Bailey Control Systems Product Instruction P91-10 MINELINE 520* Manual Loading Station Type FL Babcock &Wilcox Form 1991 10 Litho im US & 1077 ©sniey Meret Company 1977 Bailey Meter Company, US.A4 Babcock & Wilcox ey Meter Company USA WARNING I ! [ixstauction manuars 1 DO NOT INSTALL, MAINTAIN OR OPERATE THIS EQUIPMENT. WITHOUT READING, UNDERSTANDING AND FOLLOWING PROPER Babcock & Wilcox Bailey Mater Co USA INSTRUCTIONS AND MANUALS: OTHERWISE INGURY "OR ‘DAWAGE! Mav” RESULT ATTENTION I MANUELS O'OPERATION ! NE PAS METTRE EN PLACE, REPARER OU FAIRE FONCTIONNER CE MATERIEL SANS AVOIN LU. COM PRIS ET SUIVI LES INSTRUCTIONS REG LEWENTAIRES Df Babeork & Wicox Baley Meter Compeny.US.A_ TOUTE Néstigence A CeT ECARD POURRAIT ETRE UNE Cause ACCIDENT OU DE DEFAILLANCE DU MA Tene. ! TABLE OF CONTENTS: INSTALLATION PLACING IN SERVICE ROUTINE MAINTENANCE, CALIBRATION TROUBLESHOOTING OPERATION THEORY OF OPERATION 10 NOMENCLATURE SPECIFICATIONS 10 REPLACEMENT PARTS, n INSTALLATION Unpacking and Storage 1 Check for any obvious damage to shippmg carton or contents Report any damage to carer 2. Make certain that unit 15 correct range for intended service (refer to identification label). 3 If station 1s to be stored, repack im origi- nal container and store within temperature hmits 20° to 120°F (7° 049°C) Pre-Service Adjustment Check CAUTION Before placing Manual Staton 1 service, check adjustment of vertical gage unuts as outhned below Also check calibration of gage units as ovilined under **Troubleshooting”, “Ver- tucal Gage Unit Assembly" It is recommended that this check be performed at a test bench before the station 15 installed mn the panel or placed in ‘operation ATTENTION Avant de mettre la station manuelle en service, verifier le reglage des elements de yauges verticales de la facon mdiquee ct-dessous Venfier egalement le calibrage des elements de jauge comme i est mdigue dans le chapitre “Depannage’ sous le titre “Ensemble des jauges verticales” Il est recommande d'etfectuer cette venfication sur un banc d'essat avant d’installer la station sur Je tableau ou de la mettre en service Position station at the angle at whieh st will be mounted in service and check that the sndica- tung pointers of both vertical gages read slightly below minimum scale (0) If they do not. proceed as follows 1. Remove scale cover by prying outward on up at top of cover. 2 Apply 3 psig (207 KPa) and adjust zero adjustment serews (Figure 3) through holes im seale using S/64 inch Allen wrench until both pointers read mmimum scale\aesimoe o ao Jo'S05 isin mee, 82a P9110 Page 3 +008 +906'tzmn} ae 7 ann) 6d THICRNESS HORIZONTAL ARRAY 100" 25m MX PANEL, verricaL ABRAY NOTE ALL nik CONNECTIONS ARE Va" = 27NPT FIGURE 1 — External and Mounting Dimensions, Manual Loading Station, Type FL ‘Also check calibration by performing the procedures listed under “Troubleshooung”, “Vertical Gage Unit Assembly” ‘After the calibrauon check 1s complete the stauon 1s ready for panel mounting and external connections as follows: 1 Shde station through panel from front (Refer to Figure | for correct panel cutout dimen- sions.) 2 Place mounting chips (Figure 1) 1n position and tighten securely agamst panel 3 Make external connections to rear of station with 1/8" -27 NPT pipe fittings as follows (Fig- we Connection #1 - FLIQQU) Input FLAT Bras Input Connection #2 - Station Output Connecuon $ - Stanon Air Supply (For selection and installation of pneumatic con- necting tubing or process connecting piping, refer to Batley Product Instruction GI8-1 or G18-2 } 4 Remove protective tape from plastic scale covers Use a cleanng solvent (eg hghter fluid or kerosene) to remove any excess adhesive on scale cover Wipe off solvent with a damp cloth CAUTION Apply solvent to scale covers only, making