Calibration and Switching Module, CSM, User`s Manual
Contents
1. Relief Valve in System 1 Connect a variable pressure source to the sample assembly inlet 2 Slowly increase the pressure until the valve opens 3 Decrease the pressure until the valve closes 4 If the valve does not open at the set pressure factory set to 75 of the pressure gauge range remove the valve from the system according to steps 1 through 3 of Relief Valve Removed From System 5 Remove the outlet adapter from the top of the valve tighten or loosen the adjusting screw as necessary then replace the outlet adapter Reverse steps 1 through 3 of Relief Valve Removed From System and reinstall the relief valve Alternatively replace the relief valve Relief Valve Removed from System 1 When multiple inlets are present remove the relief valve outlet header 2 Unscrew the screws attaching the relief valves to the substrate and remove the valves from the substrate 3 Remove the modular adapters and exhaust manifold from the valves 4 Connect each valve to an external pressure supply 1 4 in NPT connection and a suitable exhaust header 1 4 in Swagelok tube fitting connection 5 Slowly increase the pressure until the valve opens 6 Decrease the pressure until the valve closes 7 If proper operation has been observed reverse steps 1 through 3 and reinstall the relief valve If the valve does not open at the set pressure factory set to 75 of the pressure gauge range remove the outlet adapter from the top o2. 222 Note CSM systems containing flow indicator s must be installed vertically allowing the flow through the flow indicator s to be in the upward direction Dimensions in inches millimeters are for reference only and are subject to change A Swagelok Pre Engineered Subsystem Calibration and Switching Module 10 Plate Dimension L Inlet Stream Configuration Designator Dimension L in mm Bypass Option No No Yes Yes No Yes No Manual Calibration No No No Yes Yes Outlet Designator 3 X 1 2 A All 3 A X 1 2 F Filter FIA 12 0 305 15 0 381 15 0 381 18 0 457 23 0 584 G Gauge GIA 12 0 305 15 0 381 15 0 381 18 0 457 23 0 584 L Flow loop LIA 1 inlet 23 0 584 28 0 711 28 0 711 28 0 711 28 0 711 L Flow loop LIA 2 inlets 23 0 584 28 0 711 28 0 711 28 0 711 34 0 864 L Flow loop LIA 3 or more inlets 28 0 711 28 0 711 28 0 711 34 0 864 34 0 864 P Pressure regulator PIA 15 0 381 23 0 584 23 0 584 23 0 584 23 0 584 R Relief valve RIA 15 0 381 18 0 457 18 0 457 18 0 457 23 0 584 V Valve VIA 12 0 305 15 0 381 15 0 381 18 0 457 23 0 584 Plate Dimension W Number of Inlet Streams Dimension W in mm Bypass Option No No Yes Yes Yes No Yes Manual Calibration Yes No Yes No No No Yes Yes No Yes No Outlet Designator 2 X
3. KCP Series Regulators Maintenance Instructions Body cap assembly Spring button Dimple Lubricate lightly Body threads Lubricate lightly Lubricate lightly Bottom face Body cap assembly A Swagelok Pre Engineered Subsystem Calibration and Switching Module 39 19 Thread body cap assembly onto body Tighten to 25 ft lb 160 N m 3 5 m kg Note If your regulator assembly is used on a Swagelok MPC substrate proceed to step 23 20 Insert filter ring in the inlet port marked HP 21 Insert the filter into the inlet port with the course mesh facing away from the inside of the regulator KCP Series Regulators Maintenance Instructions HP Filter ring HP Filter 22 Insert the retaining ring into the inlet port until the ring is fully seated into the groove inside the port 23 Test and set the regulator for proper operation A Swagelok Pre Engineered Subsystem Calibration and Switching Module 40 Pressure Regulators User s Guide CAUTION SWAGELOK REGULATORS AND KENMAC ADJUSTABLE REGULATOR RELIEF VALVES ARE NOT SAFETY ACCESSORIES AS DEFINED IN THE PRESSURE EqUIPMENT DIRECTIVE 97 23 EC DO NOT USE THE REGULATOR AS A SHUTOFF DEVICE Installation Bottom Mounting Mount the regulator using the two M5 10 32 mounting holes located on the regulator base Panel Mounting Warning Failure to mantain the handle and stem position could result in downstr
4. no flow control Connect the tubing leading to the process analyzer to the tube fitting adjacent to the white lockdown bar labeled AO The fitting size is either 1 8 in or 3 mm Connecting Remaining CSM Connections System vent connections 1 Connect the system vent on the SSV end block to a sample disposal The fitting size is either 1 8 in or 3 mm Note See Stream Selector System For Process Analyzer Applications MS 02 326 for information on an alternate vent location 2 Connect the vents from the relief valves in pressure regulator inlet assemblies relief inlet assemblies and flow loop inlet assemblies to a sample disposal The fitting size is either 1 4 in or 6 mm Bypass option when present 1 Connect the tubing leading to the system bypass outlet to the tube fitting adjacent to the green lockdown bar labeled BO The fitting size is either 1 4 in or 6 mm 2 CSMs without manual calibration option connect the pneumatic supply line to the fitting adjacent to the green lockdown bar labeled PNI The fitting size is 1 8 in or 3 mm Installation A Swagelok Pre Engineered Subsystem Calibration and Switching Module 16 Manual Calibration Option Installation The manual calibration option is available with one or two calibration inlets It can be operated in three different modes depending on your system and the desired function All fittings are either 1 8 in or 3 mm Assemble all connections according
5. 1 X 1 2 1 2 X 3 A 3 A 2 12 0 305 15 0 381 12 0 305 18 0 457 18 0 457 15 0 381 18 0 457 3 12 0 305 15 0 381 15 0 381 18 0 457 18 0 457 18 0 457 23 0 584 4 15 0 381 15 0 381 15 0 381 18 0 457 18 0 457 18 0 457 23 0 584 5 18 0 457 18 0 457 18 0 457 18 0 457 23 0 584 23 0 584 23 0 584 6 18 0 457 18 0 457 18 0 457 23 0 584 23 0 584 23 0 584 28 0 711 7 18 0 457 18 0 457 23 0 584 23 0 584 23 0 584 23 0 584 28 0 711 8 23 0 584 23 0 584 23 0 584 23 0 584 23 0 584 23 0 584 28 0 711 9 23 0 584 23 0 584 23 0 584 28 0 711 28 0 711 28 0 711 34 0 864 10 23 0 584 23 0 584 28 0 711 28 0 711 28 0 711 28 0 711 34 0 864 11 28 0 711 28 0 711 28 0 711 28 0 711 28 0 711 28 0 711 34 0 864 12 28 0 711 28 0 711 28 0 711 34 0 864 34 0 864 34 0 864 34 0 864 Dimensions in inches millimeters are for reference only and are subject to change Mounting A Swagelok Pre Engineered Subsystem Calibration and Switching Module 11 Installation The assemblies within the CSM are color coded Blue Process sample assemblies Orange Calibration assemblies Green Bypass assemblies White Outlet assemblies Note Close all inlet ball valves before connecting the CSM to your system Assemble all connections according to the Swagelok Tu
