Barton 202E recorder manual
Contents
1. KR SHAFT MERS nna 3 O CLOCK REF 50 D P RECORDER CLIP 9 SHOWN LOCKED POSITION EUM LOCK SCREW DIE CAST COUNTERWEIGHT The static pressure connection is located on the back of the recorder case Static pressure introduced through the tubing causes the spiral or helix to unwind A reduction of pressure within the tubing causes the element to wind more tightly Sensor elements are available in various alloys for a variety of pressure ranges See Static Pressure Element Table on next page 4 Static Pressure Element Table Range 0 20 to 0 33 0 34 to 0 65 0 66 to 0 120 0 66 to 0 132 0 121to 0 180 0 121to 0 183 0 133to 0 240 0 181to 0 272 0 184to 0 264 0 241to 0 370 0 265to 0 390 0 273to 0 420 0 371to 0 600 0 391 to 0 600 0 421to 0 615 0 601to 0 850 0 616to 0 850 0 851to 0 1200 0 1201 to 0 1870 0 1871 to 0 3100 0 3101 to 0 4800 0 4801 to 0 6800 0 4801 to 0 7200 Beryllium Copper Part Number 0044 0028 T 0044 0029 0044 0101 T 0044 0097 T 0044 0018 T 0044 0098 T 0044 0019 T 0044 0020 0044 0022 0044 0024 0044 0026 316 Stainless Steel Steel Part Number 0044 0040 T 0044 0035 T 0044 0099 T 0044 0036 T 0044 0044 T 0044 0041 T 0044 0100 T 0044 0042 0044 0046 0044 0048 0044 0050 0044 0054 Part Number 0044 0102 T 0044 0103 T 0044 0104 T2. PRESS CONN SEE TABLE PRESS CONN 8 PLACES SEE TABLE PRESS CONN TYR 2 PLACES SEE TABLE ALT 2 OR SLIP PIPE LENGTH TO SUIT MTG BRKT SINGLE STRAP SIDE VIEW CLAMP 2 N P T OUTLET 0000 5 UNIT 2 AL PIPE SIDE VIEW MTG BPKT WALL REF PIPE MOUNTING OF CASE CONNECTIONS WHEN CONNECTIONS ARE SWITCHED TO BOTTOM OF CASE 2 PIPE NIPPLE LENTGH TO SUIT ALL STANDARD PIPE FITTINGS FURNISHED BY CUSTOMER 2 0 SUITABLE FOR USE WITH AMINCO FITTINGS AMERICAN 2 FLOOR FLANGE INST SILVER SPRINGS MD OR EQUAL ALTERNATE FITTING CAN BE REVERSED WHEN ORDERED OR CAN FOR WALL MOUNTING BE ROTATED 180 IN THE FIELD NOTES 1 12 FORGED ALLOY STL 4140 FORGED ST STL 36 __ MONEL K500 FORGED STL 15 1 CER ALUMINUM 35076 TOP BOT TOM NO OF N AT ERIAI PRESS CONNECTION BOLTS HOUSING MATERIAL 28 PULSATION DAMPNER DUST CAP PRESS GAUGE CONN T HSG CHART DRIVE CONN 5 M RT THD FOR REAR VIEW CONDUIT PIPE MOUNTING 35 8 Be 4 PLS PULSATION DAMPNER 4 SIDE VIEW 2 PANEL MOUNTING PANEL MOUNTING CUTOUT E ALLOW A SPACE OF 9 FROM SIDE OF OTHER APARATUS TO OF INSTRUMENT 29 SECTION 5 INSTALL DIMENSIONAL DRAWINGS Cont Model 202E w Temp Element 0202 1011 3 BOTTOM PRESS CONN TYP 2 PLACES SEE TABLE
3. 0 75 of full scale SP Accuracy tii 1 0 of full scale Product Warranty A Warranty NuFlo Technologies Inc warrants that at the time of shipment the products manufactured by NuFlo Technologies Inc and sold hereunder will be free from defects in material and workman ship and will conform to the specifications furnished by or approved by NuFlo Technologies Inc B Warranty Adjustment 1 2 3 If any defect within this warranty appears Buyer shall notify NuFlo Technologies Inc immediately NuFlo Technologies Inc agrees to repair or furnish a replacement for but not install any product which within one 1 year from the date of shipment by NuFlo Technologies Inc shall upon test and examination by NuFlo Technologies Inc prove defective within the above warranty No product will be accepted for return or replacement without the written authorization of NuFlo Technologies Inc Upon such authorization and in accordance with instructions by NuFlo Technologies Inc the product will be returned shipping charges prepaid by Buyer Replacements made under this warranty will be shipped prepaid C Exclusions from Warranty 1 2 3 4 THE FOREGOING WARRANTY IS IN LIEU AND EXCLUDES ALL OTHER EXPRESSED OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE Components manufactured by any supplier other than NuFlo Technologies Inc
4. User Manual Manual No 10060 Rev B 05 2004 Section 1 Introduction Page 1 Pressure Elements Chart Drive Tables sss Page 5 6 Section 2 Installation Calibration Check Page 7 Section 3 Maintenance amp Calibration sessist Page 13 Section 4 Troubleshooting Page 26 Section 5 Installation Drawings eee Page 28 Section 6 Parts 1184 2 1 34 Specification DPU Instrument sse Page 39 SECTION 1 INTRODUCTION General The Barton Model 202E single DP Flow Recorders measure and record system operation parameters including gas and liquid flow rate liquid level in a vessel and other system variables that can be measured by differential pressure and static pressure methods Main Components Differential Pressure Unit The Barton Model 199 Differential Pressure Unit DPU actuates the recorders The DPU is a dual bellows assembly enclosed within pressure housings The bellows are liquid filled and withstand overranges equal to the working pressure of the housing without calibration change Movement of the bellows is transmit ted through a torque tube from the DPU to the recording mechanism The torque tube is hermetically sealed to eliminate friction and leakage it does not require lubrication SAFETY Before installing this instrument become familiar with the installation instructions i
5. DRIVE ARM DPU TORQUE TUBE SHAFT DRIVE ARM LOCK SCREW FULL SCALE Bc OVER RANGE STOP RECORDER PEN COUNTERWEIGHT AT 50 POSITION GWU KD LA 3 O CLOCK REF 50 DP Wh A iw TIME LINES RECORDER DETAILA CHART RECORDER HUB CLIP LOCKED POSITION DIE CAST COUNTERWEIGHT Static Pressure Element This element measures static pressure in a piping system from 0 to 30 inches of Hg mercury vacuum or from 0 to 10 000 psi The sensor element is a bourdon tube consisting of a slightly flattened cross section of tubing coiled into a helix or flat spiral The outer end of the tubing is sealed and attached to a drive arm which is attached to the static pressure connection tubing The Static Pen mechanism is shown below RANGE ARM amp COUNTERWEIGHT PEN MOUNT LOCK SCREW 22 9 Q S ES STATIC PRESSURE SESS ELEMENT Y T PEN SHAFT FABRICATED COUNTERWEIGHT RANGE ARM SEE DETAILA CLAMP BLOCK SCREW DRIVE LINK LINK TAB e UBING 2 LINK SCREWS RECORDER ADJUST LEVER ARM SCREW ASSEMBLY FOR FINE 5 DRIVE ARM ADJUST THUMB NUT FOR FINE ADJUST THUMB NUT NN LOCK SCREW STATIC PRESSURE PEN DED SHOWN AT ZERO POSITION b DIFFERENTIAL PRESSURE 2 Sy N SHOWN AT 50 POSITION 2 Eh s 22 DETAIL IN N 2 AS
