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ITOfRISER Model:/KS50/KS100/KS150/KS200/KS300

LPG Vaporizer Instruction Manual

ITO KOKI CO., LTD. ITO f SYSTEM CORPORATION

Introduction Thank you for purchasing our product. Please observe applicable laws and regulations of the

regions in which the product is used, and read this instruction manual carefully in order to use the

product safely. This manual should be retained for future reference. After you have read the manual,

be sure to keep it handy, so you can consult it whenever you need to.

Signal words and symbols used in this manual

Be sure to comply with the following.

This means prohibited action.

Keep away from fire.

WARNING

Incorrect handling can lead to a grave result, such as death or a serious injury.

CAUTION

Incorrect handling can lead to injury to humans and/or

damage to property, such as to a house or furniture.

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1. Standard Specifications

Model Items

KS-50 KS-100 KS-150 KS-200 KS-300

Vaporization Capacity (kg/h) 50 100 150 200 300

Gas Type LPG

Method of Heating Electro-heating Hot-water Heating Type

Design Pressure (MPa) 1.80

Proof Test Pressure (MPa) 3.00

Air-tightness Test Pressure (MPa) 1.80

Design Temperature () -25 80

Working Pressure Range (MPa) 0.2 1.56

Liquid-spill Prevention Mechanism Float Type

Safety Valve Setting Pressure (MPa) 1.76

Heat Source

Heater Capacity (kW) 7.5 15 22.5 30 45

Voltage (V) 3 380V3 220V

Rated Current (A) 11.4/ 19.7

22.8/ 39.4

34.2/ 59.1

45.6/ 78.8

68.4/ 118.1

Hot Water Control Temperature () 60 75 (setting at 70)

Superheat Prevention Device () 80 (setting at 80)

Connection Liquid Inlet Flange JIS 20K 20A

Gas Outlet Flange JIS 20K 20A JIS 20K 25A

External Dimensions

Width (mm) 430 430 490 590 590

Length (mm) 595 595 654 757 757

Height (mm) 1103 1102.5 1173 1123 1223

Capacity of Hot Water Tank () 65 73 112 160 185 Approximate Product Weight (kg) 100 110 140 170 190

Rust-preventive Agent (m) 250 250 400 500 650

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2. Appearance 2.1 Appearance Configuration

NLiquid Inlet NGas Outlet NDrain Valve NSafety Valve NHot Water Drain Valve NReset Valve NReset Button NPower Source

Connection Port Note: G and H denote the base dimensions.

I and J denote the positional dimensions for setting anchor bolts. L denotes joint dimensions for conduit.

2.2 Dimensions mm Model

KS-50 595 430 1103 420 1029 295 390 390 350 280 618 G1(PF)

KS-100 595 430 1103 420 1029 295 390 390 350 280 618 G1(PF)

KS-150 654 490 1173 480 1099 325 430 450 390 416 688 G1 1/4(PF)

KS-200 757 590 1123 580 1049 325 530 550 490 516 628 G1 1/2(PF)

KS-300 757 590 1223 580 1149 325 530 550 490 516 728 G1 1/2(PF)

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3. Name of Parts

Name Function

Temperature Regulator

This device controls hot water temperature at 60 to 75 setting at 70.

Superheat Prevention Device

This device starts functioning to prevent superheating if temperature regulator fails (setting at 80).

Liquid-spill Prevention Valve

This valve prevents un-vaporized LPG liquid from spilling out to the outlet if decreasing in the ability to vaporize occurs due to power failure.

Level Switch This device shuts off the power to the heater to prevent boil-dry if hot water level lowers to a certain level.

Pilot Lamp This lamp is turned off when superheat prevention device or level switch is activated.

Safety Valve This valve releases gas to the atmosphere in order to prevent the vaporizer from being damaged if the pressure inside the heat exchanger exceeds the set level 1.76MPa.

Reset Valve This valve resets the liquid-spill prevention valve. It must be closed when starting operation.

Drain Valve This valve removes the condensate accumulated in the heat exchanger.

Reset Button This button resets the liquid-spill prevention mechanism. Open the reset valve first and then push this button.

Pressure Gauge This device indicates the pressure inside the heat exchanger. An indicator falls rather than liquid inlet pressure at the time of a liquid-spill prevention valve is operation.

Thermometer This device indicates the hot water temperature. Water Level Gauge This device indicates the level of water.

Liquid Inlet Safety Valve

Gas Outlet

Main Valve of Pressure Gauge Reset Valve

Liquid-spill Prevention Valve

Water Level Switch Superheat Prevention Device

Temperature Regulator

Power Supply

Pilot Lamp

Electric Heater

Hot Water Drain Valve

Pressure Gauge

Thermometer Water Level Gauge Feed Water Inlet

Hot Water Tank

Overflow

Grounding Connection

Drain Valve

Float Heat Exchanger

Reset Button

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4. Electric Wiring Diagram

5. Safety Precautions 5.1 Instructions This product has been carefully assembled. Do not disassemble or modify the product yourself,

or you risk causing a malfunction.