6. A Swagelok Pre Engineered Subsystem Calibration and Switching Module Introduction The Calibration and Switching Module CSM is a part of an analytical sampling system The CSM selects the process or calibration fluid which is then directed to a process analyzer The CSM contains multiple streams with modular components including a stream selector system SSV series The series of components which handle the process fluid are called sample inlet assemblies The series of components which handle calibration fluids are called calibration inlet assemblies The SSV within each stream selects a fluid for analysis in response to a pneumatic pressure signal from an external source typically the analyzer The signal opens one of the SSV s double block and bleed valve modules corresponding to the stream containing the fluid to be analyzed The selected fluid flows through the CSM to the process analyzer A Swagelok Pre Engineered Subsystem Calibration and Switching Module 4 SSV FI MV CV PI PI PI PI PI PR RV PI FP BV PSV SHV BV C Gas System with Three Sample Inlet Assemblies and Two Calibration Inlet Assemblies Shown with Bypass ARV and Manual Calibration Options A Swagelok Pre Engineered Subsystem Calibration and Switching Module 5 Introduction Inlet Assembly Configurations Your CSM will be configured using one of these six inlet assemblies plus any selected outlet configuration and opti
7. PV NV FI Pressure regulator PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Pneumatic switching valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Relief valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Shuttle valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Stream selector valve Configuration Symbols A Swagelok Pre Engineered Subsystem Calibration and Switching Module 6 Pressure indicator Filter Ball valve Stream selector valve Filter Inlet Assembly FIA Only assembly for calibration inlets BV SSV PI FP Common Vent Outlet Flow Loop Sample Inlet Stream selector valve Pressure indicator Ball valve Gauge Inlet Assembly GIA BV SSV PI Common Vent Outlet Flow Loop Sample Inlet A Swagelok Pre Engineered Subsystem Calibration and Switching Module 7 Inlet Assembly Configurations Pressure regulator Relief valve Stream selector valve Pressure indicator Ball valve Filter Stream selector valve Pressure indicator Ball valve Filter Relief valve
8. Pressure Regulator Inlet Assembly PIA BV SSV PI FP RV Common Vent Outlet Flow Loop Sample Inlet BV SSV PI FP RV PR Common Vent Outlet Flow Loop Sample Inlet Relief Inlet Assembly RIA Inlet Assembly Configurations A Swagelok Pre Engineered Subsystem Calibration and Switching Module 8 Ball valve 2 inlet Relief valve Stream selector valve Pressure indicator Ball valve 1 loop Filter Sample inlet Flow indicator Flow Loop Inlet Assembly LIA BV2 NV NV RV FI PI1 BV1 FP SSV Common Vent Outlet Flow Loop Sample Inlet Bypass Outlet Liquid Gas Inlet Assembly Configurations A Swagelok Pre Engineered Subsystem Calibration and Switching Module 9 Mounting The size of the mounting plate is dependent on the number and type of sample streams the number of calibration streams options included and fluid type gas or liquid The tables on the next page contain the mounting plate dimensions Attach with fasteners with a maximum diameter of 1 4 in or 6 mm not provided in the four mounting holes on the plate 5 50 14 0 A 1 00 25 4 1 09 27 7 0 75 19 0 L W 4 mounting holes for 1 4 in 6 mm socket head cap screw or hex head bolt or similar fastener CSM Configuration A in mm CSM with flow indicator or relief valve 6 80 173 CSM with flow loop inlet assembly 8 75
9. Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy visit swagelok com or contact your authorized Swagelok representative
10. assembly when lifted Set aside for later use 5 Turn body assembly upside down and remove piston assembly by applying low pressure air to an outlet port marked LP CAUTION Applying pressure greater than 5 psig 0 34 bar could cause personal injury or damage to the piston 6 Remove the piston seal s For high pressure regulators also remove the piston guide 7 Use socket wrench to remove seat assembly poppet and poppet spring CAUTION Be careful not to scratch the inside of the body Leakage could result Cap assembly handle Over 375 psig regulators Lower spring button Body cap Handle Piston seal Low pressure Piston Discard Poppet spring Seat retainer assembly Discard Poppet Low pressure piston assembly Outlet port LP High pressure Piston Piston seal Discard Piston seal Discard Piston guide KCP Series Regulators Maintenance Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 37 Note If your regulator assembly is used on a Swagelok MPC substrate proceed to step 10 8 Use needle nose pliers or similar tool to remove retaining ring from the inlet port marked HP Note Be careful not to scratch the sides of the inlet port 9 Remove the filter ring and filter Note Tap the body by hand to allow the filter ring to fall out Note Prod the filter with the pliers to tip it until the filter falls
11. out Reassembly CAUTION Ensure all components are free of debris or damage or leakage could result 10 Fit the seat into the seat retainer until flush Lightly lubricate the threads only 11 Place the poppet through the center of the seat 12 Place the poppet spring onto the exposed end of the poppet 13 Keep the seat retainer assembly inverted with the poppet spring on the top and thread it into the body Lubricate lightly Seat Seat retainer Seat Poppet Poppet Poppet spring Seat retainer assembly Body Inlet port HP Retaining ring Filter Filter ring Discard HP KCP Series Regulators Maintenance Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 38 14 Tighten seat retainer to 15 ft lb 20 3 N m 2 1 m kg 15 Lightly lubricate piston seal s and install onto piston For the high pressure piston press the second seal onto the piston guide from the concave side 16 Press the piston assembly into the body until it seats against the seat retainer Note Do not to damage the piston seals Lubricate lightly Low pressure High pressure Lubricate lightly Lubricate lightly Concave side Piston assembly Body 17 High pressure regulators only put a small amount of lubricant in the the dimple of the spring button and place into the body cap assembly 18 Lightly lubricate the body threads and the bottom face of the body cap assembly
12. scale or the LED display Installation The variable area flowmeter must be installed as vertically as possible to ensure the most accurate flow reading with the exception of the Swagelok MH horizontal model Direction of flow is from bottom to top in vertical models and can be either right to left or left to right in horizontal models as specified when ordering Align the pipe or tube leading to and from the flowmeter axially with the connections on the flowmeter to keep them free of stress If necessary support the pipe or tube leading to and from the flowmeter to prevent vibration being transmitted to the flowmeter Reading the Flowmeter 1 For accurate flow measurement the system media pressure and temperature should be consistent with the calibration of the flowmeter 2 Close the integral metering valve on the flowmeter before the system is pressurized Note M3 and MH models do not contain an integral metering valve 3 Open the shutoff valves upstream and downstream of the flowmeter 4 Add system pressure slowly NOTICE Open the metering valve slowly when starting the flow to prevent damage to the float 5 Adjust the metering valve until the flowmeter shows the desired flow rate Startup For optimal performance prior to installation flush out the pipe or tube leading to the flowmeter For gas flow applications dry the pipe or tube leading to the flowmeter G Series Vertical Mount Left to