certain fluid does not run or dnp over ‘tram pieces or station front plate Also, do not use solvents which will scratch cover finish or react with plastic cover (eg ketones, esters and aro- matic or chlorinated solvents such as carbon tetra chlonde, chlorothene or tri chloroethylene) ATTENTION N’appliquer des dissolvants que sur les couverctes des graduations en faisant attention que le liquide ne coule pas mi ne deborde sur les garmitures ou le panneau avant de la station Ne pas utiliser non plus de dissolvants qui ns- queratent de decaper le verms des couvercles ou attaquer les bortters en plastique (Dissolvants tels que les cetones, esters, dissolvants aro- matiques ou chlores. commee ie tetra chlorure de carbone, le chloretone ou le tri chloroethylene)Babcock & Wilcox Baiey Meter Comoany USA $- Adyust arr supply to 18 to 20 psig (124 to 140 kPa) for 3 to 15 psig (20710 103 KPa) range 30 to 35 psig (20 6 to 241 3 kPa) for 3 10 27 psig RANGE (20 7 to 186 kPa) range AOSUSTMENTS LINEARITY. ‘ADSUSTMENTS — BIAS STATION FIGURE 3 — Vertical Gage Umit Range, Linearity ecuaron and Zero Adjustments BASIC/SET POINT/ TIE-BACK STATION FIGURE 2 — External Connection and Tubing Diagram, Manual Loading Station, Type FLP91-10 Page 5 = PLACING IN SERVICE After the Manual Station has been installed an the control panel 1 Turn on supply pressure to station 2 Check all external tubing connections for leakage with a soapsuds solution 3. Adjust manual control knob on front plate {Figure 4) until desiced output 1s indicated on vertical gage NOTE. See Figures 5 through 8 and refer 10 apph- cable heading below for typical applications Basie Manual Station (Figure 5) Output pressure from the Basie Manual Station 1s normally apphed to a power unit (control drive, valve, etc) for remote control The output pres: sure 1s produced by a regulator (Figure 10) which 1s manually adjusted by a knob on the station front plate A double pointer vertical gige unit mdicates Manual Station output pres- sure and the input pressure to the Controller (measured variable) Set Point Manual Staion (Figure 6) Output pressure from the Set Pomt Manual Station 1s normally applied to a Controller 10 establish the control set point The output pres- sure 1s produced by a regulator (Figure 10) which 1s manually adjusted by the knob on the station front plate A double pointer vertical gage unit indicates Manual Station output (set point) pressure and input pressure to the Cantrol- ler Ti jack Manual Station (Figure 7) Output pressure from the Tre-Back Manual Station 15 normally applied to a Manual/ Auto ‘Transfer Stanon to control the output pressure of a Controller The Manual Station output pressure 1s produced by a regulator (Figure 10) which 1s SERVICE LEGEND Manual, CONTROL KNOB FIGURE 4 — Type FL Manual Loading Station manually adjusted by the knob on the station front plate A double pointer vertical gage unt indicates Manual Station output (tie-back) pressure and Controller output pressure Bias Manual Station (Figure 8) Output pressure from the Bias Manual Station 1s normally applied 10 a power um (control dnve, valve, etc) for remote control The output pres- sure ts produced by a regulator (Figure 10) which 1s manually adjusted by a knob on the station front plate A double pomter vertical gage unit indicates input (loading) pressure from a Con- troller and Manual Station output (bias) pres- sureBabcock & Wilcox Baiay Meter Company USA POWER UNIT (CONTROL DRIVE, POSITION SIGNAL MANUAL outeur PRESSURE REGULATOR KNOS L FIGURE 5 — Typical Application of Basic Manual Station TRANSMITTER CONTROLLER “| Measuned| VARIABLE CONTROLLER, oureut manuaL oureut PRESSURE (SETPOINT) REGULATOR KNOS FIGURE 6 — Typical Application of Set Point Manual Station CONTROLLER JawTeGRaL action) MANUAL