6. c Apply 50 pressure The pen should be on the 50 chart line If the pen is low lengthen the linkage to make a correction 40 times as great in the low direction Adjust the pen to 50 as in step 8 a refer to page 12 If the pen is high shorten the linkage to make a correction 40 times as great in the high direction Adjust the pen to 50 as in step 8 a Assure all linkage screws are retightened Repeat step 8 until calibration of all three points 0 50 and 100 indication is achieved To assure accuracy a nine point calibration check 1 24 50 74 and 100 ascending and descending must be run Adding Counterweight to 2 Pen DP Refer to page 12 A Fabricated Counterweight For 3 or 4 Pen Flow Recorders T 2 3 4 Disconnect the drive link from the range arm Remove the 2 pen from the pen mount note approximate position from range arm Remove the range arm from the shaft and slip the counterweight to about mid point Position approximately as shown on page 12 and secure in place Replace the range arm to approximate position note step 2 and secure in place Reassemble in pen mount and prepare for calibration For 2 Pen Flow Recorders t9 4 Disconnect drive link from the range arm Remove the 2 pen from the pen mount Slip the counterweight over the shaft in front of the pen shaft length is approximately 9 16 and position approx as shown on page 12 and secure in place R
7. Range Arm and Drive Arm Lock Screws Continued TEST APPROXIMATELY Y INCH DRIVE ARM DRIVE ARM CLAMP BLOCK CLAMP SCREW WRENCH 0163 0044 C TO TIGHTEN 4 Test for tightness by moving free end of drive arm approximately 1 2 inch in either direction Drive arm should spring back without yielding B Overrange Stops Adjustment Refer to pages 2 and 12 Note Prepare a calibration chart by cutting a chart into the wedge shape shown on page 12 and gluing it to a piece of similarly shaped cardboard of stiffener This allows calibration of the pens and permits access to the flow recorder mechanism when linkage adjustments are necessary Overrange stops may be adjusted to prevent the pen from excessive overtravel check for interference at zero and full span per the following 1 2 3 gt 10 11 12 13 14 Unlock the flow recorder hub clip Remove the chart Remove the chart plate by disengaging the chart plate latches on both sides and sliding the chart plate retainer brackets Mount a calibration chart onto the flow recorder hub and lock in place Loosen the screws on zero and full scale overrange stops Vent the DPU low pressure housing Apply sufficient pressure to the high pressure housing to move the pen approximately 3 8 inch above 100 indication Position the zero overrange stop so that it contacts the drive arm Tighten the zero scale overrange stop screw Apply sufficient pressure to the
8. 0044 0105 T 0044 0106 T 0044 0107 T 0044 0108 T 0044 0109 T 0044 0110 T 0044 0111 T 0044 0112 T 0044 0113 T Chart Drive Spiral wound chart drives electrical or mechanical can be selected to fit a wide variety of chart speeds or time intervals to reduce maintenance time All chart drives are interchangeable and fitted with a flow recorder hub clip which locks the chart in place Explosion proof electrical drives are also available Spring Wound Macnick Electric Lux Wind 8 Day Wind 110V 60 Cycle Rotation Part Number Part Number Part Number 96 Minute 0043 0001 T 2 Hour 0042 0022 T 3 Hour 0042 0023 T 4 Hour 0042 0024 T Consult Factory 6 Hour 0042 0025 T 8 Hour 0042 0026 T 0043 0006 T 12 Hour 0042 0027 T 0043 0002 T 24 Hour 0042 0015 T 0042 0001 T 0043 0003 T 72 Hour 0043 0008 T 7 Day 0042 0016 T Consult Factory 0043 0004 T 8 Day 0042 0030 T Consult Factory 30 Day 0043 0011 T 24 Hour 96 Minute 0042 0020 T 24 Hour 7 Day 0042 0017 T 24 Hour 8 Day 0042 0031 T electric Drive Rotation can be increased 60 times by the use of a 60 RPM motor Bellows Unit Assembly BUA y Drive Arm Hole Plug Su Do Not Loosen Range Spring Assembly Torque Tube Gland Nut Do Not Loosen Torque Tube Gland Nut Range Spring 4 Do Not Loosen Post Torque Tube Range Spring Shaft 4 Asse
9. SIDE VIEW PIPE MOUNTING PRESS CONN 2PLS SEE TABLE amp OF PULSATION DAMPNER FAST RESPONSE OPTIONAL N PT PIPE BRKT OF TEMP GAGE pie Mie CASE ALTERNATE SINGLE STRAP CLAMP 2 FLOOR FLANGE 2 NPT OUTLET ALTERNATE FITTING FOR WALL MOUNTING WALL REF LOW PRESS REAR VIEW HIGH PRESS HOUSING PIPE MOUNTING HOUSING N P FEMALE FOR CONDUIT CONNECTION ELECTRIC CHART DRIVE PULSATION DAMPNER DAST CAP 30 SIDE VIEW PANEL_MOUNTING DPU DATA PLATE ALT 2 STL SLIP ON PIPE NTG BRET 1p xiO STD LENGTH FIFYIRLE SPIRAL ARMOR Bears BENDABLE EXTENSION 4 3 SEPARABLE SOCKET PANEL MOUNTING CUTOUT PSI P OS ISSUED E E ALLOW A SPACE OF 9 FROM SIDE toorr AT GOO F AT 80 OF OTHER AFARATUS TO 4 OF SEPAPABLE SOCKET PRESSURE RATING FORGED ALLOY STL_4142 FORGED STN STL 329 a FORGED ALLOY STL 4142 12 STL 329 12 FORGED ALLOY STL 442 FORGED TINE STL 96 MONEL K 500 FORGED STL 5 C1018 FORGED STNL STL 3 FORGED STL 157 CAST ALUMINUM 36070 NPT NO OF PRESS CONNECTION POLT S HOUSING MATERIAL 4 ALL DIMENSIONS IN INCHES 3 ALL STANDARD PIPE FITTINGS FURNISHED BY CUSTOMER 2 SUITABLE FOR USE WIT
10. Use the toque values listed on page 21 7 Calibrate in accordance with the technical manual for the actuated instrument C 3 3 4 Inch Diameter Bellows With Kickoff anti stick Spring NOTE The kickoff spring is supplied with the 0 40 w c and lower range DPUs as standard equipment It is optional with 0 50 w c DPUs 1 Remove the instrument from service Set the pointer or pen at zero using the instrument zero adjustment 2 Remove the pressure housing bolts and remove the low pressure hous ing 3 With the pointer set at zero remove the lock nut four spring retainer nuts washer and lock nut and range spring assembly NOTE The pointer will shift from zero This is a normal action and the pointer should not be readjusted at this time 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 NOTE 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 NO AND SIZE OF SPRINGS AS SPECIFIED Y LOCK NUT V KICK OFF SPRING Y E ANT STICK SPACERS SPRING SPUD Lock NUT WASHER PUSH ROD 005 NOTE OBTAIN p29 DIM BY ADDING SPACERS RETAINER NUT 5 Position the range spring assembly over the retainer posts and replace the retainer nuts 23 Insert the tubing between the range springs
11. wiring available upon request Chart Installation Perform the following steps to install the chart 1 Open the recorder door and release the chart lock on chart drive hub 2 Raise the pen lifter arm and slide the chart between the pen s and the chart plate Insert the chart in the chart guides in the chart plate and locate the hole in the chart onto the chart hub Place the pressure chart onto the chart hub Then lower the pen lifter arm and position the chart to place the pen s on the desired chart time line 3 Secure the chart in place with the chart hub lock Startup Note careful not to subject the DPU to unnecessary shock or overrange pressure during operations 1 Always start with the block valves closed Note Do not perform a zero check with only one block valve closed If seal pots are used some of the sealing fluid will be lost or displaced In gas service a standard wave effect may occur that will displace the zero reading 10 2 Perform zero check on the instrument per the following For Gas Service a Verify the instrument is mounted approximately level and is properly connected to the pressure source b Tighten process connections to each DPU housing Check manifold and piping for leaks 1 Close shutoff valves open the equalizer or bypass valve s and then slowly open one shutoff valve to pressurize the instrument 2 When system is pressurized close both valves opened in Step 1 3 Any
