BARTON® NUCLEAR MODEL 289A DIFFERENTIAL PRESSURE INDICATING SWITCH User Manual Part No. 9A-C10310, Rev. 01 January 2012 Contents Safety............................................................................................................. 2 Section 1—Introduction.................................................................................. 3 General.......................................................................................................... 3 Main Components.......................................................................................... 3 Indicating Switch ....................................................................................... 4 Relays........................................................................................................ 5 Wiring......................................................................................................... 5 Differential Pressure Unit (DPU)................................................................ 5 Specifications ................................................................................................ 5 Nuclear Qualifications................................................................................ 6 Section 2—Installation.................................................................................... 7 General.......................................................................................................... 7 Mounting/Piping/DPU Installation.................................................................. 7 Electrical Connection (Switches/Relays)....................................................... 7 Switch Use..................................................................................................... 7 Startup........................................................................................................... 8 Switch and Relay Wiring Diagrams............................................................... 9 Section 3—Maintenance and Calibration.................................................... 15 Tools............................................................................................................ 15 Bezel/Lens (or Cover) Installation and Removal......................................... 15 Calibration Check........................................................................................ 16 Pointer Installation and Removal................................................................. 17 Pointer Installation ................................................................................... 17 Pointer Removal....................................................................................... 17 Indicator Calibration..................................................................................... 18 Drive Arm Tightness Test.......................................................................... 20 Drive Arm Stop Adjustment ..................................................................... 21 Switch Calibration ...................................................................................... 21 Calibration Setup...................................................................................... 21 Calibration Procedure ............................................................................. 22 Changing Switch Set Point ......................................................................... 23 Definitions of Terms.................................................................................. 23 Best Practices for Set Points.................................................................... 23 Changing Set Point of an In-Service Instrument (Not Recommended for Nuclear Qualified Units)........................................................................... 24 Changing Set Point of an Out-of-Service Instrument............................... 25 Range Changes....................................................................................... 25 Troubleshooting .......................................................................................... 26 Section 4—Assembly Drawing and Parts Lists.......................................... 29 Section 5—Installation/Dimensional Drawings.......................................... 35 Appendix A—Model 199 DPU User Manual................................................A-1 Safety Before installing this product, become familiar with the installation instructions presented in Section 3 and in the Model 199 DPU manual (Appendix A), and all safety notes throughout. ! WARNING: This symbol identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. CAUTION: Indicates actions or procedures which if not performed correctly may lead to personal injury or incorrect function of the instrument or connected equipment. IMPORTANT: Indicates actions or procedures which may affect instrument operation or may lead to an instrument response that is not planned. 2 Model 289A Differential Pressure Indicating Switch Section 1 Section 1—Introduction General The weatherproof Model 289A is a differential pressure indicating switch. The Model 289A has a NEMA-4 watertight die-cast aluminum case (finished with a weather-resistant black epoxy resin paint). The cover lens is secured in the bezel with an elastomer ring to reduce the possibility of accidental breakage. This ring also acts as a seal between the bezel and the case to ensure a moisture, fume and dust-free atmosphere for the indicator and switch mechanism. The large cover lens allows maximum readability of the indicating pointer. Switches and all adjustments are readily accessible when the cover is removed. The built-in switches energize either single or dual alarm circuits when the measured differential pressures exceed predetermined limits. These limits may be either maximum, minimum, or both. Main Components Switch Lock Stop Screw Stop Screw Actuating High Alarm Cam Low Alarm Switch Switch Switch Lock Plunger Screw Plunger Screw Differential Drive Arm Low Alarm Relay High Alarm Relay Switch Link Hex Hub Zero Adjust Terminal Strip Movement Assembly Low Alarm Switch Adjust Pointer Range Adjust High Alarm Switch Adjust Figure 1.1—Switch components 3 Section 1 Model 289A Differential Pressure Indicating Switch Indicating Switch (refer to Figure 1.2, Figures 2.1 to 2.6, and Table 2.1) Rotation of the DPU torque tube shaft is coupled through connecting linkage within the switch case to move the pointer across the scale plate. An actuating cam, directly connected to the torque tube shaft, rotates with the motion of the shaft. Two cam follower roller/actuator arm assemblies, one for each switch, respond to torque tube rotation by opening and closing the switches as they ride on and off the cam. The levels of differential pressure at which the switches actuate are adjustable with high and low alarm switch adjustments on the scale plate. Mid-point DP BOTH SWITCHES RELAXED 50 0 CAM 100 CLOSED CONTACTS SWITCH OPEN CONTACTS A (LEFT) YELLOW & BLUE RED & YELLOW B (RIGHT) VIOLET & ORANGE VIOLET & BLACK BLACK VIOLET ORANGE SWITCH “B” (RIGHT) HIGH BLUE RED SWITCH PLUNGER SCREW YELLOW SWITCH “A” (LEFT) LOW TERMINAL BLOCK IN CASE Zero DP SWITCH “A” ACTUATED/SWITCH “B” RELAXED 50 0 SWITCH “A” (LEFT) LOW SWITCH “B” (RIGHT) HIGH 100 CLOSED CONTACTS SWITCH OPEN CONTACTS A (LEFT) RED & YELLOW YELLOW & BLUE B (RIGHT) VIOLET & ORANGE VIOLET & BLACK Maximum DP SWITCH “A” RELAXED/SWITCH “B” ACTUATED 50 0 SWITCH “A” (LEFT) LOW SWITCH “B” (RIGHT) HIGH CLOSED CONTACTS OPEN CONTACTS A (LEFT) YELLOW & BLUE RED & YELLOW B (RIGHT) VIOLET & BLACK VIOLET & ORANGE SWITCH Figure 1.2—Switch actuation example 4 100 Model 289A Differential Pressure Indicating Switch Section 1 Standard models can have one or two alarm switches. Each switch can be connected to operate normally-opened or normally-closed. The direct-set switch contacts are adjustable over a scale range of 5-95% nominal for SPDT switches and 6-94% for DPDT switches. The cam rotates counterclockwise with increased pressure. In Figure 1.2, the low switch is set at 25% differential pressure, and the high switch is set at 75% differential pressure. Switches are available in several variations. • • • SPDT: This is the standard model (low, high, or both) DPDT: Two switches are stacked and actuated by a single lever (low, high, or both) Three or four SPDT: Switches have independent switch points. Switches 1 and 3 are usually low switches set for decreasing pressures; switches 2 and 4 are usually high switches set for increasing pressures. Relays Relays are actuated by internal switches and are available in several variations: • • one or two SPDT switches one or two DPDT switches Wiring No. 22 AWG is used for internal wiring and No. 18 AWG is used for external wiring. Differential Pressure Unit (DPU) For detailed information on the DPU, see the Model 199 DPU user manual in Appendix A. Specifications General: Actuating Unit (DPU)���������������������� Model 199 DPU Dial Size����������������������������������������� 6 inches (150 mm) Temperature Limits (Ambient)�������� -40°F (-40°C) to +180°F (+82°C) Switch Repeatability����������������������� ±0.25% of full scale Switch Deadband��������������������������� ±5% (SPDT); ±6% (DPDT) Switch Type������������������������������������ Mechanical, Snap-Acting; all switches are SPDT (DPDT switches are stacked SPDT switches with a common actuator) Relay Contact Type������������������������ Single Pole, Double Throw (SPDT) Double Pole, Double Throw (DPDT) Adjustability������������������������������������ 5% to 95% of factory calibrated scale Activation���������������������������������������� Increasing or decreasing scale 5 Section 1 Model 289A Differential Pressure Indicating Switch Switch Contact Rating: 5.0 Amps @ 125 VAC 5.0 Amps @ 250 VAC, 50/60 Hz1 3.0 Amps @ 30 VDC (resistive)1,2 1.0 Amp @ 30 VDC (inductive with arc suppression)1,2,3 0.4 Amp @ 125 VDC (resistive) 0.2 Amp @ 125 VDC (inductive w/arc suppression) 1. CSA Approved 2. CE Approved (Voltage limited to less than 50 VDC or 35 VAC for CE applications) 3. Arc suppression recommended for inductive loadings Relay Contact Ratings: 10 Amps @ 150/250 VAC 10 Amps @ 14/28 VDC 1.0 HP @ 208/240 VAC Relay Coil Voltages: 120 VAC @ 5VA Max. 110 VDC @ 2W Max. Coil Power Requirement: DC Relay���������������������������������������� 1.5 Watts AC Relay���������������������������������������� 2.75 Volt Amps Accuracy of Indications Standard (1 or 2 SPDT Switches)......................±1% of factory calibrated span (10-349 inches wc) ......................±1.25% of factory calibrated span (350 inches wc to 115 psig) 1 or 2 DPDT Switches (S401)........................... Add ±1/2% to standard accuracy Near switch setpoint (±10% full scale).............. Add ±1/2% to standard accuracy For suppressed ranges..................................... Add ±1/4% to standard accuracy 3 or 4 SPDT Switches....................................... Add ±3/4% to standard accuracy Switch Deadband: SPDT���������������������������������������������� ±5% of full scale DP (max) DPDT���������������������������������������������� ±6% of full scale DP (max) Accuracy of Repeatability��������������� ±0.25% of full scale DP Nuclear Qualifications The following nuclear qualification applications are based on Cameron Engineering Report 9A-CR3-288A-13 with switch chatter sensitivity addressed in Cameron Engineering Report 9A-CR3-288A-19: • One or two SPDT switches: Radiation Augmented (3 MRads), Full Functional, 12G, Mild Environment Applications • One or two DPDT switches: Structural and Pressure Boundary Integrity Applications • One or two relays: Structural and Pressure Boundary Integrity Applications • Three or four independently adjustable SPDT switches: Structural and Pressure Boundary Integrity Applications 6 Model 289A Differential Pressure Indicating Switch Section 2 Section 2—Installation General The instrument should be inspected at time of unpacking to detect any damage that may have occurred during shipment. IMPORTANT: The DPU was checked for accuracy at the factory. Do not change any of the settings during examination or accuracy could be affected. For applications requiring special cleaning/precautions, a polyethylene bag is used to protect the instrument from contamination. This bag should be removed only under conditions of extreme cleanliness. Mounting/Piping/DPU Installation Dimensional drawings are provided in page 35. See the Model 199 DPU user manual in Appendix A for DPU installation and maintenance information. Electrical Connection (Switches/Relays) Units are supplied with either single or dual alarm switches and/or relays (depending on customer order). The direct-set switch contacts are adjustable over 5% to 95% of the scale range for SPDT switches and 6% to 94% of the scale range for DPDT switches. Table 2.1, page 8, shows switch and relay wiring color coding for legacy and current configurations. Figures 2.1 through 2.6 show switch and relay wiring. The high switch and low switch set point adjustment procedures are covered in Changing Switch Set Point, page 23. For physical location of switches, see Figure 1.1, page 3. Switch Use Switch contact life is influenced by various application conditions such as temperature, humidity, airborne contamination, vibration, amount of plunger travel, cycling rate, and rate of plunger travel (and others), as well as by the electrical (circuit) characteristics. IMPORTANT: Arc suppression for inductive loads will prolong the life of the switch contacts. 