Any large impact on the product can cause problems, such a gas leak. Do not drop or hit it, or

allow anything to crash into it, or drop anything heavy on it.

If you install the product in a place exposed to heavy snow, be sure to protect the product

appropriately, for example with a cabinet.

Be sure to operate the valves very slowly to avoid any malfunction. 5.2 Emergency Measures

If you find any abnormality, immediately stop the gas supply and contact our agency.

6. Installation Works Be sure to comply with applicable laws of country in which the product is used. 6.1 Installation Site

Be sure to install the product in a place that satisfies the following requirements:

T/R Transformer *220V Specifications without T/R L/S Water Level Switch T/C.N Temperature Regulator Temp Control T/C.H Superheat Prevention DeviceSuperheat PreventionMC Magnet Switch PL Pilot Lamp

WARNING

CAUTION

- 5 -

A place far away from any source of ignition and in a place not affected by flames or radiant

heat.

A well-ventilated place.

A place with no exposure to corrosive gases, such as ammonia or sulfur dioxide.

A place that does not expose the product to any gas that might damage it, such as ozone.

A place that is not subject to high temperatures or high humidity.

A place where the product can easily be accessed for inspection / repair work.

In case of installing it indoors, be sure to create ventilation openings and provide enough

space for well ventilation. Ventilation openings should be created more than at two places so

that the total space for ventilation is more than 3% of the floor area.

Be sure to take measures for any unauthorized person to stay away from the site such as

providing a special housing, fences or walls.

Set up signs such as FLAMMABLE or KEEP OUT in order to invite neighbors attention to

hazardous object installation site.

Regularly provide dry chemical extinguishing units with more than 8kg chemicals in it at the

site.

Never put flammables including gasoline, kerosene, heavy oil, and timbers etc. around the

site.

Be sure to provide a gas leak alarm unit(s) in the installation site.

6.2 Space for Maintenance and Inspection Provide enough space for inspection and overhaul inspection around the installation site according

to the diagram below.

A B C D HKS-50

600 800 600 600

1800KS-100 1800 KS-150 2000 KS-200 2000 KS-300 2000

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6.3 Construction Only a qualified or skilled person should install this product.

This product is delivered with devices such as caps or seals, etc., on its outlet and inlet

connections to prevent entry of dust. Be sure to remove these protective devices before

installation.

The vaporizer must be installed horizontally on a concrete foundation or a floor having

equivalent strength, which must be 10 to 15cm higher than the ground surface, secured

with anchor bolts, and connected with cable for grounding.

Be sure to provide a main valve and a strainer whose mesh is 100 or more in the liquid inlet

piping.

Install a first stage regulator in the immediate vicinity of the gas outlet piping, and provide

pipe systems to prevent LPG from accumulating or being re-liquefied. In addition, install a

gas outlet valve on the downstream of the first stage regulator.

Support and fix the piping at the inlet and outlet with pipe hanger or stands or the like.

Do not expose the product or piping to excessive force.

Be sure to use gaskets, bolts and nuts that are suitable for the connections. (Tighten bolts

and their nuts in diagonal sequence.)

For checks and inspections, install pressure gauges on both the inlet and the outlet.

To facilitate repair and replacement, install valves on both the inlet and outlet.

To facilitate repair and replacement, be sure to provide a bypass line or take some

alternative measures to supply gas.

Select pipes, fittings and valves that have sufficient strength against the working pressure.

When piping, to ensure secure attachment, completely remove any scale or dust in the

piping, as well as any other foreign objects.

Place additional pipes from the outlet of safety valve and drain valve to a safe place so that

the outgoing gas will not stay around the outlet when gas is released from such valves.

Use specified items for electric wires and ground fault interrupters to be connected to the

terminal box.

Be sure to provide explosion-proof electric work when lead-in wire is placed because the

terminal box is constructed explosion-proof.

Perform an air-tightness inspection using an unreactive gas.