12. DP range of the DPU WARNING Explosion Hazard No Organic compounds oil grease dirt or scale of any kind can be tolerated in an oxygen installation Calibration Check Note There should be enough pen pressure to produce a continuous line The pen should spring free of chart when chart is pushed inward about 1 8 inch If necessary adjust pen pressure by bending pen arm in the required direction A Differential Pressure Pen To adjust the instrument to factory set calibration levels 1 Verify the instrument is positioned approximately level and is securely mounted 2 Connect the high pressure housing into the calibration setup INSTRUMENT TO BE CALIBRATED NOTE CHANGE PRESSURE SLOW LY IN DISCRETE STEPS DO NOT USE A BLEED SYSTEM REGULATOR BLOCK VALVE j MANOMETER OR SIMILAR PRESSURE REFERENCE GAGE VENT VALVE TYPICAL CALIBRATION SETUP ACCURATE INDICATOR WITH THE DESIRED RANGE INSTRUMENT TO BE CALIBRATED VENT THE LOW PRESSURE HOUSING OF BOTH INSTRUMENTS TO ATMOSPHERE FLEXIBLE HOSE CONNECT THE HIGH PRESSURE HOUSINGS IN PARALLEL SQUEEZE BULB TO SIMULATE DIFFERENTIAL PRESSURES PORTABLE CALIBRATION SETUP 3 Vent the DPU low pressure side to atmosphere by removing vent plug from the low pressure housing 4 Remove the dust cap of the pulsation dampener valve using a regular screwdriver Open the dampener valve by turning it fully counterclock w
13. SOCK SCREW 3 O CLOCK POSITION PEN SHAFT 50 DP PIVOT POINT 11 FABRICATED RANGE COUNTERWEIGHT PEN ZERO gt RANGE ADJUST SEE DETAIL ADJUST SCREW SN SCREW FINE ADJUST LINK SCREWS LINEARITY ADJUSTMENTS DRIVE LINK DRIVE LINK POINT TYPICAL LINEARITY ADJUST SCREW DRIVE ARM FINE ADJUST DPU TORQUE TUBE SHAFT DRIVE ARM LOCK SCREW FULL SCALE OVER RANGE STOP RECORDER PEN COUNTERWEIGHT AT 50 POSITION p M 950 D P MAR TIME LINES RECORDER HART RECORDER HUB CLIP LOCKED POSITION MIDNIGHT 986 DETAIL DIE CAST COUNTERWEIGHT 12 SECTION 3 MAINTENANCE AND CALIBRATION Required Tools Tool Purpose 1 2 inch Open End Wrench Pushrod Bellows Cup Connection Modified Box Open End 7 16 inch Wrench Kickoff Spring Lock Nut Torque Wrench 100 ft lbs Pressure Housing Bolts Screwdriver Bracket Screws Maintenance Generally Barton recorders require no maintenance other than replacement of the chart replenishment of the ink winding of the spring wound chart drives and occasional calibration In addition the operator should periodically check the door seal for wear and the pressure fittings for tightness Differential Pressure Pen Calibration Refer to page 12 To calibrate the DP pen 1 Make sure chart plate is on same plane and flush with hub fl
14. Spring Adjsutment Not Shown Keys Set of Hex Not Shown 0199 0142 0016 0013 Indicates recommended spare parts A R As Required When ordering parts specify instrument serial number 38 199 DPU Specifications uodn ejqejre e 94 IJAN 08 S4 L0 HIA 3OVN 120W payloads eq requi Sz 0 M 01 y JO eui 5 ezis ueewjeq zou sBuuds pue doi 2 1 suonoeuuoo 1 uodn q N Y SIN sqnis suonoeuuoo Jo sed pue sezis JOYIO reg 6 9 0 01 09 0 154 001 0 01 29 02 0 eunsseud eyerpeuueju requi 66 0 S2 7274 0 0 10 requi 29 0 29 9 M 92 0 92 eq eBuei requi 21 0 09 0 1 jeroeds seDuei 1148 10 191092 0497 G310N 21298 ini jo 01 0 9125 N Jo GO O ejeos Jo 5 0 eq 6 9 0 01 1 0 134 001 0 01 51 0 ejeos Jo 9 0 requi 66 0 09 0 2 00 0
15. cl DRIVE S 9 LINI LINK TAB Ty H TUBING N CONNE PEN ZERO 542 RECORDER ADJUST MNK SCREWS LEVER ARM CHART SCREW ASSEMBLY FOR FINE DRIVE ARM THUMB NUT FOR FINE ADJUST THUMB NUT LOCK SCREW STATIC PRESSURE PEN up M SHOWN AT ZERO POSITION DIFFERENTIAL PRESSURE PEN SHOWN 50 POSITION p DETAIL A PEN SHAFT 3 O CLOCK REF 9 50 DP LOCK SCREW DIE CAST COUNTERWEIGHT RECORDER HUB CLIP SHOWN IN LOCKED POSITION 16 Static Pressure Pen Calibration Refer to page 16 To calibrate the static pressure pen and associated linkage proceed as follows 1 Adjust the static range arm and drive arm at precisely the same distance from the back of the case 2 static drive link in the fourth hole from the pen shaft of the range arm 3 Adjust static pressure linkage to form 90 angles between the drive link see above illustration and pivot points of the associated linkage as follows a Apply 50 static pressure center thumb nut on the drive arm and arrange static linkage as shown on page 16 b Seta 90 angle between drive arm amp link Tighten clamp block screw c the length of link to get a 90 angle between range arm and link d Slip the range arm on pen shaft to 50 on chart Notice Verify that all linkage is free Adjust range arm and drive arm at precisely the same
16. leakage will be indicated by pen movement up or down the scale If leakage is indicated check all manifold and piping joints Tighten as necessary 4 Repeat Steps b 1 through b 3 until no pen movement occurs c The pen should indicate zero If it does not indicate zero check for gas or liquid entrapment in the lines or in the DPU depending upon orientation of piping and service If no entrapment is found set the pen to zero using the pen zero adjustment screw d Close equalizer valve and observe the pen 1 If zero no further check is needed 2 If upscale a leak may exist on the low pressure side Check and tighten connections 3 If downscale a leak may exist on the high pressure side Check and tighten connections 4 If still slightly off make a fine adjustment using the pen zero adjustment screw For Liquid Service a service lines with process fluid Vent and bleed each side of DPU before tightening the vent plugs b Perform Steps 2 a through 2 d in For Gas Service procedure above Open shutoff valve Leave the equalizer valve closed Flow recorder is now operational 3 Adjust the dampener valve as required Operation To place the instrument into operation 1 Turnon drive 2 Verify that the pen has ink and is in contact with chart 3 Turn on pressure to the recorder 11 RANGE ARM 4 COUNTERWEIGHT