7 Section 2 Model 289A Differential Pressure Indicating Switch IMPORTANT: Due to their size, subminiature switches have small mechanical clearances; therefore, no rating above 250 VAC has been established. Table 2.1—Switch/Relay Wire Color Coding (4/06c) 289A LEGACY CONFIGURATIONS (prior to Apr. 2006) NO C 289A CURRENT CONFIGURATIONS NC NO C NC SPDT SWITCHES Low Red Yellow Blue Red Yellow Blue High Black Green White Black Violet Orange DPDT SWITCHES Low #1 Red Yellow Blue Red Yellow Blue Low #2 White/Red White/Yellow White/Blue White/Red White/Yellow White/Blue High #1 Black Green White Black Violet Orange High #2 White/Black White/Green White/Violet White/Black White/Violet White/Orange 4-INDEPENDENTLY ADJUSTABLE SWITCHES Low #1 Red Yellow Blue Red Yellow Blue Low #2 White/Red White/Yellow White/Blue White/Red White/Yellow White/Blue High #1 Black Green White Black Violet Orange High #2 White/Black White/Green White/Violet White/Black White/Violet White/Orange SWITCHES FOR RELAYS Low Red Yellow Blue (Note 1) White/Brown Brown White (Note 1) High Black Green White (Note 1) White/Gray Gray White (Note 1) Low #1 Gray Blue Brown Red Yellow Blue Low #2 White/Gray White/Blue White/Brown White/Red White/Yellow White/Blue High #1 Violet White Orange Black Violet Orange High #2 White/Violet White/Black White/Orange White/Black White/Violet White/Orange Coil Legacy Ver.: Low = Red and High = Black RELAYS Wiring: Current Ver.: Low = White/Brown and High = White/ Gray Note 1: Wire is NOT connected. Startup For startup procedures, warnings, and other information, refer to the Model 199 DPU user manual in Appendix A. IMPORTANT: To ensure the unit calibration is within factory-set calibration tolerances, perform the Calibration Check procedure on page 16. 8 Model 289A Differential Pressure Indicating Switch Section 2 Switch and Relay Wiring Diagrams IMPORTANT: Figures 2.1 through 2.6 show: switch & relay contacts in the relaxed (shelf) condition, the low switch set to trip at a position below the pointer scale position, and the high switch set to trip at a position above the pointer scale position. NO = Normally Open in (shelf) condition. NC = Normally Closed in (shelf) condition. C= Common. C NO VIOLET CASE GROUND 10 GREEN 9 BLACK 8 3 BLACK NC ORANGE RED YELLOW CASE GROUND GREEN BLUE YELLOW 2 1 BLUE RED NO C NC ORANGE HIGH SPDT SWITCH VIOLET LOW SPDT SWITCH LOW & HIGH SPDT SWITCHES 7 BLACK VIOLET 8 9 10 CASE GROUND 6 GREEN 5 VIOLET 4 BLACK ORANGE C NO ORANGE 3 BLUE RED 2 YELLOW 1 NC BLUE YELLOW RED NO C NC Figure 2.1—Low/high SPDT switch diagrams (current configuration color codes - see Table 2.1, page 8) 9 10 RED WHITE/ORANGE LOW & HIGH DPDT SWITCHES 10 11 12 Figure 2.2—Low/high DPDT switch diagrams (current configuration color codes - see Table 2.1, page 8) CASE GROUND GREEN 9 BLACK VIOLET 8 WHITE/BLACK WHITE/VIOLET 7 ORANGE 6 WHITE/BLACK WHITE/VIOLET WHITE/ORANGE 5 CASE GROUND 9 NC C NO BLACK WHITE/BLACK WHITE/VIOLET WHITE/ORANGE BLACK VIOLET ORANGE BLUE YELLOW RED LOW DPDT SWITCH HIGH DPDT SWITCH NO C NC NC C NO NO C NC GREEN 8 C NO VIOLET CASE GROUND GREEN WHITE/BLUE 6 BLACK ORANGE NC VIOLET BLUE NO C NC ORANGE 7 WHITE/BLACK 6 WHITE/VIOLET 5 WHITE/ORANGE 4 WHITE/BLUE 3 WHITE/YELLOW 2 WHITE/RED 1 BLUE WHITE/YELLOW 5 YELLOW NO C NC 4 RED 3 WHITE/RED BLUE 2 YELLOW WHITE/BLUE RED YELLOW 1 WHITE/YELLOW WHITE/RED WHITE/BLUE WHITE/YELLOW WHITE/RED Section 2 Model 289A Differential Pressure Indicating Switch NC C NO 10 RED NC 6 8 9 CASE GROUND GREEN BLACK VIOLET NC BLACK ORANGE 7 VIOLET NO C NC ORANGE WHITE/BLUE WHITE/YELLOW 5 WHITE/BLACK BLUE WHITE/RED YELLOW RED 4 WHITE/VIOLET WHITE/ORANGE RED 3 BLUE WHITE/BLUE WHITE/YELLOW WHITE/RED 2 YELLOW 10 1 CASE GROUND GREEN BLACK WHITE/ORANGE WHITE/BLACK WHITE/VIOLET BLACK NO C NC BLACK 9 C NO VIOLET ORANGE 3-SWITCHES SPDT LOW & DPDT HIGH VIOLET 8 NC ORANGE BLUE YELLOW NO C NC ORANGE 7 WHITE/BLACK 6 WHITE/VIOLET 5 WHITE/ORANGE 4 WHITE/BLUE 3 WHITE/YELLOW 2 WHITE/RED 1 BLUE RED NC C NO VIOLET NC C NO YELLOW NO C NC CASE GROUND 9 GREEN 8 WHITE/BLUE ORANGE 7 BLACK 6 VIOLET 5 WHITE/BLACK 4 WHITE/VIOLET 3 WHITE/ORANGE BLUE YELLOW RED NO C NC WHITE/YELLOW WHITE/RED RED 2 BLUE 1 YELLOW Model 289A Differential Pressure Indicating Switch Section 2 3-SWITCHES DPDT LOW & SPDT HIGH C NO 10 Figure 2.3—3-switch diagram (current configuration color codes - see Table 2.1, page 8) 4-SWITCHES INDEPENDENTLY ADJUSTABLE C NO 10 11 12 Figure 2.4—4-switch diagram (3 or 4 independently adjustable switches) (current configuration color codes - see Table 2.1, page 8) 11 Section 2 Model 289A Differential Pressure Indicating Switch LOW SWITCH WITH SPDT RELAY WHITE/GRAY GRAY WHITE WHITE WHITE/BROWN BROWN NO BLUE ORANGE NC YELLOW VIOLET C RED BLACK NO WHITE/BROWN WHITE/GRAY WHITE/BROWN WHITE/GRAY CASE GROUND 10 GREEN 9 BLACK GRAY 8 VIOLET 7 6 ORANGE 5 WHITE/GRAY 4 CASE GROUND RED YELLOW 3 GREEN 2 1 BROWN NO NC C WHITE/BROWN C BLUE NC HIGH SWITCH WITH SPDT RELAY NO C NC WHITE/GRAY GRAY WHITE NO ORANGE NC YELLOW VIOLET C RED BLACK NO WHITE/BROWN WHITE/GRAY WHITE/BROWN WHITE/GRAY 9 10 CASE GROUND 8 GREEN 7 BLACK 6 VIOLET 5 GRAY 4 ORANGE 3 WHITE/GRAY 2 BROWN RED 1 WHITE/BROWN NO NC C BLUE BLUE C YELLOW NC BROWN WIRE NUT (TYPICAL) WHITE/BROWN NO C NC WHITE LOW & HIGH SWITCHES WITH SPDT RELAYS Figure 2.5—Low/high switch(es) w/SPDT relay(s) diagrams (current configuration color codes - see Table 2.1, page 8) 12 Model 289A Differential Pressure Indicating Switch Section 2 LOW SWITCH WITH DPDT RELAY HIGH SWITCH WITH DPDT RELAY WHITE/RED WHITE/BLACK NC C NO NO C NC WHITE/GRAY WHITE BROWN C GRAY WHITE/ORANGE NC WHITE WHITE/VIOLET WHITE/BLUE WHITE/BROWN WHITE/YELLOW NC C NO NO NC YELLOW VIOLET C RED BLACK NO WHITE/BROWN WHITE/GRAY WHITE/BROWN WHITE/GRAY CASE GROUND GREEN 10 BLACK 9 VIOLET GRAY WHITE/GRAY 8 ORANGE 7 6 5 CASE GROUND 4 GREEN 3 BROWN 2 WHITE/BROWN 1 RED LOW & HIGH SWITCHES WITH DPDT RELAYS NO C NC WHITE/ORANGE WHITE/GRAY WHITE C WHITE NC WHITE/VIOLET WIRE NUT (TYPICAL) BROWN WHITE/BLUE WHITE/BLACK NC C NO WHITE/YELLOW GRAY WHITE/RED WHITE/BROWN NC C NO NO ORANGE NC YELLOW VIOLET C RED BLACK NO WHITE/BROWN WHITE/GRAY WHITE/BROWN WHITE/GRAY 10 CASE GROUND 9 GREEN 8 BLACK 7 6 VIOLET 5 ORANGE 4 GRAY 3 WHITE/GRAY 2 BROWN 1 WHITE/BROWN NO BLUE BLUE C YELLOW NC RED NO ORANGE BLUE C BLUE YELLOW NC Figure 2.6—Low/high switch(es) w/DPDT relay(s) diagrams (current configuration color codes - see Table 2.1, page 8) 13 Section 2 14 Model 289A Differential Pressure Indicating Switch Model 289A Differential Pressure Indicating Switch Section 3 Section 3—Maintenance and Calibration The following checks are recommended for preventive maintenance: • • • Periodically inspect alarm switch mechanism to verify that all mounting screws are seated properly. Inspect linkage for wear. Inspect integrity of electrical circuits. Tighten as necessary. When repairs are necesssary, review this section for maintenance procedures such as bezel/lens installation and removal, pointer installation and removal, indicator calibration, switch calibration, and switch set point changes. IMPORTANT: DPU maintenance is not addressed in this manual. See the Model 199 DPU user manual in Appendix A for related warning/caution notices and instructions on DPU inspection, cleaning, service, repair, range change, and BUA replacement. Never perform maintenance/repair on the instrument or DPU without first reviewing all procedures and warning/ caution notices in the DPU manual. Tools The following tools are recommended for general maintenance of the Model 289A DP indicating switch. Table 3.1—Tools Equipment Purpose Pointer Puller Pointer removal Small Screwdriver Calibration adjustment Medium Screwdriver Bezel removal and replacement 1/4" and 1/8" Open-end Wrenches Zero (1/4") and Range (1/8") adjustments 1/8 Hex Allen Wrench Switch set point adjustment Bezel/Lens (or Cover) Installation and Removal To remove the bezel and lens (or cover), perform the following steps, using Figure 3.1 for reference. 1. Loosen the three screws on the front of bezel. 2. Tilt the bottom of the bezel and slide the bezel upward. To reinstall the bezel and lens, assemble the components per Figure 3.1, page 16. The two snubbers (Part No. 9A-C0266-0028C) on the scale plate should not be compressed against the lens cover and the pointer should not touch the lens. 15 Section 3 Model 289A Differential Pressure Indicating Switch Bezel (9A-C0277-0029C) Cover (Lens) (9A-C0181-0038C) Gasket (9A-C0277-0026C) Case Figure 3.1—Bezel and lens cover IMPORTANT: Ensure the bezel gasket is properly oriented before placing the instrument back in service. Incorrect gasket orientation will cause the instrument indicator to jam, resulting in inaccurate readings. Calibration Check To ensure the unit calibration is within factory-set calibration tolerances, perform the following procedure. IMPORTANT: Review all procedures, WARNINGS/NOTICES in the Model 199 DPU user manual (Appendix A) BEFORE performing this procedure. Pointer "slipped" rotated on hub HUB Hub held in place with 1/4" wrench Figure 3.2—"Slipping" pointer 1. Mount the instrument in an approximately level position and connect to a standard pressure source (see the Model 199 DPU user manual in Appendix A). 2. If the zero indication is incorrect, adjust it as follows: a. Remove the bezel/lens assembly. b. Using a 1/4" open-end wrench (included in calibration toolkit, Part No. 9A-0288-1032B), hold the hexagon pointer hub fixed and rotate the pointer with fingers until the pointer indicates zero on the scale. See Figure 3.2. c. Replace the bezel/lens assembly. 16 Model 289A Differential Pressure Indicating Switch Section 3 3. To test for reverse travel, connect the pressure source to the LP housing and vent the HP housing. Apply pressures approximately 150% of the DP range. The pointer should move approximately 5% to 10% below zero. 4. To test for overtravel, connect the pressure source to the HP housing and vent the LP housing. Apply pressures approximately 150% of DP range. The pointer should move approximately 5% to 10% above full scale. 5. Apply 0, 50, and 100% of full scale pressure. If indication is within specified limits, no adjustments are necessary. If indication is not within specified limits, perform a complete calibration (see Indicator Calibration, page 18). 6. Make sure the instrument zero indication is correct; otherwise, repeat step 2. 7. Verify the switch set points (refer to Changing Switch Set Point, page 23). Pointer Installation and Removal During adjustment and calibration of the unit, it may be necessary to remove and reinstall the pointer according to the following procedures. Pointer Installation 1. Position the pointer on the movement shaft with the pointer set at zero scale. Obtain 75% to 90% pointer hub engagement on the movement pinion shaft. The pinion shaft must not extend through the pointer hub. It may be necessary to enlarge the hub hole, using a tapered broach (included in the calibration toolkit, Part No. 9A-0288-1032B). 2. Lightly tap the pointer hub with a hand-set or other flat-end tool. Use perpendicular blows to avoid bending the shaft. 3. Check the calibration of the indicating switch over its entire range (refer to Indicator Calibration, page 18). If the indicating switch is correctly calibrated, secure the pointer to the movement shaft by tapping the hub with a hand-set or other flat-end tool. 4. Test the pointer for tightness by moving the pointer from the zero to the 50% position manually, and then letting the pointer return freely to zero. If the pointer indicates a shift, tap the pointer hub to tighten it to the shaft. Pointer Removal The pointer is removed with a pointer puller shown in Figure 3.3, page 18. This tool is included in the calibration toolkit, Part No. 9A-0288-1032B. To remove the pointer, perform the following steps: 1. Slide the pointer puller along the pointer until the pin protruding from the tip of the screw in the pointer puller is directly over the movement shaft and the arms of the pointer puller are directly under the pointer. 17 Section 3 Model 289A Differential Pressure Indicating Switch 2. Gently turn the knurled head of the screw clockwise, pushing the pin against the movement shaft and lifting the pointer with the arms. Finger pressure should be sufficient to pull the pointer free. If more pressure is required, an Allen wrench (inserted into head of the screw) can be used. However, care should be exercised to avoid breaking the pin. POINTER PULLER HUB POINTER HUB MOVEMENT SHAFT Figure 3.3—Pointer puller (Part No. 9A-0163-0005B) Indicator Calibration A complete calibration of instrument is required whenever the DPU assembly is replaced. IMPORTANT: Review all procedures, WARNINGS/NOTICES in the Model 199 DPU user manual (Appendix A) BEFORE performing this procedure. 