NIR7953<2> JAN.5.

2005

NON—FLOW ALARM
S YS TEM

SERVICE MANUAL
TYPEzYFA—MHS—O l—VSI
FOR LUBR I CATOR

YAMASHINA
llajec
SEIKI CO. , LTD. SHIGAJAPAN
 TABLE OF CONTENTS
Precautions for Safety Operations

Check and caution points before operation

Caution for operation

Periodic inspection

Outline

Non-flow alarm system

2. 1 Specifications of detector

2 . 2 Details of Non-flow alarm system

2. 3 Junction box

Fig.2 Non-flow alarm system YFA—MHS-OLVSI

2. 4 Electrical wiring

2 . 5 Adjustment method

Cautions for installation and at start of operation

Maintenance and inspection 10

Parts drawing 11

Parts List 12
 Check and caution points before operation

Make sure to check the following points before stating operation of

YFA—M*S-01-V non—flow alarm system.

If you discovered any abnormal condition on the system, find out

the cause and restore the normal condition before stating operation.

A CAUTION

Confirm that power supply voltage is 24V DC.

Confirm that the {+) wire is connected to the terminal @ on the

terminal block and the F) wire is connected to the terminal @.

When you need to change the connection on the terminals @, @

or @ on the terminal block, carefully read and understand the
instructions given in the attached instruction manual before
attempting to change the connection.

0 Confirm that the terminal block securing screws or others are

tightened securely.

Confirm that oil is dischargingfrom the lubricator.

Confirm that there is no leakage on the pipeline.

GOOD

Confirm that no abnormal noise or vibration is heard or sensed.

Confirm that there is no damage or any other abnormal condition

on the non-flow alarm system, lubricator and pipeline system
2 . Cautions for operation

A DANGER

0 Be careful not to touch the wires connected to the terminal block

or other live parts during operation. There is a risk of electrical
shock.

Q When there is any wiring connected to a power supply of other

than 24V DC at the vicinity of the system, make sure to mark such
clearly. Wrong wiring could not only break down the system but
also is very dangerous.

3 . Periodic inspection

A CAUTION

O Some of sections on the non-flow alarm system must be inspected

at regular intervals.

0 Inspect such section as specified by the attached instruction

manual.
2 . Non-flow Alarm System
Our non-flow alarm system consists of the fully electronic "Detector" that monitors the
flow rate of oil, and the "Junction Box" that is composed of a relay to increase the contact
rating and a circuit board.

Detector
Junction box

—‘—i i: Input power supply(DC24V)

———~> Output
(To alarm panel of main engine)
Pipe

\
Lubrication to main engine

Lubricatorf Detector adapter

Fig.1 Schematic diagram of Non-flow Alarm System

Specifications of detector
Operating power supply DC24V
Output switching current DC400mA
Internal voltage drop (At ON) 2.5V or less
(Under maximum load)
Internal consumption current (At OFF) 80mA or less
Fluid temperature —25
~ 80 °C
°C
Flow speed setting range 3cm/sec ~ 300cm/sec
Withstanding pressure 80kgf/cm2
Indicator _
10 LED
Switching point temperature by button
Operating ambient temperature -20 °C ~ 80 °C
Protective structure IP67 (IEC144)
Worm-up time after power ON MAX. 40 sec

AKASAKA
2 . 2 Details of Non-flow Alarm System
As shown by Fig.1, oil discharged from the lubrication flows in from the arrow
direction, and the oil flow is monitored by the detector designed to monitors the oil
flow within the detector adapter. The detector emits an ON signal if there is no
problem in the lubrication, or an OFF signal if the lubrication is interrupted (You
may invent the signal emission by changing the detector leads so that OFF signal is
emitted at an interrupted lubrication and ON signal during normal lubrication.)
Refer to page 4 for further details.

\Vrth the junction box, a C contact and bipolar system relay is assembled.

Since our non-flow alarm system uses a full electronic sensor, the detector will not
turn ON and OFF repeatedly even if the oil is discharged intermittently.