17. 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 four case retaining screws and remove the case assembly 4 Remove three mounting bracket screws and remove bracket 18 5 Remove the pressure housings bolts and pressure housings 26 6 Place the pressure housings 26 on the replacement bellows unit assembly 1 and insert and start only the pressure housing bolts 7 Attach the case mounting bracket 18 to the replacement assembly using three mounting bracket screws 8 Support the DPU and tighten and torque the pressure housing bolts to the specifications listed on page 21 9 Attach the case assembly using four case retaining screws 10 Attach linkage to DPU torque tube shaft WRENCH 1 8 HEX a Tighten clamp screw OUTPUT SHAFT until snug b Tighten further 1 3 to 1 2 turn of screw c Test by moving end of drive arm approx TEST 1 2 11 Replace adjust nents removed moved to gain access to DPU case mounting screws 12 Calibrate the instrument before returning it to ser vice DRIVE ARM CLAMP SCREW TORQUE TUBE LINK TO POINTER 25 SECTION 4 TROUBLESHOOTING Recorder Troubleshooting Table Problem Probable Cause Corrective Action Sources Loose links or movements Tighte
18. shall bear only the warranty made by the manufacturer of that product and NuFlo Technologies Inc assumes no responsibility for the performance or reliability of the unit as a whole In no event shall NuFlo Technologies Inc be liable for indirect incidental or consequential damages nor shall the liability of NuFlo Technologies Inc 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 NuFlo Technologies Inc for the products delivered hereunder The warranty does not extend to any product manufactured by NuFlo Technologies Inc which has been subjected to misuse neglect accident improper installation or to use in violation of instructions furnished by NuFlo Technologies Inc The warranty does not extend to or apply to any unit which has been repaired or altered at any place other that at NuFlo Technologies Inc s factory or service locations by persons not expressly approved by NuFlo Technologies Inc NuFlo Measurement Systems Canada 877 891 6540 A NuFlo Technologies Company helpdesk nuflotech com NuFlo Measurement Systems Singapore 14450 John F Kennedy Blvd Houston TX 77032 65 6737 0444 281 582 9500 www nuflotech com singapore nuflotech com Bognor Regis UK 44 1243 826741 uk nuflotech com For technical support in North America 1 800 654 3760 nuflotech nuflotech com Copyr
19. DPU low pressure housing to move the pen approximately 3 8 inch below zero indication Position the full scale overrange stop so it is in contact with drive arm Tighten the full scale overrange stop screw Unlock the flow recorder hub clip Remove temporary calibration chart Replace the chart plate by sliding it into the chart plate retainer brackets and engaging each side into the chart plate latches Install a regular recorder chart and lock it into place with chart hub clip Check the pens to make sure that they touch the chart if necessary straighten pens by sliding them between two fingers and curling in and out 19 DPU Replacement Before installing a replacement DPU the new DPU should be checked for proper torque tube rotation Torque 1 Mount the DPU on a suitable pipe stand and connect to Tube a standard pressure source Shaft 2 Adapt a graduated degree scale to torque tube housing 3 Adapt a pointer to exposed end of the torque shaft 4 Apply 100 percent differential pressure to the high pressure housing of the DPU The pointer attached to the torque tube shaft should indicate 8 degrees of travel DPU Cleaning and Inspection WARNING HIGH PRESSURE GAS INSTALLATIONS AND PRESSURES GREATER THAN 200 PSIG HIGH PRESSURE GAS HAZARD ON DISASSEMBLY OF THE DPU BEFORE REMOVING THE DPU HOUSING BOLTS PERFORM THE PRESSURE CHECK PROCEDURE See STEP below Notice If accumulation of solids or semi so
20. H AMINCO FITTINGS AMERICAN INST CO SILVER SPRING MD OR EQUIV 1 CAN BE REVERSED WHEN ORDERED OR CAN BE ROTATED 180 IN THE FIELD NOTES 31 SECTION 5 INSTALL DIMENSIONAL DRAWINGS Cont Model 199 DPU 0199 0903 3 HIGH PRESSURE HOUSING PRESSURE CONN TOP d BITTON SEE TABLE QS LOW PRESSURE HOUSING PRESSURE CONN 4 BOTTOM SEE TABLE NORMAL SHAFT ROTATION COUNTERCLOCKWISE MODEL 99 DPY WITH RECORDER BRACKET ALL OTHER DIMENSIONS AND INFORMATION AS ABOVE ALTERNATE PIPE MOUNTING ADAPTER 27 2 MATL STEEL THREADEL FOR Te OR WITH INCICATOR BRACKET 2 STANOARL PILE SEE NOTE 5 ELI ES 3000 PSI Qu ver FORGED 8 4500PS FORGED ALLOY ST 6000 FORGED ALLOY ST sa FORGED 557 17 4PH FORGED ALLOY ST 4142 6000 PSI FORGED SST 17 4PH 9 9 16 18UNF miau PRESSURE ousa marena NO OF BOLTS PRESSURE 32 PIPE MOUNTING ADAPTER MATL CAST ALUMINUM NOH THREADED FOR 1 2 STANDARD PIPE SEE NOTE 5 0 OF BOLTS SEE TABLE PULSATION DAMPNER OPTIONAL NO OF BOLTS TABLE S PIPE MOUNTING ADAPTER OF CAST ALUM WiLL BE FURIISHEL UNLESS OTHERWISE SPEC TIED SPECIFY PIPE 5 2 amp WHEN ORDERING THREADED STEEL ADAPTER 554 748 FOR USE KITH AMICO FITTINGS AMERICAN NST CO SILVER SPRINGS OQ E
21. IU BE REVERSED WHEN OR CAN BE ROTATED 30 THE FIELD ZUSE A QD CLEARANCE HOLE CASE FOR DIMENSION MARKED 8 4 TEMPERATURE RATING 200 NOTES 33 SECTION 6 PARTS DRAWING LIST 202E Parts Drawing 49 16 47 46 48 58 34 202E Parts List WN Description Door Assembly Flow Recorder Case Flow Recorder Assembly Pen Lifter Riser Chart Drive Door Latch Overrange Stop Riser Chart Plate Screw Fil Hd Chart Plate Bushing Door Stop Screw Cap 1 4 20 x 5 8 Riser Hinge Door Gasket Cover Plate Connection Pen Mount Assembly Dual Pen Mount Assembly Single Not Shown 0238 0013 B Static Pressure Connection Assembly 0238 0046 B Link Assembly 0238 0015 B Screw Rd Hd Self Tapping 6 32 x 1 4 0938 0001 J Screw Fil Hd 10 32 x 1 2 0114 0031 J Screw Rd Hd 10 32 x 5 16 0111 0085 J Screw Self Tapping 10 24 x 1 4 0946 0002 J Screw 10 24 x 5 8 SST 0918 1009 J Screw Rd Hd Plug 10 32 x 1 4 Not Shown 0111 0086 J Washer No 10 Flat Washer No 10 Shakeproof Plate Data Flow Recorder Screw Self Tap 1 4 20 Not Shown Hex Hd C Sunk Washer Chart Plate Not Shown Door Stop Assembly Door Latch Hook Assembly Gasket Cover Glass Glass Cover Clip Cover Glass Assembly Handle Door Latch Bushing Door Handle Not Shown Not Used Not Used Screw Self T
22. O 02 0 O 28 4 O8t 012 o d 0 syw einjejeduje 224409 wng reunan aqn 31228 aqn enbsoL SNOILVOIHIO3dS 09 SZ 51 00 29 20 00 51 00 28 60 H 09 92 92 09 OLS d H 06 0 S 06 0 S peo I0A TN Hd v Z1 19916 ssejureis 19915 1991 requi 66 0 724 00 0 eq 6 9 0 ISd 001 0 66 0 00 0 69 0 ISd 001 0 0 equi 09 0 M 02 0 1 0 isd 91 0 requi 62 0 o m 01 0 eq 1 0 184 91 0 91 19915 ssejureiS 4 81019 15 91 10915 359141215 91998 1529 Q O 66 59 8 1 2 q o 66 99 8 1 2 jeuoou ssejureig Buisnoy SAONVY 3unssaud 3 18VTIVAV 39 Instrument Specifications Die cast aluminum black epoxy resin paint waterproof and weather resistant hinged door neoprene gasket seal DP Accuracy 0 20 w c to 0 349 w c 0 5 of full scale 0 350 w c to 0 75 psi