1. Securely mount the instrument in an approximately level position and connect the DPU (see the Model 199 DPU user manual in Appendix A). 2. Remove the bezel/lens assembly. 3. Align the linkage between the drive arm and the movement at 50% differential pressure (DP) as shown in Figure 3.4. Inspect parts for straightness and pivot-fit without binding. Figure 3.4—Range/linearity adjustment (50% DP) 18 Model 289A Differential Pressure Indicating Switch Section 3 4. Check the pointer for zero indication. If necessary, set the pointer to zero by slipping the pointer on the hub, per Calibration Check, step 2, page 16. 5. Apply 100% pressure. If the pointer exceeds full-scale, lengthen the movement range arm by adjusting the range adjust screw with a 1/8-in. open-end wrench. 6. Release pressure. Set the pointer to zero, by slipping the pointer on the hub, per Calibration Check, step 2, page 16. 7. Repeat steps 4 and 5, as necessary, to obtain the correct zero/full-scale. 8. Apply 50% DP. If the pointer indicates 50%, proceed to step 9. If the pointer does not indicate 50% scale, adjust linearity as follows. a. Loosen the drive arm screw (Figure 3.5) and move the arm to shift the pointer in the direction of the error a distance of about 10 times the linearity error. b. Check to see that the drive arm clears the end of torque-tube housing by approximately 0.030 in. before retightening the drive arm screw to prevent interference. c. While supporting the block/shaft, tighten clamp screw until snug to shaft. d. Still supporting block/shaft, tighten clamp screw an additional 1/3 to 1/2 turn. (This screw can normally turn one full revolution before breaking.) e. Perform the Drive Arm Tightness Test described on page 20. SINTERED CLAMP BLOCK LINK .03 (approx) DRIVE ARM M199 SHAFT CLAMP SCREW 1/8” WRENCH (PN 9A-0163-0044C) TO TIGHTEN Figure 3.5—Drive arm to torque tube connection 9. Release pressure and reset the pointer at zero. Check the span. If the gear in the movement reaches a limit of travel as a result of linearity adjustment (step 7), slip the range arm along the gear approximately 5 degrees from the normal 37.5 degree angle to approximately 43 degrees (see step 2). The range arm is slipped by applying pressure to the range arm with 19 Section 3 Model 289A Differential Pressure Indicating Switch thumb, while holding the gear firmly in place. Retest the pointer response at 50%, 0%, and 100% of full-scale differential pressure, and adjust the linkage until the readings are acceptable. 10. Apply 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25%, and 0% of full-scale differential pressure consecutively to the instrument without overshoot. Lightly tap the indicator to overcome friction. The pointer should accurately indicate each applied pressure. 11. Test the instrument repeatability by applying 0%, 50%, 0%, 50% of fullscale differential pressure. The indicator should accurately indicate each applied pressure. 12. Set the drive arm stop to prevent the pointer from striking the snubbers on the scale. (See Drive Arm Stop Adjustment, page 21.) 13. Test the pointer for tightness per the pointer installation instructions on page 17. 14. If the drive arm screw has been loosened, verify that it is adequately tight by performing the Drive Arm Tightness Test described below. 15. Reassemble the unit per the cover installation instructions on page 15. Drive Arm Tightness Test This procedure tests the tightness of the drive arm's connection to the torque tube by applying torque developed by the DPU onto a fixed drive arm. Care should be taken to apply pressure slowly, as torque is being applied to the connection through the torque tube drive shaft. 1. With the pointer at normal 0% torque tube rotation position (0% on a normal 0 to 100% scale unit), adjust the drive arm stop bracket (or use alternate means) to prevent the pointer from moving (stop bracket interferes with drive arm movement). IMPORTANT: On reverse acting/split range units, it will be necessary to pressurize the DPU to move the pointer to maximum minimum scale position, and on suppressed units, it will be necessary to apply pressure to establish a reference point to check for "zero" shift. 2. Pressurize the DPU to full calibrated scale DP (100% of full scale range) to achieve 8 degrees of torque tube equivalent torque onto the connection. 3. Observe the shift in the unit "zero" following DPU depressurization (as required) and drive arm stop bracket readjusting (to allow free movement of drive arm and pointer). A downscale (counter-clockwise) shift in "zero" of greater than 1/2% is indicative of drive arm slippage, necessitating further clamp block tightening. 20 Model 289A Differential Pressure Indicating Switch Section 3 Drive Arm Stop Adjustment 1. Apply sufficient pressure to the high-pressure housing to deflect the pointer against the full range stop snubber on the scale plate. 2. Slide the upper drive arm stop bracket against the drive arm and tighten the drive arm stop bracket screw. 3. Apply sufficient pressure to the low pressure housing to deflect the pointer against the zero stop snubber on the scale plate. 4. Bend the zero drive arm stop against the drive arm. 5. Verify calibration as applicable. Switch Calibration Before performing a complete calibration procedure, verify that the instrument is out of calibration, by performing a calibration check procedure (page 16). If the instrument is out of calibration, before performing a complete calibration procedure, remove the bezel/lens and scale plate and inspect the switch mechanism (Figure 3.6) to verify the following: • • • • • The roller rotates without wobble or binding. The cam does not touch the roller side shields. The actuator arm moves freely on its pivot. All switch mounting screws are tight. Linkages are straight and do not bind at the pivots. Correct any problems that are observed. Switch CAM Roller Actuator Arm Plunger Screw Stop Screw CAM Figure 3.6—Switch mechanism Calibration Setup 1. Connect the lamp or buzzer to the switch output leads. 2. Connect a test voltage to the switch input terminals on the terminal strip. (A low voltage is recommended for safety.) If a relay is installed in the instrument, coil voltage must be applied to the switch. 3. Unlock the switch plate and move the plate until the roller is positioned at the top of the cam. 4. Advance the plunger screw until the switch actuates, then advance the plunger screw an additional 60° (one flat). 21 Section 3 Model 289A Differential Pressure Indicating Switch 5. Exercise the switch roller across the top of the cam to verify steady operation. Advance the stop screw to touch the switch, then back out the screw 1.5 turns (9 flats). Calibration Procedure To calibrate the switch linkage (required when the unit is rebuilt), perform the following steps. Refer to Figure 3.7 as needed. 1. Loosen the three linkage screws and turn the crank to the 12 o’clock position. 2. Use a 1/8-inch Allen wrench to hold the index shaft and slip the index pointer to 0 on the switch index. Tighten the screw on the crank to the mid-slot position. 3. Turn the switch index pointer to “1” (index numbers refer to numbers on outer edge of scale plate). 4. Apply 10% differential pressure and adjust the switch plate until the switch actuates. Lock the two linkage screws. 5. Rotate the index pointer to “9.” Apply 90% differential pressure and adjust the crank radius until the switch actuates. 6. Recheck 10% and 90% set points. Adjust the crank radius and the index pointer until both set points are 2% accurate (nominal). Figure 3.7—Linkage arrangement 7. If the switch is to be field-set at low differential pressure values (1% or 2% of pressure range), check the crank to prevent a top-dead-center position. Otherwise, the minimum set point position will be restricted and the set point may become reversed. 22 Model 289A Differential Pressure Indicating Switch Section 3 8. Adjust the switch to actuate at the desired pressure by applying test pressures in a decreasing direction, in discrete steps. Allow the unit and the pressure system to stabilize. Then change the pressure by a small amount. The magnitude of the pressure change is determined by the desired accuracy of the test. Tighten the lock screw before testing the switch performance. IMPORTANT: The high switch is usually set to actuate at increasing pressure — when calibrating the high switch, apply test pressure in an increasing direction. This amount of loading will prevent cam-runout of a similar condition. IMPORTANT: Excessive plunger loading (more than 3 flats) may cause the roller to drag on the cam. Cam friction will be apparent by excessive hysteresis, erratic pointer readings and inconsistent switch operation. 9. Check the switch deadband, (actuate to reset) by applying differential pressure, first in a decreasing direction, then in an increasing direction (opposite for high switch direction). Observe pressures. To reduce deadband, advance the plunger screw (two flats maximum). 10. Adjust the high switch to actuate at the desired pressure. The procedure is the same as for the low switch. Changing Switch Set Point (Tools: Screwdriver, 1/8-in. hex Allen wrench) Definitions of Terms Set Point. The measured pressure at which the snap-switch actuates and thereby changes the states of the N.O and N.C. contacts. For example, the set point of the low switch is 24 psid with decreasing pressure. Deadband. The difference in measured pressures between switch-actuation and switch-reset. Deadband is usually expressed as percent of full scale (% of F.S.). Deadband is not adjustable. For example, the switch in the set point example above was found to reset at 26.4 psid with increasing pressure. The deadband was 2.4 psi, or 4% of the full scale for a unit calibrated 0 to 60 psid. Best Practices for Set Points 1. Always check the set point after tightening switch lock screws. 2. Switch setpoints may be set at any point of the scale range, except in a location that will prevent the deadband from enabling the switch to reset itself. For example, the high switch (right side of scale) may be set at full scale, but should not be set near zero. The low switch may be set at zero, but should not be set near full scale. (Observe deadband values for specific models). 23 Section 3 Model 289A Differential Pressure Indicating Switch 3. If switch performance is unsatisfactory (set point does not repeat, deadband is excessive, pointer exhibits hysteresis, contacts are unstable, etc.), remove the scale and inspect the switch and the switch mechanism. The scale is split to allow for removal without pulling the pointer. Changing Set Point of an In-Service Instrument (Not Recommended for Nuclear Qualified Units) Use the following procedure to set a set point for an instrument that is in service, when calibration pressures cannot be applied. See Figure 3.8 for specific locations denoted by items A, B, C and D. 1. 2. 3. 4. Remove the bezel/cover. Do not remove the pointer or scale. Insert hex wrench in the switch adjust post. Loosen the switch lock-screw, (item B), 1/2 to 1 turn. With a hex wrench, move the index pointer (item C) to the new set point as indicated on the switch index (item D). 5. If possible, check the set point by varying the process pressures and observing the pointer readings when the switch actuates. (Open the manifold bypass valve slowly and watch for “pointer-jump” at the set point or by electrical signal.) Adjust the setting, if necessary, and repeat the test several times to verify stability. Figure 3.8—Set point adjustment 24 Model 289A Differential Pressure Indicating Switch Section 3 IMPORTANT: The switch index has 10 divisions, marked 0, 5, and 10. These match the markings on the outer edge of the scale. Example: Scale has range of 0-60 psid. Set point is 24 psid, with decreasing pressure, (24/60 x 10 = 4). 1. Move the index pointer (item C) for the low switch from division 0 to division 4. 2. Tighten switch lock (Item B) snug plus 1/4 turn to place the set point within ±2% of full scale. Do not overtighten. 3. Repeat step 1 for the high switch, moving the index pointer from division 10 to division 4, and tighten the switch lock as described in step 2. Changing Set Point of an Out-of-Service Instrument Use the following procedure to set a set point for an instrument that is out of service—typically, an instrument that is disconnected from process lines or mounted on a bench. 1. Drain and vent housings. 2. Attach the calibration pressure source (air or N2) to the DPU HP housing. 