-Ia
DRM. PRESS
PV
Set Point
SP F.O. Control value
Shifter
Integration Time
IT
2.6. MANU. setting
1) In this system when label of”F.W. MV [%]” on programmable terminal is touched,

screen of manu.setting appears.
S-P-Ia control is interrupted and MANU.setting becomes possible.
At this time S-P-Ia control is follow up mode.
Display for CV SET MANU.
After pushing “CV SET MANU.", this key turns yellow and shows MANU. mode.
Touching up or down key enables CV to increase or decrease every 1%
BM-09
3. Combustion capacity control
3.1. Devices for combustion control

The following devices are equipped for combustion control.
1) PLC（Programmable logic controller）
2) SDC15（DIGITAL PROCESS CONTROLLER）
SDC has 4 setting points and change combustion capacity by switching
setting point

Device switching is carried out by “ACC switch”
Position of
Conformation
Devices ACC Features
of control
switch
■ Control based on DRM. PRESS. and steam
PLC AUTO. S-P-Ia consumption
■ Control with little hunting
■ When “OPERATION”switch is set to Em’y”

position, purge and ACC-FREE action are
carried out automatically by signal from
emergency operation relay board.
Fixed
SDC15 Em’y ■ When “OPERATION” switch is set to
(4points)
“AUTO.” position, purge and ACC-FREE
action are not carried out.
Changing combustion capacity by 4 setting
point is not carried out.
Note) When PLC is normal, set ACC switch to”AUTO.”position.
3.3. Combustion capacity control

1) When ACC switch is set to “AUTO.”, after setting time passes (standard:
10seconds) since combustion starts, system becomes ACC-FREE.
In condition of ACC FREE, combustion capacity is controlled by S-P-Ia control.
2) S-P-Ia control condition
OPERATIO
ACC
N S-P-Ia Remark
switch
switch
AUTO.
AUTO. Yes
Em’y When ACC switch is set to AUTO,
AUTO. S-P-Ia control is active.
Em’y No
Em’y
3) S-P-Ia control is active during steam-up.
4) S-P-Ia control takes action depending on output in the following condition.
■ MANU. SET CV for F.O. FLOW is active.
■ Following combustion order from master in slave mode
During follow up mode, S-P-Ia computing continues so that control moves
smoothly (bump less) at follow up mode release
BM-09
3.4. Action in steam –up mode
1) After system starts combustion and becomes ACC-FREE, steam- up mode
starts.
DRM. PRESS. HIGH STOP End of
STEAM UP MODE
SP Read PV , Set SP for
STEAM UP MODE
PV PV
DRM. PRESS. LOW START SP for STEAM‐UP

0.1MPa/3min.
COMBUSTION ORDER
COMBUSTION
ACC FREE
STEAM UP MODE
2) When steam consumption is low, burner burns at minimum

combustion .Because at this time the rate of DRM. PRESS. rise is bigger than
the rate of SP rise, shift of SP follows PV.
DRM. PRESS. HIGH STOP
SP
PV
DRM. PRESS. LOW START SP for STEAM‐UP

0.1MPa/3min.
3) STEAM UP MODE is carried on when system becomes ACC FREE, and turns
from LP-MODE to HP-MODE.
3.5. Follow-up output

1) When MANU. SET CV for F.O. FLOW is active, or system follows combustion
commands from master in slave mode, normal operation of S-P-Ia control
causes problems.
So S-P-Ia control is operated in follow-up mode.
2) In follow-up mode, CV (calculated value of S-P-Ia) is calculated to be equal

to command value (MANU. SET value or combustion commands value from
master)
Em’y
S-P-Ia SETTER
MANU. TABLE
SET Selector
MANU. ▲ ▼
D.O.
M.G.O. H.F.O.
BM-09
During follow up mode, S-P-Ia computing continues so that control moves
smoothly (bump less) at follow up mode release
3.6. MANU setting
1) In this system when label of”F.O. Flow [l/h]” on programmable terminal is

touched, screen of manu.setting appears.
S-P-Ia control is interrupted and MANU. setting becomes possible.
At this time S-P-Ia control is follow up mode.
MANU. setting display
After pushing “CV SET MANU.", this key turns yellow and shows MANU. mode.
Touching up or down key enables CV to increase or decrease every 1%
4. Control for combustion air capacity(Air damper control)
4.1. Devices for combustion air capacity control

The following devices are equipped for combustion air control.
1) PLC（Programmable logic controller）
2) SDC15（DIGITAL PROCESS CONTROLLER）
SDC has 4 setting points and change amount of combustion air capacity by
switching setting point

Device switching is carried out by “ACC switch“
Position of
Conformation
Devices ACC Features
of control
switch
PLC AUTO. Table control ■ Control based on F.O. Flow CV
■ When “OPERATON”switch is set to”Em’y”
position, PURGE and ACC-FREE action
are carried out automatically by signal
from emergency operation relay board.
Fixed
SDC15 Em’y ■ When “OPERATON” switch is set to
(4 points)
“AUTO” position, PURGE and ACC-FREE
action are not carried out.
Changing combustion air capacity by 4
setting point is not carried out.
Note) When PLC is normal, set ACC switch to AUTO. position.
BM-09
4.3. Control
1) Table control is carried out following to F.O. Flow CV
2) In control of 2nd-AIR Flow, Secondary AIR Flow CV adopts the value

that F.O. FLOW CV multiplies AIR RATIO (setting in programmable
terminal).
4.4. Control of SDR-500、SDR-1000 and SDR-1500

1) In these 3 burner system, to enable low O2 concentration combustion,
position feedback signal of F.O. FLOW control motor is inverse
transformed to F.O. Flow CV.And PRIMARY-AIR Flow,
SECONDARY-AIR Flow and rotation speed of burner motor is
controlled by this CV.
5. Table setting method

5.1. Preface
1) Setting methods of each table are common. Setting method of F.O. FLOW is
explained in as an example below.
2) Table is set by programmable terminal.
(70, 60)
(60, 49.5)
31.5％
5.2. Explanation of graph

1) Graph shows value of PLC data memory.
CV ; horizontal axis in graph shows CV, using in control.

CV can be in range from 0% to 100%, by1%.
And in AIR FLOW CONTROL TABLE, because Air ratio range is 100%～
140％、horizontal axis in graph shows in range from 0% to 140%.
MV; MV shows control motor position to each CV.
BM-09
For example, in case of 40% combustion capacity order, MV is 35% and by

forward reverse control position of control motor is set to 31.5 %.( Position is
controlled by accuracy level lower 0.5%.)
2) Table right next to graph described above.

In this table setting value is shown to plot graph per 1%.
About 10 data are input in the table, and this data are connected by straight line
as coordinate points. By these coordinate points 100 or 140 data are made.
After touching yellow number, numeric keypad shows up. Touching numeric
keypad makes value of table change. Graph doesn’t change if value of table is
changed. After pushing “write table”switch , Graph (PLC data
memory) changes by this value
Note； Note; CV in this table need to increase from the top to the bottom. (CV
differences need not to be exact 10%)
And the top column is 0% and the bottom column is100%.
When CV difference is large, graph becomes distorted.
3) Display at right bottom of graph
Value at right bottom of graph shows present CV.

During combustion, control value is shown in this column.
During stop combustion, 0% is shown in this column.
The left number in this column is present F.O.FLOW rate. [L/h]

The right number in this column is percentage to rated
combustion capacity.
MV is calculated so that this percentage is nearly equal to CV
as mentioned before.
The percentage is adjusted to fixed CV by increase and
decrease of MV.
When CV is set in MANU MODE, push this switch.
When CV SET MANU is active, this switch turns yellow.
When CV SET MANU is active, this switch can increases and

decreases CV.
When CV SET MANU. is active, MV can be set by MANU.

