Product Instruction P91-7 Mini-Line® 500 Indicator-Controller Type AJ6 ley| Babcock & WilcoxPage 2 ‘Type AJ6 Indheator-Controller EXPLANATION OF NOMENCLATURE TYPE | A 1 [3 to 18 pag. 1 | Proportional Only 2 | to 27 psig 2 | Proportional + Integral 3 | Proportional + Integral + Derivative 4 | Proportional + Derivative Left Seale Legend Application. Lett** Rught** A] 1] pneumatic | Meter Set Point A|s | StPort | direct Reading | Set Point pit Loading HA B [2 | Transfer Loading Position only BIS Direct Reading D | 1 |ad Tse Back Relay ‘Tie-Back * An X many position indheates a special feature =* Indicators NOTE Complete nomenclature appears only on the Specification Sheet included in Instruction Books furmshed on system or contract )cbs When ordering parts, refer to tms nomenclature If umt 15 not furnished as part of a system, give the part number of the ind:vidual component for which the part 1s desired Part numbers of the specific Type AJ H, A Station, Type AJ enclosure assembly, and Type ‘AD Controller are given on the identification plates attached to the umts (Integral and Derivative plug 1m units for the Controller are individually identified and must be ordered as separate ems ) CROSS REFERENCES Instrument or Equipment Instruction Sect Type AJ Set Point H/A Station Pol 3 Type AJ H/A Station Pol 4 ‘Type AJ Tie-bach H/A Station P81 6 ‘Type AD Pneumatic Controller p92 1‘Type AJ6 Indicator-Controller PoL 7 Page 3 FIGURE 1 Bot ey MINI- LINE 500 Indieator- Controller, Mount ng D mens ons INSTALLATION 1 Cut out panel mounting hole to dimensions shown in Figure 1 2. Shde mounting case thru cutout from front of panel. Place mounting cps (in bag tied to case) in position on mourting case, Tighten chp screw securely agamst panel. 3. Shde Hand/Automatic Station into mount~ ing case and secure with two mounting screws on face plate 4, Plug Type AD Controller into rear of pro- gramming mamfold and secure with three cap- tive screws on Controller assembly (Figure 1), 5 Make tubing connections to bottom of pro gramming manifold (Figure 1) as amdicated in Figure 4, 5, or 6 or as given on Control Tubing Diagram for specific system 6 Adjust Type AD Controller for particular service desired (see Calibration" on page 5) 7, Set dise valves (Figure 1) to proper pust- tion in accordance with control system require- ments (see operation"), Lock disc valves in Position with retazmng screws. 8 Apply supply air to connection "S" (30 psig for 3 to 27 psig range, 18 psig for 3 to 15 psig range)‘Type AJ6 Indicator-Controller OPERATION ‘The Indicator Controller consists of a Type AD Pneumatic Controller connected to a Type AJ Hand/Automatie Station by means of a pro grammung manifold. ‘The programming manifold co tains sia tub ang connections (Figure 1) and four dise valves (Fimure 2) Each disc valve has up to sr¥ rota tional positions Each position provides a vari ation in the interconnecting air passages be tween the Selector Station and the Controller Figure 3 1s a schematic drawing of the inter connecting air passages Table Ais a tabula tion of the interconnections for specific disc valve settings ee jens af wmrcoe (2 * TY ee Figures 4, 5, and 6 shows the Indicator Con troller as it 18 used in three commo} control modes Tf an Indicator Controller 1s used as part of a control system, the required connec ons will be shown on the system schematic tubing diagram, and the dise valve settings will be given on the Controller calibration sheet ‘The operation of the Type AJ H’A Station and Type AD Controller are described inthe ap plicable instructions sections Listed in “Cross References” on page 2 The operation of these units is identical to that described in the speci fie instruction section except Lor the addition of fold rei fey Og) lt nin ten ® F.GURE 2 - Schemat © of D se Va ve Connect ons CONTROLLER Pal EPL A Th TE FAL PROGRAMM No MAN FLD FIGURE 3 Schematic of Ind cotor Contro ler Showing Interconnect ons‘Type AJ6 Indicator Controller P91-T Page 5 CALIBRATION Calibration of the Incieator-Controller con sists of adjusting the Type AD Controller for service as described in Instruction Section P92-1 under "Adjustment and Calibration’ . However, modify the procedure for making the required connections as follows 1 Pisregard steps 1 thru 4 under Adyust ing for Service" on page 7of Iistruction Section P92-1, Make required connections with Control Jer mounted on Incheator~Controller program nung manifold 2, Set integral and derivative switches or plug in valves, direct reverse’ switch, and “proportional-proportional plus integral switch to positions indheated in Table B (page 7) Set Controller yain adjustme xt at 1.0. (Lock gain arm im place each fame it 18 positioned ) NOTE If integral or derivative plug in units are employed, valve will be open’ or “closed” when adjusting screw 1s turned to 1ull clock wise or counterclockwise position respectively 3. Connect separate variable inputs to In ducator-Controller programming manifold (Fi ure 1) Plug output connection "0" . Set Indica tor Controller dise valves (Figure 2) as follows wa ya X-3 ai 4, Apply midrange pressure to mput con nections, If full range 18 not used mm particular system apphation, apply midrange pressure of ‘actual input range employed, (1.e., for a range span of 10 to 15 psig, applied pressure should be 12,5 psig). Apply air to supply connection "3", 30 psig for 3 to 27 psig range, 18 psig for 3 to 15 psig range. 5. Place Type AJ H/A Station in HAND po sition, Read input pressures applied to pro- gramming manifold on H/A Station gages Gage A reads El pressure Gage B reads E2 pressure Gage C reads "O" sressure (Controller output) Gage D reads E3 pressure NOTE Refer to H/A Station instruction section for gage identification, On H/A Stations which do not include all the above gages (or if greater accuracy 18 required), attach separate gages or manometers to the variable input pressure nes. 6. Proceed with "Adjustment and Calibra- tion” in Instruction Section P92-1, page 7, be- gmning with step 5. ‘The H/A Station requires no adjustments be- fore placing in service. However, of operating faults occur which are traced to the H/A Station, refer to "Adjustments" in Instruction Section for particular Station. TABLE A MANIFOLD CONNECTIONS VS DISC VALVE SETTINGS Pise Valve Position Connection Station 1 to mamsfold ESR Station 1 to Station 5 Station § to manifold £2 and Controller E2 Station 1 to mantfold E2 and Controller E2 Staion 1 to mamfold E1 and Controller E1 Manifold E3R to mamfold El and Controller E1 Controller O to Station 6, Controller ESR to mamfold EIR. Station 6 to mamfold ESR Station 6 to Controller 0 Controller E3R to mamfold EIR ‘Station 7 to Controller E2 and manifold E2 Station 6 to Station 7 Station 6 to Controller E1 and manifold Et Station 7 to Controller E1 and mamfold El Station 7 to Controller output Controller output to Controller E2 and manifold E2 INNS N\enaded|oxex|eeeace Station 4 to Station 5, Station 3 to Controller E3 and mamfold E3 Station 3 to Controller E3 and mamfoli B3 Controller output to manifold E3 Controller output to Station 5, Controller E3 to manifold E3‘Type AJG Indicator Controller MAINTENANCE The air supply to the Indicator Controller must be clean and free from oil or moisture Felt filters are provided in the supply and out put ports of the programming manifold Chech both filters shortly after the unit is rst placed an operation and at regular intervals thereafter Replace the filters sf they appear dirty Check all connections to the programming manifold for leakage with a soapsuds solution All connections must be kept air tight 1! the unit FIGURE 4 App scat on of Ind cotor Contra ler SngeE ement Conte. System = afetel, FE] [ree] | —— 1 | Lopes y FIGURE 5 Appl cot on of Ind cator Control er to, ‘Ant e potor Computer Control System 4s to function properly The dise valves (W, X, ¥, and Z) should be checked tor air leahage witha scapsuds solution each time reposiaoning 15 required It sufficient sealing pressure can not be obtained with the retaimng screw, re place the dise valve Maintenance of the H/A Station portion as covered in mdividual ansiruction section, see "Cross References", page 2 The AD Controller as covered in Section P92 1 PR waRy VAR ABLE TRANSM TTER JR NTRELLER a coura wen | span A Tow.t .star-¥ Sieeeage |* 3] wow acastacé ser ‘SecCNOARY