13. the installed plug and connect the pneumatic signal line s from the analyzer to B 3 Remove the installed plug and connect the pneumatic supply line going to the analyzer to D Mode 3 Manual Calibration only Two Calibration Inlets 1 Connect a pneumatic supply line to A 2 Verify there are plugs in B C and D One Calibration Inlet 1 Connect a pneumatic supply line to A 2 Verify there are plugs in B and D Notice The analyzer will remain in control of the sample inlets and the calibration inlet not set to MANUAL There is the possibility of a mixture of calibration and or sample fluids if the analyzer sends a signal to the CSM One Calibration Inlet A B D Two Calibration Inlets D A B C A Swagelok Pre Engineered Subsystem Calibration and Switching Module 17 System Startup 1 CSM with flow loop inlet assemblies or the bypass option open the metering valve s on the flowmeter s by turning the handle counterclockwise until it stops 2 Shut off the flow to the analyzer by turning the metering valve handle clockwise until it stops For outlet configurations 1 and 3 the metering valve is on the flowmeter Note Outlet configuration X does not contain a flow control device to the analyzer 3 Open all of the sample inlet ball valves Note Flow loop sample inlets will display flow on the flowmeter s Flow can be adjusted by turning the handle of the metering valve on the flowmeter clockwise
14. tight 9 Place the new label on the filter body 10 Test the product for proper operation Bonnet Body Bonnet Body TF Series Tee Type Filter Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 34 Disassembly 1 Remove the filter from the system 2 Loosen the male body from the female body 3 Remove the components Note Use a blunt tool to loosen the filter element if necessary Reassembly 4 Clean all components 5 Press the open end of the filter element into the female body 6 Place the gasket on the body seal surface of the male body Female body Filter element open end toward body 7 Insert the spring into the male body 8 Thread the bodies together Note There will be no space between the gasket and the male body hex when the bodies are fully threaded 9 Tighten the male body according to table below Series Torque in lb N m Stainless Steel Alloy 400 Alloy C 276 Alloy 600 Brass 1F 2F 3F MM 135 15 2 125 14 1 4F 6F MM 350 39 6 325 36 7 6F 8F 10F MM 12F MM 500 56 5 450 50 8 10 Place the new label on the female body 11 Test the product for proper operation prior to reinstallation in system Male body Spring Hold the female body stationary with a wrench Female body Hold the female body stationary with a wrench Male body Gasket Body seal surface Male body Filter element
15. to decrease flow or counter clockwise to increase flow 4 For systems with pressure regulator inlet assemblies adjust all of the sample inlet regulators to the same pressure to maintain similar flow rates to the analyzer 5 Send a pneumatic signal to the first sample inlet SSV actuator to confirm valve actuation For systems with the bypass option you should see full flow to the bypass flowmeter Open the analyzer metering valve until the desired flow rate is indicated on the analyzer flowmeter Bypass flow can be adjusted by partially closing the bypass metering valve 6 Close the inlet SSV actuators by removing the pneumatic signal 7 Repeat steps 5 and 6 for the other sample inlets 8 Open all of the calibration inlet ball valves 9 Send a pneumatic signal to the first calibration inlet SSV actuator to confirm valve actuation For systems with the bypass option the bypass SSV should be closed and you should see no flow to the bypass valve 10 Close the calibration SSV actuators by removing the pneumatic signal 11 Repeat steps 9 and 10 for the other calibration inlet Gas System shown with Bypass Option Outlet Option 2 Bypass option flowmeter valve Metering valve A Swagelok Pre Engineered Subsystem Calibration and Switching Module 18 Operation 1 Verify all sample and calibration inlet ball valves are open 2 The sample and calibration inlet SSV valves will be opened by your control system not include
16. to the Swagelok Tube Fitting Instructions for 1 in 25 mm and smaller fittings page 25 Mode 1 Automatic and Manual Calibration with an Independent Pneumatic Supply Two Calibration Inlets 1 Connect a pneumatic supply line to A 2 Remove the installed plugs and connect the pneumatic signal line s from the analyzer to B and C 3 Verify there is a plug in D One Calibration Inlet 1 Connect a pneumatic supply line to A 2 Remove the installed plug and connect the pneumatic signal line s from the analyzer to B 3 Verify there is a plug in D Notice The analyzer is in control of the sample inlets and the calibration inlet when not set to MANUAL There is the possibility of a mixture of calibration and or sample fluids if the analyzer sends a signal to the CSM Mode 2 Automatic and Manual Calibration with the Pneumatic Supply to Analyzer Routed through Manual Calibration Assembly Note The purpose of this mode is to prevent inadvertent pneumatic signals from the analyzer to the CSM inlets The ARV option must still be connected to a pneumatic supply line to allow those SSV s to open Two Calibration Inlets 1 Connect a pneumatic supply line to A 2 Remove the installed plugs and connect the pneumatic signal line s from the analyzer to B and C 3 Remove the installed plug and connect the pneumatic supply line going to the analyzer to D One Calibration Inlet 1 Connect a pneumatic supply line to A 2 Remove
17. to the reference vent to the tube fitting adjacent to the white lockdown bar labeled AV ARV outlet SSV actuator pneumatic inlet Connect the tubing to the two tube fittings adjacent to the white lockdown bar Connect the tubing to the pneumatic supply line The fitting size is either 1 8 in or 3 mm Note Use the same supply line as the process inlets for the ARV SSV actuators to ensure simultaneous actuation Outlet configuration 1 upstream flowmeter Connect the tubing leading to the process analyzer to the tube fitting adjacent to the white lockdown bar labeled AO The fitting size is either 1 8 in or 3 mm Outlet configuration 2 upstream metering valve Connect the tubing leading to the process analyzer to the tube fitting adjacent to the white lockdown bar marked AO The fitting size is either 1 8 in or 3 mm ARV pneumatic inlets A Swagelok Pre Engineered Subsystem Calibration and Switching Module 15 Outlet configuration 3 downstream flowmeter 1 Connect the tubing leading to the process analyzer to the tube fitting adjacent to the white lockdown bar labeled AO The fitting size is either 1 8 in or 3 mm 2 Connect the tubing leading from the process analyzer to the tube fitting adjacent to the white lockdown bar labeled AI 3 Connect the tubing leading back to the process or disposal to the tube fitting adjacent to the white lockdown bar labeled REC Outlet configuration X
