JK II Manual

Document NO.
T-1480E-R5
Operation Manual
for
JK-2 Field Test System
FUKUISEISAKUSHO Co., LTO
Contents
1.
1.1
1.2
1.3
System Overview
What is jacking test
System configuration
How to determine setting pressure
2.
Components
2.1 Names and functions
2.2 Functions of JK-2
2.2.1
Front of JK-2
2.2.2 Right flank of JK-2
3.
How to Use System

3.1 Selecting sensors
3.2 Assembling load cell
3.3 Installing pressure sensor
3.4 Connecting load cell and pressure sensor to JK-2
3.5 Installing mechanical components of jack
3.6 Operation hydraulic pump
3.7 Activating JK-2 and conducting jacking test
3.8 Auxiliary functions in jacking test mode
3.8.1
Confirming or changing sensor calibration values
3.8.2 Changing effective area of hydraulic cylinder
3.8.3 Changing parameter of blow off detection
3.8.4 Changing data after blow off detection
3.9 Entering data after testing (batch processing mode)
3.10 Troubleshooting during jacking test
4.
4.1
4.2
5.
Miscellaneous Functions of JK-2

Digital display mode
Sensor calibration mode
Precautions in Handling
Appendices
Appendix 1.
Appendix 2.
Appendix 3.
Appendix 4.
Area of valves exposed to pressure
Standards for sensor selection
Comparison table of turnbuckles
JK-2 screen flow in jacking test mode
1.
System Overview
1.1
What is jacking test?
It is important that a safety valve should pop off at a preset pressure. The popping (opening) pressures of
safety valves in power plants are checked and adjusted during routine inspections of the boilers.
During check and adjustment, safety valves installed on actual equipment are actually operated under
raised pressures. This is what is known as a field test.
Field tests on the actual installation are very expensive and unproductive. Besides, a large amount of
spouting fluid produces loud noise, and the sonic flow of fluid passing through valve openings wears
valve seats and impairs seat tightness.
Under these circumstances, jacking test has found increasing use recently, thanks to its low energy
consumption and low cost.
Jacking test measures the pressure difference between the pressure (held constant) inside the
equipment and the popping pressure of the safety valve to make it possible to adjust and verify the
popping pressure.
Jacking test allows to.
1) use normal operating pressures inside the equipment during testing, which offers following
advantages:
automatic equipment operation requiring less staff,
reduced fuel costs, and
no overload on equipment, and
2) keep the amount of spouting fluid at a very low level, which offers following advantages:
no rapid change in pressure and temperature produced and conducted to equipment by safety valve,
no fear of impairing seat tightness of the safety valve,
reduced test time due to eliminated necessity to raise pressure inside the equipment, and
low noise
1.2
System configuration
JK-2 field test system is an up-to-date safety valve jacking test system incorporating a microcomputer
based sensors.
As shown in Figure 1, the system consists of a hydraulic jack for applying load on the spring of safety
valves, sensors (load cell and pressure sensor) for measuring the pressure difference between set
pressure and popping pressure of the safety valve, and an input I output device (JK-2) for processing
sensor signals and producing output.
The system is very easy to operate and you can rely on it completely. Once you have installed the
system on the safety valve and switched on the input I output device (JK-2), the system measures the
popping pressure of the safety valve automatically. The operator has only to operate the hydraulic pump.
lIydrauli e PlIlIIP
~~
_r--_
--<CJ
. ~-~_._-> --::.:~
':'--"1..
,"
Hydraulic cyIi nder
Turnbuckle
JK-2
10k.
Valve stem!
I
Safety 'ahe
__
. ,,_,,_,_._ .._._ _1
Figure 1
1.3
How to determine setting pressure
Forces acting on the disk of a safety valve are given by,

F ! = Fs = (Ps*As)
F t = Pb x As
~~~.
(1)
(2)
Load cell
-Uydraulie cy Ii nder
Where,
F ! : Down load
F l : Up load
Fs: Spring setting load
Ps: Safety valve popping pressure
As: Valve disk pressure area
Pb: Primary pressure (base pressure) of safety valve
Va Ive stem
Spring
Valve disk
When the safety valve is closed, the relationship between forces

is F ! >F t , creating a valve closing pressure (.LIF):
F! =.LIF+F t
(3)
During jacking test, the primary pressure (Pb) is held
constant and .LIF is raised by hydraulic pressure to cause the
valve to pop off.
By substituting (1) and (2) in (3) and rearranging the result,
we obtain,
(4)
Ps=.LIF I As + Pb
Thus. using expression (4), we can derive the popping pressure
of the safety valve from .LI F and Pb.
FiB,ure 2
2.
2.1
Components
Names and functions
JK2
_ _~~'""'""" Mela. rill' gaskels

Hydra..lie crt inlier
Turnbuck Ie .
Yoke
,- <-:
Iii glt pressure hose
! ......" ~
Safdy- valve
,.J
Iii gure 3
JK-2: A simple device for testing safety valves with the aid of hydraulic pressure jacked from a
hydraulic pump. Measures and displays the popping (opening) pressure of safety valves.
Pressure sensor: Detects the primary pressure (base pressure) of safety valves.
Sensor cable: Connects JK-2 with the pressure sensor.
Gauge adapter: Installed between the primary pressure tap of the safety valve and the master gauge,
for connecting the pressure sensor.
Metal ring gaskets: Used when installing the gauge adapter, master gauge, and pressure sensor.
Power supply cable: Connects to an external power supply (85V-265V AC, 50 160Hz).
Load cell: Detects pressure difference between safety valve popping pressure and base pressure.
Yoke: Mounts on top of the safety valve and connects the hydraulic cylinder with the load cell.
Turnbuckle: Connects the valve stem of the safety valve and the hydraulic cylinder.
Hydraulic cylinder: Lifts the valve stem of the safety valve by hydraulic pressure.
Hydraulic pump: Applies pressure on the hydraulic cylinder.
High pressure hose: Connects the hydraulic cylinder and the hydraulic pump.
2.2
Functions of JK-2
JK-2 has 4 operation modes:
1. Jacking test mode: Automatically monitors the behavior of a safety valve during jacking test, and
displays and prints out the popping pressure of the safety valve.
2. Digital display mode: Functions as an ordinary digital display unit, and prints out the readings of the
sensors at a given interval with the help of an interval timer.
3. Sensor calibration mode: Calibrates the sensor being used, under actual load.
4. Batch processing mode: Prints out and deletes the test results stored during the jacking test mode.
You can select one of the modes by choosing the appropriate key from the Select Mode screen
(Screen I) after switching on your JK-2.
ACTION
F1
Jacking test mode:
[F1]
DISPLAY
F2
Digital display mode:
[F2]
CALIBRATION
F3
Sensor calibration mode:
[F3]
BATCH
F4
Batch processing mode:
[F4]
Screen 1
2.2.1
Front of JK-2
Liquid crystal screen
Interactively displays sensor readings,
measurement results, and instructions
for operations.
Mode display
Normally, indicates the operation mode
with LED. In the jacking test mode.
this indicates states of popping
pressure detection. See Figure 1.
U~id
tt7d&1
scrten
..,
Keys
Used for selecting modes, setting
functions, and entering numeric data.
See Figures 2 and 3.
T'.:' .f ....... ealibnll.... I
Printer
Prints out. results of jacking test and
readings of sensors.
Table of sensor calibration values
Lists calibration values of the
sensors included with the system.
Table 1: Mode display

LED for mode display
Description
DISP
CAL
Set P
ACT
O... LED is off
Indicates that the system is operating in the jacking test

mode. (Red LED)
Indicates that the system is operating in the digital display
mode. (Yellow LED)
Indicates that the system is operating in the sensor
calibration mode. (Green LED)
Indicates that jacking test is ready or that zero adjustment
is in process.
Indicates in the jacking test mode that calculation of
popping pressure is completed.
*..
.... LED is on
LED is flickering
Table2: Functions of keys during mode selection and function setting
[CANCEL]
[START]
[PRINT]
[ENT]
[F1 I !]
[F21 -]
[F31 -]
[F41 T]
Goes back to previous screens one by one.