ourur PRESSURE (THEBACK) ‘CONTROLLER oureuT PRESSURE REGULATOR KNOB | FIGURE 7 — Typical Application of Tre-Back Manual Station — ‘CONTROLLER MANUAL irur ourpuT PRESSURE (was) (woaDIna) REGULATOR NOB FIGURE 8 — Typical Application of Bias Manual StationP9L-10 Page 7 ROUTINE MAINTENANCE 1 Mamtain a clean aur supply, tree of oil or morsture 2. Check filter sn supply inlet port in rear of station, shortly after installation (Figure 9). It replacement 15 necessary, remove wire mesh disc, felt pad and second wire mesh disc Install new wire disc, Felt pad and second wire disc Make certain wire mesh dise 1 inserted in ralet_ port before mserting Felt pad Whenever nevessary, clean the aryl er as described under “Installation”, Adjustment Cheek” © seale cov re-Service supper inter’ FIGURE 9 — Supply, input and Output Ports for Manual Loading Station, Type FL CALIBRATION Cahbration procedures for the Vertical Gage Umt Assembly are found under ““Troubleshoo!- ing” in this manual Calibration of the Pressure Regulator Assembly 1s performed at the factory Ifany adjustment 1§ necessary oF the unit becomes anoperauive. the entire assembly should be removed from the station and returned to the factory Follow the procedure outhned under **Trouble- shooting", “Pressure Regulator Assembly"" TROUBLESHOOTING If operational faults occur which are traced to the following assemblies, make the listed ad- justment checks found under the particular assem- bly Vertical Gage Unit Assembly (Figure 3) 1 Remove side covers from station by remov- sng retaining screws and sliding covers to rear 2 Remove rear snapout cover, side cover and seale cover (refer to PDP91-10-2) from vertical gage unt assembly for access to adjustments 3. Position station at angle at which it will be mounted in service and check adjustment of input and output pointers as follows. a Apply regulated input pressure with 1% input gage accuracy to port 1 to check left hand ‘anput) pomter reading Check for leakage by applying a soapsuds solution to connection points, b To check night hand (output) pointer, apply supply pressure to port $ and install a test gage (£1% accuracy) in port 2 Adjust regulator knob and compare vertical pointer gage (0 test gage Check for leakage by applying @ soapsuds solu- tion to connection points NOTE. If a pressure leak 1 discovered, replace entire gage unit Unit may be returned to factory for repair Refer to section titled “Removal at Replacement of Vertical Gage Unit Assembly for this procedure, 4 Check links to make sure they are properly connected and move freely with bellows beam movement 3. Make certain indicating pointers do not rub against side or face of scale It necessary, bend pointer slightly 6 Apply pressure 10 gage unit equal to first major scale division above 0% scale If pointer91-10 Page 8 ee em does not read correctly turn zero. adjustment Screw (Figure 3) until desired reading 15 obtained Zero adjustment 1s accessible from front of station by removing scale cover and inserting a 5/64 inch Allen wrench thru hole m scale 7 Apply pressure t gage unt equal to first mayor scale division below 100" scale If pointer does not read correctly, turn range adjustment screw (Figure 3) until desired reading is obamed. 