Model Series 66 Amplifying and Reducing Relays

Transcription

1 Siemens Energy & Automation INSTALLATION AND SERVICE INSTRUCTION INTRODUCTION Model Series 66 Amplifying and Reducing Relays SD66 Rev 11 January 2006 Supersedes Rev 10 The Model Series 66 Amplifying and Reducing Relays are used in control circuit to amplify and reduce pneumatic signals. The output of a relay is proportional to its input by the fixed gain factor of that relay model. This instruction has six major sections: Introduction, Installation, Principle of Operation, Maintenance, Warranty, and Parts List. Model Designation Model Series Material and Function A Brass, Amplifying R Brass, Reducing Input-to-Output Ratio 2-1:2, Model 66BA2 2:1, Model 66BR2 3-1:3, Model 66BA3 3:1, Model 66BR3 66 BA 2 4-1:4, Model 66BA4 4:1, Model 66BR4 6-1:6, Model 66BA6 6:1, Model 66BR6 Specifications Supply Pressure Normal psig Minimum... 1 psig above maximum required output Maximum psig Normal Operating Range... 3 to 15 psig Operating Range Limits Amplifying Relay... Not to exceed 80 psig output Reducing Relay... Not to exceed 80 psig input Overrange Limits psig to any connection Ambient Temperature Limits to +180 F (-40 to +82 C)

2 INSTALLATION Shipping and Storage If the relay is to be stocked, stored, or shipped to another location prior to piping, make sure that the factory installed plastic plugs are in the ports to prevent entry of moisture, dirt, or other contaminants. Mounting Mount the relay in any position, in a reasonably vibration-free location. Make sure that the exhaust vent shown in Figure 1 is not blocked. The direction of relay air flow is indicated by an arrow on the bottom forging of the Relay. PNEUMATIC CONNECTIONS Refer to Figure 1 for the pneumatic connections; all connections are 1/4" NPT. Recommended piping is 1/4" O.D. tubing, although any scale-free piping may be used. 1. Blow out all piping before connections are made to prevent the possibility of dirt or chips entering the relay. 2. Use pipe sealant sparingly, and then only on the male threads. A non-hardening sealant is strongly recommended. 3. Connect the relay to a source of clean, dry, oil-free relay air. See Instrument Air Requirements. Figure 1 Installation CAUTION Exceeding the specified ambient temperature limits can adversely affect performance and may cause damage to the relay. Pressures in excess of those stated in the Specifications section may cause damage to the relay. Instrument Air Requirements Connect the instrument (i.e. relay) to a source of clean, dry, oil-free instrument air. Failure to do so will increase the possibility of a malfunction or a deviation from specified performance. CAUTION Use of process fluids other than instrument air is not recommended. No claim is made as to the suitability of this product for use with other process fluids, such as hazardous gases, except as listed on the appropriate certificate. Non-approved instruments are suitable for use with instrument air only. Optional features and modifications such as tapped exhaust do not imply suitability for use with hazardous gases except as listed on the approval certificate. There are many types of synthetic compressor lubricants. Some may not be compatible with the materials used in construction of the instrument. Wetting of these materials by such an oil mist or vapor, etc., may cause them to deteriorate. This may ultimately result in failure of the instrument. The following materials are in contact with the instrument air: ALUMINUM, BRASS, NEOPRENE, NICKEL PLATE, and STAINLESS STEEL. 2

3 CAUTION Synthetic compressor lubricants in the air stream at the instrument may cause it to fail. The requirements for a quality instrument air supply can be found in the Instrument Society of America's "Quality Standard for Instrument Air" (ISA-S7.3). Basically, this standard calls for the following: Particle Size Maximum particle size in the air stream at the instrument should be no larger than 3 microns. Dew Point The dew point, at line pressure, should be at least 10 C (18 F) below the minimum temperature to which any part of the instrument air system is exposed at any season of the year. Under no circumstances should the dew point, at line pressure, exceed 2 C (35.6 F). Oil Content Maximum total oil or hydrocarbon content, exclusive of non-condensable, should not exceed 1 ppm under normal operating conditions. PRINCIPLE OF OPERATION The input-to-output ratio is determined by the effective areas of the input diaphragm and output diaphragm assembly. The input diaphragm of an Amplifying Relay has a larger effective area than the output diaphragm assembly, which requires the output to be proportionally higher for the relay to be in balance (see Figure 2, Amplifying View). Conversely, the input diaphragm of a Reducing Relay has a smaller effective area than the output diaphragm assembly, which requires the output to be proportionally lower for the relay to be in balance (see Figure 2, Reducing View). Operation An increase in input pressure forces the input diaphragm and output diaphragm assembly downward, closes the exhaust port, and moves the plunger to open the supply port; see Figure 2. Supply pressure is admitted to the output and to the output diaphragm assembly. The output will increase until the upward force of the output pressure acting on the output diaphragm assembly equals the downward force of the input pressure acting on the input diaphragm. All actions are reversed for a decrease in input pressure. Figure 2 Schematic 3