Starts measuring popping pressure (in the jacking test mode)
Sets the interval timer (digital display mode)
Starts calculating sensor calibration values
(sensor calibration mode)
Starts printing
Confirms existing or entered values
Selects a mode. Switches to a sub screen
Selects a mode. Selects a sensor option
Table3: Functions of keys for numeric data entry
[0] to [9]:
[.]
[SP]
[CANCEL]
[ENT]
[F2 I -]
[F31 -]
[F4\ .... ]
Correspond to digits 0 to 9.
Decimal Point
Space key (Erases existing data digit by digit to the right)
Goes back to previous screens one by one.
Confirms values entered
Moves the cursor to the left
Moves the cursor to the right
Moves the cursor to the head of the next line
Table 4: Sensor calibration values
TYPE
[PG-20KU]
Rated capacity
[20MPa]
Rated output
[2.005mVN]
Serial No.
[YG021 0006]
TYPE:
Indicates the type of sensors. Basically, TYPE of a pressure sensor

begins with letters PG, and TYPE of a load cell begins with letters LUK.
Rated capacity:
Indicates the maximum permissible capacity of a sensor.
Rated output:
Indicates the output characteristic (calibration value) of a sensor.
SERIAL No.:
Indicates the manufacture's serial number of a sensor.
Note: The sensor calibration value is the value of rated capacity plus the value of rated output.
Before conducting a jacking test, make sure that the sensor calibration values preset on JK-2
agrees with the calibration values of the sensors being used.
2.2.2
Right flank of JK-2

Sensor connectors (CH1,
CH2, CH3): Connectors
for connecting sensors.
In the jacking test mode,
make sure to connect the
load cell to CH 1 or CH2
and the pressure sensor
to CH3.
Receptacl
/
Sensor connector (CH1, CH2)
for load cell
Sensor connector (CH3)-_
for pressure sensor
Power switch
Receptacle: Plug socket

for receiving the power
supply cord.
Power switch
Power cord: Plugged into

an external power supply
to activate JK-2.
FigureS
3.
How to Use System
JK-2 processes the Valve-closing load (LlF in expression (4) in Section 1.3 above) from the load cell and
the safety valve primary pressure (Pb in the same expression) from the pressure sensor, and
automatically calculates and displays the popping pressure of the safety valve. Even if a pressure sensor
cannot be connected to the actual equipment on which safety valves are installed, you can measure the
popping pressure by manually entering the safety valve primary pressure. (However, we recommend you
to use a pressure sensor to take full advantage of this system.)
The following chart outlines the procedures for conducting a jacking test with this system.
* The numbers in [ ] indicate the sections where you can find detailed descriptions.
Select sensors and decide base pressure for testing [3.1]
Install load cell and pressure sensor [3.2, 3.3]
Connect sensors to JK-2 [3.4]
Switch on JK-2 and zero adjust sensors [3.7]
Install mechanical components of jack [3.5]
Operate hldrauliC pump (to measure popping pressure) [3.6]
Process test results (output, store, retest) [3.7]
10
3.1
Selecting sensors
When conducting a jacking test, you should use the most suitable sensors to improve the accuracy of
measurement. Each sensor has its measuring range and using it outside its measuring range will result
in increased errors and may break the sensor itself.
To select sensors, proceed as follows:
1) Determine the following values.
a) Specified popping pressure of safety valve to be tested (Ps) MPa
2
b) Surface area of valve exposed to pressure *1 (As) cm
c) Base pressure at the time of testing *2
(Pb) MPa
*1: See Appendix 1 for safety valves manufactured by our company. For other company's products, use
the values recommended by the manufacturer.
*2: Base pressure is the primary pressure of the safety valve. This should be set at 60% to 85% of the
specified popping pressure of the safety valve.
2) Determine the test load (Lt) by substituting the values of Ps, As, and Pb defined above in the following
expression.
.
Test load (Lt) = (Ps - Pb) x As /10 (kN)
3) Select the type of sensors from Table5 using the values of Pb and Lt determined above.
Table 5
Measuring range of sensor
Pressure sensor
O. 2MPa ~ Pb
lMPa ~ Pb
2MPa ~ Pb
5MPa ~ Pb
~ 1.8MPa
~
9MPa
~ 18MPa
~ 45MPa
*Load cell
0.25 kN ~ Lt ~ 4.5 kN
1.0 kN ~ Lt
18: 0 kN
4.5 kN ~ Lt
45.0 kN
s
s
Type
PG-20KU
PG-100KU
PG-200KU
PG-500KU
LUK-A- 5KN
LUK-A-20KN
LUK-A-50KN
Example:
Assume that Ps = 14 MPaG, As = 5.007 cm 2, and Pb = 10 MPaG.
Substituting the values into the above equation, We obtain,
Lt (14 - 10) x 5.007/10 2.0028 kN
Which indicates that suitable sensors are,

Pressure sensor ... PG-200KU
Load cell ... LUK-A-5KN
LUK-A-5KN and LUK-A-20KN shall be supplied as standard.

In case that the safety valve specification is over the range of Table 4, LUK-A-50KN shall be
supplied instead of LUK-A-20KN.
Please inform us before order if LUK-A-50KN is required.
11
3.2
Assembling load cell
Assemble the selected load cell on the hydraulic cylinder as follows (see Figures 6 and 7).
1) Install the load cell [(2) or (11)] on the top face of the cylinder: pass the pull rod [(2-2) or (11-2)]
connected to the load cell through the center hole of the cylinder and fit the under surface of the load cell
into the top face of the cylinder.
2) Fasten the load cell andcylinder with 4 hexagon socket head cap screws [(2-4) or (11-4)].
Figure 6: LUK-A-5KN
Figure 7: LUK-A-20KN
Caution: Make sure to turn the correct surface of the load cell to the cylinder.
The letters on the name plate on the load cell flank should be upside down.
12
3.2
Installing pressure sensor
Connect the gauge adapter to a gauge mounting hole where safety valve primary pressure can be
measured, and install the pressure sensor selected in 3.1.
Refer to Figure 8 and follow the procedure below.
1) Connect gauge adapter (4-1) to siphon pipe.

2) Connect pressure sensor (3-1) to gauge adapter.
(When mounting and dismounting pressure sensor, grip its flatted round face.)
3) Insert sensor cable (3-2) into pressure sensor to the root and fasten them with the screw on sensor
cable. (Sensor cable has its orientation. Align the notches and insert it correctly.)
4) Attach Bourdon gauge to gauge adapter.
*For installation of metal ring gaskets, See Figure 9.
Gauge adapter, Bourdon gauge

~ressure sensor .
-----
COUP I ing
.... Meta 1 r i "If gaske 1
Gauge adapter. siphon pipe

Figure 9
Figure 8
13
3.4
Connecting load cell and pressure sensor to JK-2.
Connect to JK-2 the load cell and pressure sensor you have installed in Sections 3.2 and 3.3 respectively
(See Figure 10).
1) Connect load cell to upper or middle connector, and pressure
sensor to lower connector.
(Incorrect connections will cause incorrect measurements.)
p""",
"""~
2) After connections, render sensors unloaded. Install load cellI
hydraulic cylinder assembly to yoke and place them on a plat
place free of vibrations (Figure 11). Close the main valve of
Bourdon gauge of pressure sensor and loosen the drain plug
(Figure12).
Figure 10
Fi gure 12
Figure
Caution: Align the match mark on the plug (from pressure sensor and load cell) with the match mark on
the corresponding connector (on the JK-2 body) and insert the plug until you hear a click.
If the pressure sensor cable does not reach JK-2 due to a long distance between pressure sensor
installation site and safety valve, you can use up to 2 extension cables (Figure 13) which will make the
total distance equal to 13m.
Pressure sensor
\
Fi gure 13
14
3.5
Installing mechanical components of jack
When you have zero-adjusted the sensors with JK-2 switched on (Step 4 in 3.7), install the mechanical
components of the jack on the safety valve, as described below.
1) Screw turnbuckle (10) into pull rod (2-2) or (11-2). (See Figure 14.)
Note that the thread is left handed.
2) Install safety valve (with adjusting screw up) on yoke (8). (See Figure 15.) If yoke is shaky, use yoke
spacers (9) provided. (Valve stem thread sizes of up to M22 can be used.)