23. T Steel Bolt Housing Stainless Steel 1000 psi Units Steel 2500 3000 and 4500 psi Units Alloy Steel Stud 1 2 20 x 6 5 8 6000 psi Units Screw Pipe Mounting Adapter Screw SCH Cap Steel 3 8 16 1 1 2 Lg Screw 3 8 16 x 5 8 Steel For Item 13 Adapter Pipe Mounting Nut Spring Retainer Stainless Steel For 3 3 4 Bellows Specify 0199 0019 0199 0049 0111 0049 J Specify 0199 0144 0199 0191 0199 0192 0199 1345 0199 0085 0199 1001 0210 0012 J 0220 1102 J 0310 0013 J 0199 0988 C 0500 0028 J Assembly Range Spring For 3 3 4 Bellows Specify Spacer Indicator Bracket 0199 0006 C Screw Indicator Bracket 0240 0003 J Bracket Specify Screw Indicator Bracket 0002 1009 T Screw Recorder Bracket 0002 0034 T Deleted Gasket Torque Tube Deleted Screw Recorder Bracket Gasket Pressure Housing 1000 psi Aluminum Units 2500 3000 and 4500 psi Steel Units 1000 3000 and 6000 psi Stainless Steel amp Monel Units Housing Pressure 0199 0209 C 0002 0033 T 0199 0026 C 0199 0027 C 0199 0184 C Washer Lock 3 8 Used with Items 10 amp 11 Specify Deleted 0003 0012 K Nut 1 2 20 6000 and 3000 psi Monel Units Used with Item 9 0199 1002 C Plug Dampener Valve Not Shown 0117 0015 J Deleted Wrench Range
24. TIONS PRESSURES GREATER THAN 200 PSI HIGH PRESSURE GAS HAZARD ON DISASSEMBLY OF THE DPU BEFORE REMOVING THE DPU HOUSING BOLTS PERFORM THE PRESSURE CHECK PROCEDURE See Cleaning and Inspection on page 20 NOTE 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 A 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 NOTE The pointer will shift from zero This 15 normal action and the pointer should not be readjusted at this point 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 conterclockwise u
25. UA photos on page 6 The built in Pulsation Dampener controls the flow of fill liquid between the high and low pressure bellows with an externally adjustable needle valve In applications where pulsation is not a problem the needle is set to the full open position 2 Adjusting Pulsation Dampener 1 Remove dust cover and insert 1 8 hex key into needle valve 2 Turn valve clockwise to closed position approx 3 turns 3 Back out valve 1 2 turn or as required to 2 5 reduce pulsations or shock pressures Recording Mechanism NEEDLE The recording mechanism is a linkage and pen DUST system that permanently records data It converts mechanical inputs from the and static pressure element to transcribe lines on a revolving chart All operative parts of the recorder mechanism are made of stainless steel for a longer field life The pen mount is exceptionally rugged All lines are adjustable Screw adjustments for zero range and linearity assure fast and accurate calibration The DP Pen mechanism is shown below PEN MOUNT RANGE ARM amp COUNTERWEIGHT LOCK SCREW 3 OCLOCK P PEN SHAFT up 4 FABRICATED RANGE ARM COUNTERWEIGHT PEN ZERO RANGE ADJUST SEE DETAIL ADJUST SCREW SCREW FINE ADJUST LINK SCREWS LINEARITY ADJUSTMENTS DRIVE LINK ZERO OVER RANGE STOP LINEARITY ADJUST SCREW FINE ADJUST DRIVE LINK POINT TYPICAL
26. and tighten the inboard lock nut Zero the pointer by adjusting the spud on the push rod Be sure that the kickoff spring is not engaged during this operation 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 during this operation 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 the original position The lock nut requires a special wrench for tightening See illustration below for information on how to modify a 7 16 inch 12 point box wrench 10 11 12 13 14 7 16 BOX OPEN END 9 32 154 E p Check the back clearance between the kickoff spring and the slot Use a wire feeler gage or comparable measuring device The clearance will vary between each individual slot but must be at least 0 005 inch for any one slot to prevent interference with instrument zero Add or remove washers as required to obtain the proper clearance Tighten the lock nut securely Install the jam nut and lock the spud to the push rod Hold with pliers If the spud was moved in step 9 return the spud to the proper position before tightening the jam nut Apply 100 percent negative pressure to the high pressure side of the DPU and repeat the clearance check and adjustment of step 9 Appl
27. ange The chart must be flat with the hub locked Also make sure the pens and pen arms are correctly connected and that they do not interfere with one another 2 With a chart locked into place move the pen from zero to full span and back to ensure that the pen travels along the time line If adjustments are needed loosen the two pen mount screws adjust the pen mount position until the pen follows the time line then tighten the pen mount screws 3 Disconnect the differential pressure drive link from the range arm Move both differential and static pressure pens to full span Adjust the static pen so that pens are approximately 7 15 minutes apart by adjusting the static pen arm mounting location on the pen arm shaft assembly Move both pens to the 50 indicating position Ensure that the pens don t interfere with one another Adjust static pens as necessary do not alter the differential pressure pen once it has been adjusted to the time line 4 Assure that there is enough pen pressure against the chart to produce a continuous line If necessary adjust the pen pressure by bending the arm in the required direction 5 Unlock the flow recorder hub clip Remove the chart and chart plate Note Prepare a calibration chart by cutting a chart into the wedge shape and gluing it to a piece of similarly shaped cardboard of stiffener This allows calibration of the pens and permits access to the flow recorder mechanism when linkage adjustmen
28. apping 0946 0002 J Flat Washer 0003 1064 K Pew Pe 202E Parts List continued 36 Description Pin Not Shown Gasket Door Arm Fountain Pen 1st or 2nd from Chart Pen Fountain Static 1st from Chart Pen Fountain Differential 2nd from Chart Static Shaft Arm Assembly Range Arm Assembly Block Clamp Lever Arm Assembly Drive Arm Assembly Element Static Pressure Drive Chart Shaft Pen Arm 1st from Chart Shaft Pen Arm 2nd from Chart Hub Chart Chart Drive Not Shown Rotation 30 Day 31 Day 24 Hour 7 Day 24 Hour 8 Day Screw 51 Hex 8 32 x 1 4 Pen Mount Top Plate Washer Lock 8 Pen Mount Top Plate Screw SI Fil Hd 6 40 x 1 4 Chart Drive Screw Set 2 56 x 5 32 Drive Arm Differential Pressure U nit Not Shown Counterweight Screw Counterweight Clamp 0003 0022 T 0096 1003 T 0238 0088 C 0014 0001 T 0014 0002 T 0202 0034 B 0238 0012 B 0250 0003 C 0238 0031 B 0238 0004 B See Table 1 2 See Table 1 3 0238 0006 B 0238 0007 B 0238 0033 B 0042 1006 T 0042 1004 T 0042 0017 T 0042 0031 T 0116 0014 J 0003 0036 K 0114 0017 J 0200 0040 C Specify 199 DPU Parts Drawing 199 DPU Parts List Bellows Unit Assembly Post Calibration Spring Retainer For 3 3 4 Bellows Rod Spring Push Screw Retainer 6 32 x 5 16 For 2 1 8 Bellows Spring Assembly Calibration Tension For 2 1 8 Bellows Nut Lock Plug Pipe 1 4 NPT Steel Plug Pipe 1 2 NP