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6.4 Drawing of Recommended Piping

Model

Liquid

Automatic

Change-over

Liquid Inlet

Main Valve

(w/ Strainer)

First Stage

Regulator

Second Stage

Regulator

Vapor-phase Inlet

Main Valve

(w/ Strainer)

Automatic

Change-over

Separate Type

Regulator

Second Stage

Regulator for

Vapor-phase

KS-50 LAX-20C D7-20F CM-50V GL-50-2 D7-20F AX-50-0 GL-50-2

KS-100 LAX-20C D7-20F GMF-100V G-32A-2 D7-25F AXF-100-0 G-32A-2

KS-150 LAX-20C D7-20F GMF-200 G-36C-2 D7-25F AXF-200-0 G-36C-2

KS-200 LAX-20C D7-20F GMF-200 G-36C-2 D7-25F AXF-200-0 G-36C-2

KS-300 LAX-20C D7-20F GMF-300V GL-300-2 D1-40F+D2-40F AXF-300-0 GL-300-2

Voltage

Model

220V, 3-phase Electric Wire

Conduitmm Capacity of

Electric Wire

Capacity of Ground

Fault Interrupter

KS-50 8mm23C 30A G28 KS-100 14mm23C 50A G36 KS-150 22mm23C 75A G42 KS-200 38mm23C 100A G42 KS-300 60mm23C 125A G70

Voltage

Model

380V, 3-phase Electric Wire

Conduitmm Capacity of

Electric Wire

Capacity of Ground

Fault Interrupter

KS-50 5.5mm23C 20A G28 KS-100 8mm23C 30A G28 KS-150 14mm23C 50A G36 KS-200 22mm23C 75A G42 KS-300 38mm23C 100A G42

Bypass Line

Automatic Change-over Separate Type Regulator

Liquid-phase Line

Second Stage Regulator

Vapor-phase Inlet Main Valve (w/ Strainer)

First Stage Regulator

Liquid Automatic Change-over

Liquid Inlet Main Valve

Liquid Inlet Main Valve (w/ Strainer)

Gas Outlet Valve

Second Stage Regulator for Vapor-phase

Change-over Pressure Measuring Line

- 8 -

7. Installation Works 7.1 Preparation for Operation Water Supply

Prior to water supply, add the supplied rut-preventive agent by the specified amount

KS-50250KS-100250KS-150400KS-200500mKS-300650, and then supply city water until water is just to overflow. *Note: Be sure to use city water. Use of ground water may cause corrosion.

Confirmation of Valve Condition

Confirm that main liquid inlet valve, gas outlet valve, drain valve and reset valve are

closed.

Before turning on the power supply, confirm the following items.

- Value of insulation resistance of external wiring in heater and control circuit line: 0.4 M

or greater.

- Value of grounding resistance of ground work: 100 or lower

*Note: The above items should be confirmed by professional power distribution workers.

Installation failure can cause malfunction and short circuit. Lack of grounding can bring

about electrification.

7.2 Starting Operation Turn on the main power supply and confirm that the pilot lamp lights.

Confirm that the temperature of hot water is 60 or higher.

Confirm that drain valve and reset valve are closed.

Confirm that the main valve of pressure gauge is open.

Push the reset button.

Gradually open the main valve of liquid inlet valve.

Gradually open the gas outlet valve and confirm that gas is being supplied.

Purge the regulator completely with the gas supplied. Do not expose the product to

external sources of ignition and purge an unreactive gas completely.

7.3 Stopping Operation For short-period operation stop

Confirm the gas outlet valve is closed and the other valves and the main power supply

remain operating condition.

For extended operation stop

1) Close the main valve of the liquid inlet.

2) Consume all amount of gas in the vaporizer, or fully discharge the gas through the drain

valve to a safe place.

3) Close the gas outlet valve and turn off the main power supply.

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7.4 Method of Restoration after Actuation of Liquid-spill Prevention Valve If gas is consumed under power failure, low water level or overload condition, hot water temperature

will lower, LPG liquid level will rise, and further, the liquid-spill prevention valve will be activated by

the float buoyancy, which will cause stop of gas supply.

Be sure to close the gas outlet valve. Resolve the cause that shut-off system actuates such as stop of power source supply

caused by power failure or over-capacity of gas consumption, then turn on the main

source of electrical power.

Confirm that the temperature of water rises and indicates more than 60.

Open the reset valve and push the rest button.

Confirm that a float has fell down and the outlet pressure has increased (the shut-off

system is deactivated)

After the shut-off system is deactivated, be sure to close the reset valve.

Confirm that no gas leak is found, and gradually open the gas outlet valve to check the gas

supply.

If gas is not supplied, follow the procedure from again.

7.5 Restoration Method of Level Switch (the cause of actuation of shut-off system is low water level)

Supply city water (groundwater is not available) from feed-water inlet until water is just to

overflow.

Apply the restoration procedures above 7.4.

8. Maintenance

If you find any abnormality, do not disassemble the product and please contact our agency. 8.1 Daily Check Frequency of Check: At the start of operation, during operation and the stop of operation Check Items: gas leak, pressure, water level, hot water temperature and if drain valve and

reset valve is closed.

*Note: Be sure to discharge the drain accumulating in the vaporizer from the drain valve.