18. A Swagelok Pre Engineered Subsystem Pre engineered subsystems available in weeks not months Field tested design ensures optimum system performance A Swagelok Pre Engineered Subsystem User s Manual Calibration and Switching Module A Swagelok Pre Engineered Subsystem Calibration and Switching Module Contents Calibration and Switching Module System Manual 3 Introduction 4 Inlet Assembly Configurations 6 Mounting 10 Installation 12 Manual Calibration Option 17 System Startup 18 Operation 19 Maintenance 20 Troubleshooting 22 System Component User Instructions 25 Swagelok Instructions Swagelok Tube Fitting Instructions for 1 in 25 mm and smaller fittings MS 12 01 25 Packing Adjustment for 40 Series Ball Valves MS INS 40 26 Stream Selector Valve SSV Series Assembly and Service Instructions MS CRD SSV 27 TF and F Series Filter Service Instructions MS CRD 0007 33 KCP Series Regulator Maintenance Instructions MS CRD 0109 36 Pressure Regulators User Guide MS CRD KREG 41 Variable Area Flowmeters Installation Instructions MS CRD 0111 43 Calibration and Switching Module CSM System Manual Gas System with Three Sample Inlet Assemblies and Two Calibration Inlet Assemblies Shown with Bypass ARV and Manual Calibration Options A Swagelok Pre Engineered Subsystem Calibration and Switching Module 3
19. Gasket If replacing gasket discard old gasket If replacing filter element discard old element F Series Inline Filter Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 35 KCP Series Regulators Maintenance Instructions Kit Contents Poppet Poppet spring Lubricant with MSDS WARNING Before removing a regulator from the system for service you must depressurize system purge the system to remove any residual system media left in the regulator Filter Retaining ring Filter ring High pressure kits only over 250 psig 17 2 bar Piston guide seal Seat retainer Seat Piston seal Tools Required Tool Size Component Needle nose pliers Filter Socket 5 16 in Seat retainer Crow s foot 1 1 4 in Body cap Open ended wrench 1 1 4 in Body cap Torque wrench Capable of 15 ft lb 20 3 N m 2 1 m kg Seat retainer Capable of 25 ft lb 160 N m 3 5 m kg Body cap A Swagelok Pre Engineered Subsystem Calibration and Switching Module 36 Disassembly 1 Place the regulator in a vise Note Take precautions to protect the body from being scratched by the vise 2 Turn handle counterclockwise until it stops 3 Loosen body cap 4 Remove cap assembly and handle as one piece and set aside for later use Note In high pressure regulators over 375 psig 25 8 bar the lower spring button may fall from the cap
20. Series Assembly and Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 31 Safe Product Selection When selecting a product the total system design must be considered to ensure safe trouble free performance Function material compatibility adequate ratings proper installation operation and maintenance are the responsibilities of the system designer and user Caution Do not mix or interchange parts with those of other manufacturers Testing Perform a shell test and check for proper operation prior to system installation O Ring Replacement 1 To replace base block seals or right end base block seals 9 007 remove block s according to Adding Removing Base Blocks See Fig 8 2 To replace the DBB module face seals 9 007 remove the module from the base block according to step 1 of Flange Replacement See Fig 8 3 To replace the DBB module body seal 9 022 or actuation air seal 9 004 remove the module and flange according to steps 1 and 2 of Flange Replacement See Fig 9 4 Remove the O ring from the counter bore using an O ring pick or similar tool CAUTION Be careful not to scratch the counterbore surface with the removal tool System performance could be affected by any scratches 5 For the DBB module body seal 9 022 only lubricate the new O ring with the provided lubricant 6 Press the new O ring s into the appropriate counterbore 7 Reas
21. be Fitting Instructions for 1 in 25 mm and smaller fittings page 25 Gas System shown with Bypass ARV and Manual Calibration Options Process inlets Calibration inlets ARV inlet from analyzer Pneumatic supply connections ARV outlet to analyzer Bypass outlet ARV outlet to low pressure header Relief valve vent Bypass option pneumatic supply connection Calibration inlet pneumatic supply connection with bypass option Manual calibration outlet SSV vent Manual calibration pneumatic supply connection Pneumatic supply connection with bypass option and no manual calibration option A Swagelok Pre Engineered Subsystem Calibration and Switching Module 12 Installation Connecting Inlets of the CSM Process inlets all assemblies except for flow loop inlet assembly Connect the tubing from the process sample line to the tube fitting adjacent to the blue lockdown bar on the inlet assembly The bar identifies each sample stream The fitting size is either 1 4 in or 6 mm Process inlet flow loop Connect the tubing from the process line to the tube fitting with the blue tag on the inlet assembly The bar identifies each sample stream The fitting size is either 1 4 in or 6 mm Return Connection flow loop Connect the tubing leading to the process return to the flow loop assembly at the tube fitting adjacent to the blue lockdown bar on the flow loop assembly The bar identifies each samp
22. d 3 Adjust the flow loop assembly or the bypass flow rate by opening or closing the metering valve on the flowmeter s on those lines as needed 4 Adjust flow to the analyzer by turning the metering valve handle counterclockwise to increase flow or clockwise to decrease flow For outlet configurations 1 and 3 the metering valve is on the flowmeter Note Outlet configuration X does not contain a flow control device to the analyzer 5 To isolate an inlet close that inlet s ball valve 6 For a pressure regulator inlet turn the regulator handle clockwise to increase the pressure or counter clockwise to decrease the pressure Manual Calibration Option For Modes 1 and 2 the calibration inlet stream actuator s are connected to the pneumatic signal lines coming from the analyzer when the calibration valve s are in the AUTO OFF position This allows calibration to be controlled by the analyzer For Mode 3 manual calibration only the AUTO OFF position for this mode is off as there are no calibration pneumatic signal connections made to the analyzer For normal operation place the CAL 1 valve and the CAL 2 valve in the AUTO OFF position To select calibration stream 1 for analysis by the process analyzer rotate the CAL 1 valve to the manual position leaving the CAL 2 valve in the AUTO OFF position To select calibration stream 2 for analysis by the process analyzer rotate the CAL 2 valve to the MANUAL posi
