. 7 SECTION ~ Bailey P91-4 PRODUCT INSTRUCTIONS MINI-LIVE* 500 HAND/AUTOMATIC STATION trea ws FAT oF. BAILEY METER COMPANY e WICKLIFFE, OHIO 44092Page 2 H/A Station INDEX Page INSTALLATION 3 Pre Service Adjustment Check 3 ‘Mounting H/A Station on Panel 3 Instalhng Connecting Tubing 3 Cleaning Seale Cover 3 ‘OPERATION 4 Transfer from AUTO to HAND 4 ‘Transfer from HAND to AUTO 4 Alternate HAND to AUTO ‘Transfer 4 ROUTINE MAINTENANCE 6 CORRECTIVE MAINTENANCE 7 Vertical Gage Umt Adjustment 7 Hand Relay Disassembly 8 Hand Relay Adjustment a Front Plate Disassembly 3 Shut Off Valve Disassembly 9 Valve Operator Lever and Shaft Disassembly 9 Drive Shaft Disassembly (Control Knob to Relay) 8 ‘SCHEMATIC OPERATION 9 ‘Typical Application of Hand/Automatae Station 9 Hand Relay 10 REPLACEMENT PARTS au Spue Parts Kits u Ordermnz Indy idual Parts u EXPLANATION OF NOMENCLATURE aH/A Station FIGURE 1 - Removing Vertical Gage Unt from H‘A Station Page 3 Sets. ise" ~ ss" FIGURE 2 Vertical Gage Unt ‘Zero Adjustment Screws INSTALLATION Pre Service Adjustment Chech IMPORTANT: Betore placing H ‘A Station in service, check adjustment of vertical gage units as outhned below For convemeice, perform this checkat a test bench before the H,’A Station 16 installed 1n the panel 1 Position HA Station at angle at which it will be mounted in service Apply pressure cor- responding to 10% scale toH A Station 1iput, connection If pointer reads correctly, proceed to step 4 2 If pointer doos not read correctly, re move vertical gage unit from HA Staton as out led in Figure 1 3. Remove snapout cover (Figure 2) and turn zero adjustment screw until pomter reads cor rectly Reistall cover 4 Apply pressure to gage umt correspond ing to 90% and 50% scale If pointer readings are correct, proceed to step 5 If readmgs are meorrect, refer to. Vertical Gage Unit Adjust ment", page 7 Mounting H_A Station on Pane! Hand Automatie Stations are designed for plug im mounting in a panel mounted enclosure (Figure 3) Install e iclosure as follows 5 Make panel cutout in accordance with Figure 3 6 Loosen meunting screws on front plate which secure H_ A Station to enclosure and re move Station 7 She enclosure thru cutout from front of panel 8 Place mounting clips (in bag tied to en closure) 1n position on enclosure Tighten clips securely agaist panel 9 Shde H A Station into enclosure and se cure with mounting screws in front plate Installing Connecting Tubs 1g, 10 Connect external tubing to manifold con nections on rear of enclosure (Figure 3) Con nection ports are 1 418 NPT female Use 1/4 inch OD copper, aluminum, ot plastre tubme Cleaning Seale Cover 11 Remove protective tape t1 om scale cover Clean cover with toothpaste or Plastar. plas fae cover cleaner and polish (obtainable from. Barley Meter Company in 10 ounce yar specity Part Number 199274 1) CAUTION: Do not use a solvent which will serateh caver finish or react with plastic cuverH/A Station = FIGURE 3 ie H/A Station Mounting Dimensions OPERATION Belore transter conditions within the eon trcl system must be set so there 1s little or no variation in control pressure (> the power umt as transier takes place Procedures fur trans Jerring trom AUTO to HAND and from HAND to AUTO are outlined below. Reler tu Figures 4 and 5 1 With HAND control knub pressure (kage C) equal to control pressure (gaze D) set transter 2 Turn transfer switch to HAND Transte Lrom HAND to AUTO 1 With HAND control knub_ slowly set con tol pressure (gaye D) equal to transfer pressure igaze C) 2 Turn tr Alternate HAND to AUTO Transier ‘The procedure above for transferrmg from HAND to AUTO may not always be practical In ims case the alternate nethod given below may he followed. CAUTION This alternate procedure should be used only where the H/A Station transfer pres sure Ge , system set point, controller output, ete .) may be changed without endangerinz the process 1. Adjust set puint (or other system cond: tion) until