3) Screw hydraulic cylinder / turnbuckle assembly (assembled above) into yoke from above, and
screw turnbuckle into valve stem of safety valve (Figure 16), holding cylinder by hand and turning
turnbuckle.
4)Turning turnbuckle to the right reduces the clearance (L) between cylinder and yoke (Figure 17).
Tighten turnbuckle lightly, paying attention to the fit between yoke top and cylinder bottom, until they
come into close contact. Then loosen turnbuckle a 1/6 turn.
5) Connect hydraulic pump, high pressure hose, and hydraulic cylinder (Figure 18): plug nipple at
each end of hose snugly into collar on cylinder and pump, and screw couplings of collars over
nipples securely.
.
Figure 14
Figure 15
Figure 17
Figure 16
Fi gore i8
15
3.6
Operating hydraulic pump
When you have prepared for testing (Step 8 in 3.7), operate the hydraulic pump to test the safety valve,
following the steps described below.

1) Fully close release valve of hydraulic pump.
Lever
Fi gure 19
2) Raise hydraulic pressure by moving the lever up

and down. Begin to raise hydraulic pressure slowly,
when "Reduced P" has exceeded 90% of "Set Pop. P"
or "Load" has exceeded 90% of "Est. load". Continue
applying pressure until safety valve blows off and "Set
P" on mode display comes on.
3) When "Set P" has lit, fully open release valve of
hydraulic pump to lower the pressure. (However, if
pressure sensor is not connected, read base pressure
when safety valve pops off).
Caution: For some low pressure small valves, fully opening the release valve may not close the
safety valve. In that case, loosen the turnbuckle immediately and close the safety valve.
16
Step
Screen display or printout
Enter the date. format is YY/MM/DD

Press [ENT] key to confirm.
Enter date and

press ENT key
5
08/10/01
Screen 4
Serial No.
Valve area
Popping P
Base press.
=
=
=
=
811234
7.985
16.45
12.5
Screen 5
Descriptions of operations
Press START key to

start measurement
Screen 6
Note: Cursor "_" is placed at the left end

of line for date entry. As you enter data,
cursor moves rightward. To correct
input errors, move cursor by [-] or [-]
key and overwrite data.
Enter data about valve to be tested.
Meanings of screen terms, number of
digits you can enter, and units of data
are as follows:
Serial No.: Manufacturer's serial
number of valve to be tested. (8 digits,
numeric only) Change alphabetic
characters into numeric.
Valve area: Pressure area of valve to
be tested. (5 digits, up to 3 decimal
positions)
Popping P: Specified popping pressure
of valve to be tested. (4 digits, up to 2
decimal points)
Base press. = Base pressure at the
time of testing (4 digits, up to 2 decimal
positions)
Units of data area: area
cm 2
pressure
MPa
Enter all data and press [ENT] key
Note: To move cursor to next item, use
[T] key. (After "Base press." cursor
wraps around to "Serial No.")
Jacking test is pending. "Set P" on
mode display flickers, prompting you to
start testing. When preparations listed
below are completed, press [START]
key.
1) Install jack to safety valve.
2) Tighten drain plug of pressure
sensor manually.
3) Fully open main valve of gauge,
and apply pressure to Bourdon
gauge and pressure sensor.
18
Example of entry
081001 [ENT]
Oct. 01 '08
811234
7.985
16.45
12.5
[T]
[T]
[T]
[ENT]
=811234
Valve area =7.985 cm
Serial No.
Popping pressure
=16.45 MPa
Base pressure
=12.5 MPa
[START]
Starts jacking test
3.7
Activating JK-2 and conducting jacking test
When you have completed preparations, switch on JK-2 and start jacking test. The procedures for the
operation of JK-2 are interactively displayed on the screen, and keys to be used are indicated. If you
make inappropriate keyboard entries, you are warned by 2 beeps.
The basic keys are as follows:
Function keys (F1 to F4: START, PRINT, ENT):

Allow you to select a mode or set a function.
Ten-key pad:
Allows you to enter numeric data.
CANCEL:
Allows you to return to the previous screen (Use this key when you made a mistake in
entering data or setting a function).
. operations.
The f0 IIowmg tab Ie rIStS t he basic
Step
ACTION
=
DISPLAY
=
CALI BRAT ION =
BATCH
=
Screen
[FI]
Select Mode screen appears.
Enter [FI] key to select jacking test
Selects
mode.
Red LED comes on under "ACT" on

mode
mode display.
FI
F2
F3
F4
Select load sensor CH.

CHl = Fl
CH2 = F2
Screen 2-1
3
Do you want to
pressure sensor?
No
= F3
Yes = F4
Screen 2-2
Example of entry
Turn ON switch on flank of JK-2
use
When reading become

stable, press ENT
CHl = 0.2
CH3 = -0.3
Screen 3
Select load sensor channel CH1 or

CH2.
If you want to use pressure sensor,
enter [F4] key. If you are not going to
use pressure sensor, enter [F3] key.
Note: When you select [F4] base
popping pressure of safety valve is
automatically read into JK-2 If you
select [F3], you have to correctly read
base popping pressure from another
gauge and enter it manually in Step 9.
You are going to zero-adjust. sensors.
JK-2 display loaded conditions of
sensors, and "Set P" on mode display
flickers. Remove load from sensors
(Section 3.4), and when sensor
readings (CH1, CH2) become stable,
press [ENT] key. Sensor readings on
display are forcefully set at zero.
Note: To ensure accuracy of zero
adjustment, [ENT] key is locked while
"Set P" is flickering (approx. 3 min.)
Press [ENT] key after "Set P" goes off.
17
jacking
test
[F1] or [F2]
[F4]
You will use pressure
sensor.
[ENT]
Confirms zero
adjustment.
Step

Set Pop. P = 16.. 45
***** Measuring *****
Reduced P = 15.35
Base press. = 12.35
Screen 7-1
Estm. Load = 31. 4
***** Measuring *****
Load
= 2.395
Pressure = 12.35
Screen 7-2
Example of entry
Jacking test starts, and states of

measurement are displayed. Operate
hydraulic pump as described in Section
3.6. As hydraulic pressure is raised,
value of "Reduced P" or "Load"
increases. JK-2 automatically detects
blow off of safety valve, and after
turning on "Set P" on mode display,
advances to step 9.
If you are not using pressure sensor,
read base pressure when "Set P"
comes on, and enter the data in step 9.
Note: Screen 7-1 is default screen in
this step. However, you can access to
screen 7-2 by using [F1] key.
Data displayed are: <Screen 7-1>

Set Pop. P: popping pressure you have
set in step 6, which is also specified
popping pressure of valve being tested.
Reduced P: Pressure being applied to
safety valve (measured from load of
lifting valve stem and base pressure).
Base press.: Primary pressure
(pressure sensor reading) of safety
valve (base pressure entered in step 6,
if no pressure sensor is connected).
<Screen 7-2>
Estm. Load: Estimated load of blow off
of valve being tested.
Load: Current value (load cell reading)
of load of lifting valve stem.
Pressure: The same as base value in
screen 7-1
Set Pop. P = 16.45

***** Results ******
Popping P = 16.35
Base press. = 12.35
Screen 8
Display specified popping pressure of

valve tested and results of testing.
Confirm and press [ENT] key.
Note: If you are not using a pressure
sensor, read and enter base pressure
as described in Section 3.8.4 below.
19
[ENT]
Confirms popping
pressure measured
Step

Select one option.
Retest
= START
Print out
PRINT
Store data = ENT
Screen 9
10
TEST No. 1
DATE : 08/10/01
S No. : 811234
AO
= 34.361
As =
Pb
Lt
Po
Pk
Ps
7.985
= 12.32
= 3. 194
= O. 93
= 4.0
= 16.32
Example of printout
Select one of options according to what
you want to do with test results.
[START]: Retests valve. When you
press this key, you return to step 7.
[PRINT]: Prints out test results.
(See example)
[ENT]: Stores test results. For output
and deletion of stored test results, see
Section 3.9 (batch processing mode).
[ ! ]: Feeds paper for printer.