3. Apply varying pressures and observe pointer readings for accuracy. Use a pressure standard (Heise gage or equiv.) for reference. Change pressures slowly in discrete steps. A “bleed-pressure” method may cause errors. 4. Change switch set point as described in In-Service Instruments, page 24. 5. Check the set point by changing measured pressure to actuate the switch. For example: To verify a low-switch set point of 24 psid, apply approximately 30 psi. Reduce pressure to approximately 25 psid, hold for a few seconds, then continue in 1/4 psid steps until the switch actuates. If the set point is incorrect, continue instructions in In-Service Instruments, page 24. 6. To measure the switch deadband, reduce the pressure to zero, then increase pressure until the switch resets. 7. To verify repeatability of a set point, repeat step 5 several times. For improved accuracy, use smaller increments of pressure. Allow extra time for slow response gages and for test systems that have long runs of smallbore tubing. High alarm switches (right side of the scale) are adjusted in a similar manner. Apply increasing pressure to establish the switch set point, and apply decreasing pressure to measure the deadband. Range Changes Changing the range of a Model 289A differential pressure indicating switch typically requires replacment of the 199 DPU. 25 Section 3 Model 289A Differential Pressure Indicating Switch Troubleshooting For troubleshooting tips, see Table 3.2 below. For information related to the DPU, see the Model 199 DPU user manual in Appendix A. Table 3.2—Troubleshooting Problem Possible Source Low or No Indication Primary Element or DPU (Refer to DPU Manual) Primary Element to DPU Piping (Refer to DPU Manual) Bellows Unit (Refer to DPU Manual) Probable Cause Orifice installed backwards or oversized Replace orifice Flow blocked upstream from run Clean out run or open valve Loss of liquid in reference leg (liquid level) Refill reference leg Density changes in process media or reference leg Refill reference leg with same density liquid as process media Pressure tap holes plugged and/or piping plugged Clean out piping Bypass valve open or leaking Close bypass valve(s) and/or repair leaks Liquids or gases trapped in piping Vent piping Block or shutoff valves closed Open block or shutoff valves Piping leaks on HP side Repair leaks Housing filled with solids restricting bellows movement Clean out housing Gas (liquid service) or liquid (gas service) trapped in housing Vent housing HP housing gasket leak Replace gasket DPU tampered with Return BUA for repair IndicaLoose linkage or movement tor, Alarm Out of calibration Switch Mechanism Pointer loose 26 Corrective Action Tighten or replace Calibrate Tighten pointer Dirty or corroded mechanism Clean or replace Wiring interfering with movement Re-route wiring Dirty mechanism Clean mechanism Model 289A Differential Pressure Indicating Switch Section 3 Table 3.2—Troubleshooting Problem High Indication Erratic Indication Possible Source Corrective Action Primary Source Orifice partially restricted or too small Clean out or replace Primary Element to DPU piping Piping leaks on LP side Repair leaks Bellows Unit (Refer to DPU Manual) Gas (liquid service) or liquid (gas service) trapped in housing Vent housing LP housing gasket leak Replace gasket Range spring broken or DPU tampered with Return BUA for repair Loose linkage or movement Indicator, AlarmOut of calibration Switch Mechanism Tighten or replace Primary Element Flow pulsating Install dampening device upstream of DPU run Primary Element to DPU piping Liquid (gas service) or gas bubble (liquid service) trapped in piping Remove Vapor generator incorrectly installed Re-pipe Reference leg gassy or liquid vaporizing See piping instructions in DPU Manual Obstructed bellows travel Clean bellows Gas trapped in DPU HP or LP housing Remove (see startup procedure) Linkage dragging or dirty Adjust or clean Pointer dragging on scale plate Adjust pointer position Power Supply Blown fuse Replace fuse Broken or loose wire Repair Alarm Switch Switch not properly adjusted Adjust switch Dirty or burned Replace switch contacts Bellows Unit (Refer to DPU Manual) Inaccurate or No Electrical Alarm Probable Cause Calibrate 27 Section 3 Model 289A Differential Pressure Indicating Switch Table 3.2—Troubleshooting Problem Switch Drifts (set point not repeatable) Possible Source Process Changes Calibration Techniques 28 Probable Cause Corrective Action Transients or surges cause switches to actuate prematurely Add time delay gages or add time circuit Set point and/or deadband are too wide in pressure valves Specify DP range as low as practical; set point repeatability and deadband are percentage of full range Electrical overloads affect the spring properties of the leaf actuator in the switch Examine circuits for voltage, amperes DC inductive loads cause arcing and burning of contacts Consider arc-suppression devices or relays Accumulation of fluids in piping generate artificial signal Vent gas or drain liquids from signal lines Failure to check set point after locking Verify set point repeatability after locking switch plate Rapid pressure change or venting system During calibration, make pressure changes in slow, discrete steps Pressure application in reverse Test low-alarm with decreasing pressure and high-alarm with increasing pressure Reference gage inaccuracy Suitable pressure standard such as manometer, dead-weight tester, or Heisetype gage may be required Damage to switch contacts Adjust plunger screws carefully to avoid damage to internal parts of switch Model 289A Differential Pressure Indicating Switch Section 4 Section 4—Assembly Drawing and Parts Lists Figure 4.1—Model 289A 29 Section 4 Model 289A Differential Pressure Indicating Switch Table 4.1—Parts List, Model 289A Indicating Switch Item Description 1 Differential Pressure Unit (not shown) 2 Case Assembly 3 Part No. See Model 199 DPU User Manual in Appendix A Per Unit 1 1 1/2 NPT Conduit, 1 & 2 Switches 9A-C0289-0003B 3/4 NPT Conduit, 1 & 2 Switches 9A-CS666-0051Z 1/2 NPT Conduit, 3 & 4 Switches 9A-CS469-0017Z 3/4 NPT Conduit, 3 & 4 Switches 9A-CS469-0078B Drive Arm Assembly 1 Drive Arm Assembly, 1 & 2 Switches 9A-C0288-0037B Drive Arm Assembly, 3 & 4 Switches 9A-CS469-0030Z 4 Link Assembly 9A-C0288-0036B 1 5 Movement Assembly 9A-C0288-0035B 1 6 Movement Riser 9A-C0277-0035C 2 7 Snubber 9A-C0226-0028C 2 8 Stop Bracket 9A-C0288-0028C 1 9 Bracket, Terminal Block 1 10-Position (Standard) 9A-C0288-0029C 10-Position (For 14 AWG Terminal Blocks) 9A-C0288-1161C 12-Position 9A-CS469-0060Z 10 Screw, Rd Hd, 6-32 x 3/8, BRS, NP 9A-C0111-0015J 2 11 Screw, Sl Fil., Hd., 4-40 X 3/16, SST 9A-C0114-0023J 4 12 Screw, Bd Hd, 4-40 x 3/16, SST 9A-C0117-0012J 1 13 Screw, Bd Hd, 6-32 x 3/16, SST 9A-C0117-0013J 4 14 Terminal Block 15 1 10-Position (Standard) 9A-C0038-0033T 10-Position, 14 AWG 9A-C0288-1160C 12-Position 9A-CS469-0061Z Strip, Insulator 1 10-Position (Standard) 9A-C0038-1345T 10-Position (For 14 AWG Terminal Blocks) 9A-C0038-1379T 12-Position 9A-C0038-1351T 16 Screw, Bezel 9A-C0181-0007C 3 17 Screw, Flat, Skt Cap, 10-32 x 1/2, SST (Riser/DPU) 9A-C0240-0019J 2 30 Model 289A Differential Pressure Indicating Switch Section 4 Table 4.1—Parts List, Model 289A Indicating Switch Item Description Part No. Per Unit 18 Screw, Flat, Skt Cap, 1/4-20 x 5/8, SST (Case to DPU bracket) 9A-C0240-0009J 4 19 Gasket, Torque Tube 9A-C0199-0209C 1 20 Stud, Drive-Lok, Retaining, Bezel 9A-C0004-0005K 1 21 Screw, Relay Mtg. Hole Filler (if relay is not installed, 2 per relay, not shown) 9A-C0111-0007J A/R 22 Ground Wire Assembly, External Wire See Table 4.2, page 33 A/R 23 Ground Screw, Hex HD, 8-32 x 5/16, Grn 9A-C0117-1012J 1 24 Washer, Lock, Internal Tooth, #8, SST 9A-C0003-0066K 1 25 Washer, Lock, ET, #8, SST 9A-C0003-0050K 1 26 Switch and Plate Assembly: (Tefzel Insulation-Radiation Resistant) see also item 29 A/R Low, SPDT 9A-CS666-0135Z-N Low, DPDT 9A-CS401-0110Z Low Relay 9A-CS666-0189Z Low #1, Independently Adjustable* 9A-CS666-0135Z-N Low #2, Independently Adjustable* (not shown) 9A-CS666-0136Z-N *Note: If 3 or 4 independently adjustable switches are used, Low #1 is installed in the upper left position, and Low #2 is installed in the lower right position. 27 External Wire Assembly, Low See Table 4.2, page 33 A/R 28 External Wire Assembly, High See Table 4.2, page 33 A/R 29 Switch and Plate Assembly: (Tefzel Insulation-Radiation Resistant) see also item 26 A/R High, SPDT 9A-CS666-0137Z-N High DPDT 9A-CS401-0113Z High Relay 9A-CS666-0196Z High #1, Independently Adjustable* 9A-CS666-0137Z-N High #2, Independently Adjustable* (not shown) 9A-CS666-0138Z-N *Note: If 3 or 4 independently adjustable switches are used, High #1 is installed in the upper right position, and High #2 is installed in the lower left position. 30 Low Alarm, Drive Plate Assembly 9A-C0288-0026B A/R 31 Section 4 Model 289A Differential Pressure Indicating Switch Table 4.1—Parts List, Model 289A Indicating Switch Item Description Part No. Per Unit 31 Low Switch, Switch Adjustment Index Assy 9A-C0288-0028B A/R 32 High Alarm, Drive Plate Assembly 9A-C0288-0027B A/R 33 High Switch, Switch Adjustment Index Assy 9A-C0288-0029B A/R 34 Washer, Spring (1 per switch) 9A-C0257-0019C A/R 35 Screw, Lock (1 per switch) A/R Switch #1 and #2 9A-C0317-0012C Switch #3 and #4 (not shown) 9A-CS469-0045Z 36 Washer, 1/2 OD x 0.14 ID, SST (1 per switch) 9A-C0317-0019C A/R 37 Grip Ring (1 per switch) 9A-C0087-0011T A/R 38 Link Plate (2 required when both low and high switches are used) 9A-C0288-0016C A/R 39 Strap 9A-C0288-0017C A/R 40 Screw, 3-48 x 3/16, SST, Binding Hd. (3 per switch) 9A-C0117-0007J A/R 41 Screw, 8-32 x 1/4, SST, Binding Hd. (1 per switch) 9A-C0117-0016J 1 42 Retaining Ring (1 per switch) 9A-C0087-0015T A/R 43 Washer, Flat, #3, SST (5 per switch) 9A-C0003-0045K A/R 44 Bezel Assembly (Bezel, Lens Cover, and Gasket) 9A-C0277-0018B 1 Bezel (part of 9A-C0277-0018B) 9A-C0277-0029C Lens Cover (part of 9A-C0277-0018B) 9A-C0181-0038C Gasket (part of 9A-C0277-0018B)* 9A-C0277-0026C 45 Disc, Sealer, 1/2" (w/3M 468 Adhesive) 9A-C0192-1035T 1 46 Washer, Split Lock, #8, SST (1 per switch) 9A-C0003-0036K A/R 47 Sealing Compound, RTV 103 9A-C0006-1001V A/R 48** Scale Plate 49* 50 32 1 White, 1 & 2 Switches 9A-C0288-1014C Black, 1 & 2 Switches 9A-C0288-0031C White, 3 & 4 Switches 9A-CS469-0025Z Black, 3 & 4 Switches 9A-CS469-0068Z Pointer Assembly 1 White 9A-C0288-0030B Black 9A-C0288-0031B Tape Seal Patches 9A-CIT10-1045G 10 Model 289A Differential Pressure Indicating Switch Section 4 Table 4.1—Parts List, Model 289A Indicating Switch Item Description Part No. Low Relay Assy (not shown) (with Tefzel insulated wires) Coil Voltage Wired SPDT 115 VAC 9A-CS666-0238Z 110 VDC 9A-CS666-0231Z High Relay Assy (not shown) (with Tefzel insulated wires) Coil Voltage Wired SPDT 115 VAC 9A-CS666-0237Z 110 VDC 9A-CS666-0230Z * Per Unit 1 Wired DPDT 9A-CS666-0245B 9A-CS666-0256B 1 Wired DPDT 9A-CS666-0246B 9A-CS666-0279B Spacer, Switch Plate (used w/ single high switch or 3 independently adjustable switches when #3 position is not used, not shown) 9A-C0258-0007C 1 Screw, Switch Lock Hole Filler (if switch is not installed, 1 per switch, not shown) 9A-C0111-0028J A/R Screw, Strap Hole Filler (if switch is not installed, 1 per switch, not shown) 9A-C0119-0042J A/R Calibration Kit (not shown) 9A-0288-1032B A/R * Recommended spare part ** If the scale plate is not identified with an SCR number, provide the following information: Square root or linear graduations, Scale (e.g., 0-100, 25-0-100, etc.) Number of graduations (linear scales only) Data (e.g., PSI, bar, inches of water column, meter, etc.) Additional Notes: 1.A/R indicates as required. 2.When ordering parts, specify serial number of instrument. 3. For 199 DPU parts, refer to the Model 199 DPU user manual in Appendix A. Table 4.2—Tefzel Insulation (Radiation Resistant) External Wire Leads (Table 4.1, Items 27 and 28) Wire Type Low #1 2.5 ft 10 ft 15 ft 20 ft 9A-CS666-0213Z 9A-CS666-0190Z 9A-CS666-0194Z 9A-CS666-0201Z High #1 9A-CS666-0140Z 9A-CS666-0191Z 9A-CS666-0195Z 9A-CS666-0202Z Low #2 9A-CS666-0166Z 9A-CS666-0241Z 9A-CS666-0268B 9A-CS666-0203Z High #2 9A-CS666-0167Z 9A-CS666-0242Z 9A-CS666-0269B 9A-CS666-0204Z Low Relay 9A-CS594-0137Z — — — High Relay 9A-CS594-0138Z — — — Ground 9A-CS666-0270B 9A-CS666-0271B 9A-CS666-0272B 9A-CS666-0273B 33 Section 4 34 Model 289A Differential Pressure Indicating Switch Model 289A Differential Pressure Indicating Switch Section 5 Section 5—Installation/Dimensional Drawings IMPORTANT: For DPU dimensional information, refer to the Model 199 DPU user manual in Appendix A. Figure 5.1—Model 289A, front view Table 5.1—Model 289A Dimensions (see Figures 5.2 and 5.3, page 36) 1,000 (6.9) 3,000 (20.7) HOUSING MATERIAL FORGED STNL ST 316 PRESSURE CONNECTION TOP BOTTOM 1/2" NPT 1/4" NPT 1/4" NPT 1/2" NPT 1/4" NPT 1/4" NPT 1/2" NPT 1/2" NPT DIM. A INCHES (mm) DIM. B INCHES (mm) DIM. C INCHES (mm) DIM. D INCHES (mm) # BOLTS PRESSURE RATING PSI (MPa) 9-29/32 (251.6) 6-5/8 (168.3) 2 (50.8) 2-9/64 (51.2) 12 10-5/32 (257.9) 7-1/8 (181.0) 2 (50.8) 2-9/64 (51.2) 12 NOTES: Cast aluminum pipe mount supplied, unless otherwise specified. Specify pipe size when ordering threaded steel adapter. Metric conversions are approximate. 