transfer pressure (gage C) 18 equal to control pressure (cage D) 2 Turn transfer switch to AUTO. 3. Return set puint to desured value,HAND POSITION ne of H/A StationHYA Station ROUTINE MAINTENANCE 1 Maintain a clean aur supply, free of of or mtoisture 2 Check falter an supply inlet port at man sfold shortly after installation If filter (item 3B and 8C, Figure 11) must be replaced, remove wire mesh dise felt pad, and Secund wire mesh dise Install new lilter, making certain wire mesh dise 18 inserted in inlet port before insert ang felt pad 3. Periodically depress orifice clean out plunger (Figure 6) on rear of hand relay to in- Sure that the orufice remaans open and clean CAUTION This operation should only be per formed when relay 1s bemg bench tested since depressing the plunger while relay 15 in service may disrupt the process 4 Whenever necessary. clean plastic scale cover as follows a Remove (and replace) scale cove a> shown in Figure 7 bb Clean cover wath a soft cloth which will not scratch the plastic surface Use tooth paste or "Plastar’ . plastic cover cleaner and Te PEM ok TOU TELL flee EF ‘at FIGURE 7 Lust CORRECT FS eLeanour “RCE AND se Bcneen’ Feu 2 Seder a h aay a a FIGURE 6 Rear View of H/A Station (Removed from Enclosure) polish (obtainable from Bailey Meter Company m 10 ounce jar specify Part No 199274 1) Do not use a solvent which will scratch cover finish or react with plastic cover. —« F + Be Tee ne Te fe Beste Steg Came te Removing and Replacin, Vertical Gage Umit Seale CoverP91-4 Page 7 CORRECTIVE MAINTENANCE Vertical Gage Umt Adjustment Af operational faults occur which are traced to the vertical gage units, make the following adjustment checks: 2 1. Remove gage umt from H/A Station as shown in Figure 1 Pry off snapout cover and remove side cover for access to gage unit ad justments (see Figure 2) 2. Apply pressure to Bourdon tube and check block assembly for leakage with a soap suds solution If a leak 1s found, replace entire gage unt The damaged umt may be returned to the factory for repair 3. Check all links to see that they are prop- erly connected and that they move freely with Bourdon tube movement 4. Make certain that indicating pointer does: not rub against side or face of scale If neces- sary, bend pornter slightly until it clears scale 8 Check pomter adjustment as outhned below a Apply pressure to gage equivalent to furat mayor scale division above 0% scale If pointer does not read correctly, turn zero ad justment screw (Figure 6) until desired read ang 18 obtained MN MUN STOP ou yeast rourer [se urer eour B3eeb || ASSEMBLY coven zero aogustment Sehews 2 ¢ souRnok TUBE 4 Exp. S108 even Gear sect on 86 Z ance Z Sovesrwens > \ Senews t BACKLASH SPR NG SECT ON AA BOURDON TUBES ~ b Apply pressure to gage equivalent to first major scale division below 100% scale If pointer does not read correctly, turn range ad- justment screw (Figure 8) until desired reading 1s obtained : ¢ Repeat steps Sa and 5b until pointer reads correctly at both scale divisions Apply pressure to gage equivalent to midscale division If pointer does not read cor~ rectly, but does read correctly in steps 5a and 5b above, alter the shape of U-lnk at {ree end of Bourdon tube as follows: 1) If mdscale point er reading 15 low, spread link slightly, or 2) If midscale pointer’ reading 1s hgh, close link shghtly 6 Repeat steps 5a thru 5d until pointer reads correctly over full scale 7 Apply 2 psig to Bourdon tube (pointer will cad slightly below wusunuis scale sark) Lous en minimum stop serews (Figure 8) and post tion minimum stop next to Bourdon tube end stop. tughten screws 8 Apply pressure to Bourdon tube corres- ponding to maximum scale value plus 0 25 psig (pomter will read slightly above maximum scale mark) Loosen maxamum stop screws and po sition maaimum stop next to Bourdon tube end stop, tighten screws 9 To return gageunitto service, reversethe order of the opera tons outlined