Example of entry
[PRINT]
<Print out>
[ENT]
<Stores data>
[START]
<Retests valve>
<Data to be printed out and stored>

TEST No.: Number assigned to test
results to be stored
DATE: Date when test was conducted
S No.: Serial No.
Ao: Area of hydraulic cylinder
(cm 2)
As: Pressure area of valve
(cm2)
Pb: Base pressure of blow off
(MPa)
Lt: Load of blow off on valve stem (kN)
Po: Reduced pressure
(MPa)
Pk: Corrected pressure
(MPa)
Ps: Measured popping pressure (MPa)
These 10 steps complete a series of operations.
When you adjust the popping pressure of a safety valve, use the results of at least two tests instead of
one to allow them to level off. Also, allow an interval of at least 3 minutes between two successive tests.
Turn off the power after testing, regardless of the instructions on the screen.
20
3.8
Auxiliary functions in jacking test mode
In addition to those basic functions described above, the jacking test mode has several auxiliary
functions.
3.8.1
Confirming or changing sensor calibration values
To confirm or change the sensor calibration values preset on the system, proceed as follows on
screen 2 (See Step 3 in Section 3.7 above).
Do you want to use
pressure sensor?
No
F3
Yes = F4
[F1]
Change calibration
CH1= 5kN
(2.000)
CH2=20kN
(2.000)
CH3= 2 MPa (2.001)
[ENT]
Do you want to use

pressure sensor?
No = F3
Yes = F4
Screen 2-1-1
Screen 2-2
Screen 2-2
1) Press the [FI] key when Screen 2-2 is on display.
2) The sensor calibration values currently registered on JK-2 will appear on the screen (Screen 2-1-1).
The screen displays the rated capacity and rated output (in the parentheses) for the load cell in CH1,
CH2 and for the pressure sensor in CH3.
3) Check the SER No. or TYPE on the body of the load cell and pressure sensor to be used for testing.
4) Compare the values on the screen to those from the table on the JK-2 body for the given SER No. or
TYPE. If they differ, overwrite the values on the screen with the correct ones from the table.
<Example of entry>
Suppose you replace the values on the screen with the following values.
Load cell for CH2 rated capacity: 20 kN, Load cell rated output: 2.05 mVN.
Pressure sensor rated capacity: 20 MPa, Pressure sensor rated output: 1.998 mVN.
Screen
Change calibration
CH1 =
kN (2.000)
CH2 = 20 kN (2.050)
CH3 = 20 MPa (1.998)
go
Keyboard entry
[~][~]
20
[~]
2.05[~]
20[~]
1.998
[ENT]
5) After making changes, press the [ENT] key to update the sensor calibration values (or to confirm
the existinq values, if you chose not to update them) and to return to Screen2-2.
Caution: Make sure to confirm or update the sensor calibration values registered on JK-2, before
conducting tests and after changing sensors. The registered values are retained, even while the
power is OFF.
21
3.8.2
Changing effective area of hydraulic cylinder
If you prefer to use a hydraulic cylinder other than that provided with this system, proceed as follows on
Screen 5.
Serial No.
Valve area
Popping P
Base press.
= 81123
=7.985
[F1]
------+
Enter cyl inder area
Cyl. area
= 34.361
[ENT]
Screen 5-1
Screen 5
Serial No.
Valve area
Popping P
Base press.
= 811234
= 7.985
Screen 5
1) Press the [F1] key when the Screen 5 is on display.

2) The effective area of the hydraulic cylinder provided with this system is displayed (Screen 5-1).
Overwrite the data with new data (significant digit: 5; up to 3 decimal positions).
3) After entering digits, press the [ENT] key to update the data and to return to Screen 5. (To return to
Screen 5 without updating the data, press the [CANCEL] key.)
3.8.3
Changing parameter of blow off detection
If "Set P" does not come on when the safety valve blow off, or "Set P" comes on when safety valve does
not blow off, change the parameter of blow off detection. Proceed as follows on Screen 6 (Step 7in
Section 3.7 above).
Press START key to

start measurement
Screen 6
[F1]
Change parameter of
blow off detection
Parameter = 4
Screen 6-1
[ENT]
Press START key to

start measurement
Screen 6
2) The standard parameter (4%) appears on the screen (Screen 6.-1).
3) If "Set P" does not come on when the safety valve blows off, enter a value smaller than the standard
parameter. If "Set P" comes on when safety valve does not blow off, enter a value larger than the
standard parameter. Overwrite the existinq data with a valid value, which is between 0.1 and 99, of which
a value of 1 to 10 is normally used.
4) After entering new data, press the [ENT] key to update the data and to return to Screen 6. (To return to
Screen 6 without updating the data, press the [CANCEL] key.
22
3.8.4
Changing parameter of blow off detection
If you entered wrong data in Step 6, or if you are not using sensors and you have to enter the base
pressure manually, reenter data on Screen 8 (Step 9 in Section 3.7 above), as follows.
Cyl. area = 34.361
[F1]
Set PoP. P = 16.45
*****ResuI ts****
Popping P = 16.35
Base press. = 12.35
[F1]
r~
[ENT] or [CANCEL]
Ser i aI No. =811234

Valve area = 7.985
Popping P =16.35
Base press. =12. 45
Screen 8-1
Screen 8
[ENT]
Set Pop. P = 16.45

*****Results****
Popping P =16.45
Base press. =12.45
Screen 8

2) The data entered in Step 6 appears on the screen (Screen 8-1). Overwrite the data you want to
change (as described in Step 8). To change the effective area of the hydraulic cylinder exposed to
pressure, use the [F1] key and follow the same procedure as in Section 3.8.2.
3) After entering new data, press the [ENT] key to update the data and to return to Section 8. To return to
Screen 8 without updating the data, press the [CANCEL] key.
Note: If you have changed "valve area" or "Base press." (when you are not using a pressure sensor), the
"Results" (Screen 8) are recalculated.
<Example: when you are not using a pressure sensor>
(Changed only base pressure)

Set Pop. P = 16.45
*****ResuI ts****
Popping P = 16.35
Base press. = 12.35
Screen 8
[F1]
Serial No. =811234

Valve area =7.985
Popping P = 16.35
Base press. =12. 35
Serial No. =811234

Valve area =7.985
Popping P = 16.35
Base press. =12. 40
Screen 8-1
(Before changes)
Screen 8
(After changes)
Set Pop. P = 16.45

*****Results****
Popping P = 16.40
Base press.= 12.40
Screen 8
23
[ENT]
3.9
Entering data after testing (batch processing mode)
To print out data after completing all tests of safety valves, or to delete stored data, select the batch
processing mode. Data stored durill9 testlrtq are retained, even while the power is OFF (setup 10 in
Section 3.7).
Two methods of data identification are available for printing out or deleting stored data:
1) Specify TEST No.: Prints out or deletes all data with matching TEST No.
2)Specify SERIAL No.: Prints out or deletes all data with matching SERIAL No.
The basic functions of the keys are the same as in Section 3.7.
The following table lists the basic operations.
Step
Example of entry
=
=
=
=
ACTION
F1
DISPLAY
F2
F3
CALI BRA Tl ON
BATCH
F4
Screen 1
Do you want to pr i nt
TEST No.1 SERIAL No.?
YES
F1
NO
= ENT
Screen 2
TEST
TEST
TEST
TEST
1 I 811234
2 I 811234
3 I 811234
4 I 811234
Select mode screen appears.

Press [F4] key to select batch
processing mode
[F4]
Press either [F1] or [ENT] key.
[F1]
[F1]: Prints out a list of all test numbers

and serial numbers, starting from TEST
NO.1.
Prints out data
Selects batch
processing mode
(If you want to discontinue printing,

press [CANCEL] key.)
[ENT]: No printout. Transfers you to
Step 4.
----- ----- -- ------ ----.----

Example of printing
Select one action

Delete
= F1
Print out
PRINT
Exit
ENT
Screen 3
=
=
Select one of options according to

what you want to do with data.
[F1]: Deletes specified data.
[PRINT]: Prints out specified data.
[ENT]: Transfers you to select mode
screen. (Step 1, Screen 1)
Note: When you select [F1] or [ENT],
you are transferred to Step 1.