35 Section 5 Model 289A Differential Pressure Indicating Switch Figure 5.2—Model 289A, side view; see Table 5.1, page 35 for dimensions A, C and D Figure 5.3—Model 289A, rear view; see Table 5.1, page 35 for dimension B IMPORTANT: Model 289A version configurations are limited to nuclear applications; also refer to the Model 199 DPU user manual in Appendix A. 36 Product Warranty A.Warranty Cameron International Corporation ("Cameron") warrants that at the time of shipment, the products manufactured by Cameron and sold hereunder will be free from defects in material and workmanship, and will conform to the specifications furnished by or approved by Cameron. B. Warranty Adjustment (1) If any defect within this warranty appears, Buyer shall notify Cameron immediately. (2) Cameron agrees to repair or furnish a replacement for, but not install, any product which within one (1) year from the date of shipment by Cameron shall, upon test and examination by Cameron, prove defective within the above warranty. (3) No product will be accepted for return or replacement without the written authorization of Cameron. Upon such authorization, and in accordance with instructions by Cameron, the product will be returned shipping charges prepaid by Buyer. Replacements made under this warranty will be shipped prepaid. C. Exclusions from Warranty (1) THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER EXPRESSED OR IMPLIED WARRANTIES OF MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE. (2) Components manufactured by any supplier other than Cameron shall bear only the warranty made by the manufacturer of that product, and Cameron assumes no responsibility for the performance or reliability of the unit as a whole. (3) "In no event shall Cameron be liable for indirect, incidental, or consequential damages nor shall the liability of Cameron arising in connection with any products sold hereunder (whether such liability arises from a claim based on contract, warranty, tort, or otherwise) exceed the actual amount paid by Buyer to Cameron for the products delivered hereunder." (4) The warranty does not extend to any product manufactured by Cameron which has been subjected to misuse, neglect, accident, improper installation or to use in violation of instructions furnished by Cameron. (5) The warranty does not extend to or apply to any unit which has been repaired or altered at any place other than at Cameron's factory or service locations by persons not expressly approved by Cameron. Product Brand Barton® is a registered trademark of Cameron International Corporation ("Cameron"). 37 38 APPENDIX A BARTON NUCLEAR MODEL 199 DIFFERENTIAL PRESSURE UNIT (DPU) ® User Manual Part No. 9A-C10034, Rev. 02 February 2012 Contents Technical Support.......................................................................................A-2 Section 1—Introduction...............................................................................A-3 General.......................................................................................................A-3 Product Description....................................................................................A-3 Specifications..............................................................................................A-4 Section 2—Theory of Operation..................................................................A-5 Basic Components......................................................................................A-5 Pressure Housings..................................................................................A-5 Bellows....................................................................................................A-5 Range Springs........................................................................................A-7 Torque Tube Assembly............................................................................A-7 Pulsation Dampener................................................................................A-8 Section 3—Installation/Operation...............................................................A-9 Unpacking...................................................................................................A-9 Mounting.....................................................................................................A-9 Flush or Panel Mounting.........................................................................A-9 Piping—Standard Practices........................................................................A-9 All Applications (Flow and Liquid Level)..................................................A-9 Flow Applications..................................................................................A-10 Liquid Level Applications.......................................................................A-10 Piping Diagrams.................................................................................... A-11 General Startup Practice Considerations.................................................A-17 Section 4—Maintenance, Adjustment, & Calibration..............................A-19 Tools Required for Maintenance and Calibration......................................A-19 DPU Inspection and Cleaning...................................................................A-19 Pressure Check Procedure...................................................................A-19 Inspection and Cleaning Procedure......................................................A-20 Calibration Setup......................................................................................A-21 Torque Tube Rotation Check (Replacement Units)..................................A-22 Range Change..........................................................................................A-22 2-1/8-inch Diameter Bellows.................................................................A-22 3-3/4-inch Diameter Bellows Without Kickoff Spring (>47" w.c.)...........A-23 3-3/4-inch Diameter Bellows with Kickoff Spring ..................................A-24 Setting Bellows Travel..............................................................................A-26 Bellows Unit Assembly (BUA) Replacement.............................................A-26 Attaching Drive Arm to Torque Tube.........................................................A-27 Drive Arm Tightness Test..........................................................................A-28 Adjusting Pulsation Dampener.................................................................A-28 Troubleshooting........................................................................................A-28 Section 5—Parts Drawing/List..................................................................A-31 Section 6—Dimensional Drawings...........................................................A-37 Safety Before installing this product, become familiar with the installation instructions presented in Section 3 and all safety notes throughout. WARNING: This symbol identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. CAUTION: Indicates actions or procedures which if not performed correctly may lead to personal injury or incorrect function of the instrument or connected equipment. IMPORTANT: Indicates actions or procedures which may affect instrument operation or may lead to an instrument response that is not planned. Technical Support Cameron Measurement Systems Division 14450 John F. Kennedy Blvd. Houston, TX 77032 Phone: 1-800-654-3760; 281-582-9500 Fax: 281-582-9599 Barton is a registered trademark of Cameron. © 2012 Cameron International Corporation (“Cameron”). All information contained in this publication is confidential and proprietary property of Cameron. Any reproduction or use of these instructions, drawings, or photographs without the express written permission of an officer of Cameron is forbidden. All Rights Reserved. Printed in the United States of America. A-2 Model 199 Differential Pressure Unit (DPU) Section 1 Section 1—Introduction General The Barton® Model 199 Differential Pressure Unit (DPU) (see Figure 1.1) is a mechanical device which accurately measures differential pressure relative to a gas or liquid flowing through a process system, or to the level of a liquid contained in a process vessel. Figure 1.1—Model 199 DPU unit For process flow measurements, the DPU is connected across a primary device (a venturi, an orifice plate or a flow tube) located in the process system. For liquid level measurements, the DPU may be connected in a variety of ways to measure the difference in pressure caused by variations in the level of the liquid in the process vessel. Product Description The Model 199 DPU is a dual bellows assembly enclosed within pressure housings. The dual bellows assembly consists of two opposing internally connected liquid-filled bellows, a center plate, range springs, overrange valves, and a torque tube assembly. The pressure housings are connected by pipe or tubing to the primary device located in the system piping. Variations in differential pressure within the pressure housings cause the bellows to expand or contract in a linear direction towards the side having the lowest pressure. The linear movement of the bellows is converted into angular rotation when transmitted to the torque tube shaft by the drive arm and this mechanical motion actuates the mechanism of the process monitoring instrument. The process monitoring instrument that is connected to the torque tube assembly may be an indicator, a switch, a transmitter, a recorder, or other process control device. A-3 Section 1 Model 199 Differential Pressure Unit (DPU) Specifications Housing Material���������������������������� Torque Tube Rotation (full scale DP) Torque Tube Material���������������������� Temperature Limits������������������������� Maximum Non-linearity:������������������ ������������������������������������������������������� Repeatability����������������������������������� Housing Materials/Ranges������������� Forged 316 Stainless Steel 8° ±10% Beryllium Copper (BeCu) -40°F (-40°C) to +180°F (+82°C) 0-10" w.c. to 0-400" w.c. (0-25 mbar to 0-993 mbar) ±0.5% of full scale with appropriate linkage 0-401" w.c. to 0-100 psi (0-996 mbar to 0-6.9 bar) ±0.75% of full scale with appropriate linkage 0.20% of full scale DP Refer to Table 1.1 Table 1.1—Differential Pressure Ranges for Model 199 DPUs SWP - psi (bar) 1,000 (69) Stainless Steel or Inconel Bellows 2 1/8”(55 mm) O.D. 3 3/4” (95 mm) O.D. 0-15 psi to 0-115 psi (0-1 bar to 0-7.9 bar) 0-10" w.c. to 0-400" w.c. (0-25 mbar to 0-995 mbar) Net Volume, L.P. Head (cu. in.) 35 cu. in. (575 cc) 30 cu. in. (490 cc) Net Volume, H.P. Head (cu. in.) 31 cu. in. (510 cc) 26 cu. in. (425 cc) Displacement (cu. in.) for full-scale travel 0.5 cu. in. (8.2 cc) 1.5 cu. in. (25 cc) 3,000 (207) NOTES: Zero center or split ranges available on special order (e.g., 0-50" w.c. (0-124 mbar) range may be ordered 25-0-25" w.c. (62-0-62 mbar) or 10-0-40" w.c. (25-0-99 mbar). Intermediate DP ranges available from 0-20" w.c. to 0-100 psi (0-50 mbar ot 0-6.9 bar). Standard pressure connections are 1/2" (top) and 1/4" (bottom) NPT. Range springs are not interchangeable between the different size bellows. Metric conversions are approximate. Dimensional drawings available on request. A-4 Model 199 Differential Pressure Unit (DPU) Section 1 Section 2—Theory of Operation Basic Components Torque Tube Shaft Center Plate Torque Tube Low Pressure Bellows Range Spring High Pressure Bellows High Pressure Overrange Valve Low Pressure Housing Temperature Compensator Low Pressure Overrange Valve HP Housing Housing Bolts Pulsation Damper Valve Stem Damping Valve Plug Figure 2.1—199 BUA cutaway Pressure Housings The two pressure housings of the Model 199 DPU are available in the various safe working pressure ratings defined in Table 1.1, page A-4, and in the dimensional drawings in Section 6. Each pressure housing has two tapped connection ports: one port is located in the top of the housing, the other port is located in the bottom of the housing. Bellows The bellows of the Model 199 DPU are available in the various materials and sizes (refer to Table 1.1, page A-4) to accommodate the various calibration ranges. A-5 Section 2 Model 199 Differential Pressure Unit (DPU) The DPU has two bellows. One end of each bellows is sealed. The open end of each bellows is attached and sealed to a side of the center plate (one bellows on each side) as shown in Figure 2.2. The bellows and center plate are filled with fill liquid via the drive arm hole plug. An opening through the center plate provides a passageway for the transfer of fill liquid between the two bellows. This opening