When MV SET MANU. is active, switch turns yellow.
MV SET MANU. is active, this switch can increases and decreases

MV.
And when MV SET MANU .is active, MV is increased and

decreased by touching numbers directly.
Note; Adjustment of F.O.FLOW RATE is to set combustion capacity (F.O.FLOW)

according to CV .CV is fixed and MV SET MANU is increased and decreased so
that F.O. FLOW (percentage to rated combustion capacity) becomes nearly equal
BM-09
to CV. After F.O. FLOW becomes nearly equal to CV, CV and MV at this time are
input in table (right next to graph above described). After execution of “write
table” CV and MV are reflected in the graph
.
Note; Without CV SET MANU. and MV SET MANU., CV and MV can be input
directly in table and reflected in the graph.
5.4. Method to reflect numbers in graph (TABLE)
1) Push “write table”
2) shows up.
3) Touch keyboard above.
4) shows up.
Password is 『 SHIP No. 』

After entering passwords, push”ENTER”key
5) shows up.
6) Push "Yes" and then graph changes to new data.
6. Automatic setting
6.1. Burner and Function

1) SDR-500, SDR-1000 and SDR1500 have a function for automatic setting
of combustion capacity.
BM-09
2) SDR-500, SDR-1000 and SDR1500 with differential pressure transmitter
between wind-box and furnace (option) have a function for automatic
setting of amount of combustion air.
6.2. Automatic setting of combustion capacity.
1) Burners described above are equipped with Flow Mater and Return valve.
When combustion stops and F.O. PUMP is operated, F.O. is circulating through
return valve.
(At this time F.O. is nearly equal to combustion capacity.)
2) Position of F.O. Flow Control Motor connected to F.O. Flow Control valve is
moved gradually, F.O. Flow rate is measured.
3) Table is made up automatically by this measured value. (This procedure takes
about 8 minutes)
Return
Valve
F.O.
Return
F.O. To
In F Burner
Main Main
Flow Flow Valve Valve
Control mater
valve
6.3. Operation for automatic setting of combustion capacity.

1) SET “OPERATION” switch to “STOP” position
2) Operate F.O. PUMP in MANU mode, and set oil pressure to setting vale
(standard 0.3 [MPa])
3) Carry out "AUTO.CALIBLATION” on programmable terminal.
4) After screen is changed automatically, increase MV value by 10 % and measure

CV automatically.
Next make up table on right side of screen.
BM-09
Then “WRITE TABLE” is carried out and graph is plotted automatically.
BM-09
Protection of control data
１． Preface
This system is operated by many control data. To handle problems like black out,
control data are managed and invested in many ways
1.1. Control data

1) This system uses about 2000 control data.
2) Control data includes all sorts of necessary data to operate burner.
 Standard value; rated evaporation capacity data of boiler and rated
combustion capacity of burner are included.
 Timer setting value; Some of timers used in control sequence can be set
externally.
 Table; Table data to run each control motor.
 Other;
1.2. Backup
1) PLC in this system is not backed up by battery.
2) Control system is backed up by the following ways.

■ Backup by program; When power source is supplied to PLC, program writes
control data to data memory of PLC. Because program writes data, data
changed after test operation are not reflected.
■ Backup by compact flash memory; Compact flash memory(CFM) installed
PLC has files for control data. When program finishes backup, PLC reads
files in CFM, and writes data into data memory of PLC.
2. Data of compact flash memory
2.1. This screen shows switches to write data to CFM and read data from CFM.
BM-09
2.2. Switch
This switch writes data to ”TBLE2”of 2nd file in CFM. This switch is protected by
a secret password. In vessel this switch is inoperable.
Note; This ”TBLE2” is used to restore default condition. (During test operation)
This switch is made to write data set by SUNFLAME to ”TBLE”of this file during
test operation.
2.3. Switch
This switch writes data to ”TBLE1”of 1st file in CFM. When control data is
changed and needs to be backed up, push this switch and overwrite control data
to ”TBLE1”.
Note; After changing control data by PT, data memory in PLC is changed and
operated by this data. It is possible to operate without backup, but when blackout
occurs, system restores to previous condition (TABLE1).
2.4. Switch
If you want to restore default condition in any reason, push this switch.
Table made by SUNFLAME during test operation can be read.
2.5. Switch
When the power source is supplied to CPU, this operation is automatically

executed.
For example, when data is changed without backup, and test operation is carried
out having trouble, push this switch to restore previous condition.
Note; When control data is changed, carry out test operation without backup.
Backup after confirmation that operation has no trouble.
BM-09
3. Operation Procedure
3.1. When switch is pushed, input password is required.
The following procedure need to carry out to enter password as requirement.

Password is 『 SHIP No, 』
Touch ”Keyboard” of screen above. Then the following screen shows up.
After entering passwords, push ENTER key.
3.2. After checking password, the following display to confirm execution shows up.
When Yes switch is pushed, writing executes. If execution doesn’t have problem,
the following display shows up for several seconds.
BM-09
————————————————————————————————————————————－
<Compliment>
READ TABLE
・ Program memory in CPU is nonvolatile memory (Flash memory), but Data
memory is volatile memory that data disappears when the power source is
stopped. (Data memory). To prevent control data disappearance, CPU unit
equips Compact Flash memory(CFM）.Read Table is processing to read
control data to data memory of CPU unit from Compact Flash Memory. When
the power source is supplied, this processing automatically executes once.
(by TABLE1)
Compact Flash CPU UNIT

Memory
Flash memory
Program and Program
Control data
Control data Program memory

TABLE1
Data memory
Control data （Control Data）
TABLE2 READ TABLE TABLE
WRITE TABLE
・ Write table is processing to transfer data of data memory in CPU unit to
memory for backup, execution takes place by switch on PT screen.
Compact Flash CPU UNIT

Memory
Flash memory
Program and Program
Control data
Control data Program memory

TABLE1
Data memory
Control data （Control Data）
TABLE2 SUNFLAME TABLE
Note) In compact flash memory important data is recorded. Be careful not to lose it.
————————————————————————————————————————————－
BM-09
Functions of each device
１． Operation switch
1.1. Operation source switch
When “OPERATION SOURCE”switch is pushed,(or set to”ON”position),Aux’

relay (8×or88X）starts self holding and control.
When SOURCE FAILURE occurs, Aux’ relay (8×or88X）releases self holding.
1.2. Emergency switch

When Em’y”switch on Local control panel or consol is pushed, BNR. TRIP
occurs in case of "Em'y switch pushed"
1.3. Reset switch

After elimination of BNR. TRIP cause, when this switch is pushed (or
turned),Trip is released.
When this switch is pushed for short time, lamp stops flicker action.
When this switch pushed for over 1 second, reset action executes.
1.4. LAMP TEST switch
When this switch turns to this position, the entire lamps put the light on to check
broken lamp.
1.5. OPERATION switch
“STOP”position
1) Burner during combustion stops operation after STOP SEQUENCE. is

carried out.
2) In automatic operation, when burner stands by for combustion, burner
stops combustion immediately.
3) In the system with function of secondary fan delay stop, secondary air fan is
stopped during operation.
4) The function of F.O. TEMP. LOW PUMP CONTROL is not canceled when
H.F.O.is used (THERMOSTAT BY-PASS switch is OFF)
“MANU.”position(or Em’y”position)
1) Manual operation is started in this position.
“AUTO.”position
1) Automatic operation is possible in this position.