VAR ABLE ‘TRANSM TER contac Lier |" HAND AUTOMAT ¢ 1 TeeaD | SIATCN CONTRELLED POWER DEV CE FIGURE 6 App cot on of Ind cor Coscede Conta. System Contra ter t0P91-7 ‘Type AJ6 Indicator Controller Page? TABLE 6 CONTROLLER DISC SWITCHES 7 DISC SWITCHES PLUG-IN UNITS FUNCTION OR ACTION p-R | Ppa | int. per | ie. | Der Direct Prop. D P| Closed Open | None | None Reverse Prop R P| Closed Open | None | None Differential D P| Closed Open | None 2’ Element Coutrolles D P| Closed Open | None ‘Totalzing D> p | Closed Open | None Signal (Range) Conversion] D P | Closed Open | None Subtracting R P| Closed —_Open_| None Floating (Pure Integral) D pa | None open | Closed | None Differential Floating D pa | None Open | Closed | None Prop. Plus Integral D Pat | None Open | Closed | None Diff. Plus Integral D Pat | None Open | Closed | None Averaging, Damped input | _D P| None Open_| Open _| None Prop Plus Derivative D P| Closed None | None | Open Dit, Plus Derivative D P| Closed None | Xone | Open Prop. Plus Int. Plus Der, | D pac)] None None} Closed | open Ditt. Plus Int Plus Der. D Pu) | None None | Closed_| Open +P for adjustment, Psl am service‘Type AJO Indieator Controller REPLACEMENT PARTS Spare Parts Kit The Spare Parts Kits referred to cn the Parts, Drawing (Figure 7) should be carried in stock. Specify the Spare Parts Kit part number to order a.complete kit. ‘Ordering Indwidual Parts A Parts Drawing for the Railey Indicator Controller 1s shown in Figure 7. Normally this drawing will apply to the units furnished, However, there may be individual differences an specific umts because of a, Design changes made since the printing of this Instruction Section. b. Special design of the Indicator Controller furmshed to make it suitable for a special application, ‘Therefore, when ordering parts, assure the receipt of correct replacements for the Indi~ ator Controller furnished by specafvang on the order 1, The Nomenclature and Part Number of the unit for which parts are desired, 2. The Parts Drawing on which each part 1s mMustrated, (The Parts Drawing Number ts gaven in the ttle for the Figure.)‘Type AJ6 Indicator-Controller P91 7 Page 9 type ap conrnorien (Wooster euay (iD SEE PARTS OWG LST Te ay wevovauroware star on™ SEE PARTS OWGL ST ‘SEE PARTS OWG LST : u TEN [PART NO AME 1 | som201 | PROGRAMMING MaNTFO“D INCLUDES rive 2 TARD 22 2 | sszzs<0 x swrrcn Asey. 3 | seaasee 2 SWITCH ASSY & | sozasaa 1 Ww ‘swrren assy 5 | saagaes 2 Y SWITCH ASSY 8 | Sea T 5 CONN PLUG 1 | to'sega | en ND CAD PL srt screw, «¢REQD a | sonae'n | ome s Rego. 9 | sszaie | Fett Pap, 6 ReaD 10 | suas 1 | Wine Mbsi bise- 12 rap | xov10 SPRING LOCKWASHER CAD PL STL MED 12 | 320001 | VaLve cones REQD 1 | Satta 3 | ofniNG“s REQD' | fosasne | Panu sLov gens ecr «REO 13_| ssaseas' 1" | Swiver Block Assy LIST OF ADDITIONAL PARTS DRAWINGS INDICATOR CONTROLLER | INSTRUCTION | _ REFERENCE ‘COMPONENT. Secrion | PARTS DRAWING CONTROLLER pee Pen BOOSTER RELAY e210 pert SET POINT HA STATION Pos pee 1 A STATION (BASIC) Pod Per 10 THE BACK HA STATION Pei per ary TEM NO, ® @ 5 5 2 10 3 is ts Drow ng PITS, Ba ey MNI-LINE 500 nd cctor Contro erProduct Warranty eS. factory tra call for prompr, in plane marntenance Telephone or wine Your nearby Bailey Dtrct OMe 10 make arrangements forthus serviceBAILEY METER COMPANY mEADQUAR™ERS. 22801 Euc d Ave we Wek tHe, On 6 44092 USA OSTRCTOFF ces a forma Los Ange ss Ga forva Sen Fram sco © orado, Denver {Go nec cur Naw Have 1 Georg, At ante noe ch cape Kentucky Lousy € Lous ena New 0. eors Marne’ Auguste Marpsy Drv Minnesota St POs Noth Gare. 1a Char ote New Jensy_ East O ange ‘Now York’ Syracu= One Cove and Permy van 2 Priisuroh Tease, On es Vigna, Retnond War ngion Seatt BA LEY METER COMPANY L M TED. PO NTE CLA RE 730, QUEBEC A barta Edmonton Grrancoumoa Vancotver ‘Nove Seat a Ha tax Ontaro Toronto BA LEY METER AUSTRAL APTY LTO REGENTS PARK NSW 2143, NSW Syavey Gueent and @ sbene South Aunte 9 Ade a ge Western Austra © Perth NTERNAT ONAL REPRESENTAT VES Argent na BL enos A res Gh Sant ago fey Man Japon Tokyo Mon ca Mon co Cty OF Sean Madr d Turkey Ankara And Other Prneps Cte Bialille| a Subs d ary of Babcock & W cox USA Form 9917 720