24
[F1]
Deletes data
[PRINT]
Prints out data
Speci fy data ID
(Action = Print out)
TEST No. = F1
SERIAL No = F2
Screen 4
Speci tv TEST No.

(Action = Printout)
Start = 10
End
= 20
Screen 5
Printing
CANCEL =
Stop printing
Screen 5-1
Example of entry
Specify a method of data retrieval.

(The second line includes the action
you selected in Step 4.)
[F1]
Selects data with
matching serial number
[F1]: Carried out (in Step 6) action

specified in Step 4 on all data with a
test number that matches the one you
will specify in Step 6. (Go to step 6.)
[F2]: Carries out (in Step 7) action
specified in Step 4 on all data with a
serial number that matches the one you
will specify in Step 7. (Go to step 7.)
[F2]
Selects data with
matching test number
Specify range of test numbers you want

to delete or print (The second line
indicates the action you selected in
Step 4.)
Relationship between entered numeric
and result of action is:
1) Start = 0 ]
All data
End
0
10 [T] 20 [ENT]
2)
=
Start =X ]
Data X only
End = 0
Delete
TEST No. 10-20
YES
F1
NO = ENT
Screen 5-2
3)
=X]
Data between X and Y
End =Y
Start
After specifying "Start" and "End", carry

out action by pressing [ENT] key. If you
have selected "Printout" in step 4,
Screen 5-1 appears and prints out
results of measurement.
(If you want to cancel printout, press
[CANCEL] key.) If you have selected
"Delete" in step 4, Screen 5-2 appears.
If range of test numbers you selected is
correct, press [F1]. If it is wrong, press
[ENT].
When action is completed or canceled,
you are transferred back to step 4.
25
Specifies range of test

numbers from 10 to 20.

Specify SERIAL No.
(Action
Printout)
SERIAL NO.
811234
Screen 6
Printing
7
CANCEL
Stop pr i nt i ns
Screen 6-1
Delete data with
SERIAL No. 811234?
YES
F1
NO
ENT
Screen 6-2
=
=
3.10
Example of entry
Specify serial number on which you

want to carry out action on. (The
second line indicates the action you
select in step 4.)
811234 [ENT]
Specifies serial No.
811234
Enter serial number, and press [ENT]

key to carry out action on all applicable
data.
If you have selected "Printout" in step 4.
Screen 6-1 appears and prints out
results of measurement. If you want to
cancel printout, press [CANCEL] key. If
you have selected "Delete" in step 4,
Screen 6-2 appears. If serial number
you selected is correct, press [F1] key.
If is wrong, press [ENT] key.
When action is completed or canceled,
you are transferred back to step 4.
Trouble shooting during jacking test
If something is wrong with .IK-2 or results of measurement, check the system referring to the following
table. If the cause of a malfunction would turn out to be operational errors, read this manual once more
and use the system correctly.
Problem
Readings unstable during zero
adjustment.
Safety valve blow off does not

turn "Set P" ON
"Set P" comes ON before safety

valve blow off
Possible causes
1) Sensor cables connected
improperly.
2) External noise present.
3) Sensors subject to vibrations
or loaded.
1) Lower adjust ring out of
adjustment.
2) Parameter of blow off
detection set inappropriately.
3) Insufficient hydraulic
pressure
1) Hydraulic pressure raised
irregu larly.
2) Parameter of blow off
detection set inappropriately.
26
Solutions
1) Connect Sensor cables
properly.
2) Remove causes of noise.
3) Remove vibrations or Loads.
1) Check position of ring.
2) Set smaller value as
described in Section 3.8.3.
3) Boost pressure by hydraulic
pump until "Set P" comes on.
1) Operate hydraulic pump
properly to avoid fluctuation
of "Reduced P" and "Load".
2) Set larger value as described
in Section 3.8.3.
Possible causes
Problem
Results of measurement do not
level off
1) Too many tests at too short

intervals.
2) Pressure raised too quickly.
Readings during measurement

(Step 8 in section 3.7) too large or
small compared to rated capacity
of sensors.
1) Inappropriate sensor
calibration values present on
JK-2.
"Reduced P" or' Load" does not

increase, even though hydraulic
pump is operating.
1) Sensors connected to wrong

connectors
2) Load cell installed on wrong
side (wrong side of load cell
facing hydraulic cylinder).
Readings of pressure sensor differ

from those of other gauges.
calibration values present on
.IK-2.
1) Sensor selection
inappropriate.
calibration values preset on
JK-2.
Sensor readings exceeded rated

capacity.
Following message displayed in

jacking test mode.
Running out of
memory.
Stored data
=
Remaining space =
71
28
Hydraulic pump does not raise

pressure.
1) Number of data items stored in

JK-2 has exceeded 70.
(This is a warning message
reminding you of special
available for further date
storage.)
Meaning of terms:
Stored data: Number of test
results already stored.
Remaining space: Number of
test results that can still be
stored.
1) Release valve open.
2) High pressure hose constricted
or bent sharply.
3) High pressure hose connected
improperly.
4) Low fluid level.
5) Cylinder piston at too.
27
Solutions
1) Allow a sufficient interval

between tests (approx. 3 min.)
2) Regulate hydraulic pump to
make lowest-order digit of
"Reduced P" or "Load"
increase slowly just before
blow off.
1) Check and change sensor
calibration values as described
in section 3.8.1.
(Turn off power once, then turn
it on again.)
1) Check sensor connections
(See Section 3.4).
2) Check direction of load cell
(See section 3.2).
(When changing connections
or reinstalling load cell, turn off
power once, then turn it on
aqain.)
calibration values (See 3.8.1)
1) Select other sensors (see 3.1).
calibration values (see 3.8.1).
(When changing sensors or
their calibration values, turn off
power once, then turn it on
again.)
1) Delete or print out stored data
(Step 9 in 3.9): If number of data
items in subsequent tests are
likely to exceed "Remaining
space", press [CANCEL] key to
return to select mode screen,
printout or delete stored data in
batch mode, and then select
jacking test mode again.
If expected number of data
items does not exceed
"Remaining space", press [ENT]
key.
1) Close release valve fully.
2) Remove constriction or bend.
3) Check connection (See 3.5).
4) Check and fill fluid.
5) Lower the piston.
4.
Miscellaneous Functions of JK-2
4.1
Digital display mode
To use JK-2 as an ordinary digital display unit, select the digital display mode. In addition, JK-2 has an
ability to print out sensor readings at a reset interval (interval timer function).
After connecting sensors, proceed as f oows.
II
Step
Screen display or print out
ACTION
=
=
DISPLAY
CALI BRATI ON =
BATCH
=
Screen 1
F1
F2
F3
F4
3
Select load sensor CH
CH1 &CH3 = F3
CH2 &CH3 = F4
Screen 2-2
Example of entry
Select load sensor CH

CH1 = F1
CH2 = F2
CH3 USE = F3
Screen 2-1
Select Mode screen appears. Enter [F2] key to

select digital display mode.
Yellow LED on mode display comes on.
[F2]
Selects digital
display mode
Select one of options according to which

sensor Channel you want to use.
[F1]: To use only sensor connector 1.
[F2]: To use only sensor connector 2.
To use CH3, press [F3] and go to next screen
2-2.
Press [F4] to enter sensor calibration mode on
screen 2-1.
[F3]: To use both sensor connectors 1 and 3.
[F4]: To use both sensor connectors 2 and 4.
Note: For sensor connector numbers, see
Figure 5 in 2.2.2. To enter sensor calibration
values, change screens by using [F1] key and
follow procedure described in 3.8.1.
[F1]
To select CH1
When readings become

stable, press ENT
CH1 = 0.2
CH3 = -0.3
Screen 3
Zero-adjust sensors: First remove load from

sensors, and when sensor readings (CH1, CH3)
become stable, press [ENT] key (See step 4 in
section 3.7)
Note: To ensure accuracy of zero adjustment,
[ENT] key is locked while "Set P" is flickering
(approx. 3min.). Press [ENT] key when "Set P"
goes off.
*****Measuring****
CH1 = 15.35
Ch3 = 12.32
PRINT = printout
Screen 4
Displays sensor readings. On this screen, keys

have following functions.