8 Repeat steps 6 and 7 unul pointer reads correctly at both seale divisions 9 Apply pressure to gage unit equal to mid- scale division If pointer does not read correctly. but does read correcily in steps 6 and 7 above, adjust angularny pivot shatt (Linearity adjustment) to bring pointer reading to midscale (Figure 3) 10. Repeat steps 6 thru 9 unl porter reads correctly over full scale HL Apply pressure 10 gage uni equal 10 mavi- mum seale value plus 0 25 psig (1 7 KPa) (Pointer will read shghtly above mawimum scale mark) Loosen maximum stop screws, position over travel stop bracket against range spring retaining. nut and retighten screws 12 Apply 28 psig 193 kPa) to gage unit (Pointer will read slightly below maximum scale mark) Turn elastic stop nut against over travel stop bracket 13° Replace scale cover, gage side cover, rear snapout cover and station side covers Removal and Replacement of Vertical Gage Unit 1 Remove vertical gage scale cover, regulator Knob and six flat head screws (PDP91-10-1, Item 33) 2. Remove front plate (5) Babcock « Wilcox Baty Met Campany USA 3 Remove two serews (4) 4 Disconnect tubing from vertical gage fittings and remove unit from station 5. Install new gage by reversing above proc dure New tubing and clamps are supplied with new vertieal gage untt Pressure Regulator Assembl The pressure regulator assembly (Figure 10) includes a cleanout screw Periodically, remove the screw and clean the onfice by inserting « wire, 008 inches (2 mm) or less in diameter, through screw hole in regulator body If the pressure regulator becomes imoperative, the entire assembly should be removed from the station and returned to the factory Procedure for removal of the regulator 1s as follows. 1 Remove side cover from station by remov- ing retaining screws (PDP91-10-1) and shding covers to rear 2 While holding shaft extender (Item 11), loosen jam nut (30) 3 Remove four screws (32) which hold regu- ator in place 4 While holding elastic stop nut, rotate shaft extension by turning control knob on front of station 5. When regulator adjustment shaft 1s free of shaft extension, remove tubing from end of regu- lator and remove regulator from station 6. Install new regulator by reversing above pro- cedure New bing and clamps are supplied wath new regulatorP91-10 Page 9 OPERATION ‘The Type FL Manual Staion provides a means of manually adjusung @ pneumatic output signal for remote manual operation of pneumatic control elements, or generation of set point or tie-back signals and positive or negative biasing of an input signal The station consists of a double pomter verti cal indicator gage and a pressure regulator assem- bly The vertical indicator gage uses a spring opposed bellows assembly to convert pneumatic signals to pointer positions Left Gage Pointer In baste, set point, tte back stations this pointer displays an input or measured variable. In bias stations the left gage pointer displays a bias input ‘which 1s also applied to the station’ bias regulator. Rughi Gage Pointer In bias, baste, set pomt and te back stations thy pointer displays the station's output To effect an output change the regulator knob fon the station front plate is rotated while ob- serving the right hand gage pointer The operation of the pressure regulator assembly 1s explained be- low Pressure Regulator Assembly (Figure 10) Basic, Set Point and Tie-Back Manual Station input force agamst the diaphragm 1s variable as the regulator knob 1s tumed and the spring assembly 13 compressed or depressed An unbalance between the input pressure provided by the spring assembly and the output pressure m the feedback chamber moves the diaphragm Movement of the diaphragm 1s trans- mitted to the vane, of the vane and nozzle assem- bly through the vane stem Movement of the vane agaist the nozzle changes the amount of air venting through the nozzle As vane resistance varies. pressure in the nozzle backpressure cham- ber varies which allows the nozzle assembly to shift position permitting more supply air into the output chamber by lifting the valve stem off the seat It reduces output pressure in the output chamber by allowing the nozzle assembly to move off the valve stem and vent through the center of the nozzle assembly and through the exhaust chamber to atmosphere Pressure remaining. m the output