2) Automatic operation is started in the following case.
■ In case of operation command by DRUM PRESS LOW
■ In case of operation commands by master boiler in 2 boiler system
3) In the following case, automatic operation is stopped and burner becomes
standby condition.
■ When "DRM. PRESS”increases over setting value（DRM. PRESS. HIGH
STOP COMBUSTION）
■ In case of stop commands from master boiler in 2 boiler system
4)"AUTO. MODE” is released when "BNR TRIP" occurs.
BM-09
“AUTO.”ON”position
1) Operation is started when "DRM PRESS HIGH STOP" command is not sent.
2) When burner trip occurs, "DRM PRESS HIGH STOP" is released and”AUTO.
MODE” returns to set to“AUTO.”ON”position after reset
1.6. FLAME-EYE BY-PASS switch
“NORMAL”position
1) Normally, operation is carried out in this position.

2) No.1and No.2 flame-eye detect flame.
“No.1 ”position
1) No.2 Flame-eye is used in this position.

2) When No.1 Flame-eye is broken, operation can be continued by changing to
this position temporarily.
Note) Don’t operate at this position except necessary case in the security of
this vessel.
“No. 2”position
1) No.1 Flame-eye is used in this position.

2) When No.2 Flame-eye is broken, operation can be continued by changing
to this position temporarily.
Note) Don’t operate at this position except necessary case in the security
of this vessel.
1.7. ACC switch(in control panel)
“AUTO. ”position
1) Normally, operation is carried out in this position.
“Em’y ”position
1) When PLC is broken, ACC switch is changed to this position.

2) SDC controller controls water level.
3) During 2 boiler parallel operation, in ramp up period engineer‘s operation
is required to prevent hunting of water level.
Hunting is reduced in the following procedure.
■ When DRM.PRESS. of boiler which starts combustion after another
increases and boiler starts to generate steam,(water level
increases),the SDC is set to”MANU.”
■ Output of SDC is set about 30 %( In case F.W. FLOW CONT.
VALVE takes reverse action, about 70%)
■ After about 30 seconds, the SDC is returned to ”AUTO.”
4) Combustion capacity is changed by setter and selector switch
Note) In the case of changing the position on ACC switch,

please do that when burner stops. (At SDR-350-700 only.)
BM-09
1.8. MASTER BOILER switch
No.1 position
1) In 2 boiler system with master- slave function, MASTER BOILER switch sets
No.1 boiler as Master.
No.2”position
1) In 2 boiler system with master- slave function, MASTER BOILER switch sets
No.2 boiler as Master.
Note. In the following case, MASTER/SLAVE relationship is released.

■ At least in one burner, trip occurs.
■ At least in one burner, automatic operation is released.
1.9. THERMOSTAT BY-PASS switch
OFF position
1) When H.F.O. is used, this switch is set to this position.

2) Function of F.O. TEMP. LOW TRIP is active.
ON” position
1) When D.O. is used, this switch is set to this position.

2) The function of F.O. TEMP. LOW TRIP is released.
3) The function of F.O. TEMP. LOW PUMP CONTROL is released.
4) At change D.O. to H.F.O., THERMOSTAT BY-PASS switch keeps this
position while THERMOSTAT BY-PASS lamp continues to light up.
When fuel temperature rises up, and THERMOSTAT BY-PASS lamp
flashes, this switch is turned back to OFF position.
1.10. THERMOSTAT BY-PASS lamp
Extinction
1) This lamp lights out when THERMOSTAT BY-PASS switch is OFF.
Lighting up
1) This lamp lights up when fuel temperature is low and THERMOSTAT

BY-PASS switch is ON.
Flashing
1) This lamp flashes when fuel temperature rises to the temperature required
for H.F.O. combustion （ F.O. TEMP. LOW TRIP doesn ’ t occur ） and
THERMOSTAT BY-PASS switch is ON.
1.11. OIL HEATER switch
“STOP”position
1) This switch stops F.O.HEATER in this position.
BM-09
2) In D.O.combustion, this switch is set to this position.
“AUTO”position
1) F.O.HEATER controls temperature by F.O. TEMP.controller.
1.12. BOILER MODE SWITCH
1) This switch changes to BLR-MODE（HIGH PRESS MODE）and ECO-MODE

（LOW PRESS MODE）.
1.13. F.O. PUMP switch
“OFF”position
1) In this position F.O. PUMP cannot operate.

2) If local switch is equipped, LOCAL switch setting has priority.
Don’t set this switch to OFF position during burner combustion.
“ON” or ”MANU.”position
1) F.O. PUMP is forced to operate.

2) If local switch is equipped, LOCAL switch setting has priority.
“AUTO.”position
1) F.O. PUMP is operated automatically in this position.

2）If local switch is equipped, LOCAL switch setting has priority.
1.14. F.O. PUMP SELECT switch (If local switch is equipped, LOCAL switch setting
has priority.)
“No.1 USE”position
1) No.1 F.O. PUMP is used in this position.
“No.1 USE No.2 ST-BY”position

No.2 F.O. PUMP is in standby condition when F.O. PUMP switch is set to”
AUTO.
2) When Trip of No.1 F.O. PUMP occurs, or F.O. PRESS. LOW PUMP CONTROL
switch works; No.1 PUMP is switched to standby No.2 PUMP.
“No.2 USE”position
“No.2USE No.1 ST-BY”position

2) No.1F.O. PUMP is in standby condition when F.O. PUMP switch is set to”
AUTO.
BM-09
3) When Trip of No.2 F.O. PUMP occurs, or F.O. PRESS. LOW PUMP CONTROL
switch works, No.2 PUMP is switched to standby No.1 PUMP.
1.15. FEED WATER PUMP switch (If local switch is equipped, local switch setting has
priority.）
“No.1”Position
1) No.1 F.W.PUMP is used in this position.
“No.2”Position
1) No.2 F.W.PUMP is used in this position.
２． Control devices
2.1. DRM. LEVEL CONTROLLER
1) This device carries out Water level control.
2.2. F.O. TEMP. CONTROLLER
1) This device carries out F.O.HEATER CONTROL.
2.3. F.O.PRESS CONTROLLER
1) This device carries out F.O.PRESS control.

2) F.O.PRESS control by SDC is carried out automatically when operation
command signal for F.O.PUMP is input
When operation command signal for F.O.PUMP is not input, F.O.press
control valve is fixed to about 80%open.
This prevents pressure from increasing abnormally when F.O.PUMP starts
operation.
BM-09
Confirmation after installation
１．Confirmation of installation condition
First, make sure the following point.
1) Is the intensity of installed device enough? Confirm spanner screws tighten.

2) Does control panel cool down appropriately by the air?
3) Make sure if wiring fix tightly and connect to terminal correctly.
4) Is not each device broken?
Warnings are indicated when mishandling this product might result in

g death, serious injury to the users or significant physical damage to this
product.
1) Don’t carry out insulation resistance test and withstand voltage test for Control line of
DC24V (blue line.). Devices will be broken if they are carried out.
2) Disconnect electric devices (AC/DC converter, controller, smoke sensor) with input terminal
and earth terminal of AC100V or 200V when insulation resistance test and withstand voltage
test for these terminals are carried out. Devices will be broken if disconnecting is not carried
out.
２． Confirmation before turning switch gear of control room on
Before power source is supplied, make sure the following points

1) Do wirings connect correctly?
2) Is rating of wiring correct?
3) Are connections fixed tightly?
4) Are ratings of power source (rated voltage, rated current, rated frequency,
and phase) correct?
5) Does earth control panel with ground?
6) Are entire switch gears (NFB) of control panel side OFF?
３． Confirmation after turning switch gear of control room on.
After power source is supplied, make sure the following points
Confirmation in control room

1) Does switch gear occur trip?
2) Is Needle deflection of ammeter 0?
Confirmation on control panel side

1) Do you smell something burning?
2) Are voltages between each terminals correct?
3) Is phase of three-phase power line correct?
４． Confirmation after turning switch gear (NFB) of burner control panel on
After turning switch gear (NFB) of burner control panel on, make sure the following
points.