[START]: Used to set or cancel interval timer.
When you press this key, you are transferred to
step 6.
[PRINT]: Prints sensor reading of the moment
when this key was pressed.
[ ! ]: Feeds paper for printer.
--------
CH1
CH3
= 15.35
= 12.32
-------------
Example of printout
28
[F4]
To use both
sensor channels
2 and 3.
[ENT]
Confirms zero
adjustment.
[PRINT]
Prints sensor
readings
Step

Set interval timer
Time = H M 15S
Press ENT to confirm
Screen 5
------------------
CH1
CH3
= 15.35
= 12.32
Example of entry
Set an interval on interval timer. If timer is

already in operation, cancel setting and return to
step 5.
Enter data in the order of hours, minutes, and
seconds, and press [ENT] key to confirm. (Then
you are transferred to step 5).
Note: Method of numeric data entry is the same
as in step 5 in section 3.7. Minimum interval that
can be set is 15 seconds.
[-] [-] [-]

[-] 15
------------------
Example of printout
29
Sets interval at
15 seconds.
4.2
Sensor calibration mode
To calibrate the sensors used with .1 K-2, select the sensor calibration mode. The method consists of
applying a known pressure on the sensor and calculating calibration values from the result of the load
application.
After connecting sensors, proceed as follows.
Step
Example of entry
Turn ON switch on flank of .IK-2

ACTION
=
DISPLAY
=
CALI BRATI ON =
BATCH
=
Screen
Fl
F2
F3
F4
3&4
Select Mode screen appears.

Enter [F3] key to select sensor calibration mode.
Green LED comes on under "CAL" on mode
display.
[F3]
Selects sensor
Calibration mode
Steps 3 and 4 are the same as in Section 4.1.

Select load sensor CH.
CHl = Fl
CH2 = F2
CH3 = F3
Screen 4-1
When readings become

stable, press ENT
CHl = 0.2
Screen 4-2
Apply load on sensor

and press START key.
Screen 5
Select sensor channel CH 1, CH2 or CH3.

[F1]: To calibrate sensor connected to sensor
connector 1. (Go to step 6)
[F1]
To calibrate
sensor
connected to
CH1.
Zero-adjust sensors: First remove load from

sensors, and when sensor readings become
stable, press [ENT] key.
[ENT]
Confirms zero
adjustment.
System is ready to measure load. Apply a stable

known load on sensor with a standard or a
testing machine. Use a load as close to rated
capacity of sensor as possible. Then press
[START] key to go to step 7.
[START]
Starts
measurement
30
Example of entry
Enter CHl sensor

data, press ENT.
Rt Capacity 5.000 kN
Act load
5.000 kN
Screen 6
Enter rated capacity and actual load applied

in step 7, and then press [ENT] key to
confirm
(Go to Step 8).
5.0 [~]
5.0 [ENT]
Cal ibration results.

Press ENT to confirm
Rt Capacity
5
Rt Output
2.005
Displays results of sensor calibration.

Press [ENT] to confirm.
[ENT]
Confirm
Select either option according to what you

want to do with results of calibration.
[START]: Cancels results of calibration and
returns to step 5.
[ENT]: Updates existing data with new
results and prints out new results. Then
returns to step 5.
[ENT]
Update / print
Step
=
=
Rated capacity: 5kN

Actual capacity: 5kN
=
=
Screen 7
Select one option.
Once more
START
Update / print
ENT
Screen 8
5.
Precautions in handling
* JK-2 and sensors
These are precision instruments. Never drop them or give shocks to them.
Do not use or store them under hot humid conditions. (Use them at temperatures of 10 to 40 "C and
humidity of below 90% RH.)
They are not dust proof or water proof. Do not use them in places exposed to rain.
When you connect .IK-2 to an external power supply, use AC85 to 265V 50 / 60 Hz.
Connect the sensors securely to the sensor connectors and keep the connections free of water, oil,
dust, and other foreign matters.
Check the rated capacities and calibrated values of the sensors before testing. Do not put the sensors
under loads greater than their rated capacity.
Do not constrict or bend the sensor cables and power cable. Constrictions and bends may cause
disconnection.
Thoroughly remove oil and water from the equipment and store it properly.
* Mechanical components of jack.
Always bleed air from the hydraulic cylinder and high pressure hose before testing.
Insufficient bleeding may results in incorrect measurements.
When connecting the high pressure hose, avoid constrictions and bends.
Check the oil level of the hydraulic pump before testing. Oil level should be 80% of the full capacity.
When installing a safety valve on the jack, make sure that the safety valve is horizontal.
Do not store the jack under extremely hot humid conditions.
31
Appendices
Appendix 1. Area of valves exposed to pressure (excerpts)
This table applies to standard valves as of 1st October 2008.
Some of the figures may not apply to older valves.
[Standard valves as of 1st August 20]
<Table 1: Pressure areas for valves of SL series>

Class
~
F1
G1
K,J3
K2
K3,L
SL100-300
3.157
5.208
8.683
12.914
18.857
28.369
SL400
4.909
4.909
8.683
12.914
18.857
25.518
27.572
SL500-1000
8.683
8.683
8.683
12.914
18.857
24.85
27.572
Class
~
M,M2
N2
00
01
SL100-300
37.122
49.327
65.755
106.6
152.84
263.02
SL400
37.122
49.327
62.912
78.54
92.033
106.6
152.84
246.06
SL500-800
36.853
49.327
62.211
78.148
91.609
106.6
152.84
<Table 2: Pressure areas for valves of SJ series>
~
Clas
SJ100
300
[Standard valves as of 1S October 2008]
F2
G2
H2
J2
L1
N3
P2
02
03
5.208
8.683
12.914
18.857
28.369
37.122
54.106
65.755
92.033
106.60
152.84
263.02
25
32
40
50
65
80
90
100
115
125
150
SJ400
4.909
6.720
10.463
16.439
27.572
37.122
49.327
62.912
78.540
92.033
127.68
Class
32
Appendix 2.
Comparison table of turnbuckles

(Left -hand thread)
Hydralll ic cr l inder side
Coarse screw thread

Valve slem side
M8
M10
M12
M16
M20
M22
F-H
K-M
N,P
R,T
SL300
F,G
J,K
L-N
P,Q
R,T
SL400
F,G
H.J
K-L
SL500
F-H
J,K
SL600
F-H
F,G
Valve stem size

SL100.200
Model
SL700,800
M24
M27
M30
M33
M36
N2
QO
Q1
R,T
K2,L
N2
QO
Q1
K2
M-N2
K2,L
H,F1,G1
K,L
SL900
M,M2
K2,L
M,M2,N2
SL1000
SJ100,200
F2,G2
H2
J2-M
N3,P
Q2,Q3
R,T
P2
Q2
R
80mm
90mm
SJ300
F2
G2
H2,J2
L1
N3
SJ400
25mm
32mm
40,50mm
65mm
Appendix 3.