chamber 1s the output pressure and 1s tied to the feedback chamber For Basw. Set Pomt and TieBack Stations ‘Output = Spring Force Bias Manual Staion operation 1s tdentical t0 the other Manual Stations except that force against the diaphragm 1s the bias mput pressure plus or minus the tension on the spring assembly For Bias Manual Stations Output = Bias Chamber Pressure + Spring Force. NOZZLE BACKPRESSURE CHAMBER: ORIFICE BIAS CHAMBER \ TY FIGURE 10 — Pressure Regulator AssemblyBabcock & Wilcox Bainy Water Company US A THEORY OF OPERATION ‘A Bailey Type PS Double Pomter Gage displays the actual signal magnitude The left pointer displays either bras mput ot a measured vanable The night hand gage displays station output or, set point, tie back or bias signals ‘The gage itself, employs a spring-opposed bellows assembly to convert pneumatic signals to point- er positions Access t0 zero adjustments 1s provid- ed through the front of the station, by removing the gage scale cover and inserting an Allen wrench through the holes provided in the scale ‘The regulator is a mimature, multrstage, precision pressure regulator A force balance system compares the input with a feedback force produced by the output The input may be the result of loading by the range spring assembly or from a bias input pressure in the bias chamber, or a combination of both An unbalance between the mput(s) at the output causes deflection which 1s transmitted to the second stage by the vane stem ‘The nozzle assembly may be considered an “operator"” for the second stage The vane stem deflects the vane which seals off the nozzle ‘The resultmg change 1m bach pressure moves the nozzle assembly and the output valve stem This “power assist” effect of the moving vane and nozzle assembly provides greater capacity and bet- ter accuracy of the output pressure with respect 10 the mput(s) Operauion of the output valve stem supplies or exhausts output air unul the output pressure feedback to the first stage brings the unit to balance at an output pressure which corresponds to the new input The ability of the nozzle to move with the second stage prouides a munor feedback loop which provides for greater regulator stability NOMENCLATURE Descrpti09 Manuel Loading Station Universal (Base, Setport, Tie Back) 3 to 18 PSIG (207 to 108 KPe) output 3 to 27 PSIG (20 7 to 186 KPa) outeut Standard 0-100% Direct reading seaSPECIFICATIONS. “Accuracyt Bias Regulator 2% o san Vertical Gage 11% of sen Tnpet/Output Signal 3 0 15PSIG (20 70 105 KPa) Range 2 © 27 PSIG (20 7 to 106 KPa) For 3 t0 18 PSIG (207 to 109 Kral ‘signal ange 16 1126 to 138 kal ir Supply 25816 (072 Wr mwa For 3 to 27 PSIG (207 to 186 K?s) saral range 30PSIG (207 KPal recommended 35 PSIG (241 kPa} manure ‘Air Consumption. ‘(Steady State) Rept Spy 2 nn OOS Capacity 5: mc range Fey a Ta RR TTP fe mee a ae ae ‘Supply Pressure 01 for 1 PSIG chonge w supply prem Effect su. maximum 01 sctm (472 x 104m 3/5), maximum External Connections 1/8 men -27 NPT temsle Operating Novel 40" to 140°F (aa to OTC] Temperature Ranges i4yximum - 20° to 140°F (44° to 60°C) Temporature Effect «2 0% per 100°F (378°C) ‘Mounting Mounts dectiy ito panel cutout Length 33/16" (Bt mel Standard Marking white dwsions and Indicating Scale figures on biack styrene plaetic Standerd Range _0 100% ‘Service Legend 1 or 2 rows, 13 cheractes, 01” hgh Weight Net 218ibs 114519) Shipping 394 los (579 kal fo 145" W137 mam) x 625" H (189) | Size 511.25" 0 (288mm) ‘Ths defined by SAMA Standard PMC2O 1 P91-10 Page 11Babcock & Wilcox Baley Meter Company USA REPLACEMENT PARTS. Ordering Individual Parts ‘The following Parts Drawings represent the ‘Type FL Manual Station and internal assemblies Normally, these drawings apply to the unit fur- nished However, there may be individual