4 MAINTENANCE Most problems associated with pneumatic instruments can be prevented by providing clean, dry, oil-free instrument air (see Instrument Air Requirements). If these requirements are met, routine maintenance should not be necessary. Cleaning of the plunger and the supply and exhaust ports may be required, on an occasional basis, as outlined in the Cleaning section. Troubleshooting CAUTION Before disassembling the instrument, turn off supply air pressure to the instrument. Table 1 provides troubleshooting information in a symptom, cause, and remedy format. Symptoms are listed in the order they are most likely to occur. Table 1 Troubleshooting SYMPTOM CAUSE REMEDY Output pressure will not Plunger is not seating properly in supply port due to dirt, chips, etc. plunger and supply port. decrease or decreases with a decrease in input pressure. Exhaust port is clogged due to build up on the plunger and/or exhaust port. plunger and exhaust port. Exhaust port is obstructed. Clear obstruction. Output pressure will not Plunger is not seating properly in exhaust port due to dirt, chips, etc. plunger and exhaust port. increase or increases with an increase in input pressure. Supply port is clogged due to build up on the plunger and/or supply port. plunger and supply port. Supply pressure is too low. Raise supply pressure. Excessive exhaust from exhaust vent. Ruptured input diaphragm or output diaphragm assembly. Refer to Maintenance to replace input diaphragm or output diaphragm assembly. Cleaning Plunger is not seating properly in exhaust port due to dirt, chips, etc. plunger and exhaust port. To clean the plunger and the supply and exhaust ports: 1. Remove supply and input pressures. 2. Remove the retaining nut from the bottom forging (see Parts List). The plunger and plunger spring should fall out. 3. Clean the plunger with non-abrasive solvent. 4. Clean the supply and exhaust ports with non-abrasive solvent (see Figure 2). The supply port is readily accessible; the exhaust port can be reached with a tobacco pipe cleaner. NOTE If there is excessive buildup on the supply or exhaust port, the relay must be disassembled for thorough cleaning. Refer to the Parts List for parts orientation during disassembly and assembly. 5. Refer to the Parts List and install the plunger, plunger spring, and retaining nut. 6. Check the calibration of the Relay per the following Calibration. 4

5 Calibration The only calibration adjustment for the relay is the adjustable exhaust seat which sets the output span. This adjustment must be made if the relay has been disassembled for parts replacement, ratio change, etc. Equipment Required: Regulator and test gauge for setting supply air Regulator and test gauge for adjusting input Output test gauge 1/16" Allen wrench Procedure 1. Connect supply regulator and test gauge to the supply connection (see Figure 1). 2. Connect the input regulator and test gauge to input connection. 3. Connect output test gauge to output connection. 4. Turn on supply air. 5. Exercise the relay by adjusting the input regulator as follows: Amplifying Relay Lower input range value to upper input range value. Reducing Relay Upper input range value to lower input range value. 6. Check the output span while exercising the relay. If the output span is too small, turn the exhaust seat counterclockwise. If the output span is too great, turn the exhaust seat clockwise. NOTE To gain access to the exhaust seat, turn off the supply air. Refer to the Parts List and remove the retaining nut, plunger and plunger spring. 7. Insert a 1/16" Allen wrench through the exhaust port in the bottom forging; make adjustment. 8. Install plunger, plunger spring, and retaining nut. 9. Repeat steps 4 through 8 until span is set. Function and Ratio Change The function and/or ratio of a Relay can be changed using standard parts. To change the function from amplifying to reducing or vice versa with the same ratio (e.g., Model 66BA2 to Model 66BR2), reposition the diaphragm ring and replace the output diaphragm assembly. To change the input-to-output ratio (e.g., Model 66BA2 to 66BA4) or both the function and ratio (e.g., Model 66BA2 to 66BR4), replace the diaphragm ring and output diaphragm assembly. Parts Determination 1. Refer to the Model Designation and locate the Model Number of the relay with the desired function and inputto-output ratio. This Model Number will, in effect, be the new Model Number of the relay after the change. 2. Refer to Table 2 and locate the new Model Number. Read straight across and obtain the diaphragm ring and/or output diaphragm assembly part numbers as required. 3. Refer to the Parts List for ordering information. Procedure 1. Refer to Parts List. Remove top forging, input diaphragm, diaphragm ring, and output diaphragm assembly. 2. Install the new output diaphragm assembly. 5