23. eam pressures exceeding the maximum rating of the regulator Rotate the handle as far down as possible then rotate back one quarter turn Note position of handle notch for reassembly Holding the handle stationary loosen and remove the lock nut Be careful to also keep the stem stationary Turn the handle counterclockwise to remove After panel mounting replace handle and rotate as far down as possible then rotate back 1 4 turn Replace and tighten lock nut Torque to 120 to 150 in lbs 13 5 to 16 9 N m Hold the handle and stem stationary when torquing lock nut Connections to System Before connecting to system verify the regulator is closed by turning the handle or adjusting screw counterclockwise when viewed from above until it stops for pressure reducing regulators clockwise when viewed from above until it stops for back pressure regulators Caution Do not allow any loose tape or thread sealant to enter the regulator or fluid stream Caution Verify that the inlet marked HP for pressure reducing inlet for back pressure regulators and outlet marked LP for pressure reducing outlet for back pressure regulators are in the proper orientation Operation Note All handle directions are when viewed from above Allowances must be made for the differences of back pressure regulators Turning the control handle clockwise will increase the upstream p
24. eck the pneumatic control system Troubleshooting A Swagelok Pre Engineered Subsystem Calibration and Switching Module 24 Swagelok Tube Fitting Instructions for 1 in 25 mm and smaller fittings Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 Installation These instructions apply to both traditional fittings and to fittings with the advanced back ferrule geometry 1 Fully insert the tube into the fitting and against the shoulder rotate the nut finger tight Fig 1 High Pressure Applications and High Safety Factor Systems Further tighten the nut until the tube will not turn by hand or move axially in the fitting 2 Mark the nut at the 6 o clock position Fig 2 3 While holding the fitting body steady tighten the nut one and one quarter turns to the 9 o clock position Fig 3 Note For 1 16 1 8 and 3 16 in 2 3 and 4 mm tube fittings tighten the nut three quarters turn to the 3 o clock position Gaugeability On initial installation the Swagelok gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tightened Position the Swagelok gap inspection gauge next to the gap between the nut and body Fig 4 If the gauge will not enter the gap the fitting is sufficiently tightened If the gauge will enter the gap additional tightening is required Reassembly Instructions You may disassemble and reassemble Swagelok tube fittings many times Warning Always d
25. ed incorrectly Adjust the metering valve setting by turning the handle counterclockwise to increase the flow The inlet regulator is adjusted too low If process stream of your CSM is not a pressure regulator inlet assembly this is the regulator upstream of the CSM Adjust the regulator setting by turning the handle clockwise to increase the pressure The system supply flow rate to the CSM has decreased Check and adjust the flow upstream of the CSM as necessary Flowmeter to the analyzer is indicating high flow The metering valve is adjusted incorrectly Adjust the metering valve setting by turning the handle clockwise to decrease the flow The inlet regulator is adjusted too high Adjust the regulator setting by turning the handle counterclockwise to lower the pressure The system supply flow rate to the CSM has increased Check and adjust the flow upstream of the CSM as necessary Bypass flowmeter is indicating low flow The metering valve is adjusted incorrectly Adjust the metering valve setting by turning the handle counterclockwise to increase the flow The filter in the open stream is obstructed Clean or replace the filter element or the filter Bypass flowmeter is indicating high flow The metering valve is adjusted incorrectly Adjust the metering valve setting by turning the handle clockwise to decrease the flow Flow loop inlet assembly flowmeter is indicating low flow The metering valve is adjus
26. epressurize the system before disassembling a Swagelok tube fitting 1 Prior to disassembly mark the tube at the back of the nut mark a line along the nut and fitting body flats Fig 5 Use these marks to ensure you return the nut to the previously pulled up position 2 Insert the tube with preswaged ferrules into the fitting body until the front ferrule seats against the fitting body Fig 6 3 While holding the fitting body steady rotate the nut with a wrench to the previously pulled up position as indicated by the marks on the tube and the flats at this point you will feel a significant increase in resistance Fig 7 4 Tighten the nut slightly Caution Do not use the gap inspection gauge with reassembled fittings Caution Do not mix or interchange parts with those of other manufacturers For additional information see the Gaugeable Tube Fittings and Adapter Fittings catalog MS 01 140 A Swagelok Pre Engineered Subsystem Calibration and Switching Module 25 IMPORTANT This valve is adjusted for factory testing with nitrogen at 1000 psig 69 bar or the rated pressure if lower than 1000 psig 69 bar Packing must be readjusted for service at higher than test pressure Warning Packing adjustment may be required during the service life of the valve to prevent leakage Before servicing any installed valve you must depressurize the system cycle the valve and purge the valve Adjust the packing by turning the packing bo
27. f the valve tighten or loosen the adjusting screw as necessary then replace the outlet adapter Reverse steps 1 through 3 and reinstall the relief valve Alternatively replace the relief valve A Swagelok Pre Engineered Subsystem Calibration and Switching Module 20 Maintenance System Component Reference for Replacement Ordering Information Ball Valve 42T series Modular Platform Components MPC MS 02 185 Check Valve CH series Modular Platform Components MPC MS 02 185 Filter TF series Modular Platform Components MPC MS 02 185 Filter element Filters MS 01 92 Metering Valve M series Modular Platform Components MPC MS 02 185 Pressure regulator KCP series Modular Platform Components MPC MS 02 185 Relief valve KVV series Pressure Regulators MS 02 230 Pressure indicator M model pressure gauge Modular Platform Components MPC MS 02 185 Stream selector valve SSV series Modular Platform Components MPC MS 02 185 Stream Selector System for Process Analyzer Applications MS 02 326 Flow indicator G1 and M1 series variable area flowmeter Variable Area Flowmeters MS 02 346 A Swagelok Pre Engineered Subsystem Calibration and Switching Module 21 Symptom Cause Remedy Flowmeter to the analyzer is indicating low flow The filter in the open stream is obstructed Clean or replace the filter element or the filter The metering valve is adjust