29. dication DPU Liquids or Gases Trapped in Piping Vent Piping Block or Shuf off Valves Closed Open Block or Shut off Valves Piping Leaks on High Pressure Side Repair Leaks Housings Filled Up with Solids Restricting Clean Out Housing Bellows Movement _ Gas Trapped in Housing in Liquid Service or Bellows Unit Liquid Trapped in Housing in Gas Service Vent Housing High Pressure Housing Gasket Leaks Replace Gasket DPU Tampered With Return BUA for Repair Primary Orifice Partially Restricted or too Small Clean Out or Replace Source Piping from Primary Element to Leak in Low Pressure Side Piping Repair High DPU Indication Gas Trapped in Low Pressure Housing in Liquid Service or Liquid Trapped in Housing in Vent Housing Gas Service Bellows Unit Low Pressure Housing Gasket Leaks Replace Gasket Range Spring Broken or DPU Tampered With Return BUA for Repair Primary Install Dampening Device Upstream Element Flow Pulsating of DPU Run Liquid Trapped Gas Piping Gas Bubble Piping from in Liquid Piping ping Remove Erratic Element to Vapor Generator Incorrectly Installed Repipe Indication DPU Reference Leg Gassy or Liquid Vaporizing See Piping Instructions Obstructed Bellows Travel Clean Bellows Bellows Unit Gas Trapped in DPU High Pressure or Low Pressure Housing Remove See Startup Procedure 27 SECTION 5 INSTALL DIMENSIONAL DRAWINGS Model 202E 0202 1010 3 123 MIN
30. distance back of the case Adjust the lever arm and pen zero adjust screws to their midpoints all 90 midscale linkage angles must be measured 4 Release pressure and reset the pen to zero indication using pen zero adjust screw for fine adjustment 10 or less For major adjustments more than 10 loosen range arm lock screw and slip the pen to zero on chart and retighten lock screw Note It may be necessary to raise or lower the pivot point of the drive link on the range arm as in step 3 If counterclockwise movement of thumb nut step 5 does not increase span sufficiently move the pivot pin up to next pivot hole if clockwise movement of the thumb nut does not decrease span sufficiently move pivot pin down to the next pivot hole 5 Apply 10076 pressure and observe the pen Make the necessary adjustments by turning the drive arm thumb nut counterclockwise if the pen is slightly underranged and clockwise if the pen is slightly overranged Repeat zero and 10076 adjustment until calibration at these two points is achieved 6 Repeat steps 3 4 and 5 until full scale calibration is obtained 7 Apply 50 pressure and observe pen indication a If pen indicates high or low adjust drive link to make a correction approximately 40 times the error in the direction of the error b Reset the pen to the 50 line by slipping the pen shaft at the range arm pivot point c Repeat this step 7 as necessary 8 Release pressure and r
31. e DPU on a solid support to minimize vibration Tighten all points using a suitable compound Leaks in piping can cause measurement errors 7 Rotate the housing as necessary to place the connection in the proper posi tion The DPU has connections in the pressure housings to accommodate various pipe sizes See Section 5 8 Install a valve manifold connecting the DPU and the source of differential pressure to facilitate operation and checking of the DPU 9 Locate all shutoff and bypass valves so they are accessible from the front of the instrument Locate block valves at the source of differential pressure Application Considerations Flow Make sure the DPU high pressure housing is connected to the upstream tap of the primary device Note To prevent overheating the DPU during blowdown the operator should monitor the temperature by placing a hand on the pipe between the DPU and the manifold pipe containing the vent valves Liquid Level The process media can be used as a reference leg seal fluid when it is of a type that will condense in the reference leg under all conditions If process or process media characteristics prevent meeting the above require ments a special reference leg seal fluid will be 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
32. eassemble in pen mount and prepare for calibration B Die Cast Counterweight These counterweights slip over the pen shaft without disassembly This is applicable to a 2 pen or 3 pen assembly 1 2 Remove lockscrew from counterweight Slip over 2 shaft at any convenient location Replace lockscrew care fully orienting the counterweight in the position shown on page 12 Note The counterweight is die cast zinc subject to bending if too much torque is applied to the lockscrew C Calibration 1 After removal of the range arm complete recalibration is required In the previous section CALIBRATION OF DIFFERENTIAL PRESSURE PEN include step 7 set the counterweight to the 3 o clock position shown on page 12 with the differential set at 50 After the addition of the counterweight in front of the DP 2 pen apply 50 differential and set the counterweight at the 3 o clock position 1 5 The addition of the counterweight causes a zero offset but has little effect on span Reset zero check span and adjust as necessary After addition of the die cast counterweight orient to 3 o clock position at 50 differential as shown on page 12 Reset zero and check span Adjust as necessary for proper calibration 15 SP Pen Mechanism RANGE ARM amp COUNTERWEIGHT LOCK SCREW PEN MOUNT pen SHAFT FABRICATED COUNTERWEIGHT RANGE ARM DETAIL CLAMP 5 BLOCK SCREW N A ex
33. eed holes that discharge corrosive vapors or gases Do not apply wrench bar pressure to recorder case All fittings must be leaktight All tubing must be secure to minimize vibration Mount the instrument as level as possible 1 Flush Mounting a Cut opening in panel to the dimensions shown in Section 5 b Drill out pilot holes located on top and bottom of case Use No 1 0 288 drill Limit drill penetration and remove chips c Attach mounting brackets to case bottom with supplied self tapping screws d Slide case from front of panel into the panel cutout e Attach remaining mounting bracket and install panel mounting screws 2 Pipe Mounting a Place a suitable length of 2 inch pipe into a well secured floor or wall flange or attach the 2 inch pipe to existing pipe with a saddle that is fitted with a 2 inch NPT outlet b Thread the DPU onto the pipe orient the instrument with wrench or bar applied to the DPU bracket only and tighten retaining screws Piping Connect the pressure element to system pressure using tubing or pipe Pressure connection on outside of recorder case is 1 4 inch NPT female Electrical Connections Two knockouts are on the bottom of the case One knockout is on the back of the case to accommodate conduit clamping connections through which wiring is fed to the terminal strip The terminal strip is below the chart drive motor The standard electrical power supply requirement is 110 VAC 60 Hz 50 Hz