L,M,M2
J3
100mm
115mm
125mm
150mm
Standards for sensor selection (excerpts from SL 100 to 1000)
<Selecting pressure sensor>

Table 3: Table for pressure sensor selection
Popping pressure (MPa)
Base pressure (%)

-2
-3
-10
-12
-14
-21
-37
60
60-65
65-70
70-75
PG-20KU
PG-100KU
75-80
80-85
33
PG-200KU
PG-500KU
<Selecting load cell>

Table 4: Table for load cell selection
Measuring range of popping pressure (MPa)
LUK-A-5KN
LUK-A-20KN
Load cell
Size
60-65
65-70
70-80
80-85
60-65
65-70
70-80
80-85
D-F
2.3-3.8
2.7-3.8
1.4-3.8
1.6-3.8
2.4-3.8
3.2-3.8
0.9-3.8
1.0-3.8
1.5-3.8
2.0-3.8
0.6-3.8
0.7-3.8
1.0-3.8
1.3-3.8
1.6-3.8
1.8-3.8
2.7-3.8
0
0
H
J
K
0.4-3.8
0.5-3.8
0.7-3.8
0.9-3.8
1.6-3.8
1.8-3.8
2.7-3.8
0.3-3.8
0.3-3.8
0.5-3.8
0.6-3.8
1.1-3.8
1.2-3.8
1.8-3.8
2.4-3.8
M
N
P
0.2-3.0
0.3-3.4
0.4-3.8
0.5-3.8
0.8-3.8
0.9-3.8
1.4-3.8
1.9-3.8
0.2-2.2
0.2-2.6
0.3-3.0
0.4-3.8
0.6-3.8
0.7-3.8
1.1-3.8
1.4-3.8
0.2-1.6
0.2-1.9
0.2-2.2
0.3-3.3
0.5-3.8
0.6-3.8
0.8-3.8
1.1-3.8
0.1-1.0
0.1-1.1
0.2-1.3
0.2-2.0
0.3-2.1
0.4-2.1
0.5-2.1
0.7-2.1
R
T
0.1-0.7
0.1-0.8
0.1-0.9
0.2-1.4
0.2-1.6
0.3-1.6
0.4-1.6
0.5-1.6
0.1-0.4
0.1-0.4
0.1-0.5
0.1-0.8
0.2-1.6
0.2-1.6
0.2-1.6
0.3-1.6
F, G
1.5-5.6
1.7-5.6
2.6-5.6
3.4-5.6
H
J
K
K2
0.9-5.6
1.0-5.6
1.5-5.6
2.0-5.6
3.3-5.6
3.9-5.6
0
0
-I
CJ)
0
0
.....
-I
CJ)
0.6-5.6
0.7-5.6
1.0-5.6
1.3-5.6
2.3-5.6
2.6-5.6
3.9-5.6
0.5-5.6
0.7-5.6
0.9-5.6
1.6-5.6
1.8-5.6
2.7-5.6
0.3-4.4
0.4-5.0
0.5-5.6
0.7-5.6
1.2-5.6
1.4-5.6
2.0-5.6
2.7-5.6
0.3-4.0
0.3-4.6
0.5-5.4
0.6-5.6
1.1-5.6
1.3-5.6
1.9.,. 5.6
2.5-5.6
M
N2
P
0.2-3.0
0.3-3.4
0.4-4.0
0.5-5.6
0.8-5.6
0.9-5.6
1.4-5.6
1.8-5.6
0.2-2.2
0.2-2.6
0.3-3.0
0.4-4.5
0.6-5.6
0.7-5.6
1.1-5.6
1.4-5.6
0.2-1.7
0.2-2.0
0.2-2.3
0.3-3.5
0.5-5.6
0.6-5.6
0.8-5.6
1.1-5.6
QO
0.1-1.4
0.2-1.6
0.2-1.9
0.3-2.8
0.4-4.9
0.5-4.9
0.7-4.9
0.9-4.9
Q1
0.1-1.2
0.1-1.4
0.2-1.6
0.2-2.4
0.4-4.8
0.4-4.9
0.6-4.9
0.8-4.9
0.1-1.0
0.1-1.2
0.2-1.4
0.2-2.1
0.3-4.2
0.4-4.7
0.5-4.9
0.7-4.9
0)
0
0
It')
-I
CJ)
Out of range
0.4-5.6
R
T
F,G
H,F1,G1
0
0
Out of range
K
K2
L
M,M2
N2
P
00
01
0
R
3.6-5.6
0.1-0.7
0.1-0.8
0.1-0.9
0.2-1.4
0.2-2.9
0.3-3.3
0.4-3.9
0.5-4.9
0.1-0.4
0.1-0.5
0.1-0.6
0.1-0.9
0.2-1.8
0.2-2.0
0.3-3.5
1.5-21.0
1.7-21.0
2.6-21.0
3.4-21.0
5.9-21.0
6.8-21.0
0.2-2.4
10.2-21.0
0.9-12.9
1.0-14.8
1.5-17.2
2.0-21.0
3.3-21.0
3.9-21.0
5.8-21.0
7.7-21.0
0.6-8.7
0.4-5.9
0.7-9.9
1.0-11.6
1.3-17.4
2.3-21.0
3.9-21.0
5.2-21.0
0.5-6.8
0.7-7.9
0.9-11.9
1.6-21.0
2.6-21.0
1.8-21.0
2.7-21.0
3.6-21.0
0.3-4.5
0.4-5.1
0.5-6.0
0.7-9.0
1.2-18.1
1.4-20.7
2.1-21.0
2.7-21.0
0.3-4.0
0.3-4.6
0.5-5.4
0.6-8.1
1.1-16.3
1.3-18.6
1.9-21.0
2.5-21.0
0.2-3.0
0.3-3.4
0.4-4.0
0.5-6.1
0.8-12.2
0.9-13.9
1.4-16.2
1.9-21.0
0.2-2.2
0.2-2.6
0.3-3.0
0.4-4.5
0.6-9.2
0.7-10.4
1.1-10.5
1.4-10.5
0.2-1.8
0.2-2.0
0.2-2.4
0.3-3.6
0.5-7.2
0.6-8.2
0.8-9.6
1.1-10.5
0.1-1.4
0.1-1.6
0.2-1.9
0.3-2.8
0.4-5.7
0.5-6.6
0.7-7.6
0.9-10.5
0.1-1.2
0.1-1.4
0.2-1.6
0.2-2.4
0.4-4.9
0.4-5.6
0.4-6.5
0.8-9.8
0.1-1.0
0.1-1.2
0.2-2.1
0.3-4.2
0.4-4.8
0.1-0.7
0.1-0.8
0.2-1.4
0.1-0.9
0.2-1.4
0.2-2.9
0.3-3.3
0.5-5.6
0.4-3.9
0.7-8.4
0.5-5.8
34
13.6-21.0
<Selecting load cell (continue
Table 4: Table for load cell selection (continue)
Measuring range of popping pressure
(MPa)
LUK-A-50KN
Load cell
60-65
65-70
70-75
75-80
80-85
H,F1,G1
21-37
21-37
21-37
21-37
Out of range
21-37
21-37
21-37
21-37
23-30
J3, K
21-37
21-37
21-37
21-37
21-37
K2
21-37
21-37
21-37
21-37
21-37
21-37
21-37
21-37
21-37
21-37
M,M2
21-32
21-37
21-37
21-37
21-37
N2
21-24
21-28
21-33
21-37
21-37
Size
0
0
0
::i
en
<Example>
Suppose you use safety valve: SL700 (K). Its specified popping pressure (Ps) is 12.5MPa and base pressure
(Pb) is 10.0MPa.
Base pressure ratio: Pb / Ps = 10.0 /12.5 x 100 =80%
From table 3, the pressure sensor which meets the base pressure ratio of 80~85% and the popping pressure
of 12.5MPa is PG-200KU. From table 4, the load cell which meets the base pressure ratio of 80% and the
popping pressure of 12.5MPa is LUK-A-20KN.