28. he wires to the positive and negative locations of the minimum maximum or both 4 Replace the cover and tighten the screws M2 Model M3 and MH Models Mounting rail Limit switch Clamping screws Clamping screw Variable Area Flowmeters Installation Instructions G Series and M Series Cable gland locations Minimum Maximum Maximum Minimum A Swagelok Pre Engineered Subsystem Calibration and Switching Module 47 Wiring Limit Switch to a Switch Amplifier With Isolated Relay Output Do not wire limit switches for initial installation while system is in operation Note The limit switch wires are brown and blue Note Additional diagram information is provided for the switch amplifier by the manufacturer Connection to Customer Switch Amplifier Connection to Swagelok Offered Switch Amplifier One Limit Switch 1 Connect the limit switch to slot 1 and slot 3 of the transistor relay 2 Connect the outputs of the limit switch to slot 7 and slot 8 for a signal when flow is above the limit switch setting normally open or to slot 7 and slot 9 for a signal when flow is below the setting normally closed 3 Connect alternating current power to slot 14 and slot 15 Metal Tube Models M1 M2 M3 and MH Models 1 Remove the screws and cover from the flowmeter 2 Slide the minimum contact maximum contact or both along the slip coupling to set the corresponding pointers to
29. le counterclockwise to lower the pressure The system supply flow rate to the CSM has increased Check and adjust the flow upstream of the CSM as necessary A calibration inlet pressure gauge is indicating low pressure The filter in the open stream is obstructed Clean or replace the filter element or the filter The calibration supply gas is running low Replace the calibration supply gas A calibration inlet pressure gauge is indicating high pressure The calibration supply pressure is set too high Lower the calibration supply pressure The analyzer returns readings significantly different than expected Process fluid mixes with calibration fluid during manual calibration Adjust the operating procedure for calibration to ensure no inlet stream will be selected during manual calibration Verify the appropriate manual calibration mode has been selected for your system Troubleshooting A Swagelok Pre Engineered Subsystem Calibration and Switching Module 23 Symptom Cause Remedy A SSV valve piston does not fully actuate The pneumatic supply line pressure is below 40 psig 2 8 bar Increase the pneumatic supply line pressure The SSV valve is not functioning properly Replace the valve seals according to SSV Series Assembly and Service Instructions page 27 Manual calibration option the valve is set to manual Turn valve handle to AUTO OFF The pneumatic control system is not functioning properly Ch
30. le stream The fitting size is either 1 4 in or 6 mm A Swagelok Pre Engineered Subsystem Calibration and Switching Module 13 Calibration inlets Connect tubing from the calibration source to the tube fitting adjacent to the orange lockdown bar The bar identifies each calibration stream The fitting size is 1 8 in or 3 mm SSV actuator pneumatic inlets 1 Connect the pneumatic supply line to the fittings on the side of the SSV actuator The fitting size is 1 8 in or 3 mm The working pressure range is 40 to 150 psig 2 8 to 10 3 bar for CSM systems without the bypass option and 40 to 100 psig 2 8 to 6 8 bar for systems with the bypass option Note If your CSM includes the manual calibration option there will be no direct connection to the calibration inlet SSV pneumatic actuators Fitting for pnueumatic supply line Installation Fitting for pnueumatic supply line A Swagelok Pre Engineered Subsystem Calibration and Switching Module 14 Installation Connecting Outlets of the CSM Your CSM will have one of the following outlet configurations ARV outlet configuration System connections the fitting size is either 1 8 in or 3 mm 2 Connect the tubing leading to the process analyzer to the tube fitting adjacent to the white lockdown bar marked AO 3 Connect the tubing coming from the process analyzer to the tube fitting adjacent to the white lockdown bar labeled AI 4 Connect the tubing leading
31. lot 9 for a signal when flow is below the setting normally closed 4 Connect the outputs for the maximum limit switch to slot 10 and slot 11 for a signal when flow is above the limit switch setting normally open or to slot 10 and slot 12 for a signal when below the setting normally closed 5 Connect alternating current power to slot 14 and slot 15 RL Power supply 4 to 20 mA Variable Area Flowmeters Installation Instructions G Series and M Series 4 to 20 mA Output Signal Do not wire output signal for initial installation while system is in operation This 2 wire system connects the power supply flowmeter and monitoring device in a series circuit This creates a current loop with the flowmeter functioning as a measurement device The 4 to 20 mA interface requires an auxillary power of 14 8 to 30 V dc Swagelok suggests use of a 24 V dc power supply Maximum Load Equations Milliampere Output Signal 2 Wire Output 4 to 20 mA Supply V 14 8 to 30 V dc Max load RL V dc 14 8 0 02 Terminals See drawings The output will be proportional to the measured flow based on the scale on the flowmeter Wire the loop according to the appropriate diagram below M2 Model M3 and MH Models RL Power supply 4 to 20 mA A Swagelok Pre Engineered Subsystem Calibration and Switching Module 49 Swagelok TM Swagelok Company 2011 Swagelok Company April 2011 R0 MS 13 217
32. lt clockwise in 1 16 turn increments until leak tight performance is achieved Always verify proper operation upon installation 40 Series Valve Packing Adjustment A Swagelok Pre Engineered Subsystem Calibration and Switching Module 26 SSV Series Assembly and Service Instructions Contents Tool Requirements 1 Components and Hardware 2 Port and Mounting Dimensions 3 General SSV Assembly 4 Mounting MPC Style Assemblies 5 Tool Requirements Adding Removing Base Blocks 5 Flange Replacement 5 Cap Replacement 6 O Ring Replacement 6 Torque Wrench 0 to 45 in lb 0 to 5 1 N m with hex drivers 7 64 in 9 64 in 5 32 in O Ring Pick or similar tool A Swagelok Pre Engineered Subsystem Calibration and Switching Module 27 Components and Hardware Base Block Standard Outlet MPC Standard MPC Outlet ARV Base Block End Base Block Right Left Module DBB ARV Flange Cap Ten per bag of chosen color Screws Standard MPC mounting Flange Insert O Rings Three 9 004 Eight 9 007 One 9 022 SSV Series Assembly and Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 28 Port and Mounting Dimensions Dimensions in inches millimeters are for reference only and are subject to change Inlet View Top Vie
33. new Pcal 273 Tcal 273 Tnew where F conversion factor cal fluid density of calibrated scale new new fluid density Pcal pressure of calibrated scale Pnew new pressure Tcal temperature of calibrated scale in C Tnew new temperature in C Note For temperatures in F replace 273 in equation with 460 Example Calibrated scale New fluid or conditions 1 5 kg m3 1 5 kg m3 P 7 bar P 10 bar T 30 C T 60 C F 1 5 1 5 10 7 273 30 273 60 1 14 Multiply 1 14 by the calibrated scale to determine the flow rate Example The flowmeter reading is 100 L h 100 L h 1 14 114 L h Variable Area Flowmeters Installation Instructions G Series and M Series A Swagelok Pre Engineered Subsystem Calibration and Switching Module 45 46 3 Place a screwdriver in the opening lift and remove the terminal block 4 Feed the connecting cable max 16 AWG or 1 31 mm2 through the cable gland of the plug and screw down the cable gland 5 Connect the wires to the positive and negative locations on underside of the terminal block for the minimum maximum or both 6 Reinstall the terminal block into the plug snapping in place 7 Reinstall plug onto junction box and replace the screw Tighten screw Variable Area Flowmeters Installation Instructions G Series and M Series Wiring a Limit Switch With a Junction Box Glass Tube Models 1 Loosen screws and