BM-09
５． Confirmation after “OPERATION SOURCE”switch of burner control panel is turned
on
After“OPERATION SOURCE”switch of burner control panel is turned on, make sure

the following points.
3) Do contactor (8×or 88×)work correctly?
Warnings are indicated when mishandling this product might result
Warning in death, serious injury to the users or significant physical damage
to this product.
Set F.O.PUMP switch to “STOP” position, before operation switch is turned on.
６． Confirmation of F.O. and D.O PUMP rotation
Confirm direction of each pump rotation.

.
1) Is direction of rotation correct?

Warning in death, serious injury to the users or significant physical damage
to this product.
Turn on electricity as short as possible at rotation direction check. If PUMP spin in the opposite
direction, PUMP seals will be broken.
７． Setting of F.O. PRESS.
1) Operate F.O.PUMP and set F.O. PRESS

2) Set SP value (Set Point) in system with controller (SDC e.t.c.). Set F.O. PRESS. in
system with pressure adjusting relief valve.
Setting value is refer to specification.(standard value: 0.3MPa)
3) When F.O.PUMP is operated at first time, it is possible for safety valve of F.O.
circulating line to blow. Pay attention to the following point.
・ Make sure valve of F.O. circulating line open and close. (Is F.O. circulating line
normal?)
・ Operate F.O.PUMP after setting controller to MANU. and relief valve open in
system with controller (SDC e.t.c.).
Operate F.O.PUMP after turning setting handle to low pressure (in a
counterclockwise direction) in system with pressure adjusting relief valve.
BM-09
８．Confirmation by “OPERATION”switch of burner control panel
When “OPERATION”switch of control panel is set to ”MANU.”or”Em’y”position,

make sure the following points.
1) Does primary-AIR FAN turn?

2) Does secondary–AIR FAN turn?
3) Does burner motor work?
Turn operation switch on control panel back to ”STOP”position and confirm rotation
direction of the motor . If external rotation at motor’s back is lighted by penlight, rotation
direction can be seen before stop motor.
4）Does Burner motor turn in the right direction?
5) Does secondary Air Fan turn in the right direction?
6) Does primary air fan turn in the right direction?

Warning in death, serious injury to the users or significant physical damage to
this product.
Don’t put fingers or objects close to rotation parts of motor to avoid winding up in motor.
BM-09
Confirmation by operation
１． Test operation
1.1. Confirmation of condition for boiler and related devices
Carry out burner test operation after confirmation of condition for boiler and
related devices
1) Boiler DRM. water level
2) Condition of each valve (F.O. line ,Steam line, Feed water line)
3) F.O. PRESS Setting of F.O. Circulating line, Air release and e.t.c.
Confirm items indicated in Boiler user’s manual.
1.2. Test operation
1) Carry out first test operation in MANU.mode (Em’Y mode)to follow procedure
as described below.
2) Set each switch on control panel to the following setting.
Operation switch Position Condition

CONTROL “ON” OPERATION SOURCE lamp lights
SOURCE up
FLAME EYE NORMAL
BYPASS
THERMOSTAT “ON” D.O. combustion
BY-PASS
OIL HEATER “STOP” D.O. combustion
3) Turn “BNR. OPERATION”switch to“MANU.”or ”Em’y”

4) Primary AIR FAN starts.
5) After a few seconds (Standard; 6 seconds), secondary air fan, burner motor
and F.O.PUMP start.
6) Pre-purge starts and secondary air damper is opened.
7) After finishing pre-purge secondary air damper is closed to ignition position.
And “IGN. READY”lamp on the junction box of burner lights up.
If after 30 seconds since secondary air damper is closed to the ignition position
“IGN. READY “lamp does not lights up, make sure if limit switch connected to
secondary air damper (for detection of start position) works. If necessary, adjust
1)
Cam.中継ボックスの“IGN.”スイッチを押すと、D.O.ポンプが回り点火動作を開始します。
8) ) When IGN switch on Junction Box is pushed, D.O.PUMP turns and ignition
starts.
First ignition takes a few seconds to fill up D.O. in pilot burner line. If in 5 seconds
pressure gauge value doesn’t increase, stop ignition and check D.O.line.
9) Confirm if pressure gauge for pressure indication increases (standard value:

0.7MPa), flame of pilot burner can be seen from burner’s inspection hole.
If in 5 seconds since pressure gauge for pressure indication increases flame of pilot
burner cannot be seen, stop ignition and turn “BNR. OPERATION” switch back to
“STOP”position and check pilot burner.
BM-09
10) When flame of pilot burner is seen,(flame eye relay works),if "MAIN VALVE”
switch on junction box is turned ”ON” ,F.O. is supplied to main burner, and
main burner starts combustion.
Main valve switch may be set off soon, but”IGN”switch continues to be pushed for a
few seconds (1～5seconds)till flame becomes stable.
11) If in 5 seconds since pressure gauge for pressure indication increases flame of
main burner cannot be seen, stop ignition and turn “BNR. OPERATION” switch
back to “STOP” position and check main burner.
12) Because at first ignition, whole boiler is cool, combustion for long time is
impossible. After confirm main burner ignition ,turn "MAIN VALVE”switch OFF
and finish combustion of main burner. Post- purge starts.
13) After post- purge, turn OPERATION”switch on control panel to“STOP”, and
operation finishes.
1.3. Confirmation of automatic operation
1) After manual operation finishes, confirm automatic operation.

2) Set each switch on control panel as described below.

CONTROL “ON” OPERATION SOURCE lamp
SOURCE lighting up
FLAME EYE NORMAL
BYPASS
THERMOSTAT “ON” D.O. Combustion
BY-PASS
OIL HEATER “STOP” D.O. Combustion
3) “ Turn “BNR. OPERATION”switch to “AUTO.”(or”AUTO-ON”)

4) Primary Air fan starts
5) In a few seconds secondary air fan, burner motor and F.O.PUMP starts.
6) Pre-purge starts, and secondary air damper opens.
7) Pre-purge finishes, secondary air damper closes to ignition position and
ignition starts.
8) When flame eye detects flame, main valve opens and F.O. is supplied to main
burner.
9) Because whole boiler is cool, combustion for long time is impossible. After
confirm automatic ignition of main burner ,turn “BNR. OPERATION”switch to
“STOP” and finish combustion of main burner. Post- purge starts.
10) After post- purge, operation finishes.
BM-09
２． Confirmation of safety system
2.1. First, confirm limiter.
1) Following section1.3, confirm safety system in automatic operation.

2) Check items in the table below
Check the following 3 points.
・ To stop combustion immediately.
・ Trip lamp on control panel lights up.
・ Alarm in engine room works.
No. Check items Test procedure for safety system
1 Em’y Stop Push ”Em’y STOP”switch on console
2 DRM. LEVEL Blow slowly from bottom.(respondence is late because of 15
LOW TRIP seconds timer )
3 DRM. PRESS. Check when safety valve is checked
HIGH TRIP
2.2. Confirmation safety devices.
1) Following section1.3, confirm safety system in automatic operation.