6 3. Install a new or existing (as required) diaphragm ring. NOTE When viewed from above, diaphragm ring in amplifying position has recessed, machined area with vent path to exhaust vent hole. Note that exhaust vent hole is positioned over supply connection in amplifying and reducing relays. 4. Install input diaphragm assembly and top forging. 5. Refer to Calibration section and calibrate relay. 6. Document change on drawings, records, etc. Label the relay with the new model number. Table 2 Diaphragm Rings and Output Diaphragm Assemblies Product Support This section provides the Internet site address, address, telephone numbers, and related information for customers to access Siemens product support. When contacting Siemens for support: Please have complete product information at hand: For hardware, this information is provided on the product nameplate (part number or model number, serial number, and/or version). For most software, this information is given in the Help > About screen. If there is a problem with product operation: Is the problem intermittent or repeatable? What symptoms have been observed? What steps, configuration changes, loop modifications, etc. were performed before the problem occurred? What status messages, error messages, or LED indications are displayed? What troubleshooting steps have been performed? Is the installation environment (e.g. temperature, humidity) within the product s specified operating parameters? For software, does the PC meet or exceed the minimum requirements (e.g. processor, memory, operating system)? A copy of the product Service Instruction, User s Manual or other technical literature should be at hand. The Siemens public Internet site (see the table) has current revisions of technical literature, in Portable Document Format, for downloading. 6

7 To send an instrument to Siemens for repair, request a Return Material Authorization (RMA). IMPORTANT An instrument must be thoroughly cleaned (decontaminated) to remove any process materials, hazardous materials, or blood born pathogens prior to return for repair. Read and complete the Siemens RMA form(s). Contact Information United States of America Telephone , option 2 for Siemens and Moore brand instruments Fax PITechSupp@sea.siemens.com Hours of Operation 8 a.m. to 4:45 p.m. eastern time Monday Friday (except holidays) Public Internet Site Repair Service extension 3187 For contact information outside of the U.S.A., visit the Siemens public Internet site (see the above table for the URL), locate Customer Support Process Instrumentation, and click on the Contact Tech Support link to access the Global Support link. WARRANTY (a) Seller warrants that on the date of shipment the goods are of the kind and quality described herein and are free of non-conformities in workmanship and material. This warranty does not apply to goods delivered by Seller but manufactured by others. (b) Buyer's exclusive remedy for a nonconformity in any item of the goods shall be the repair or the replacement (at Seller's option) of the item and any affected part of the goods. Seller s obligation to repair or replace shall be in effect for a period of one (1) year from initial operation of the goods but not more than eighteen (18) months from Seller s shipment of the goods, provided Buyer has sent written notice within that period of time to Seller that the goods do not conform to the above warranty. Repaired and replacement parts shall be warranted for the remainder of the original period of notification set forth above, but in no event less than 12 months from repair or replacement. At its expense, Buyer shall remove and ship to Seller any such nonconforming items and shall reinstall the repaired or replaced parts. Buyer shall grant Seller access to the goods at all reasonable times in order for Seller to determine any nonconformity in the goods. Seller shall have the right of disposal of items replaced by it. If Seller is unable or unwilling to repair or replace, or if repair or replacement does not remedy the nonconformity, Seller and Buyer shall negotiate an equitable adjustment in the contract price, which may include a full refund of the contract price for the nonconforming goods. (c) SELLER HEREBY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, EXCEPT THAT OF TITLE. SPECIFICALLY, IT DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, COURSE OF DEALING AND USAGE OF TRADE. (d) Buyer and successors of Buyer are limited to the remedies specified in this article and shall have no others for a nonconformity in the goods. Buyer agrees that these remedies provide Buyer and its successors with a minimum adequate remedy and are their exclusive remedies, whether Buyer's or its successors remedies are based on contract, warranty, tort (including negligence), strict liability, indemnity, or any other legal theory, and whether arising out of warranties, representations, instructions, installations, or nonconformities from any cause. (e) Note: The above does not apply to any software which may be furnished by Seller. In such cases, the attached Software License Addendum applies. 7

8 PARTS LIST Siemens Amplifying and Reducing Relay, Model Series 66 Drawing 4297PL Rev 7/82 IMPORTANT Service Parts Kits are available for servicing the instrument. Contact Siemens for available kits; refer to the Product Support section of this instruction. Some parts in this Parts List may not be available for separate purchase. * Recommended on-hand spare parts. Always specify range, serial number, or other nameplate information when ordering spare parts. All product designations may be trademarks or product names of Siemens Energy & Automation, Inc. or other supplier companies whose use by third parties for their own purposes could violate the rights of the owners. Siemens Energy & Automation, Inc. assumes no liability for errors or omissions in this document or for the application and use of information in this document. The information herein is subject to change without notice. Procedures in this document have been reviewed for compliance with applicable approval agency requirements and are considered sound practice. Neither Siemens Energy & Automation, Inc. nor these agencies are responsible for repairs made by the user. 8