34. eset the pen to zero indication using pen zero adjust screw for precise adjustment 9 Repeat steps 4 through 8 until calibration of zero linearity and span 0 50 and 100 indication is achieved 10 Assure range arm lock screws thumb nut lock screw and link screws are tight 11 Reconnect the DP link and range arm 12 Unlock the recorder hub clip and remove temporary calibration chart 13 Replace the chart plate by sliding it into the chart plate retainer brackets and engaging each side into the chart plate latches 17 Static Pressure Element Replacement If the static pressure element needs replacement proceed as follows 1 2 9 10 11 12 Close all valves and turn off the power switch to the recorder Separate the drive link arm by opening the link table and disengaging the pivot pin from the clamp Loosen the clamp block screw on the lever arm assembly and separate the drive arm from the static pressure element shaft Disconnect the tubing from the static pressure element at the tubing con nection refer to page 16 Remove the mounting screws from the static pressure element and discard the damaged element Install the new element using the old mounting screws Connect tubing to the element at the tubing connection Assemble the lever arm assembly onto the static pressure element shaft do not tighten the clamp block screw yet Connect the drive link to the drive arm by engaging the pivot
35. he inside of the housings Use a solvent if possible Do not use a sharp instrument to clean between convolutions 4 Assure that there are no broken range springs 5 Replace the housings and O rings 6 Set the pressure housing bolts to the TORQUE VALUES listed below __ SST De Rotation Degrees Note 3 0199 1345 C 2500 ss 1 2 13 x 5 5 0199 0085 C 0199 1346 C 0199 1002 C Steel 1 2 20 6 uu 4 2 20 6000 Steel SST Steel 1 2 20 x 6 6 0199 1001 C Stud Steel 1 2 20 0199 1002 NOTES 1 Lubricants Molykote G paste Teflon base pipe dope graphite base grease or similar lubricants Lube first 2 threads only 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 4 Rotation reference for bolt with nut is the sum total of bolt head plus nut or total of 2 nuts ROTATION OF HEAD BOLT AND NUTS WHEN TIGHTENING STANDARD BOLT STUD LUBRICATE LIGHTLY FIRST 2 THREADS AND BEARING SURFACE 21 Range Change Changing the range of the Model 199 DPU requires replacing the bellows unit assembly with a unit of the desired range see BUA Replacement page 25 WARNING HIGH PRESSURE GAS INSTALLA
36. ight 2004 NuFlo Technologies Inc All rights reserved
37. ise until it stops turning using a 1 8 inch Allen wrench 5 Place a recording chart onto the chart plate Lock the chart into position with the hub clip 6 Set the pen precisely at zero using the pen zero adjustment screw 7 Apply 100 pressure Verify that the pen moves across scale to the 100 pressure indication 8 Apply 50 pressure Verify that the pen indicates 50 pressure on the chart 9 If the pen does not accurately indicate the pressure being applied further adjustments are necessary perform the calibration procedure outlined in DP Pen Calibration on page 13 Static Pressure Pen If the instrument includes a static pressure element use the following to check the static calibration 1 Connect the static pressure element into the calibration setup INSTRUMENT TO BE CALIBRATED BLOCK REGULATOR VALVE VENT RR DEAD WEIGHT TESTER 2 Release pressure Set the pen to zero using the zero adjustment screw 3 Apply 10076 pressure Verify that the SP pen moves across scale to the 100 pressure indication 4 Apply 50 pressure Verify that the SP pen indicates 50 pressure on the chart 5 Ifthe pen does not accurately indicate the pressure being applied further adjustments are necessary perform the calibration procedure outlined in SP Pen Calibration on page 17 Recorder Mounting Notes Before installation perform a calibration check page 8 Do not place unit near vents or bl
38. lids is extensive remove the housings carefully to prevent damaging the bellows A 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 This procedure should be performed prior to removing the DPU housing bolts if the DPU has been installed in gas applications with working pressures greater than 200 psig 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 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 NuFlo service center for repair Tag the unit and specify Gas in Bellows B Cleaning Inspection Procedure Instruments used where solids or semi solids may accumulate inside the pressure housings require periodic inspection and cleaning as follows 1 Remove DPU from service and remove the pressure housings 2 Carefully remove the pressure housings from the bellows unit assembly 20 CAUTION IF THE ACCUMULATION OF MATERIAL INSIDE THE HOUSING IS EXTENSIVE RAPID REMOVAL OF THE HOUSING MAY DAMAGE THE BELLOWS CONVOLUTIONS 3 Remove the accumulation from between the bellows convolutions and from t
39. mbly Retainer Screws Torque Tube Shaft 8 374 BUA Range Springs SECTION 2 INSTALLATION CALIBRATION CHECK General The instrument should be inspected at time of unpacking to detect any damage that may have occurred during shipment Standard Practice Considerations The following practices should be observed upon installation 1 The distances between the primary device and the DPU should be mini mized Distances exceeding 100 feet are not recommended For distances up to 50 feet use 1 4 inch or 2 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 when an air purge or blow back system is used 2 Slope all piping at least 1 inch linear foot to avoid liquid or gas entrapment 3 Provide two feet of uninsulated piping between the DPU and the primary device for each 100 F 37 8 C in excess of 200 F 493 3 C 4 Assure that the temperature of the DPU never exceeds 180 F 162 C When steam tracing is necessary the steam pressure should not exceed five pounds per square inch and insulation should not be used If pressure must exceed five pounds per square inch limit the length of tubing around the DPU to two turns and do not insulate 5 Install a suitable pulsation dampening device upstream of Severe pulsation will affect the accuracy of flow measurement Avoid severe pulsating flows such as reciprocating pumps or compressors 6 Mount th