2) Check items in table below.
Check the following 3 points.
・ To stop combustion immediately.
・ Trip lamp on control panel lights up.
・ Alarm in engine room works.
No. Check items Test procedure for safety system
SOURCE
1 Turn OFF NFB
FAILURE
AIR PRESS. LOW Loosen bushing of primary Air Press. switch line and
2
or lower the pressure.
PRIMARY-AIR
Pres. LOW Loosen bushing of secondary Air Press. switch line and
3
SECONDARY-AIR lower the pressure.
Pres. LOW
Loosen the fixed lever of burner; draw out burner slowly.
4 BNR. HINGE Open
Be careful with this check.
5 F.O. Pres. LOW Turn F.O. PRESS. LOW TRIP switch off
6 F.O. Temp. LOW Turn off THERMOSTAT BY-PASS switch
Flame-Eye Before burner operation, take off flame eye. Shine light on
7
abnormal flame eye, and start operation.
Before burner operation, take off ignition cable of burner,
start operation.
8 Miss-Ignition
Close valve if pilot burner line has valve.
During combustion take out flame eye from burner, and

9 Flame failure
block the light to flame eye by hand.
Primary-Air Fan
10 Stop thermal relay of starter by hand.
Trip
Secondary-Air Fan
11 Stop thermal relay of starter by hand.
Trip
12 BNR. Motor Trip Stop thermal relay of starter by hand.
13 D.O. PUMP Trip Stop thermal relay of starter by hand.
14 F.O. PUMP Trip Stop thermal relay of starter by hand.
BM-09
３． Steam up
To confirm check of safety valve and characteristic features of other devices,

increase pressure of boiler. Then check each device.
3.1. First confirmation

1) Make sure if DRM. water level is defined value. Because water level increases
according to DRM. Pressure increase (water temperature increase),it is no
problem that DRM Water Level is Normal or slightly less.
2) Next make sure if instrument reading of DRM.PRESSURE GAUGE and DRM.
PRESS. TRANSMITTER are equal. If they are not equal, turn 0 point
adjustment of DRM. PRESS. TRANSMITTER to correspond.
3.2. Seam up
1) Start steam up
・ Burner sets minimam ombustion, and operates in manual mode.
CONTROL “ON” Operation source lamp lights up.
SOURCE
FLAME EYE NORMAL
BYPASS
THERMOSTAT “ON” D.O.combustion
BY-PASS
OIL HEATER “STOP” D.O.combustion
MANU. SET CV ON(Yellow) Set value is 20%
・ Follow boiler maker’s instruction about combustion time for steam up.
・ Repeat combustion for 1minutes and stop combustion for 5minutes and
increase combustion time according to boiler pressure rises.
2) When boiler pressure is over 0.1MPa, blow pipes of DRM. PRESS.

TRANNSMITTER and DRM. PRESS. SWITCH, remove particles.
1) After boiler pressure increases to SP (SP: setting point), check and adjust the
following devices.
・ 0 point and span of DRM. LEVEL TRANNSMITTER
・ Span of DRM. PRESS. TRANSMITTER
４． Confirmation and Adjustment for DRM.PRESS SWITCH and safety valve
4.1. Confirmation of DRM.PRESS.SWITCH
1)Before check of safety valve, check actuation of safety devices like DRM.
PRESS. HIGH ALARM ,DRM. PRESS. HIGH STOP and DRM. PRESS. HIGH TRIP.
4.2. Confirmation of safety valve
1) Actuation of safety valve is checked in manual mode

2) System with function of DRM. PRESS. HIGH STOP needs to cancel actuation of
this switch.
3) Normally boiler has two safety valves..
５． Confirmation of each switch and safety devices
Confirm each switch actuation to take class survey.
BM-09
Steam supply
１． Before open main valve
After class survey for boiler system, and preparation of each devices connected to
steam line, steam can be supplied to the line.
Before open main valve, make sure safety condition about steam line and around
２． Steam supply
First, check no steam leaking of each part.
BM-09
Change to H.F.O., and Change to D.O./ＭＧO
１． Change to H.F.O.
1.1 When temperature of service tank for boiler (and reserve tank) increases, change to
H.F.O. is possible.
２． Confirmation and cleaning of strainer
2.2 .Before change to H.F.O., we recommend check and cleaning of strainer.
３． Change to H.F.O.
3.1. Confirm temperature of service tank for the boiler is about 80℃
3.2. Change to H.F.O. in the following procedure.

1) Start combustion automatically.
2) Change valve from D.O. to H.F.O.
3) Flow steam to the steam trace.
4) Change heater switch on control panel to ”AUTO”.
5) When “THERMOSTAT BY-PASS”lamp start flashing up, turn THERMOSTAT
BY-PASS”switch ”OFF”.
6) When thermometer in burner is over100℃,Change to H.F.O is finished.
3.3. When F.O.temperature is around 100 ℃,F.O. pressure gauge oscillates, decrease
setting temperature of F.O. TEMP. CONTROLLER to 95℃,and wait for pressure
gauge to be stable. After stabilizing temperature, return to the previous setting
value(standard :125℃).Dew condensation and vapor by temperature difference
cause this phenomenon, and it can be seen especially after bunker.
４． Change to D.O./MGO
4.1. Change to D.O. /MGOin the following procedure.

1) Start combustion automatically.
2) Stop steam of steam trace.
3) Change heater switch on control panel to“OFF”,and change“ F.O. TEMP.
DETECT SWITCH”to“CANCEL”.
4) Make sure if F.O. temperature decreases.
Note； In case of D.O./M.G.O.usage, confirmation about F.O. temperature

must be carried out. Carefully review and consideration can
detect problems with valve leakage of the steam tracing and
heater.
5) Change the valve from H.F.O. to D.O./MGO

6) After “F.O. TEMP. DETECT ”lamp changes to light up from flashing, and
temperature in burner side becomes under 60℃,change to D.O. or M.G.O.. is
finished.
BM-09
W.O.combustion
---Change to W.O.MIX.combustion and W.O.single combustion
１． About fuel change
1.1 About fuel change, we already explained in section--function of each
devices1.18.,fuel can be changed by operation of FUEL OIL SELECT SWITCH
Normally fuel is changed automatically. In case 3 way valve or change valve is
equipped in line from tank, please operate to open or close valve in line
In this system, before and during operation, kind of fuel can be changed. But fuel
change takes a certain period of time and change cannot be done immediately.
System adjusts automatically according to combustion capacity and feature of
selected oil not to cause accidental fire or smoke.
Cautions are indicated when mishandling this product
CAUTION might result in minor injury to the users, or only physical
damage to this product.
２． Fuel change before combustion start

2.1 F.O.combustion
2.1.1 Start operation
① Confirm if valves in line are open or close before operation.
② Set FUEL OIL SELECT switch (3-WMX) to F.O.
③ Set BURNER OPERATION switch (43-B) to AUTO.ON
④ Automatic operation starts.
2.1.2 Stop operation
① Set BURNER OPERATION (43-B) switch to STOP.
② After D.O.MIX post purge starts until furnace is well-ventilated.
Then operation is stopped. (About 30 seconds).
2..2 F.O. and W.O. mix combustion