in step 1 above ax mum sence stop.” SCALE COVER POWTER LEFT PONTER SOE coveR FIGURE 8 Vertical Gage Umt Adjustments~~ pera Page 8 Hand Relay Disassembly To disassemble the Hand Relay (Part No 5921995 0} for cleammg or replacement ot parts proceed as follows 1 Reler to Figure 11 Disconnect tul and remove two screws (26) holding gage sup port (13) to support bracket assembly (30) 2 Remeve screws holds mantiold te Relay and slide manitold and s.pport bracket rea ward 3 Remove two socket head screws (36) holding Relay to support bracket (30) and re move Relay 4 Refer to Figure 12 Unscrew valve cap (7) and remove valve stem (11), inlet valve seat (13), and valve seat spring (15) CAUTION Do not dusturb setting of relay adjustment screw (Figure 6) at center of valve cap ‘This setting 1s Lactory set and should not be disturbed un less control bellows has been removed or te placed (see ' Hand Relay Adjustment") 5 Unscrew orilice clean out assembly (4) and orifice (14) 6 Reheve spring compression by rotating, center adjustment gear (27) counterclockwise until 1 turns easily. 7 Remove tour nuts (at corners of valve housing 1ace) and screws securing spring hous ing (23) to valve housing (9) and separate housings: 8 Pull control bellows assembly (16) from. valve housin, (9) Cuntrol bellows assembly 15, held by exhaust valve diaphragm which suaps| into place around valve seat. 9. If desired, unscrew loading spring as sembly (18) trcm adjustment shatt (left hand) thread 10 To reassemble reverse above prcce dure observing the following precautions a_ When replacing contr 91 bellows as sembly (16) make certain exhaust valve dia phragm (28) 18 properly snapped into place around evhaust valve seat b_ When replacing orifice clean out as sembly (4), make certain that clean out wire 15 not bent and passes clean thru the arifice H/A Station ¢. Make certain that all O rinus are un damaged and properly anstalled Apply lubricant, to O rings when reassembling relay Hand Relay Adjustment 1 Connect output pressure line of Relay. thru a petcock. to a volume chamber equpped with a suitable pressure gage (0 30 psig) for indicating chamber pressure Volume chamber may be any pressure tight contamer with ¥¢l ume of about 300 cubic mches 2. Open peteock and adjust HA Station con trol knob to obtain 3 psig pressure in volume chamber 3 Close potcock and adyust control knub to obtain 15 psig (for 3 15 range) ur 27 psig (for 3 27 range) output pressure from Relay (read output pressure on H A Station gaze) 4 Open petcock and note ime rate of pres sure increase m volume chamber. 5. Close peteock and adjust control knob to obtain 3 psig output pressure trom Relay 6 Open petcock and note time rate ot pres sure decrease in volume chamber 7 Hamlet valve seat 15 properly adjusted, the time rate of pressure inerease as noted 11 step 4 will be equal to the time rate ur pressure decrease as noted 1m step 6 If these rates are not equal (or af the contr al bellows or nuzzle bellows has been replaced). at will be necessary to make the following adjustments a If time rate of pressure increase 33 greater than the rate uf pressure decrease, turn adjustment screw (Figure 6) cuunterel>ch D_ If time rate of pressure decrease 15, greater than the rate of pressure increase, turn adjustment screw clockwise NOTE By turning the relav adjustment screw (Figure 6) on the rear of the HA Stats n, the inlet valve seat position can he changed wath respect to the neutral position of the exhaust valve seat, in effect, controlling the relative ‘openings of the inlet valve and exhaust valve for a given position of th» contrel belluws Front Plate Disassembly 1 Remove vertical gage units as shown an Figme 1pol 4 Page 9 H A Station 2 Reter to Figue 11 Remove HAND cun trot knob (27) by driving oul steel lockpin (28) fand pulling knob off shait ‘Then slide knob off Shatt AUTO HAND transfer switch need not be removed 3 Remove two screws (15) at rear of front plate (17) which secures plate tc H/A Station frame 4 Tc reassemble. 