A button is provided in order to allow adjusting the time elapsed before emitting
an alarm signal after an interrupted lubrication. Refer to page 7 for details.

Major feature of this system is a highly reliable and fully electronic sensor. It is
free from any moving components, which are common causes of troubles on
conventional mechanical system, and there is no problem of worn parts. Moreover,
with most of conventional electronic system, a steel ball enclosed in an indicator is
pushed up from the position detected by a proximity switch during normal lubrication,
and the steel ball drops to the position at an interrupted lubrication. With such
construction, it is necessary to use diamagnetic material around the proximity switch
because of its characteristics, of which transparent acrylic resin is generally employed.
v” "'7
This condition fiirther causes another problem in durability because it is necessary to
reduce the distance between the steel ball and the proximity switch due to a limitation
in the sensitivity range.

Another major feature of the new system is that it has no limitation on piping.
Pipes can be connected either in vertical or horizontal direction and the system can be
mounted easily at any location on the pipeline. In addition, since the inlet and the
outlet are identical, either side can be used at the entrance or exit.
2 . 3 Junction box
Refer to Fig. 2 Non-flow alarm system.

Junction box is installed in order for protection of the detector and to increase the
contact rating of the alarm circuit

Type Type YFA-MHS-Ol

Input poewr supply (Terminal Nos. 1-2) DCZ4V
Contact raing Resistance load COS¢=1 DC3OV5A
of alarm circuit Resistance load COS¢=O.4 DCSOVSA

Type _
Type YFA-MHS-lO
Input poewr supply (Terminal Nos. 1-2) DCZ4V ‘

Contact rating Resistance load COS¢=1 ACl 10V 10A, DCZ4V 10A
of alarm circuit Reactance load COS ¢=0.4 ACl 10V 7.5A, DCZ4V 5A

X Connect wires as follows:

For alarm OFF with detector lubrication stop (Terminal 3-Brown, 4-Black,
S-Blue)
For alarm ON with detector lubrication stop (Terminal 3—Blue, 4-Black,
S-Brown)
Alarm OFF with detector lubrication stop is the standard specification (Standard
specification for AKASAKA DIESEL LIMITED)
For details of wiring, refer to Fig. 2.

X Protective structure of junction BOX is IP 55.

X Accessory
l) Amplifier terminals for external connection 1.25rnmz
2) Fuse: 1 Piece (Assembled on the junction box PCB.)

X Paint color: Munsell SB4/1

AKASAKA
 TERMINAL BOARD
JUNCTION BOX 150

UETEC TOR

1L INLEY i:

I 70 l

180

(I) (5)
0
FE 7 w
DETECTOR

wigm iii”

e; 68Iii
-——4+5L—v 119
TYPEzYFA—MHS—Ol—VSI
This diagrm is shw to flowing of oil.
For alarm off with detector lubrication stop.
For alarm ON with relay (Terminal 7-8.10-9)
'For alarm OFF with relay (Terminal 7-6 10—11)

Fig.2 TYPEIYFA-MHS-Ol-VSI NOD Flow Alarm System

AKASAKA
 4 Electrical wiring
Refer to the Item 2. 3 Junction box, regarding the power supply voltage and
switching current.
With the standard specification at shipment from the factory the connection is
made so that the output is turned OFF when there is no oil flow.
If you need to invert the connection so that the output is turned ON when there is
no oil flow, simply change the connection of leads.
When you are making wiring, refer to Fig. 2 Non-flow alarm system.

Method of adjustment

a) When you have completed wring, confirm that every wire is connected properly or
not. If it is OK, turn the power on. It takes about 40 seconds for the warm up
after power on. In the meantime, the output may be turned ON if oil is not
circulating. (When the output is connected to be OFF so far as oil is not circulated.)

b) You need not to adjust the time duration required before raising the alarm signal
because it has been preset at the factory. If you need to readjust the time duration
finely due to some reason, proceed the following steps.