② Set FUEL OIL SELECT (3-WMX) switch to W.O.MIX.
③ Set BURNER OPERATION (43-B) switch to AUTO.ON.
⑤ Automatic operation starts by F.O.
⑥ After combustion capacity is over 30%,“W.O.MIX.”mode starts.
① Set to BURNER OPERATION (43-B)switch to STOP.
② After D.O.MIX post purge starts until furnace is well-ventilated. Then
operation is stopped. (About 30 seconds).
2.3 W.O.combustion
1. Set FUEL OIL SELECT switch (3-WMX) to W.O.
2. Set BURNER OPERATION (43-B) Switch to AUTO.ON.
3. Automatic operation starts. In case of W.O.combustion, system sometimes
keeps combustion low and required amount of steam cannot be
generated. Depending on the situation, change to W.O.MIX or F.O. single
combustion.
① Set to BURNER OPERATION (43-B)SWITCH to STOP.
② After D.O.MIX,post purge starts until furnace is well-ventilated. Then
BM-09
３． Fuel change during combustion
3.1 F.O.combustion → F.O. and W.O. mix combustion
3.1.1 Fuel change during operation
① Confirm if valves in line are open or close before change.
② Set FUEL OIL SELECT (3-WMX) SWITCH to W.O.MIX.
After F.O.combustion is automatically adjusted at 30% of maximum
combustion capacity and boiler condition becomes stable, W.O.valve opens
and W.O.MIX combustion starts.
④ Due to the setting of required amount of steam, system controls F.O. flow
rate automatically depending on combustion capacity.
3.1.2 Stop combustion
① Set BURNER OPERATION (43-B) Switch to AUTO.ON.
② After D.O.MIX,post purge starts until furnace is well-ventilated. Then operation
is stopped. (About 30 seconds).
3.2 W.O.MIX combustion → W.O. single combustion

② Set FUEL OIL SELECT (3-WMX) SWITCH to W.O...
③ Ｗhen the switch is changed,adusting valve is gradually closed adjusting
automatically F.O. supply and damper opening for combustion air and
W.O.combustion starts. F.O.flow adjusting valve sets to LOW combustion,
F.O.solenoid valve is closed and W.O.single combustion is carried out.
④ In case of W.O.single combustion, combustion capacity is not changed by
steam flow. Combustion capacity is fixed in low mode.
② After D.O.MIX, post purge starts until furnace is well-ventilated. Then
operation is stopped.(About 30 seconds).
3.3 F.O. single combustion → W.O. single combustion.

② Set FUEL OIL SELECT (3-WMX) SWITCH to W.O..
③ F.O. combustion becomes to 30% of maximum combustion capacity, and
W.O.MIX mode starts. Soon after that, oil flow is decreased to the minimum
flow rate. Then the entrance of main solenoid valve is closed and W.O.single
combustion mode starts.
⑤ In case of W.O.single combustion, combustion capacity is not changed by
steam flow. Combustion capacity is fixed in low mode.
3.4 W.O.MIX combustion → F.O. single Combustion.

3.4.1Fuel change during operation
① Set FUEL OIL SELECT (3-WMX) SWITCH to F.O.
② After adjusting W.O. supply and damper opening for combustion air
automatically, W.O solenoid valve is closed and F.O.combustion starts.
② After D.O.MIX,post purge starts until furnace is well-ventilated. Then operation
BM-09
is stopped. (About 30 seconds).
3.5 W.O.MIX combustion → W.O. single combustion.

② Set FUEL OIL SELECT (3-WMX) SWITCH to W.O..
③ Ｗhen the switch is changed,adusting valve is gradually closed adjusting
automatically F.O. supply and damper opening for combustion air and
W.O.combustion starts. F.O. flow adjusting valve sets to LOW combustion,
F.O.solenoid valve is closed and W.O. single combustion is carried out.
④ In case of W.O.single combustion by only W.O., combustion capacity is not
changed by steam flow.
operation is stopped.(About 30 seconds)
3.6 W.O. single combustion → F.O.single combustion.

② Set FUEL OIL SELECT (3-WMX) SWITCH to F.O..
③ F.O.solenoid valve is open.F.O flow.adjusting valve is gradually open and
W.O.MIX combustion starts.After stable W.O.MIX combustion and adjusting
automatically F.O. supply and damper opening for combustion air,
W.O.solenoid valve is closed and F.O.combustion starts.
④ Automatic boiler operation starts.
② After D.O.MIX, post purge starts until furnace is well-ventilated.Then operation
is stopped.(About 30 seconds)
3.7 W.O.MIX combustion → W.O.MIX. combustion.

3.7.1Fuel change during operation
② Set FUEL OIL SELECT (3-WMX) SWITCH to W.O.MIX..
③ F.O.solenoid valve is open. .F.O.flow adjusting valve is gradually open and
W.O.MIX combustion starts.Depending on required steam flow, oil flow is
changed and automatic combustion control starts.
② After D.O.MIX post purge starts until furnace is well-ventilated.Then operation
is stopped.(About 30 seconds)
After W.O. Combustion

Please wash W.O.line with D.O. by operating line valve.
If W.O. is left in line,cold W.O. is adhered and it causes clog. Next W.O. combustion may not be
carried out normally.Please carry out timely maintanace.
Cautions are indicated when mishandling this product

CAUTION might result in minor injury to the users, or only physical
damage to this product.
BM-09
Troubles of devices
１． Troubles of devices and solution
1.1. AC/DC converter(DC power supply device)
1) Aspect
2) Condition of trouble
・ When it is broken completely, green LED lights out. Although green LED
lights up, the trouble that output voltage temporally undergo a change
could happen.
・ Measure voltages of both side of wires marked P（DC24V）and N（0V）, and
decide if they indicates DC24V or not. (Continuously over 23V is normal
condition.)
3) Emergency support
・ Disconnect wires connected to output of AC/DC converter(marked P
（DC24V）and N（0V）,connect those wires to instrumentation power
source(DC24V) and operate.
・ If two AC/DC converters are equipped, the wires connected to broken
AC/DC converter can be disconnected and can be connected to another
AC/DC converter.
4) Maintenance
・ About half of AC /DC converters have troubles in 5 ～7years.
・ These troubles are caused by temperature, so if it is kept as spare since
new ship ,it becomes depleted.( deterioration speed is slow)
We recommend spare should be bought at 5th year dock.
5) Preventation
・ Troubles of AC/DC converter are almost caused by heat deterioration.
When temperature drops 10℃ lower, operating time is twice longer.
BM-09
1.2. Programmable logic controller （PLC）
1) Aspect
Source unit Each I/O unit