35
<Selecting load cell>

Table 5: Table for load cell selection
Measuring range of popping pressure (MPa)
LUK-A-5KN
Load cell
~
%
Size
60-65
LUK-A-20KN
65-70
70-S0
SO-S5
F2
1.4-3.3
1.6-3.3
2.4-3.3
3.2-3.3
G2
0.9-3.3
1.0-3.3
1.5-3.3
2.0-3.S
H2
0.6-3.3
0.7-3.3
1.0-3.3
1.3-3.3
0.9-3.3
60-65
65-70
70-S0
SO-S5
Out of range
J2
0.4-3.3
0.5-3.3
0.7-3.3
L1
0.3-3.3
0.3-3.3
0.5-3.3
0.6-3.3
1.1-3.3
1.2-3.3
1.S-3.3
2.4-3.3
0.2-3.0
0.3-3.3
0.4-3.3
0.5-3.3
0.S-3.3
0.9-3.3
1.4-3.3
1.S-3.3
N3
0.2-2.0
0.2-2.3
0.3-2.7
0.4-3.3
0.6-3.3
0.7-3.3
1.0-3.3
1.3-3.3
M
0
"""J
(/)
P2
0.2-1.7
0.2-1.9
0.2-2.2
0.3-3.3
0.5-3.3
0.6-3.3
0.S-3.3
1.1-3.3
02
0.1-1.2
0.1-1.4
0.2-1.6
0.2-2.4
0.4-3.3
0.4-3.3
0.6-3.3
0.S-3.3
03
0.1-1.0
0.1-1.2
0.2-1.4
0.2-2.1
0.3-3.3
0.4-3.3
0.5-3.3
0.7-3.3
0.1-0.7
0.1-0.S
0.1-0.9
0.2-1.4
0.2-2.2
0.3-2.2
0.4-2.2
0.5-2.2
0.1-0.4
0.1-0.4
0.1-0.5
0.1-0.S
0.2-1.6
0.2-1.6
0.2-1.6
0.3-1.6
25
1.5-5.0
1.7-5.0
2.6-5.0
3.4-5.0
32
1.1-5.0
1.3-5.0
1.9-5.0
2.5-5.0
40
0.7-5.0
0.S-5.0
1.2-5.0
1.6-5.0
2.S-5.0
1.1-5.0
3.2-5.0
2.1-5.0
4.S-5.0
1.S-5.0
1.1-5.0
1.3-5.0
1.9-5.0
0.9-5.0
1.4-5.0
1.S-5.0
0.7-5.0
1.4-5.0
1.1-5.0
50
0
0
"""J
(/)
65
80
0.5-5.0
0.3-4.0
0.2-3.0
0.2-2.2
0.6-5.6
0.3-4.6
0.S-5.0
0.5-5.0
0.3-3.4
0.4-4.0
0.6-5.0
0.5-5.0
0.3-3.0
0.4-4.5
Out of range
3.1-5.0
4.1-5.0
2.5-5.0
100
0.2-1.7
0.2-2.6
0.2-2.0
0.2-2.3
0.3-3.5
0.S-5.0
0.6-5.0
0.5-5.0
0.6-5.0
1.1-5.0
0.S-5.0
115
0.1-1.4
0.2-1.6
0.2-1.9
0.3-2.S
0.4-5.0
0.5-5.0
0.7-5.0
0.9-5.0
125
0.1-1.2
0.1-1.4
0.2-1.6
0.2-2.4
0.4-4.S
0.4-5.0
0.6-5.0
0.S-5.0
150
0.1-0.S
0.1-1.0
0.1-1.1
0.2-1.7
0.3-3.5
0.3-4.0
0.4-4.7
0.6-5.0
90
36
Appendix 4.
JK-2 screen flow in jacking test mode

<Screen 1>
ACTION
=
DISPLAY
=
CALIBRATION =
BATCH
=
Fl
F2
F3
F4
Screen 1: select Mode screen
(Select jacking test mode)
trn
[CANCEL]. I
<Screen 2-1>1 ...
Screen 2-1: Select load sensor screen
(Select CH1 or CH2)
Select load sensor

CH.
CHI = Fl
CH2 = F2
[CANCEL]. I [Fl or F2]
<Screen 2-2)1 ...
Do you want to use
pressure sensor?
No = F3
Yes = F4
[CANCEL]
<Screen 3)
<Sen
[F1J
~
..
[ENT]
r:::---:-:-:---:----,
Change caI i brat i on
values of sensors
CHI = 5 kN (2. 014)
CH2 =10 MPa (2. DOl)
I [F3]
Not to use sensor use

... [F4] To use sensor
[ENT] 3 min after
Enter date and

press ENT key
08/10/01
[CANCEL]
[ENT]
<Scree 5)
Serial No. = 811234
Valve area = 7.985
Popping P=16.45 MPa
Base
Dress. =12. 5
[CANCEL] t
[ENT]
<Screen 6)
Press start key to
start measurement
"Set p" goes off

Screen 4: Enter date screen
(Enter date)
<Screen 5-1)
[F1J
~
~"r-----

cyl. area = 34.361
[ENT]
<Screen 6-1>
..
trn
[ENT]
Change parameter of
bI ow off detect i on
parameter = 4
<Screen 7-2)
trn
[ENT]
Estm. Load = 3.154

*****Measuring****
Load
= 2.395
Pressure = 12.35
<Screen 8-1)
<Screen 8)
Set Pop. P = 16.45
***** Resu Its *****
Popping P = 16.35
Base press. = 12.35
..
trn
[ENT]
[START]
[CANCEL]
[ENT]
<Screen 9)
SeI ect one opt ion.
Retest = START
Pr i nt out = PR INT
Store data = ENT
Screen 2-1-1: Sensor calibration screen
(Preset on JK-2, calibrated valves of sensor to be
used in testing)
Screen 3: Zero adjustment screen
(set reading of unloaded sensor at Zero)
When reading become

stable, press ENT
CHI = 0.2
CH2 =- 0.3
[CANCEL]t
Screen 2-2: Select sensor screen
(Do you want to use pressure sensor?
select "Yes" or "No")
[PR INT]
~
~"f-----
Ser i al No. = 811234

Valve area = 7.985
Popping P
Base press.
TEST No. 1
DATE : 08/10/01
S No. :811234
Ao
= 34.361
As
= 7.985
Pb
Lt
Po
Pk
Ps
= 12.32
= 3.194
= 0.93
4.00
= 16.32
37
Screen 5: Safety valve data screen
(Enter serial number, pressures area, specified
popping pressure, and base pressure)
Screen 5-1: Enter cylinder area screen
(Enter effective surface area of cylinder exposed
to pressure)
Screen 6: stand by measurement screen
(Ready for measurement)
Screen 6-1: Change blow off parameter screen
(Enter new value of blow off criterion)
Screen 7-1: Measurement information screen
(Display reduced pressure and base pressure)
Screen 7-2: Measurement information screen
(Displays jacking load and base pressure)
Screen 8: Results screen
(Displays results of measurement)
Screen 8-1: Change valve data screen
(Confirm or change existing data)
Screen 9: Results screen
(Select "Restart", "Print out", or "Store data")

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Document NO.

JK-2 Field Test System

FUKUISEISAKUSHO Co., LTO

How to determine setting pressure

2.2 Functions of JK-2

2.2.2 Right flank of JK-2

How to Use System

3.2 Assembling load cell

3.3 Installing pressure sensor

3.4 Connecting load cell and pressure sensor to JK-2

3.5 Installing mechanical components of jack

3.6 Operation hydraulic pump

3.7 Activating JK-2 and conducting jacking test

3.8 Auxiliary functions in jacking test mode

3.8.2 Changing effective area of hydraulic cylinder

3.8.3 Changing parameter of blow off detection

3.8.4 Changing data after blow off detection

3.9 Entering data after testing (batch processing mode)

3.10 Troubleshooting during jacking test

Miscellaneous Functions of JK-2

Sensor calibration mode

Area of valves exposed to pressure

Standards for sensor selection

Comparison table of turnbuckles

JK-2 screen flow in jacking test mode

Hydraulic cyIi nder

How to determine setting pressure

Forces acting on the disk of a safety valve are given by,

When the safety valve is closed, the relationship between forces

_ _~~'""'""" Mela. rill' gaskels

Iii glt pressure hose

Jacking test mode:

Digital display mode:

Sensor calibration mode:

Batch processing mode:

Liquid crystal screen

Interactively displays sensor readings,

measurement results, and instructions

Normally, indicates the operation mode

with LED. In the jacking test mode.

this indicates states of popping

pressure detection. See Figure 1.

Used for selecting modes, setting

functions, and entering numeric data.

See Figures 2 and 3.

T'.:' .f ....... ealibnll.... I

Prints out. results of jacking test and

Table of sensor calibration values

Lists calibration values of the

sensors included with the system.

Table 1: Mode display

O... LED is off

Indicates that the system is operating in the jacking test

Table2: Functions of keys during mode selection and function setting

Goes back to previous screens one by one.

Table3: Functions of keys for numeric data entry

Table 4: Sensor calibration values

Indicates the type of sensors. Basically, TYPE of a pressure sensor

Indicates the maximum permissible capacity of a sensor.

Indicates the output characteristic (calibration value) of a sensor.

Indicates the manufacture's serial number of a sensor.

Right flank of JK-2

Sensor connector (CH3)-_