MODE/
ENTER
.
0 FLOW RATE -
9 LEARN /
SET

LED

Details of sensor display part

AKASAKA
(D This adjustment is locked before the shipment from the factory in order to
prevent unintentional change of setting. Release the lock condition as follows.
Simultaneously press MODE/ENTER button and LEARN/SET button for
about 10 seconds to release the lock condition. (All of LED will go off for
about 1 second after you have pressed these buttons.)
If the above method does not release the locking: Press the MODE/ENTER
button four times, and keep it pressed down the fourth time. Then press and
hold down the LEARN/SET button with the MODE/ENTER button pressed
down. Keeping both buttons pressed down for about 10 seconds will release
the locking.

(2) Press one time MODE/ENTER button so that the unit enters in the program
mode and the current switch point (%) is displayed.
(LED ON: 10% display)
(LED flicker: 1% display)

Note) ‘ In the operation mode (the state when the power is

turned on), do not press and hold down the LEARN/SET
button, or it will change the initial settings and cause an alarm
malfunction.

Follow 2.5 (c) to change the configuration when an initial setting is

required by an accidental operation.
- Press MODE/ENTER button four times to return to the Action Mode
(the situation as when power is supplied)

(PD If you hold down LEARN/SET button, LED illumination will start to change
about 5 seconds later. Continue to hold down the switch till a desired switch
point is displayed.
(Even if you remove your finger from the button after the LED illumination
started to change, second push on the same button will make the LED starting to
change again. The display will increase at a rate of 1% and return to 0% after it
displayed 9%.)

@ Press MODE/ENTER button to complete the setting.

AKASAKA
 6) In order to prevent unintentional change of setting, press simultaneously
MODE/ENTER button and LEARN/SET button for about 10 seconds.

X If you need to reduce the time duration before raising the alarm signal, select
a larger switch point or smaller one to extend the duration.
X If you do not press the button for more than 20 seconds during the setting,
the unit returns by means of a sensor to the operation mode without changing
the setting.
X If you fail to complete the setting properly, all of red LED turn on and then
the unit returns to the operation mode which you have been in before starting
the setting.

c) How to Initialize
Initial Setting has been adjusted at the time of shipment from our company.
Follow the following instruction to adjust the Initial Setting when necessary.
Please perform this setup at the temperature near to the operating condition. (We
perform the setup at our factory when the temperature of the sensor is around 30
degree centigrade.)

Q) Follow 2.5 (b)® to unlock.

(2 Adjust the flow rate and the speed of the lubricator at those of the "minimum
discharge" . Wait about 5 minutes to stabilize the flow, and then operate as
follow.

® Make sure the system is in the operation mode, and press and hold down the
LEARN/SET button. LED 0 and 9 will flash, then the LED will light in the
sequence 0, 1, 2, 3. When LED 3 lights, release the button. When all of the LED
(up to 9) have lighted, the system will return to the operation mode.

@ Operate as follows to completely stop the flow 3 minutes after the stop of the
delivery.

(5) Make sure the system is in the operation mode, and press and hold down the
LEARN/SET button. LED 0 and 9 will flash, then the LED will light in sequence
(0, I, 2, 3:" .) through to LED 9. Keep the button held down.

AKASAKA
 © As the button is still held down, the LED will now light in reverse sequence
(9, 8, 7, 6 .) . Release the button when LED 6 lights. When all of the LED
(down to 0) have lighted, the system will return to the operation mode.

® Check if the alarm operates properly when the step G) to (£3 have been
operated.

After all the operations have been done, lock on in accordance with 2.5 (b) 6)
to prevent a faulty operation.

Note) Carrying out setting change operations in a place where the system is not stable
could cause malfunctions, so make sure the system is in a stable condition before
performing such operations.