CPU unit
2) Trouble condition
・ Confirm if Green LED (RUN indicator) on upper right CPU unit lights up.
・ When green LED lights up, operation is carried out.
・ When red LED flashes, non- fatal error occurs. (Operation can be carried
out.)
・ When red LED lights up continuously, (green LED lights off.)fatal-error
occurs.
・ When all of LED lights off, power source on left of CPU unit is abnormal.
・ Operate setting OPERATION switch to”Em’y”position and setting ACC
switch to”Em’y”position.
4) Maintenance
・ About half of CPU unit have troubles in 10 ～15years.
・ We recommend source unit and CPU unit should be bought in 10th
years dock.
5) Preventation
・ Troubles are almost caused by heat deterioration. When temperature
drops 10℃ lower, operating time is twice longer. Cool down control
panel by the air.
Note) Compact flash memory in CPU unit records all of control data and program.
Don’t discard it when CPU unit is changed.
BM-09
1.3. Programmable terminal (Touch panel)
1) Aspect
・ When nothing displays on the screen, condition of ”RUN”LED on right side
of the screen shows the troubles as described below.
Color of Condition
Buzzer Trouble details
LED of LED
Green or In case connection is displayed on lower
light up None
orange right, communication trouble to CPU.
Light
Light out None
up In case nothing is displayed ,trouble of
Orange Light up None system program
Green Light up None
Green Buzzer
Flash Trouble of back light
sound
Red Light up none Trouble of main body
・ Trouble of programmable terminal has no effect on control action.
・ Carry out emergency support leaving as it is.
4) Maintenance
・ Programmable terminal (NS8 series or NS12 series) has lithium battery built
in for back up of calendar clock.
 Battery life: About 5years at room temperature
 Battery exhaustion: Front LED of programmable terminal turns green to
orange.
In case of black-out for over 5 minutes, built –in calendar clock resets.
Battery exhaustion does not affect other performance.
5) Preventation
 Troubles are almost caused by heat deterioration. When temperature
drops 10℃ lower, operating time is twice longer. Cool down control panel
by the air.
Note) Compact flash memory in CPU unit of PLC records all of control data and
program. Don’t discard it when CPU unit is changed.
BM-09
1.４. Timer
1) Aspect
RANGE RANGE
SET
LED(INPUT) VAL.
MODE EXCHA.
MODE
LED(OUTPUT)
・ When LED of INPUT or OUTPUT doesn’t light up, check voltage between
A1-A2 terminal, and B1-A2 terminal (refer to voltage of control power
source, and drawings)
・ If measured voltage is not 0V, and LED lights off, devices
trouble occurs.
・ Most of this timer is used as input of burner trip circuit by hard
wired sequence.
・ Without timer function, operation is not carried out. Change to
spare.
・ In case of change to spare, set value in front of timer and set
setting switch on the bottom.
Setting switch
4) Maintenance
・ Timer is necessary to operate. Always keep spares.
5) Preventation
・ Troubles are almost caused by heat deterioration. When temperature drops
10℃, lower, operating time is twice longer. Cool down control panel by the
air.
BM-09
1.5. Relay
1) Aspect
This system uses different forms of relay depending on the intended use.
When Relay is changed, make sure its type and specification.
・ Coil voltage is not 0V, but contact does not close.
・ Coil voltage is 0V, but contact closes.
・ Change to spare.
BM-09
1.6. Flame Eye /Flame eye relay
1) Aspect
FLAME EYE RELAY
2) Trouble check
・ When light receiving parts of Flame eye is removed from burner, make sure
if flame eye relay turns ”ON” or ”OFF” depending on light on or off.
・ If burner operation needs to carry out for safety of the vessel, “FLAME EYE
BY-PASS “switch on the control panel has to be changed.
4) Maintenance
・ When light receiving parts of Flame eye is dirty, detective sensitivity
decreases. Clean light receiving guard glass of Flame eye regularly.
BM-09
1.7. Water level relay
1) Aspect
2) Trouble check
・We have no record of trouble for water level relay. But check if water level
relay is ”ON” or “OFF” depending on open or close between electrode
terminals. .
・ We have no record of trouble for water level relay. In trouble, change to
spare if you have in the vessel.
・ If spare doesn’t keep in vessel, for example water level relay for DRM.
PRESS. HIGH ALARM can be used for other purpose temporally
4) Maintenance
・ Regularly block off electrode pot of water level relay from DRM.and check
the actuation of water level switch.
BM-09
1.8. Wired sequence circuit board (error control relay board)
1) When this board has trouble, automatic operation by PLC and by wired sequence
circuit board (Emergency operation relay board) is impossible.
2) Relays in this system possess higher reliability in high temperature. But if you have any
trouble, please contact us
3) We recommend keeping spare in important system.
1.9. Wired sequence circuit board (Emergency operation relay board)
1) When PLC is normal, this substrate is not used.
2) But we recommend checking actuation regularly.
TEC-070226-Ko1
MAINTENANCE MANUAL
TYPE ； For CJ1M series
Name ； Program Logic Controller

Model included in this document ；
CJ1M-CPU11 , CJ1M-CPU12 , CJ1M-CPU13

CJ1W-CLK21-V□
CJ1W-AD081-V□ , CJ1W-AD041-V□
CJ1W-DA081C , CJ1W-DA041-V□
CJ1W-TC101 , CJ1W-TC001
CJ1W-ID232 , CJ1W-ID262 , CJ1W-ID211
CJ1W-OD233 , CJ1W-OD263 , CJ1W-OD211
Revision history
26 FEB. 2007 Make doc. Maenishi
09 JUL.2007 Mistake is corrected Maenishi
21 JUN 2011 Grammars and vocabulary check Kagawa
TEC-070226-Ko1
WAY TO REMOVE THE RETACHED UNIT
Ⅰ； Cut the power supply
Ⅱ； Remove the DIN rail stopper

1) Loosen the screw on the DIN rail stopper.
2) Pull forward the DIN rail stopper, and remove

the DIN rail by pulling it up.
Ⅱ； Remove the unit

1) Release the lock by pulling forward the CPU unit and also pulling the four sliders at
the right and left side of the unit.
2) Remove the unit that is placed on the right side of the CPU unit to the right, and the
left side unit to the left. The connection of the inner connector will be released by this.
Slider
To left To right
Fixture rail
By pulling out the fixture rail, the unit will be easily removed.
3) Unlock the unit by pulling out the fixture rail. The DIN rail will be removed by pulling
the unit forward.
Ⅲ； Attach a new unit

By practicing the process from the last, a new unit will be attached.
.
TEC-070226-Ko1
HOWO REPLACEMENT CJ１M CPU-unit
CJ1M CPU UNIT

Slider
Secures the next Unit.
Memory Card Indicators
MCPWR (green): Lit when power is
supplied to Memory Card.
BUSY (orange): Lit when Memory
Card is being accessed.
Memory Card Power

Supply Switch
Press the power supply switch
to disconnect power before
removing the Memory Card.
RS-232C Port
Connected to
Programmable
Terminal.
Memory Card
Connector
Connected to
the next Unit.
Memory Card Eject Button Memory Card Connector

Press the eject button to remove Connects the Memory Card to the CPU Unit
the Memory Card from the CPU Unit.
Ⅰ； Stop the operation source supply

Turn off two the no-fuse-breakers (A101,A102) for operation source and auxiliary source.
Ⅱ； Remove the unit

1) Remove the DIN rail stopper.
・ Loosen the screw of the DIN rail stopper.
・ Pull the upper part of the unit.
2) Unlock the unit by pulling forward the unit and the four sliders at the right and left
side of the unit.
TEC-070226-Ko1
3) Remove the unit that is placed on the right side of the CPU unit to the right, and the
left side unit to the left. The connection of the inner connector will be released by this.
To left To right
Fixture rail
By pulling out the fixture rail, the unit will be easily removed.
4) Unlock the unit by pulling out the fixture rail. The DIN rail will be removed by pulling
the unit forward
Ⅲ； attach a new unit

By practicing the process from the last, a new unit will be attached.
Ⅳ； Installation of memory card

Remove the memory card that was installed in the old unit, and
install that card into the new unit.
Check the direction of the memory card when installing.
Ⅴ； Confirm installation
Confirm the following matters after reattaching the unit.
1) Are all the units locked at the fixture rail?

2) Are the unit and the sliders around the unit locked?
3) Are all the DIN rail stoppers fixed?
TEC-070226-Ko1
HOW TO INSTALL PROGRAM CJ１M CPU-unit
Ⅰ； When there is already a program that is preinstalled in the

new unit.
Do not attempt the operation that is written in section II.
Ⅱ； When there is no program in the new unit.

Follow the instructions that are written below to install a program in the new unit.
1) Check if the memory card is installed correctly.
2) Turn on only DIP switch 7.
ON
TEC-070226-Ko1
3) Turn on the switch of the control power source.
4) When the control power is supplied, the program will automatically install the
memory card.
BUSY LED (orange) will blink while installing the program.