34. nsert screws from the right end base block Add according to step 4 of General SSV Assembly or remove the desired number of base blocks using a 9 64 in hex tool 2 Replace the right end block according to step 5 of General SSV Assembly 3 Install any needed DBB modules per step 6 of General SSV Assembly Flange Replacement 1 Using a 5 32 in hex torque wrench loosen the mounting screws and remove the DBB module from the base block 2 Using a 7 64 in hex torque wrench loosen the flange screws and remove the flange from the DBB module 3 Align the air inlet and alignment pin holes on the new flange with those on the bottom of the DBB module See Fig 6 CAUTION The air inlet and alignment pin holes on the flange and valve must be oriented correctly for the DBB module to function correctly after reassembly 4 Replace the flange screws and tighten 10 to 15 in lb 1 1 to 1 7 N m 5 Attach the DBB module to the base block per step 6 of General SSV Assembly For MPC style assemblies install the entire SSV assembly to the panel using MPC mounting screws 10 32 x 2 0 in with standard 5 32 in hex head aligning the fluid port holes on the SSV assembly and the panel Torque the screws to 25 to 35 in lb 2 8 to 4 0 N m See Fig 5 Fluid port hole Mounting screw SSV assembly Panel Fig 5 Fig 6 DBB module Flange Alignment pin hole Flange screws 4 Air actuation hole O rings SSV
35. ody Crow s foot 2TF 4TF 1 in 6TF 8TF 1 1 8 in Bonnet Torque wrench Capable of 650 in lb 73 4 N m Bonnet Filter element Body Bonnet Body Kit Contents Gasket Kit Element Kit Gasket Filter element Label A Swagelok Pre Engineered Subsystem Calibration and Switching Module 33 WARNING Before removing a filter from the system for service you must depressurize system purge the filter to remove any residual system media WARNING Residual system media may be left in the filter F Series Inline Filter Service Instructions Kit Contents Gasket Kit Element Kit Filter element Gasket Tools Required Tool Size Component Open ended wrenches 2F 9 16 in 4F 3 4 in 6F 8F 1 in Body hex Crow s foot 2F 9 16 in 4F 3 4 in 6F 8F 1 in Body hex Torque wrench Capable of 500 in lb 56 5 N m Body hex Discard Definition of Symbols Label 7 Thread the bonnet onto the body until the body threads are no longer visible Note If the bonnet does not fully thread onto the body the gasket is not centered on the bonnet seal surface 8 Stabilize the body with a wrench Tighten the bonnet according to table below Series Torque in lb N m Stainless Steel Brass 2TF 4TF 3TF MM 6TF MM 550 62 2 450 50 8 6TF 8TF 8TF MM 10TF MM 12TF MM 14TF MM 650 73 4 475 53 7 All using PCTFE gasket 1 4 turn past finger
36. ons See the Calibration and Switching Module Application Guide MS 02 360 for additional information Stream selector valve Ball valve Valve Inlet Assembly VIA BV SSV Sample Inlet Common Vent Outlet Flow Loop PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Ball valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Check valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Flow indicator PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Filter particulate PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Metering valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Needle valve PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI Pressure indicator PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN
37. remove the front cover of the junction box 2 Feed the connecting cable max 16 AWG or 1 31 mm2 through the cable gland and screw down the cable gland 3 Connect the positive and negative wires Note When using one limit switch only wire to Terminal 1 When using two limits switches wire the lower switch to Terminal 1 and the upper switch to Terminal 2 Metal Tube Models M1 Model 1 Loosen the screw on the connector plug and remove the plug from the junction box 2 Remove the screw from the plug Cable gland Terminal 2 Terminal 1 Screwdriver opening Connector plug Screw Terminal block Cable gland A Swagelok Pre Engineered Subsystem Calibration and Switching Module 46 Adjusting a Limit Switch Limit switches can be adjusted after installation or set during operation Glass Tube Models 1 Remove the cover from the flowmeter 2 Loosen the two clamping screws fastening the limit switch to the mounting rail of the flowmeter 3 Slide the limit switch along the mounting rail to set the top for a minimum switch the bottom for a maximum switch or both if two switches are installed Note When setting the limit switch lay the wires so they won t get damaged during use 4 Tighten the clamping screws 5 Replace the cover M2 M3 and MH Models 1 Remove the screws and cover from the flowmeter 2 Feed the connecting wires through the cable gland max 16 AWG and screw down the cable gland 3 Connect t
38. ressure counterclockwise will allow upstream pressure to vent through the regulator Outlet and control pressure settings are obtained by adjusting the handle or adjusting screw To increase the outlet or control pressure rotate the handle clockwise To decrease the outlet or control pressure rotate the handle counter clockwise and vent the downstream side of the regulator Make the final setting in the direction of increasing pressure to obtain the most accurate set points Once fluid is flowing through the system fine tuning may be required Icing of the regulator at high flow rates or high pressure drops may occur if the gaseous media contains moisture An auxiliary upstream filter is recommended for use in all but the cleanest of media When using a liquid media the internal filter may cause a pressure drop and flow reduction Removal of the internal filter and the use of a dedicated upstream filter may be necessary Installation of a downstream pressure relief is recommended for regulator and system protection All connections should be checked for leakage Isolate the downstream LP for pressure reducing HP for back pressure regulators side of the regulator and turn the handle clockwise enough to pressurize the regulator outlet Then pressurize the regulator with an inert gas to the pressure marked on the unit and applying a liquid leak detector around the connections and any plugs A S