1ev-1se the above proce dure opserving tne following precawaons a When placing front plate (17) on Hy A Station frame, fut pins at top and bottom of plate qnto corresponding sluts in frame and align transfer switch and valve o erator lever (22) 80 that transfer switeh pin Lats anto hole at top of lever (22). b- When replacing control knobs, shde knobs on respectave shaft» Replace lockpi 10 HAND control knob shaft shut Oft valve Disassem Iv 1 Refer to Figure 11 Disconnect tubing at vertical wage umts ard remove serews at Relays 2 Remove tour screws (12) and (14) (o> at tri at end of plate and two at rear end next to Nameplate) whieh secures shut olf valve mount ing plate (top of H, A Station) te frame Do not disturb sc1ews holding valves to plate 3. Set transier switch (23) (or valve oper ator lever (22) 1 Lront plate has been remcved) tn vertical position between AUTO and HAND, 4 Shde shut off valve assembly (10) (plate valves and tubing) to rear to disengage valve ‘stems trom valve operator shalt, When disen gaued, assembly can be lifted from H'A Station SCHEMATIC ‘Typical Applocation of Hy A Staton Figure 9 shows 4 typieal control application, A signal pressure pr uportional to the measured Variable 1s applied to the A bellows of the Pro portunal Plus Intearal Controller (indicated on kau A) The Controller uipat pressure 15 transmitted thru the HA Station to the power 5 Tu disassemble inavidual shut uit valve. unscrew plug (10e) at bottom of valve and remove spring (LOd), stem (10D), and diaphragin (101). ‘To reassemble, reverse the above procedure. Valve stems nist be an alignment to engage valve operator shaft Valve Operator Lever and Shaft Disassembly 1 Remove verteal gage units (shown 1n Fag ure 1), front plate (see above) and shut off valve assemibly (see above) 2 Refer to Figure 11 Remove hea nut (25) at tront end of shaft and slide valve operator lever uff shaft 3 Unscrew bearing (9) which supports end of shatt 4 Slide shatt to rear unl front end clears: supporting bearmg Remove shalt irom frame 5 To reassemble, reverse the above proce dure Drive Shaft Disassembly (Control Knob to Relay) 1 Remove vertical gage units (as shown m Faure 1) and front plate (see above). 2 Refer to Figure 11, Remove retaming ring (84) at rear end of shalt. 3. Back off cone point set screw (32) sn per imeter of gear (33) until gear 1s free of shaft 4 Shde shaft out thru Lront of unit and re move gear 5 To reassemble, reverse the abave pro cedure. OPERATION When the H/A Station 1s in the HAND post tun, fe back pressure 1s provided from con nection 4 thru connection 5. shut off vaive V3 ‘aml connection 3. to the C bellows of the Con troller. On HAND operation, the Ue back pres sure holds the Controller output pressure ap proximately equal to the control pressure. fa mooth transfer to automatic operation the back pressure 1s not required. con lection 4 18 plugged and connections 3 and § are left open to atmusphereH/A Station | FIGURE 9 - ‘Typical Application of H/A Station Hand Relay Hand output pressure 1s established by the Hand Relav (Figure 10). Compression of the loading spring 1s opposed by pressure im the control bellows so that forces due to spring compression and output pressure are always equal when the unit 18 balanced. Pressure in the control bellows 15 regulated by the inlet exhaust valve assembly “At balance, the inlet valve 1s held closed by the dullerence between supply pressure and control bellows (output) pressure Leakaye of supply aur thru the bleed orifice mamtains the exhaust valve in a float ang position ‘Turning the HAND control hnob sn the “an crease direction compresses the loading spring cotupressing the control bellows, clos ing the eahaust valve opening the inlet valve, and admitting supply am to the control bellows Control bellows pressure increases until bel lows expansion 18 sufficient to