8.2 Periodical Inspection Perform an annual inspection to check the following items at least once or more in each

twelve-month period.

Gas-tightness Inspection

Inspection of equipment auxiliary to thermometer and pressure gauge.

Appearance inspection of vaporizer, hot water tank and others.

Replacement of hot water including rust-preventive agent.

*Note: Put specified amount of our companys recommended rust-preventive agent to use the product.

WARNING

- 10 -

8.3 Overhaul (Periodical Replacement)

- Frequency of inspection: Once every three years - Items for implementation: The following items are added to periodic inspection: Measurement of thickness of heat exchanging part Calibration of thermometer and pressure gauge Inspection of auxiliary equipments and replacement of deteriorative parts Situation of corrosion of heat exchanger, hot water tank, and others Air-tightness Inspection

*Note: Any rubber components, such as diaphragms and O-rings, as well as any metal sliding components, will deteriorate with use.

9. Inspection Items When in Anomaly

Symptom

Causes

No Gas

Supplied

Low

Temperature

of Hot Water

High

Temperature

of Hot Water

Low

Supply

Pressure

Measures

Running Out of Gas Replace the container.

Excess Consumption

of Gas

Reduce the consuming rate.

Heater

Disconnecting

Replace the heater.

Failure of MC Replace MC.

Failure of

Temperature

Regulator

Correction of settings or replacement

Defect of Superheat

Prevention Device

Correction of setting or replacement.

Water Shortage Supply water.

Defect of Level

Switch

Replace the switch.

Defect of Water Level

Gauge

Replace the gauge.

Strainer Clogging Clean the strainer.

Main liquid inlet valve and outlet valve are left closed

Open the valve.

WARNING

- 11 -

10. Warranty of Product We will warrant the product for one and a half years from the date of production, subject to the

following: The product will be repaired or replaced with a new one at no charge if the failure arises after

normal usage procedures in conformity with this manual. Repair or replacement will be performed at cost, even within the warranty period, if the failure is

attributable to one of the following causes: 1) Problems and / or damage arising from incorrect use, improper repair or conversion

2) Problems and / or damage arising from dropping, impact shock or similar

3) Problems and / or damage arising from failure to follow the instructions in this manual, e.g.:

ignoring periodic inspections

4) Problems arising from foreign SH entering from upstream pipelines. (Including insufficiency of

lockup function, clogging of strainer, etc.)

11. Exclusions Our Company does not have liability and/or responsibility for any damage caused by force

majeure such as natural disasters (including storm and flood damage, earthquake and lightning),

fire, environmental pollution (special environments), salt damage or air pollution, including

atmospheres contaminated with gases other than normal air.

Our Company does not have liability and/or responsibility for any damage caused by the act of a

third party, any other accident, a customers intentional or unintentional misuse of the product, or

its use under any other abnormal conditions.

Our Company does not have liability and/or responsibility for any incidental damage (loss of

profit, interruption of business, etc.) caused by use or non-use of the equipment.

Our Company does not have liability and/or responsibility for any damage that may be brought

about by uses other than those explained in this instruction manual.

12. Contact Offices For functional maintenance of the product and safety control, please be sure to perform daily

check and periodic inspections. We also provide highly qualified maintenance service for the product. For more details, please

inquire at any of the following agency.

- 12 -

ITO KOKI CO., LTD 10-4, Hakodono-Cho, Higashiosaka-City, Osaka 579-8038 JAPAN

(Tel: +81-72-981-3781; Fax: +81-72-987-6590)

ITO f SYSTEM CORPORATION Overseas dept. for ITO KOKI 8-6, Shinmachi, Higashiosaka-City, Osaka 579-8037 JAPAN

(Tel: +81-72-983-7017; Fax: +81-72-983-7018)

ITO f SYSTEM (SHANGHAI) CORPORATION No.479 D2-2F, ChunDong Rd, XinZhuang Industry Park, Shanghai 201108 CHINA

(Tel: +86-21-6442-3472; Fax +86-21-6442-3475)

ITO EUROPE LIMITED 9 Field View Offices, Upper Barns, Farm. UBF Industrial Park, Westcott

Buckinghamshire, the United Kingdom

(Tel: +44(0)1296-655 655; Fax: +44 (0)1296-658 615)

ITO KOKI VIETNAM CO., LTD Saigon South New City, Room 205, Sky View Building, Lot CR3-6, CR3-7, Tan Phu Ward,

District 7, Ho Chi Minh City VIETNAM

(Tel: +84-8-5414-7008; Fax: +84-8-5413-5334)

http://www.itokoki.co.jp/english/

NoteSpecifications and appearance of the product described here may be changed without prior notice.

165U-fRZ-S-04-0907-ITOKOKI