also allows the bellows to be connected internally by a valve stem. Drive Arm Hole Plug (DO NOT LOOSEN) Retainer Screws Torque Tube Gland Nut (DO NOT LOOSEN) Range Spring Assembly Push Rod Torque Tube Shaft Lock Nut Range Springs 2-1/8" Bellows Unit Assembly (BUA) Drive Arm Hole Plug (DO NOT LOOSEN) Spring Post Torque Tube Gland Nut (DO NOT LOOSEN) Range Spring Assembly Retainer Nut Torque Tube Shaft Push Rod Range Springs Spring End Cup Lock Nut 3-3/4" Bellows Unit Assembly (BUA) Figure 2.2—Bellows unit assemblies (BUAs) A-6 Model 199 Differential Pressure Unit (DPU) Section 2 Range Springs The range of the dual-bellows type DPU is determined by the force required to move the bellows through their normal range of travel. The range springs, which are available in various ranges (see Table 1.1, page A-4), act with the bellows and torque tube to balance the differential pressure applied to the unit. The number of springs used and their spring rate depends on the individual differential pressure range requirement. Torque Tube Assembly As illustrated in Figure 2.3, the torque tube assembly consists of a torque tube, a torque tube shaft, and the supporting members. The outboard end of the torque tube shaft is attached to the center plate. The torque tube shaft, located in the center of the torque tube, is welded to the inboard end of the tube. Needle Beaing Center Plate O-Ring Seal Weld Torque Tube Lock Nut Torque Tube Torque Tube Shaft 8° Drive Arm Valve Stem Disc Rotation 0.200" Bellows Travel Weld Jewel Bearing Minature Precision Ball Bearing Valve Stem Figure 2.3—Torque tube assembly Movement of the bellows is transmitted by the drive arm to the torque tube as a rotary motion. Since the torque tube is attached to the center plate, the tube must twist when subjected to torque. The torque tube shaft, which is freely supported within the torque tube at its outer end, but connected to the torque tube and drive arm at its inner end, rotates through the same angle as the differential pressure unit. A-7 Section 3 Model 199 Differential Pressure Unit (DPU) Pulsation Dampener The pulsation dampener (Figure 2.1, page A-5) controls the flow of fill-liquid between the high and low-pressure bellows with an externally adjustable pulsation dampener needle valve. Restriction of liquid flow reduces the effects of pulsation. In applications where pulsation is not a problem, the needle valve is set to the full-open position. A-8 Model 199 Differential Pressure Unit (DPU) Section 3 Section 3—Installation/Operation Unpacking The 199 DPU should be inspected at time of unpacking to detect any damage that may have occurred during shipment. IMPORTANT: The instrument was checked for accuracy at the factory. Do not change any of the settings during examination or accuracy will be affected. IMPORTANT: For application in critical media, requiring special cleaning processes and precautions, a polyethylene bag is used to protect the instrument from contamination. This protective bag should be removed only under conditions of controlled extreme cleanliness. IMPORTANT: Do not locate the instrument near vents or bleed holes that discharge corrosive vapors or gases. Mounting Flush or Panel Mounting Attach the case of the instrument (switch or indicator) to the panel or wall. Refer to the instrument's installation manual for mounting details. Piping—Standard Practices All Applications (Flow and Liquid Level) 1. Shorten the distance between the primary device and the DPU as much as possible. Distances exceeding 100 feet are not recommended. For distances up to 50 feet, use 1/4-inch or 3/8-inch pipe or tubing. For runs of 50 to 100 feet, use 1/2-inch pipe or tubing. The recommended limitation does not apply if an air purge or blow-back system is used. 2. Slope all piping at least one inch per linear foot to avoid liquid or gas entrapment. 3. Provide 2 feet of non-insulated piping between the DPU and the primary device for each 100°F (+37.8°C) in excess of +200°F (+93.3°C). 4. Assure that the temperature of the DPU never exceeds 180°F (+82°C). When steam tracing is necessary, the steam pressure should not exceed 5 pounds per square inch and insulation should not be used. If pressure must exceed 5 pounds per square inch, limit the length of tubing around the DPU to two turns and do not insulate. A-9 Section 3 Model 199 Differential Pressure Unit (DPU) 5. Install a suitable pulsation dampening device upstream of the DPU. Where severe pulsation is present, the accuracy of the flow measurement will be affected. 6. Mount the DPU on a solid support to minimize vibration. Tighten all points, using a suitable compound; leaks in piping can cause measurement errors. 7. Install a valve manifold connecting the DPU and the source of differential pressure to facilitate operation and checking of the DPU. 8. Locate all shutoff valves and bypass valves to be readily accessible from the front of the instrument. Locate block valves at the source of differential pressure. Flow Applications Assure that the DPU high-pressure housing is connected to the upstream tap of the primary device. IMPORTANT: To prevent overheating the DPU during blowdown, monitor the temperature by placing hands on the pipe between the DPU and the manifold pipe containing the vent valves. Liquid Level Applications The process media may be used as a reference leg seal fluid if it will condense in the reference leg under all conditions. If the process or process media characteristics are such that the above conditions cannot be met, a special reference leg seal fluid is required. The special seal fluid must not be volatile and must not be miscible with the process media. Also, the difference in the densities of the special seal fluid and the process media will require compensation in calculating the differential pressure range of the DPU. A-10 WARNING: Explosion Hazard—Organic compounds, oil, grease, dirt, or scale of any kind cannot be tolerated in an oxygen installation. Model 199 Differential Pressure Unit (DPU) Section 3 Piping Diagrams Diagrams for typical and special flow applications are presented on the following pages. Use the diagram best suited for the application as a guide for piping configuration. BYPASS VALVES DPU SHUT-OFF VALVES STATIC PRESSURE CONNECTION (USE ONLY ONE) VENT VALVE BLOCK VALVES PRIMARY DEVICE Figure 3.1—Gas Flow, DPU Above Run BLOCK VALVES VENT VALVE PRIMARY DEVICE SHUT-OFF VALVES BYPASS VALVES STATIC PRESSURE CONNECTION (USE ONLY ONE) DPU DRIP POTS Figure 3.2—Gas Flow, DPU Below Run A-11 Section 3 Model 199 Differential Pressure Unit (DPU) VENT VALVE STATIC PRESSURE CONNECTION (USE ONLY ONE) BYPASS VALVES DPU SHUT-OFF VALVES DRIP POTS BLOCK VALVES PRIMARY DEVICE Figure 3.3—Gas Flow, Hydrates Present PRIMARY DEVICE PLUGS BLOCK VALVES CONDENSING RESERVOIR SHUT-OFF VALVES VENT VALVES (OPTIONAL) DPU Figure 3.4—Steam Flow, DPU Below Run DPU SHUT-OFF VALVES BYPASS VALVE PRIMARY DEVICE BLOCK VALVES Figure 3.5— Liquid Flow, DPU Above Run A-12 Model 199 Differential Pressure Unit (DPU) PRIMARY DEVICE Section 3 FILL TEE AND VENT VALVE FOR HOT OR GASSY LIQUIDS BLOCK VALVES SHUT-OFF VALVES BYPASS VALVE DPU Figure 3.6—Liquid Flow, DPU Below Run BYPASS VALVE SHUT-OFF VALVES SEAL POTS DPU PRIMARY DEVICE BLOCK VALVES Figure 3.7—Corrosive Liquid Flow BLOCK VALVE SHUT-OFF VALVE BLOCK VALVE SHUT-OFF VALVE VENT VALVE DPU DRAIN VALVE HIGH-PRESSURE Figure 3.8—Cool Non-Condensing Liquid, DPU Level with Tank Bottom A-13 Section 3 Model 199 Differential Pressure Unit (DPU) BLOCK VALVE SHUT-OFF VALVE BLOCK VALVE DPU SHUT-OFF VALVE HIGH-PRESSURE DRAIN VALVE Figure 3.9—Cool Non-Condensing Liquid, DPU Below Tank 2" CROSS BLOCK VALVE REFERENCE LEG VENT VALVE SHUT-OFF VALVE DPU BLOCK VALVE SHUT-OFF VALVE HIGH-PRESSURE BYPASS VALVE DRAIN VALVE Figure 3.10—DPU Below Tank Bottom with Reference Leg A-14 Model 199 Differential Pressure Unit (DPU) Section 3 BLOCK VALVE INVERTED "U" GAS TRAP BLOCK VALVE SHUT-OFF VALVE MINIMUM LENGTH 6 INCHES DRAIN VALVE VAPOR GENERATOR DPU LOW-PRESSURE Figure 3.11—Liquid CO2 BLOCK VALVE MINIMUM LENGTH 12 INCHES INVERTED "U" GAS TRAP SHUT-OFF VALVE VAPOR GENERATOR FLAT TUBULAR SPIRAL IN OUTER 1/3 OF TANK INSULATION KEEP DEAD LEG BETWEEN BLOCK TANK AND SPIRAL VALVE 5 INCHES OR LESS HIGH-PRESSURE DPU LOW-PRESSURE Figure 3.12—Cryogenic Liquids A-15 Section 3 Model 199 Differential Pressure Unit (DPU) SIGHT FLOW GAGE INPUT GAS REGULATOR BLOCK VALVES GAS SUPPLY SHUT-OFF VALVES BYPASS VALVE DPU HIGH PRESSURE Figure 3.13—Bubbler System INPUT GAS REGULATOR GAS SUPPLY SIGHT FLOW GAGES WITH THROTTLING VALVES BLOCK VALVES SHUT-OFF VALVES BYPASS VALVE DPU HIGH-PRESSURE Figure 3.14—Liquid Specific Gravity A-16 Model 199 Differential Pressure Unit (DPU) Section 3 General Startup Practice Considerations Observe the following practices when starting up an instrument. 1. Always start with the block valves closed. 2. Perform a zero check on the instrument as follows. IMPORTANT: For gas service, it is recommended that zero check be performed with both block valves closed. If the gas flow is pulsating, there may be a standing wave effect in the process line which can displace the indicator and appear as a zero error. a. Open the bypass valve(s), then open one shutoff valve. This procedure equalizes the pressure between both sides of the instrument. The instrument should indicate zero. b. If the instrument does not indicate zero, check for gas or liquid entrapment in the lines or in the DPU (depending on the orientation of the piping layout and service). c. If necessary, adjust the pen or pointer by turning the zero adjust on the instrument. 3. Check the manifold and piping for leaks as follows. a. Open the bypass valve(s), then open one shutoff valve to pressurize the instrument. b. Close the shutoff valve and the bypass valve. c. Any leakage will be indicated by pen or pointer movement, up or down scale. IMPORTANT: Be careful not to subject the DPU to unnecessary shock or overrange pressure during operations. A-17 Section 3 A-18 Model 199 Differential Pressure Unit (DPU) Model 199 Differential Pressure Unit (DPU) Section 4 Section 4—Maintenance, Adjustment, & Calibration Tools Required for Maintenance and Calibration Cameron's calibration tool kit (Part No. 9A-0202-1005B) contains the tools necessary for calibrating the Model 199 DPU. The tools listed in Table 4.1 are also recommended for performing general maintenance. Table 4.1—Tools Description Purpose 7/16" Hex wrench Housing bolts 5/8" Hex wrench Housing bolts 1/8" Allen wrench Dampener Adjustment 1/2" Open ended wrench Push rod - bellows cup connection Modified box/open-ended wrench (7/16") Kickoff spring lock nut 100 ft-lb Torque wrench Housing bolts DPU Inspection and Cleaning Instruments used in services where solids or semi-solids may accumulate inside the pressure housings require periodic inspection and cleaning. Always check for internal pressure using the procedure below before removing the DPU housing bolts. Pressure Check Procedure WARNING: Failure to perform this procedure can result in severe injury, death or substantial property damage due to the release of internal pressure. If the DPU has been installed in gas applications with working pressures greater than 200 psig, PERFORM THIS PROCEDURE BEFORE REMOVING THE DPU HOUSING BOLTS. 1. Back off all housing bolts 4 turns. 2. Check for internal pressure by attempting to move the housing in and out along the bolts. a. If the housing moves freely, no pressure is present and servicing or repair may continue. b. If the housing does not move freely, the bellows may be pressurized and is potentially hazardous if further disassembled. Tighten the bolts and return the unit to the factory or authorized Barton service center for repair. Tag the unit and specify "Gas in Bellows". A-19 Section 4 Model 199 Differential Pressure Unit (DPU) Inspection and Cleaning Procedure Instruments used in services where solids or semi-solids may accumulate inside the pressure housings require periodic inspection and cleaning, as follows. 1. Remove the DPU from service and remove the pressure housings. 2. Carefully remove the pressure housings from the bellows unit assembly. IMPORTANT: If accumulation of solids or semi-solids is extensive, rapid removal of the pressure housings can damage the bellows. 3. Remove the accumulation from between the bellows convolutions and from the inside of the housings. Use a solvent if possible. Do not use a sharp instrument to clean between convolutions. 4. Look for broken range springs and replace as necessary. 5. Replace the housings and seals. 6. Install NEW pressure housing bolts and torque in accordance with Table 4.2. WARNING: Do not reuse housing bolts. Reuse of housing bolts, especially in critical applications like hydrogen sulfide and salt water exposures, can result in severe injury, death or substantial property damage due to bolt failure. SWP Housing Mat'l Bolt Mat'l Size Qty Part No. Lube (Note 1) Torque (lb/ft) (Note 2) Rotation (Note 3) Table 4.2—Standard Bolt Torque Ratings 1000 Stainless Steel Steel 3/8-16 x 4.5 12 9A-C0199-1345C Yes 40 270° Stainless Steel Steel 1/2-13 x 5.5 12 9A-C0199-0085C Yes 80 180° 3000 NOTES: 1. Lubricants: Molykote G paste, Teflon-base pipe dope, graphite-base grease, or similar lubricants. Lube first 2 threads only. Do not lube bearing surface. 