40. n Section 2 WARNING notes that appear on the following pages of this manual should be reviewed before proceeding 8 20 21 22 and 25 WARNING notes indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if warning is ignored CAUTION notes indicate the presence of a hazard which can cause moderate personal injury or property damage if warning is ignored The DPU is attached to the back of the recorder case torque tube is inserted through a hole in the case and connected to the DP drive arm of the recorder mechanism Movement of the bellows is transmitted by the DPU drive arm to the torque tube as a rotary motion which in turn rotates the recorder mechanism The pressure housings of the DPU are connected by pipe or tubing to the high and low pressure sides of the primary device located in the process system RECORDER MECHANISM PEN MOUNT MODEL 199 DIFFERENTIAL S PRESSURE UNIT re STATIC PRESSURE 4 ELEMENT PEN LIFTER TORQUE TUBE SHAFT N STATIC PEN DIFFERENTIAL CHART PLATE PEN RETAINER CHART DRIVE STATIC PRESSURE CONNECTION CHART PLATE LATCH The range of the 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 balance the DP applied to the unit The number of springs and their ratings depends on individual DP range requirements See B
41. n or replace Out of Calibration Recalibrate echanism Low Corrosion dirt mechanism Clean or replace Indication Pen arm loose Tighten Pen arm Pen arm bent Straighten or replace pen arm High Loose links or movements Tighten or replace Indicati Mechanism ndication Out of calibration Recalibrate Mounting Excessive vibration Secure the means of mounting Erratic Indication Mechanism Linkage dragging or dirty Adjust or clean Excessive pen pressure on chart Adjust Fuse Fuse Blown Check and Replace Fuse No Chart Electric drive not turned on Turn on Chart Drive Rotation Chart Drive Clock motor not wound Wind Chart Drive Defective Drive Replace Drive Wrong Chart Hub oct not latched Latch Hub Lock Chart Lock Speed Chart Drive Wrong Chart Drive Replace with proper Chart Drive 26 DPU Troubleshooting Table Problem Possible Probable Cause Corrective Action Sources Orifice Installed Backwards or Oversized Replace Orifice Primary Flow Blocked Upstream from Run Clean Out Run or Open Valve E or Loss of Liquid in Reference Leg Liquid Level Refill Reference Leg Density Changes in Process Media or Refill Reference Leg with Same Reference Leg Density Liquid as Process Media BL tap holes plugged and or Piping Clean Out Piping Piping from Bypass Valve Open or Leaking Close Bypass Valve s or Repair Primary Leaks 9 Element to In
42. ntil 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 bolts new gaskets are recom mended Use the torque values listed on page 21 8 Calibrate in accordance with the technical manual for the actuated instrument 3 3 4nch Diameter Bellows Without Kickoff Spring above 50 inches 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 NOTE The pointer will shift from zero This is a normal action and the pointer should not be readjusted at this point 22 3 3 4 Diameter Bellows Without Kickoff Spring Continued 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 bolts new gaskets are recom mended
43. pin and locking the link tab into place Align the static pressure linkage range arm drive link and drive arm so that it lies in the same plane without binding or bending Tighten clamp block screw Calibrate in accordance with the procedure outlined in SP Pen Calibration on page 17 Chart Drive Replacement To replace the chart drive proceed as follows OL ooo 6 7 Release the pressure to the recorder Turn off the chart drive Raise the pen lifter and remove the chart and chart plate Remove chart drive mounting screws and remove chart drive Position new chart drive at the back of recorder case and attach with mounting screws Replace chart plate and chart Lower the pen to the recording position Check the time line on first pen from chart zero and span elements Linkage Adjustments see linkage illustration on page 19 A 18 Range Arm and Drive Arm Lock Screws Note Tightening lock screws fingertight is often not tight enough but tightening them more than a full turn often breaks them l Tighten the lock screw until snug 2 Hold the drive arm at the clamp block by hand or with a 1 4 inch open wrench If a wrench is used place it between the torque tube shaft and the lock screw taking care not to damage the torque tube shaft or bearing In the case of the range arm lock screw place the wrench between the shaft and lock screw 3 Tighten the lock screw 1 3 to 1 2 turn beyond snug
44. ts are necessary 6 Mount a calibration chart onto the flow recorder hub Lock the chart in place Move overrange stops out of play Notice Verify that all linkage is free Adjust range arm and drive arm at precisely the same distance back of the case Adjust the lever arm and pen zero adjust screws to their midpoints all 90 midscale linkage angles must be measured 13 14 Apply 50 differential pressure to the high pressure side Arrange the differential pressure linkage as shown on page 12 Set a 90 angle between the drive arm and link By varying the length of the link set a 90 angle between the range arm and link Slip the range arm to 50 on the chart Remove pressure The pen should indicate zero If the pen deviates less than 10 from zero in either direction perform fine adjustment by using the pen zero adjust screw refer to page 12 and proceed to step 8 b If the pen deviates more than 10 from zero make adjustments as follows a Rotate pen arm and shaft by gripping the range arm and forcing or slipping the pen until it indicates zero The pen arm and shaft should rotate at the range arm pivot point without loosening the range arm lock screw b Apply 100 pressure Make the necessary adjustment by turning the range arm adjust screw counterclockwise if the pen is slightly underranged and clockwise if the pen is slightly overranged Repeat zero and 100 adjustments until calibration at these points is achieved
45. y 100 percent positive pressure to the high pressure side of the DPU and repeat the clearance check and adjustment of step 9 Release all pressure from the instrument and replace the low pressure housing Use new gaskets Replace the housing bolts Use the torque values listed on page 21 Setting Bellows Travel The travel of the DPU bellows must be adjusted if one of the following occurs 1 The range spring assembly is removed without following the procedure 2 Broken range springs are replaced 3 The indicator pointer has excessive overtravel 4 The indicator pointer has excessive undertravel To set 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 technical manual of the actuated instrument 24 Bellows Unit Assembly BUA Replacement Refer to page 6 WARNING HIGH PRESSURE GAS INSTALLATIONS AND PRESSURES GREATER THAN 200 PSI HIGH PRESSURE GAS HAZARD ON DISASSEMBLY OF THE DPU BEFORE REMOVING THE DPU HOUSING BOLTS PERFORM THE PRESSURE CHECK PROCEDURE ON PAGE 20 NOTES Support the 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 the bellows fill fluid will be lost The reference designations relate to 199 Parts Drawing on page 37 1 Disconnect the DPU piping and
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