3 . Cautions for installation and at start of operation

a) Entrance and exit of the detector are identical, so you can take either side as
entrance or exit You can also install the detector either in vertical or horizontal
posture, as you prefer.

b) It is strictly prohibited to use dirty oil containing dust, water or other impurities.
If the detector section is contaminated or covered with soil, erroneous "No flow"
signals may be emitted.

c) Check the piping and wiring for looseness or short-circuit

d) Turning the priming handle, bleed air completely.

e) Thoroughly check the pipeline to coanm there is no oil leakage. Any leakage
occurs between the detector and the lubricator could shorten the time it takes before
emitting the alarm.

f) Response time of output varies depending on the sensitivity setting.

g) Operating the lubricator under normal conditions, confirm that the alarm circuit is
turned ON properly and that it is turned OFF at a lapse of definite time after
stopping the lubricator. (In case of the OFF alarm)

AKASAKA
 h) Refer to the cautions indicated on the back of the junction box cover. Check and
remember them thoroughly before starting service work.
4. Maintenance and inspection
a) To adjust the time it takes before emitting an alarm, refer to the Item 2.5
Adjustment method.

b) Where you are using also the low oil level alarm, reduce the length of suction
strainer of the pump element mounted on the non-flow alarm system by about 20
mm. By doing so, when the oil level in the lubricator box goes down due to some
reasons, the shortened pump element on the suction strainer will inhale air earlier
than any other pump elements and interrupt the oil flow so that the non-flow alarm
system will an alarm.

c) In order for safe and trouble-free operations, respective parts should be checked
regularly.

d) When you are placing an order of part for replacement, check and advise correctly
the type name and production number indicated on the name plated and part number
and part name in the part list found at the end of this manual. Please note that your
warranty may become invalid when any parts other than the genuine parts supplied
by us are used.

e) When the sensor trouble is suspected, return the unit to us. In such occasion, the
detector adapter, detector adapter packing and detector packing will be replaced as an
assembly.

f) Relay may be replaced as a separate unit but the relay fixture and others are
replaced as parts of complete PCB assembly.

g) You are recommended to replace these parts as complete assemblies.

-10-

AKASAKA
TYPEIYEA—MHS-Oi—VSI NON—FLOW ALARM SYSTEM

OUTLET

L
01
mm firms—01

J
1‘
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1—43—4" i—G—L-

:
U

..... INLET

OIL

-11-

AKASAKA
 Type: YFA—MHS—Ol-VSI NON—FLOW ALARM SYSTEM
PARTS LIST

No. Name Quan. Remarks

1
Complete detector 1 YFA—MHS-Ol-VSI
2 Adapter for Detector 1

3 Packing for Detector Adaptor 1

4 Packing for Detector 1

5 Hexagon head Bolts 4 M 6 X 12

6 Plain Washers 4 M 6

7 Spring lock Washers 4 M 6

8 Complete print Board 1 YFA-MHS—O1-VSI

9 Bite type Tube Fitting 2 R1 /8 —q§ 6
10 Junction Box 1

1 1 Cover for Junction Box 1

12 Packing for Cover 1

13 Hexagon Bolts with Plain Washer 4

14 Packing for Bolts 4
15 Terminal Block for Print Board 1

16 Cross-recessed head machine Screws 4 M 4

17 Spring lock Washers 4 M 4
18 Plain Washers 4 M 4
19 Spacer 4
20 Gland 1 J18 20C
21 Compression Terminals 11 RAV 125—35
22 Relay 1
GZR-ZS, 24V-DC
23 Keep Piece for Relay 1 P2R-O8P
24 Fuse 1 0.5A
25 Spare Fuse 1 0.5A
26 Rubber Plug 1

27 Surge absorber 2

-12-

AKASAKA
AKASAKA DIESELS LIMITED
NON—FLOW ALARM SYSTEM A
For Lubricator

First edition JUL.2001

Revision 1 JAN.2002
Revision 2 JAN.2005

Type approved by class NK

Certificate No. A—439-D

Type approved by class ABS

Celtificate No.
02-Y0321089.PDA

AKASAKA
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