It will take five seconds for installing the program.
Do not cut off the operation source while installing the

Warning program.
The memory of the CPU will be destroyed.
5) MCPWR LED (green) will enable you to check if the installation has been done
correctly.
Normal Abnormal
When control source supplied Blinking once Five time blinking
While installing Lit Light off
End of installation Light off Light off
6) Turn off the control power source.
7) Turn off all DIP Switches.
OF
8) Turn on the control power source again.
9) Remove the battery.
10) The program installation is completed.
Note; When using a system that does not have a memory card, use a CPU unit that has already
installed a program
TEC-070226-Ko1
WAY OF INSTALLATION CJ１W-CLK21-V□
CJ1W-CLK21-V□ Display of unit condition
Unit No.
Node No.
Baud rate
Terminator switch
Terminal of communication
line
Ⅰ； Attentions for removing the unit

1) The units are connected with the other units by a communication line.
2) Stop all the system that is connected to this communication line when removing the
unit.
Ⅱ； Setting of the new unit

1) Match the setting of the new unit to the setting of the removed unit.
2) Follow the four instructions below.
■ Unit No. ; Follow the setting that was done in the old unit.
■ Node No. Follow the setting that was done in the old unit.
■ Baud rate; Set up the communication speed by the two switches. Follow the
setting that was done in the old unit.
■ Terminator; Turn on the Terminator switch that is placed on both sides of the
communication line.
If missing these setting you cannot get into communication.
TEC-070226-Ko1
WAY OF EXCHANGING CJ１W-AD□□□-V□
CJ1W-AD081-V□ , CJ1W-AD041-V□
Internal set
switch
Terminal
block
Unit No.
Mode switch
Lock release
lever
Note; CJ1W-AD041 does not have an internal switch.
Ⅰ； How to remove the terminal block

1) The terminal block can be removed from the main body by pulling the lock release
lever.
■ Pull the lock release lever
■ Pull the terminal block
Pull
Pull
Note ； To prevent the unit being destroyed by connected mistake, the wired terminal
block should be used for a new unit.
TEC-070226-Ko1
Ⅱ； Settings of the new unit
2) Follow the three instructions below for the switch setting.
■ Mode switch; Turn OFF the mode switch.
■ Internal switch; There is no internal switch for CJ1W-AD041.

Follow the setting that was done in the old unit for
CJ1W-AD081.
For INPUT-2
For INPUT-1
For INPUT-4
For INPUT-3
For INPUT-6
For INPUT-5
For INPUT-8
For INPUT-7
ON
For current input ; “ON”
For voltage input ; “OFF”
TEC-070226-Ko1
HOW TO REPLACE CJ１W-DA□□□-V□
CJ1W-DA08C , CJ1W-DA041-V□
Terminal
block
Unit No.
Mode switch
Lock release
lever

lever.
Pull
Pull
Note ； To prevent the unit being damaged by connection mistakes, the wired terminal
block should be used for the new unit.
TEC-070226-Ko1
2) Follow the two instructions below to set up a new unit
■ Mode switch ; Turn OFF the mode switch..
TEC-070226-Ko1
HOW TO REPLACE CJ１W-TC□□□
CJ1W-TC101 , CJ1W-TC001
Terminal
block
Unit No.
Function Sensor type

Lock release
lever

lever.
Pull
Pull
Note ；To prevent the unit being damaged by connection mistakes, the wired terminal
TEC-070226-Ko1
1) Please match the setting of the new unit to the setting of the removed unit.
2) Follow the three instructions below to set up a new unit.
■ Unit No.; Follow the setting that was done in the old unit.
■ Sensor type; Follow the setting that was done in the old unit.
■ Function; Turn off ALL the function switches. (There are eight function
switches.)
TEC-070226-Ko1
HOW TO REPLACE CJ１W-□□211
CJ1W-ID211, CJ1W-OD211
Terminal
block
Lock release
lever

lever.
Pull
Pull
Note ； To prevent the unit being damaged by connection mistakes, the wired terminal
TEC-070226-Ko1
HOW TO REPLACEMENT CJ１W-□□23□
CJ1W-ID232 , CJ1W-OD233 CJ1W-ID262 , CJ1W-OD263
MIL
Connecter
CUSTOMER SERVICE & SPARE
CUSTOMER SERVICE AND SPARE PARTS
CONTACT POINT FOR MAINTENANCE AND REPAIR
If you contact below department when you have any problem,

we will reply to you as soon as possible for better service.
CUSTOMER SERVICE DEPARTMENT
E-MAIL : [email protected]
TEL : +82-55-269-7989
SPARE PARTS TEAM
E-MAIL : [email protected]
TEL : +82-55-269-7720
We make every effort to treat your problem

and give you customer satisfaction.
NOTE
∙ We do not warranty in case of not using original parts.
∙ Any repair and modification done by unauthorized workshop,
it might cause of serious damage for system and we do not warranty.

Boiler

Uploaded by

Copyright:

Available Formats

Boiler

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Boiler

Uploaded by

Copyright:

Available Formats

INSTRUCTION MANUAL

CUSTOMER : Hanjin Heavy Industries Co.,Ltd.

HULL NO. : P0123

SERIAL NO. : PAW14HJ0123

江林重工業 (株) HEAVY INDUSTRIES CO.,LTD.

昌原工場 CHANGWON FACTORY

江林인슈(株) INSULATION CO.,LTD.

釜山工場 BUSAN FACTORY

76, YEONDEOK-RO, CHANGWON-SI, KOREA

3. F.W. SYSTEM WITH ACCESSORIES

5. F.O. SYSTEM WITH ACCESSORIES

7. SPARE PARTS AND TOOLS

8. PART INSTRUCTION MANUAL

0 15.04.27 FOR FINAL H.S.CHO - K.J.AHN

KANGRIM HEAVY INDUSTRIES CO., LTD.

KANGRIM HEAVY INDUSTRIES CO., LTD.

LIST OF DESIGN DATA

NO DRAWING NO. TITLE REV. REMARK

2 MB-TE-01 Design data

- Information table of insturments 0

- Proposal water level 0

- Proposal drum pressure setting point 0

- Thermal expansion of boiler 0

5 MB-MN-05 Soda boiling procedure 0

KANGRIM HEAVY INDUSTRIES CO., LTD.

2. Oil fired section data

KANGRIM HEAVY INDUSTRIES CO., LTD.

Information table of instruments

Diff. pressure transmitter

* NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

KANGRIM HEAVY INDUSTRIES CO., LTD.

Proposal water level

High Water Level (17.6 mA)

Low Water Level (7.5 mA)

Low Low Water Level (6.9 mA)

KANGRIM HEAVY INDUSTRIES CO., LTD.

Proposal drum pressure setting point

☞ 9.0 Safety valve open / Design pressure

☞ 8.5 High steam pressure

☞ 7.7 Dumping v/v open

☞ 7.0 Boiler working pressure

☞ 6.5 Burner start

☞ 5.5 Low steam pressure

PRESSURE UNIT : kg/㎠.G

KANGRIM HEAVY INDUSTRIES CO., LTD.

KANGRIM HEAVY INDUSTRIES CO., LTD.

1. Transportation and Handling of Boiler

As a standard the boiler plant is delivered in a 20 feet flat rack container.

FIG.1 Lifting of the boiler from the transport container

KANGRIM HEAVY INDUSTRIES CO., LTD.

FIG.2 Turning the boiler into an up-right position

FIG.3 Lifting the boiler into the hull

KANGRIM HEAVY INDUSTRIES CO., LTD.

FIG.4 Welding at the boiler and thermal expansions

KANGRIM HEAVY INDUSTRIES CO., LTD.

The support is to be arranged both longitudinally and transversally. In order to lift,

As regards“type C”only the lower“eye”is to be used when staying the boiler. We

Detail of lifting eye Detail of lifting eye

KANGRIM HEAVY INDUSTRIES CO., LTD.

FIG.5 Support of boiler installed limitation for angle and length