2. Torque on bolts is accomplished in 3 or 4 steps. Tighten UNIFORMLY. 3. Rotation of bolt head is measured after bolt is "snug," with approximately 5 lb/ft torque. DO NOT EXCEED THIS ROTATION. To tighten bolts without torque wrench, use rotation values. A-20 Model 199 Differential Pressure Unit (DPU) Section 4 Calibration Setup The test equipment required to calibrate the Model 199 DPU, when attached to an indicator or switch is shown in Figure 4.1. All Barton instruments using the Model 199 DPU as actuator are calibrated at the factory. All DPUs sold as replacement units or as actuators for other applications are checked for accuracy prior to shipment. Normally, the DPU is calibrated after installation on a specific instrument. Refer to the separate instrument manual for specific calibration procedures. Figure 4.1—Calibration setup A-21 Section 4 Model 199 Differential Pressure Unit (DPU) Torque Tube Rotation Check (Replacement Units) Prior to installation as a replacement unit, a DPU should be checked for proper torque tube rotation, per the following procedure: 1. 2. 3. 4. Mount DPU on a stable base and connect to a standard pressure source. Adapt a scale graduated in degrees to the torque tube housing. Adapt a pointer to the exposed end of the torque tube shaft. Apply 100% DP to the high pressure (HP) housing of the DPU. The pointer should indicate 8 degrees of travel. Range Change Changing the range of the Model 199 DPU may require replacing the bellows unit assembly with a unit of the desired range (see Bellows Unit Assembly (BUA) Replacement, page A-26). WARNING: High-pressure gas hazard on disassembly of the DPU in installations with pressures greater than 200 psig. To prevent possible severe personal injury, death, or substantial property damage due to the release of internal pressure, perform the pressure check before removing DPU housing bolts. IMPORTANT: If accumulation of solids or semi-solids is extensive, remove the housings carefully to prevent damaging the bellows. IMPORTANT: The calibration range of the DPU was carefully set at the factory. The following procedure maintains the original factory bellows travel setting while the range spring change is performed. This procedure must be strictly followed while changing the range spring assembly or altering the adjustment. To replace the range spring assembly with either a new assembly of the same range or one with a different range value, proceed as follows (this procedure assumes that the DPU is either connected to an indicating instrument or fitted with a scale and pointer to measure torque tube shaft movement): 2-1/8-inch Diameter Bellows 1. Remove the DPU from service. 2. Remove the pressure housing bolts and the low-pressure housing. 3. With the pointer at zero, remove the spring retainer screw, retainer springs, and the range spring assembly. IMPORTANT: The pointer will shift from zero. This is a normal action and the pointer should not be readjusted at this point. A-22 Model 199 Differential Pressure Unit (DPU) Section 4 4. Install the new range spring assembly onto the push rod, and replace the spring retainer screw. 5. If the pointer is set above zero, rotate the spring adjustment clockwise until the pointer is set at zero. If the pointer is below zero, rotate the spring adjustment counterclockwise until the pointer is set at zero. 6. Replace and tighten the lock nut. If the pointer shifts from zero, loosen the lock nut and reset the pointer as in step 5. Tighten the lock nut. 7. Replace the low-pressure housing and install NEW bolts (new gaskets are also recommended). Torque the bolts in accordance with Table 4.2, page A-20. WARNING: Do not reuse housing bolts. Reuse of housing bolts, especially in critical applications like hydrogen sulfide and salt water exposures, can result in severe injury, death or substantial property damage due to bolt failure. 8. Calibrate in accordance with the manual for the actuated instrument. 3-3/4-inch Diameter Bellows Without Kickoff Spring (>47" w.c.) 1. Remove the instrument from service. 2. Remove the pressure housing bolts and the low-pressure housing. 3. With the pointer set at zero, remove the lock nut retainer nuts, and the range spring assembly. To remove the range spring assembly, rotate the assembly counterclockwise while pulling outward on the assembly. IMPORTANT: The pointer will shift from zero. This is a normal action and the pointer should not be readjusted at this point. 4. Thread the new assembly onto the push rod, and align the holes in the range spring assembly with the spring posts. Replace and tighten the retainer nuts. 5. Using a spanner wrench, rotate the spring adjustment until the pointer is set at exact zero. Replace and tighten the lock nut. The pointer must remain at the zero setting. If the pointer shifts from zero, loosen the lock nut and repeat this step. 6. Replace the low-pressure housing and install NEW bolts (new gaskets are also recommended). Torque the bolts in accordance with Table 4.2, page A-20. WARNING: Do not reuse housing bolts. Reuse of housing bolts, especially in critical applications like hydrogen sulfide and salt water exposures, can result in severe injury, death or substantial property damage due to bolt failure. 7. Calibrate in accordance with the manual for the actuated instrument. A-23 Section 4 Model 199 Differential Pressure Unit (DPU) 3-3/4-inch Diameter Bellows with Kickoff Spring The kickoff spring (also referred to as the "anti-stick" spring) is supplied as standard equipment with 46" w.c. and lower range DPUs. Figure 4.2—Kickoff spring assembly IMPORTANT: The lock nut requires a modified 7/16", 12-point box wrench for tightening (Figure 4.3). Figure 4.3—Wrench modification 1. Remove the instrument from service. Set the pointer at zero using the instrument zero adjustment. 2. Remove the pressure housing bolts and remove the low-pressure housing. 3. With the pointer set at zero, remove the lock nut, spring retainer nuts, washer and lock nut, and range spring assembly. IMPORTANT: The pointer will shift from zero. This is a normal action and the pointer should not be readjusted at this time. A-24 Model 199 Differential Pressure Unit (DPU) Section 4 4. Install the range spring assembly, using a 1/2-inch open-ended wrench to connect the push rod to the low-pressure bellows cup. IMPORTANT: The range spring assembly consists of the range springs, kickoff spring assembly, and the push rod. The assembly is furnished as a complete and assembled unit. 5. Position range spring assembly over retainer posts and replace retainer nuts. 6. Insert the tubing between the range springs and tighten inboard lock nut. 7. Zero the pointer by adjusting the spud on the push rod. Be sure that the kickoff spring is not engaged during this operation. 8. Position the kickoff spring to prevent interference with the coil springs and tighten the kickoff spring lock nut. If clearance is needed for the wrench, note the position of the spud (measure with a scale or count threads to the end of the push rod) and move the spud for the required clearance. After the lock nut is tightened, return the spud to its original position. 9. Check the back-clearance between the kickoff spring and the slot. Use a wire feeler gage or comparable measuring device. The clearance between slots will vary, but must be at least 0.005-in. to prevent interference with instrument zero. Add or remove washers as required to obtain the proper clearance. Tighten the lock nut securely. 10. Install the jam nut and lock the spud to the push rod. Hold with pliers. If the spud was moved in step 8, return the spud to the proper position before tightening the jam nut. 11. Apply 100 percent negative pressure to the high-pressure side of the DPU and repeat the clearance check and adjustment described in step 9. 12. Apply 100 percent positive pressure to the high-pressure side of the DPU and repeat the clearance check and adjustment described in step 9. 13. Release all pressure from the instrument, replace the low-pressure housing and install NEW bolts (new gaskets are also recommended). Torque the bolts in accordance with Table 4.2, page A-20. WARNING: Do not reuse housing bolts. Reuse of housing bolts, especially in critical applications like hydrogen sulfide and salt water exposures, can result in severe injury, death or substantial property damage due to bolt failure. A-25 Section 4 Model 199 Differential Pressure Unit (DPU) Setting Bellows Travel The travel of the DPU bellows must be adjusted if one of the following occurs. 1. 2. 3. 4. The range spring assembly is removed without following the procedure. Broken range springs are replaced. The indicator pointer has excessive overtravel. The indicator pointer has excessive undertravel. Setting the bellows travel requires that the DPU be attached to the actuated instrument and connected to a test pressure source. The procedure for this adjustment is presented in the manual for the actuated instrument. Bellows Unit Assembly (BUA) Replacement Before replacing the BUA, read the following warning messages and reference Figure 2.1, page A-5, to locate parts described in the following procedure. WARNING: High-pressure gas hazard on disassembly of the DPU in installations with pressures greater than 200 psig. To prevent possible severe personal injury, death, or substantial property damage due to the release of internal pressure, perform the pressure check procedure on page A-19 before removing the DPU housing bolts. IMPORTANT: If accumulation of solids or semi-solids is extensive, remove the housings carefully to prevent damaging the bellows. IMPORTANT: Component Removal—See the manual for the actuated instrument for particular components that must be removed to gain access to DPU case mounting screws. Support DPU during disassembly. Do not loosen the drive arm hold plug (located in the top of the BUA center plate) when removing the mounting bracket. If the plug is loosened, bellows fill fluid will be lost. 1. Disconnect the DPU piping and remove the instrument from service. 2. Loosen the actuated instrument drive arm and slide off of the torque tube shaft. Do not disconnect the instrument linkage. 3. Remove the case-retaining screws and remove the case assembly. 4. Remove the indicator bracket screws and the indicator bracket. 5. Remove the pressure housings bolts and pressure housings. 6. Place the pressure housings on the replacement bellows unit assembly and insert and start (only) the pressure housing bolts. A-26 Model 199 Differential Pressure Unit (DPU) Section 4 WARNING: Do not reuse housing bolts. Reuse of housing bolts, especially in critical applications like hydrogen sulfide and salt water exposures, can result in severe injury, death or substantial property damage due to bolt failure. 7. Attach the indicator bracket to the replacement assembly, using the indicator bracket screws. 8. Attach the mounting bracket using the screws provided. 9. Support the DPU and tighten and torque the pressure housing bolts in accordance with Table 4.2, page A-20. 10. Attach the case assembly using case retaining screws. 11. Attach the drive arm and linkage. 12. Tighten the drive arm to the torque tube, as described below. 13. Replace any instrument components that were removed (refer to the "Important: Component Removal" notice on page 20). 14. Calibrate the instrument before returning it to service. Attaching Drive Arm to Torque Tube SINTERED CLAMP BLOCK LINK .03 (approx) DRIVE ARM SHAFT CLAMP SCREW 1/8” WRENCH (PN 9A-0163-0044C) TO TIGHTEN Figure 4.4—Drive arm to torque tube connection 1. Slip the drive arm over the torque tube shaft; clear the end of the torque tube housing by approximately 0.030 inches before securing to prevent interference. 2. To tighten the drive arm assembly onto the torque tube shaft: a. Supporting the block and shaft, tighten the clamp screw until it is snug to the shaft. b. Still supporting the block/shaft, tighten the clamp screw an additional 1/3 to 1/2 turn. (The screw can normally turn one full revolution before breaking.) A-27 Section 4 Model 199 Differential Pressure Unit (DPU) Drive Arm Tightness Test This procedure tests the tightness of the drive arm's connection to the torque tube by applying torque developed by the DPU onto a fixed drive arm. Care should be taken to apply pressure slowly, as torque is being applied to the connection through the torque tube drive shaft. 