resiore the anlet exhaust mechanism to its original position Gn let valve closed, exhaust valve floating) Output pressure 18 then proportional to the increased loading spring compression, ‘Turning the control knob in the “decrease” direction reverses the operation described above cover, seus SUPE HRESORE BLEO RFE Leann ne 2 alse ea tTROL PRESS, hair tween FIGURE 10 Schematic «1 Hand Relaypol 4 H/A Station Page 11 REPLACEMENT PARTS Spare Parts Kits there may be andividual differences in specific a umits because of ‘The Spare Parts Kits shown in Figure 11 12, and 13 should be carried an stock Specify a design changes made since the print the Spare Parts Kit part number to order a ang of this Instruction Section, or complete kit b. special design of the Hand/Automatie Ordering Indsvidual Parts Station to make at suitable for a special applica ~ ton Figures 11, 12, and 13 are Parts Drawings of the Hand/Automatic Station Normally. these ‘Therefore, when ordering parts, assure the drawings apply to the unit furnished. However, receipt of correct replacements by specifying the Hand/Automatic Station Module Part Number. EXPLANATION OF NOMENCLATURE H/A STATION H/A STATION | RANGE LEFT GAGE SCALE LEGEND MODULE PART NO. | NOMENCLATURE* | (PSIG) | “LEFT INDICATOR RIGHT INDICATOR) 5321605 1 Ay02B10 327 ‘Loading, 5321605 2 ‘As02B20 3-27 Loading Position 5321605 3 ‘AT02B50 3.27 } Direct Reading+* 5321605 4 ‘AJOIBIO 3-15 ‘Loading -- | 5821605-5 ‘AJOIB20 3-15 Loading Position 5321605-6 ‘AJOIBS0 3.15 | Direct Reading+* *NOMENCLATURE appears only on the H/A Station Specification Sheet included in Instruction Books furnished on system or contract jobs. A "5" in the third position of the Nomenclature indicates that the H/A Starion module 1s complete wath enclosure Part No, 5822407 2 An “X” in any Nomencla ture position indicates that the mstrument 1s special. +*SCALE LEGEND engraved an terms of variable such as, FLOW. LEVEL, PRESSURE.Page 12 HA Station FIGURE 11 Parts Drawan, P91 10, Hand Automatic Stationz Pol & H/A Station Page 13 a =~ Ten] parse wane FIGURE 12 - Parts Drawing P91 7, Hand Relay Part No. 5321995 1H/A Station B/HESH | BRS BREIES om i [ier | RRs as a ee NOTE. FOR MECHANISM ASSEMBLY SPECIFY TYPE. PART NUMBER. AND RANGE OF INSTRUMENT. ALSO FOR POINTER (ITEM 5B) SPECIFY WHETHER LEFT, RIGHT, OR BOTH LEFT AND RIGHT ARE DESIRED. FOR SCALE (ITEM 6) SPECIFY LEGEND AND RANGE FIGURES, Al FIGURE 13 - Parts Drawing P12 5 Vertical Gage UmtProduct Warranty Barley Meter Company warcants the products manufactuted by 1 o be free from defects im material and work manship and wall repair or seplace. at tts opt on, free of charge t ob ats factory, such part or parts wh ch prove efecuive within one Year from date of shipment Ia respect to ans products nian Rot an integra part of a Product urauufactured by the Conpray. the wattanty given by the henulacters thereof shal apply Shipping Damage dooney opment you spect and lst your mstrument a oon as you reeine 1 Tf he strument Perabed oF operates mpropety. nt fy the carrer for impecton of the shnment Te cea a agent will wine for erect SAREE a copy of which shuld be forwarded fo Vour nearest Bulky Braet a Service ‘The Bailey Meter Company ts vitally concerned that your Bauley mnstrument Prov des continued, fine perform, nee This mtruct on manta 1s designed to fully desenbe the coerect neal aoe f9peration and ma ntenance Replacement Parts and Supplies Complete parts dranings and recommended spare parts kit mformation are ineluded in ths nstruction manual rhe "EP acement parts or supp es are required tor ma etenanie of your Balog Astri ment contact your nearest Da ley Distr et Ofte (see back cover for fecation) Abways spec f comp ete on the instrument nameplate on seuringuty oF order ter parts Common parts are avai able for sh pmteatw th dS here speed order basisBAILEY METER COMPANY DISTRICT OFFICES, U.S.A. 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