differ- ences in specific units because of a design changes made since the printing of this Instruction Section, or b specral design of the station to make it suitable for a special application Therefore, when ordering parts, assure the re~ ceipt of correct replacements by specifying the station type and the parts drawing number on which the part is allustrated Recommended Spare Parts ‘The following listed spare parts should be stocked in the quantities listed 3320414-2 [Felt Pad (PDP91-10-1, Item 26) 5320413-2 [Mesh Disc (PDP91-10-1, Item 18)} '5327220-1 |Scale Cover (PDP9}-10-2, Item6)| 198494-5 [Knob (PDP91-10-1, Item 9)‘TYPE FL MANUAL LOADING STATION PART NO 53271001 Parts Drawing P91-10-1 2a a Lin 3 4 8 He yor AH 19 32,37 ITEM PART NO NAME. 19628512 NAMEPLATE 7 19628591 TUBING DIAGRAM, gasic | 21 121000 STL SHKPF LKwasH 5927099.1 FRAME PLATE,2 REOD SETPOINT. TIEBACK | 92 11240x260 LG HEX HD STL CAP 5327103 1 SUPPORT BRACKET 19628683 TUBING DIAGRAM, BIAS. SCA, 4 RED, 55203904 TRIM PACKAGE, 1 REQD |18 58208132 WIREMESH Disc.4REQD | 32 11240x25 LG PHILLIPS FLAT HD FER HOMIZONTAL ARRAY|1®, 19514001 CAP OMIT ON BIAS UNITS STN STL MACH SCR. 6 52271011 FRONT PLATE 20" 19514231 COMPRESSION CLIP, 6 EOD 52270781 SIDE COVER, 2 RED REGO. 34 19032375 LG PAN HO STL SEMS 52278044 DOUBLE POINTER GAGE, |2) 19620901 NAMEPLATE EXT, 2 REOD S18 F5I6 j22 SEE TABLE SCALE 25 190324375 LG PHILLIPS FLAT HO 50278042 DOUBLE POINTER GAGE, |23 SEETABLE SCALE AIB STN STL MACH SCR, 3.27 F516 oa tosza4i1 sTyLerLare 4REOD 19628512 LOGO NAMEPLATE 19515031 FITTING TUBE,2REQD | 36 11240x 188 LG PANHDSTL EMS 398985 KNOB FELT PAD ExT.2REOD 53145141 MOUNTING CLIP,2 REGD ‘ostipx ison cian | 97 112 HELICAL SPA STN STL 50271041 SHAFT, EXTENDER POLYUR TUBING LKWASH, 8 EOD 671252 | RUBBER GROMMET os *no02s.0410 ‘1721Dx 297 OD cLean | 38 11240 STNSTLHEX NUT. 53777702 REGULATOR, 315 PSIG POLYUR TUBING (SEE 4Aeo0 5277701 REGULATOR, 327 PSIG TABLED 39 138 STNSTL FLAT. 5527602 1 CONNECTOR BODY ASSY [20 11240x375 LG PHILLIPS FLAT HD WASHER, 4 REGO STNSTLMACH SCR, 40 1124083125 LG FLAT HO STN STL 19610803, 19457502 COMPRESSION CLIP.-4 EOD PULLPLUG,sREaD {3019082 NOTE Those wars are not own On drawing 4 REQD STNSTL HEX NUT MACH SCA, SEE TABLE See TABLE STATION WANUAL toaving Babcock &Wilcox Batley Meter Company.US Awor [we [ear [wn | wen va [ws mae [ae — as sas FLa0 318 | gsxr (0 major 4 Read 2 me [se | ewe, | IE | csnome i “Black ib wth white nes Notes 1 Blank sc 2 Seale ss requred {oort no. $927370 18) engraved or skscropned, lar no 5327969:38, 39, 40,.41, 42) provided Maton DIvisoNs| OIVISIONS |Parts Drawing P91-10-2 =~ DOUBLE POINTER GAGE PART NO. 5327894-; ~ =~ SEENOTE EDGEWISE INDICATOR, PER ENG DATA 5077221A2 REFLECTOR Sa27218A1 SCALE HOLDER, SPARE PARTS KIT NO 2560281 PERENG SCALE DATA ‘QUANTITY TEMNO. PERENG SCALE RIG bara 2 6 532722081 SCALE COVER NAMEPLATE STYLEPLATE sa14a96a1 SNAPOUT COVER. 17240%2/8_ PAN HO SCR, TYPE NOTE TO ORDER REPLACEMENT INDICATORS INCLUDE ALL DATA ON NAMEPLATE (ITEM 10) 15327804 1 (3 10 15 ps9) 15327894. (3 10.27 psa) Babcock &Wilcox Form PDP91 10.2 Linon USA 1077 ©paiey Macer Company 1977 Batley Meter Company.US A“Bailey Control Systems REGULATOR ASSEMBLY PART NO. 5327770-7) Parts Drawing P91-10-3 SECTION cc VWF AW SECTION AA wisi 9 \ \AY iTEM PART NO) 3277501 618405 2 19911428 2 38305 1 1971466 s7774at SEE TABLE 53777591 5327786-1 5327760 1 5377898 + 5277681 19762241 5927746 1 33277611 5027000. 1106-45 19712014 ‘SHAFT, ADJUST: MENT WASHER, NYLON ORING WASHER, LATCH RING, RETAINING. SPRING SPRING Assy STEM, VANE. Nozzie assy Nozzle asker CUP, SEAL ‘SCREW, SEALING, 4ReOD SPRING, FINGER, VANE ASSY VALVE ASSY SPACER, ROLLED Company 1977 RANGE _PARTNO ITEMS. 53277701 58277702 327768 1 153277652 Babcock & Wilcox Batley Meter Company.US.A