1. With the pointer at normal 0% torque tube rotation position (0% on a normal 0 to 100% scale unit), adjust the drive arm stop bracket (or use alternate means) to prevent the pointer from moving (stop bracket interferes with drive arm movement). IMPORTANT: On reverse acting/split range units, it will be necessary to pressurize the DPU to move the pointer to the minimum scale position, and on suppressed units, it will be necessary to apply pressure to establish a reference point to check for "zero" shift. 2. Pressurize the DPU to full calibrated scale DP (100% of full scale range) to apply 8 degrees of torque tube equivalent torque to the connection. 3. Observe the shift in the unit "zero" following DPU depressurization (as required) and drive arm stop bracket readjusting (to allow free movement of drive arm and pointer). If the "zero" shifts counter-clockwise more than 1/2%, tighten the clamp block to prevent drive arm slippage. Adjusting Pulsation Dampener Reference Figure 6.1, page A-37, for the location of the pulsation dampener valve. 1. Remove the dust cover and insert a 1/8-in. hex key into the needle valve. 2. Turn the valve clockwise to the closed position, approximately 3 turns. 3. Back out the valve 1/2 turn or as required to reduce pulsations/shock pressures. Troubleshooting See Table 4.3, page A-29, and refer to actuated instrument manual for more information. A-28 Model 199 Differential Pressure Unit (DPU) Section 4 Table 4.3—Troubleshooting Chart Trouble Low or No Indication Possible Source Primary Element or Differential Pressure Source Piping from Primary Element to DPU Bellows Unit Mechanism Probable Cause Corrective Action Orifice installed backwards or oversized Replace orifice Flow blocked upstream from run Clean out run or open valve Loss of liquid in reference leg (liquid level) Refill reference leg Density changes in process media or reference leg Refill reference leg with same density liquid as process media Pressure tap holes plugged Clean out piping Bypass valve open or leaking Close bypass valve(s) or repair leaks Liquids or gases trapped in piping Vent piping Block or shutoff valves closed Open block or shutoff valves Piping leaks, HP side Repair leaks Housing(s) filled up with solids, restricting bellows movement Clean out housing(s) Gas trapped (liquid service) or liquid trapped (gas service) in housing(s) Vent housing(s) HP Housing gasket leaks Replace gasket DPU tampered with Return BUA for repair Loose links/movements Tighten or replace Out of calibration Calibrate Corrosion or dirt in mechanism Clean or replace Pointer loose Tighten pointer A-29 Section 4 Model 199 Differential Pressure Unit (DPU) Table 4.3—Troubleshooting Chart Trouble High Indication Possible Source Clean out or replace Piping from Primary Element to DPU Leak in LP side piping Repair leaks Bellows Unit Gas trapped (liquid service) in LP housing or liquid trapped (gas service) in HP housing Vent housing LP housing gasket leaks Replace gasket Range spring broken or DPU tampered with Return BUA for repair Loose links or movements Repair or replace Out of calibration Calibrate Primary Flow pulsating Install dampening device upstream of DPU run Piping from Primary Element to DPU Liquid trapped in gas piping or gas bubble in liquid piping Remove (see Startup Procedure, Section 3) Vapor generator incorrectly installed Repipe Reference leg gassy or liquid vaporizing See piping instructions Obstructed bellows travel Clean bellows Gas trapped in DPU HP or LP housing Remove (see Startup Procedure, Section 3) Linkage dragging or dirty Adjust or clean Pointer dragging on scale plate Adjust Bellows Unit Mechanism A-30 Corrective Action Orifice partially restricted or too small Mechanism Erratic Indication Probable Cause Primary Model 199 Differential Pressure Unit Section 5 Section 5—Parts Drawing/List Figure 5.1—Model 199 DPU parts drawing (indicator and indicator switch mounting brackets vary as shown; see 200A/289A and 581A insets) A-31 Section 5 Model 199 Differential Pressure Unit Table 5.1—Model 199 Parts List Description Part No. Per Unit 1 BUA (BELLOWS UNIT ASSEMBLY) SELECT 1 2 HOUSING, PRESSURE, TAPPED (MATCH SWP AND PORTS WITH ITEM 3) Item 3 4 5 1 HOUSING, 1 K SST, 1/4 X 1/4 NPT 9A-CS787-0071C HOUSING, 1 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0061C HOUSING, 1 K SST, 1/2 X 1/4 NPT (TOP/BOTTOM) 9A-C0199-1038C HOUSING, 1 K SST, 1/2 X 1/2 NPT 9A-CS787-0025Z HOUSING, 3 K SST, 1/4 X 1/4 NPT 9A-CS787-0066C HOUSING, 3 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0057Z HOUSING, 3 K SST, 1/2 X 1/4 NPT (TOP/BOTTOM) 9A-C0199-1042C HOUSING, 3 K SST, 1/2 X 1/2 NPT 9A-CS787-0058C HOUSING, PRESSURE, DRILLED (MATCH SWP AND PORTS WITH ITEM 2) 1 HOUSING, 1 K SST, 1/4 X 1/4 NPT 9A-CS787-0072C HOUSING, 1 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0060C HOUSING, 1 K SST, 1/2 X 1/4 NPT (TOP/BOTTOM) 9A-C0199-1037C HOUSING, 1 K SST, 1/2 X 1/2 NPT 9A-CS787-0026Z HOUSING, 3 K SST, 1/4 X 1/4 NPT 9A-CS787-0067C HOUSING, 3 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0056Z HOUSING, 3 K SST, 1/2 X 1/4 NPT (TOP/BOTTOM) 9A-C0199-1041C HOUSING, 3 K SST, 1/2 X 1/2 NPT 9A-CS787-0059C BOLT, HOUSING, 1 K 9A-C0199-1345C BOLT, HOUSING, 3 K 9A-C0199-0085C 12 PLUG, PIPE, 1/4"NPT, 316 SST 9A-C0199-0214C PLUG, PIPE, 1/2"NPT, 316 SST 9A-C0199-0215C 6 GASKET, PRESSURE HOUSING, NICKEL 9A-C0199-0184C 2 7 LABEL, HIGH PRESSURE 9A-0199-0194C 1 8 LABEL, LOW PRESSURE 9A-0199-0195C 1 9 BRACKET, MOUNTING, 1 K MODEL 200A/289A 9A-C0199-1493B 1 BRACKET, MOUNTING, 3 K MODEL 200A/289A 9A-CS787-0047Z 10 BRACKET, MOUNTING, 3 K MODEL 581A 9A-C0199-1109B BRACKET, CASE MOUNTING - MODEL 200A/289A 9A-CS748-0006Z 2 1 BRACKET, CASE MOUNTING - MODEL 581A 9A-C0197-1019C 11 SPACER, INDICATOR BRACKET - MODEL 200A/289A 9A-C0199-0006C 12 SCREW, HEX WASHER HEAD, 3/8-16 X 1-1/8 9A-C0002-1009T 2 13 SCREW, HEX HD, 3/8-16 X 3/4 - MODEL 581A 9A-C0116-0007J 2 14 BRACKET SPACER 9A-C0199-0003C 1 A-32 2 Model 199 Differential Pressure Unit Section 5 Table 5.1—Model 199 Parts List Part No. Per Unit SCREW, FL HEX SOC CAP HD 3/8-16 X 7/8, ST MODEL 200A/289A 9A-C0240-0003J 1 SCREW, FL HEX SOC CAP HD 3/8-16 X 1 MODEL 581A 9A-C0240-0004J Item 15 16 17 Description TAG, S/N, MODEL 200A/289A 9A-C0199-0002G TAG, S/N, MODEL 581A 9A-C0224-0003G DRIVE SCREW, RD HD, #0 X 3/16, SS MODEL 200A/289A 9A-C0600-1003J 4 DRIVE SCREW, RD HD, #0 X 3/16, SS - MODEL 581A 1 2 18 SPACER, MOUNTING BRACKET - MODEL 200A/289A 9A-CS787-0008Z 2 19 WASHER, SPLIT LOCK, 3/8, SST 9A-C0003-0093K 5 20 SCREW, CAP HEX HD 3/8-16 X 1-1/2 ST ZP MODEL 200A/289A 9A-C0210-0011J 2 21 SCREW, CAP HEX HD 3/8-16 X 1 ST ZP, 1 K MODEL 200A/289A 9A-C0210-1007J 2 SCREW, CAP HEX HD 3/8-16 X 3/4 ST ZP, 3 K MODEL 200A/289A 9A-C0210-0012J SCREW, CAP HEX HD 3/8-16 X 3/4 ST ZP, 3 K MODEL 581A 9A-C0116-0007J SCREW, CAP HEX HD 3/8-16 X 1 ST ZP MODEL 200A/289A 9A-C0210-1007J SCREW, HEX HD, 3/8-16 X 1 - MODEL 581A 9A-C0116-0006J 22 1 23 SPACER, CENTER PLATE - MODEL 200A/289A 9A-CS787-0009Z 1 24 SPACER - BLACK EPOXY, 1 K - MODEL 200A/289A 9A-CS787-0006Z 2 25 SPRING PUSH ROD 9A-C0199-0049C 1 26 LOCK NUT, SPRING ADJUST 9A-C0199-0144C 1 27 SPRING RETAINER POST, ROUND, 10-19" WC SPRINGS 9A-C0199-0257C 8 SPRING RETAINER POST, HEX, 20-400" WC SPRINGS 9A-C0199-1337C NUT, SPRING POST, 8-32, ROUND, 10-19" WC SPRINGS 9A-C0199-0258C 28 NUT, SPRING POST, 6-32, HEX, 20-400" WC SPRINGS 9A-C0500-0028J 29 SCREW, CALIBRATION SPRING RETAINER, RD HD, 6-32 X 5/16, SST, 15-115 PSI SPRINGS 9A-C0111-0049J 30 CALIBRATION SPRING ASSEMBLY, 3-3/4 BELLOWS 8 8 1 SPRING ASSY, INC, 0 - 10" WC 9A-C0199-1385B SPRING ASSY, INC, 0 - 12" WC 9A-C0199-1387B SPRING ASSY, INC, 0 - 14" WC 9A-C0199-1388B SPRING ASSY, INC, 0 - 16" WC 9A-C0199-1392B SPRING ASSY, INC, 0 - 18" WC 9A-C0199-1393B SPRING ASSY, INC, 0 - 20" WC 9A-C0199-1389B SPRING ASSY, INC, 20 - 22" WC 9A-C0199-1386B A-33 Section 5 Model 199 Differential Pressure Unit Table 5.1—Model 199 Parts List Item 30 (cont.) 31 A-34 Description Part No. Per Unit 1 SPRING ASSY, INC, 23 - 27" WC 9A-C0199-1391B SPRING ASSY, INC, 28 - 31" WC 9A-C0199-1395B SPRING ASSY, INC, 32 - 38" WC 9A-C0199-1397B SPRING ASSY, INC, 39 - 46" WC 9A-C0199-1390B SPRING ASSY, INC, 47 - 55" WC 9A-C0199-1410B SPRING ASSY, INC, 56 - 64" WC 9A-C0199-1396B SPRING ASSY, INC, 65 - 72" WC 9A-C0199-1399B SPRING ASSY, INC, 73 - 79" WC 9A-C0199-1402B SPRING ASSY, INC, 80 - 88" WC 9A-C0199-1412B SPRING ASSY, INC, 89 - 96" WC 9A-C0199-1394B SPRING ASSY, INC, 97 - 107" WC 9A-C0199-1420B SPRING ASSY, INC, 108 - 120" WC 9A-C0199-1409B SPRING ASSY, INC, 121 - 130" WC 9A-C0199-1405B SPRING ASSY, INC, 131 - 142" WC 9A-C0199-1411B SPRING ASSY, INC, 143 - 155" WC 9A-C0199-1415B SPRING ASSY, INC, 156 - 167" WC 9A-C0199-1398B SPRING ASSY, INC, 168 - 183" WC 9A-C0199-1403B SPRING ASSY, INC, 184 - 195" WC 9A-C0199-1407B SPRING ASSY, INC, 196 - 212" WC 9A-C0199-1426B SPRING ASSY, INC, 213 - 232" WC 9A-C0199-1401B SPRING ASSY, INC, 233 - 245" WC 9A-C0199-1406B SPRING ASSY, INC, 246 - 258" WC 9A-C0199-1417B SPRING ASSY, INC, 259 - 276" WC 9A-C0199-1418B SPRING ASSY, INC, 277 - 291" WC 9A-C0199-1419B SPRING ASSY, INC, 292 - 316" WC 9A-C0199-1425B SPRING ASSY, INC, 317 - 349" WC 9A-C0199-1422B SPRING ASSY, INC, 350 - 383" WC 9A-C0199-1428B SPRING ASSY, INC, 384 - 400" WC 9A-C0199-1437B CALIBRATION SPRING ASSEMBLY, 2-1/8 BELLOWS 1 SPRING ASSY, INC, 0 - 15 PSI 9A-C0199-1400B SPRING ASSY, INC, 0 - 17 PSI 9A-C0199-1408B SPRING ASSY, INC, 0 - 18 PSI 9A-C0199-1435B SPRING ASSY, INC, 0 - 21 PSI 9A-C0199-1416B SPRING ASSY, INC, 0 - 24 PSI 9A-C0199-1414B SPRING ASSY, INC, 0 - 27 PSI 9A-C0199-1421B SPRING ASSY, INC, 0 - 30 PSI 9A-C0199-1413B SPRING ASSY, INC, 0 - 35 PSI 9A-C0199-1424B Model 199 Differential Pressure Unit Section 5 Table 5.1—Model 199 Parts List Item 31 (cont.) 32 Description Part No. Per Unit 1 SPRING ASSY, INC, 0 - 40 PSI 9A-C0199-1429B SPRING ASSY, INC, 0 - 45 PSI 9A-C0199-1427B SPRING ASSY, INC, 0 - 50 PSI 9A-C0199-1423B SPRING ASSY, INC, 0 - 60 PSI 9A-C0199-1445B SPRING ASSY, INC, 0 - 75 PSI 9A-C0199-1446B SPRING ASSY, INC, 0 - 80 PSI 9A-C0199-1464B SPRING ASSY, INC, 0 - 90 PSI 9A-C0199-1465B SPRING ASSY, INC, 0 - 100 PSI 9A-C0199-1466B SPRING ASSY, INC, 0 - 115 PSI 9A-C0199-1467B SCREW, SET, 6-32 X 1/4 - MODEL 581A 9A-C0320-1010J 1 A-35 Section 5 A-36 Model 199 Differential Pressure Unit Model 199 Differential Pressure Unit (DPU) Section 6 Section 6—Dimensional Drawings Figure 6.1—Dimensional drawing, Model 199 DPU, rear view Figure 6.2—Dimensional drawing, Model 199 DPU, side view A-37 Section 6 Model 199 Differential Pressure Unit (DPU) Table 6.1—Model 199 DPU Dimensions Pressure Rating psi (bar) Dim. A Dim. B Dim. C inches (mm) inches (mm) inches (mm) 1,000 (69) 6-5/8 (168.3) 2 (50.8) 2-9/64 (54.4) 12 3,000 (207) Ø 7 (177.8) 2 (50.8) 2-9/64 (54.4) 12 All Standard pipe fittings furnished by customer. (Metric conversions are approximate.) A-38 # Bolts Product Warranty A.Warranty Cameron International Corporation (“Cameron”) warrants that at the time of shipment, the products manufactured by Cameron and sold hereunder will be free from defects in material and workmanship, and will conform to the specifications furnished by or approved by Cameron. B. Warranty Adjustment 1. If any defect within this warranty appears, Buyer shall notify Cameron immediately 2. Cameron agrees to repair or furnish a replacement for, but not install, any product which within one (1) year from the date of shipment by Cameron shall, upon test and examination by Cameron, prove defective within the above warranty. 3. No product will be accepted for return or replacement without the written authorization of Cameron. Upon such authorization, and in accordance with instructions by Cameron, the product will be returned shipping charges prepaid by Buyer. Replacements made under this warranty will be shipped prepaid. C. Exclusions from Warranty 1. THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER EXPRESSED OR IMPLIED WARRANTIES OF MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE. 2. Components manufactured by any supplier other than Cameron shall bear only the warranty made by the manufacturer of that product, and Cameron assumes no responsibility for the performance or reliability of the unit as a whole. 3. “In no event shall Cameron be liable for indirect, incidental, or consequential damages nor shall the liability of Cameron arising in connection with any products sold hereunder (whether such liability arises from a claim based on contract, warranty, tort, or otherwise) exceed the actual amount paid by Buyer to Cameron for the products delivered hereunder.” 4. The warranty does not extend to any product manufactured by Cameron which has been subjected to misuse, neglect, accident, improper installation or to use in violation of instructions furnished by Cameron. 5. The warranty does not extend to or apply to any unit which has been repaired or altered at any place other than at Cameron’s factory or service locations by persons not expressly approved by Cameron. Product Brand Barton® is a registered trademark of Cameron International Corporation (“Cameron”). + 603.5569.0501 [email protected] RUSSIA
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