39. riable area flowmeters must be installed operated and serviced according to NEC applicable local regulations and these instructions Otherwise serious personal injuries damage or both can occur The electrical connections provided on any electronic relays should be used as originally supplied and not bypassed or modifed other than wire length Only qualified personnel should work on these products Safety Information Safe Product Use Follow any enclosed instructions and refer to the product catalog for detailed product information When using a variable area flowmeter the total system design must be considered to ensure safe trouble free performance Function material compatibility adequate ratings proper installation oper ation and maintenance are the responsibilities of the system designer and user Improper selection or misuse of the product may result in serious personal injury or property damage Glass tube models G series Metal tube models M series Safety Definitions Potential danger to life or of serious injuries Potential for personal injury from electrical shock A Swagelok Pre Engineered Subsystem Calibration and Switching Module 43 Glass Tube Models Glass Tube flowmeters are read by the position of the float or ball within the flowmeter tube The flow rate is read at the upper top edge of the float or ball Metal Tube Models The flow rate is read with the pointer on the
40. right Horizontal Mount Variable Area Flowmeters Installation Instructions G Series and M Series A Swagelok Pre Engineered Subsystem Calibration and Switching Module 44 Do not wire limit switches for initial installation while system is in operation Up to two limit switches compliant with IEC 60947 5 6 NAMUR EN 60947 5 6 may be connected to the flowmeter Connect the limit switch es to the desired monitoring device Note When using two limit switches space the limit switches a mininum of 0 63 in 16 mm apart Note Any flowmeter with a limit switch installed must be kept a minimum of 0 24 in 6 mm from any moving object containing nickel iron or cobalt Wiring a Limit Switch Without a Junction Box All Models 1 Connect the brown wire extending from the flowmeter limit switch assembly to the positive input of the monitoring device 2 Connect the blue wire extending from the flowmeter limit switch assembly to the negative input of the monitoring device Limit Switches Reading the Flowmeter using a Conversion Factor Flowmeters calibrated for one fluid at a specific pressure and temperature can be used to measure other fluids and different pressures and temperatures by using a conversion factor Use the following equation to calculate the conversion factor Multiply the conversion factor by the flowmeter reading to determine the flow rate for the new conditions F cal new P
41. semble the SSV assembly according to the section followed for disassembly Cap Replacement 1 Use an O ring pick or similar tool to remove the existing cap 2 Press the new cap into the groove so that the tabs are compressed within the undercut of the piston See Fig 7 Fig 7 Cap Groove Undercut Piston Tabs Base block seals DBB module face seals Right end base block seals Fig 9 Fig 8 Air actuation seal DBB module body seal SSV Series Assembly and Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 32 TF Series Tee Type Filter Service Instructions WARNING Before servicing any installed filter you must depressurize system purge the filter to remove any residual system media WARNING Residual system media may be left in the valve Disassembly 1 Isolate the filter from the system 2 Stabilize the body with a wrench Loosen the bonnet 3 Remove the components Reassembly 4 Clean all of the components 5 Press the open end of the filter element into the body 6 Center the gasket on the bonnet seal surface Gasket Bonnet seal surface Filter element Gasket If replacing the filter element discard the old element If replacing the gasket discard the old gasket Discard Definition of Symbols Tools Required Tool Size Component Open ended wrenches 2TF 4TF 1 in 6TF 8TF 1 1 8 in Bonnet B
42. t the outlet base block be assembled close to the center of the assembly for the most consistent flow results 5 Assemble a right end base block to the assembly aligning the right end base block O rings 9 007 with the through ports on the last base block Tighten the right end base block insert screws to the base block inserts to 35 to 45 in lb 4 0 to 5 1 N m using a 9 64 in hex torque wrench placed through the end base block See Fig 3 6 Install a DBB module on each base block with the alignment pin fitting into the alignment hole on the DBB module Using two mounting screws 10 32 x 1 2 in with standard 5 32 in hex drive tighten the DBB module to the base block to 25 to 35 in lb 2 8 to 4 0 N m See Fig 4 Note For ARV assemblies install only ARV modules to the ARV base blocks Left end base block Base block Through ports O rings Inserts Counterbores Fig 1 Fig 2 Base block insert Right end base block Base block assembly O rings Through ports Fig 3 Fig 4 DBB module Base block Alignment pin Alignment hole Mounting screw Mounting screw SSV Series Assembly and Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 30 Mounting MPC Style Assemblies WARNING Before servicing any installed valve you must depressurize the system cycle the valve purge the valve Adding Removing Base Blocks 1 Remove the i
43. ted incorrectly Adjust the metering valve setting by turning the handle counterclockwise to increase the flow The inlet regulator is adjusted too low Adjust the regulator setting by turning the handle clockwise to increase the pressure The system supply flow rate to the CSM has decreased Check and adjust the flow upstream of the CSM as necessary Troubleshooting A Swagelok Pre Engineered Subsystem Calibration and Switching Module 22 Symptom Cause Remedy Flow loop inlet assembly flowmeter is indicating high flow The metering valve is adjusted incorrectly Adjust the metering valve setting by turning the handle clockwise to decrease the flow The inlet regulator is adjusted too high Adjust the regulator setting by turning the handle counterclockwise to lower the pressure The system supply flow rate to the CSM has increased Check and adjust the flow as necessary A sample inlet pressure gauge is indicating low pressure The filter in the open stream is obstructed Clean or replace the filter element or the filter The inlet regulator is adjusted too low Adjust the regulator setting by turning the handle clockwise to increase the pressure The system supply flow rate to the CSM has decreased Check and adjust the flow upstream of the CSM as necessary A sample inlet pressure gauge is indicating high pressure The inlet regulator is adjusted too high Adjust the regulator setting by turning the hand
44. the desired limit on the scale 3 Replace the cover and tighten the screws M1 Model M2 Model M3 and MH Models Flowmeter LB SC Input 2 Switch Ampli er Supply 240 V ac 8 7 9 11 10 12 14 15 Relay Output 1 Relay Output 2 1 2 3 4 5 6 Input 1 KFA6 SR2 Ex2 W Flowmeter Input 2 Switch Ampli er Supply 240 V ac 8 7 9 11 10 12 14 15 Relay Output 1 Relay Output 2 1 2 3 4 5 6 Input 1 Maximum contact Minimum contact Slip coupling Minimum pointer Maximum pointer Maximum contact Minimum contact Slip coupling Maximum pointer Minimum pointer Maximum Slip coupling Minimum Variable Area Flowmeters Installation Instructions G Series and M Series A Swagelok Pre Engineered Subsystem Calibration and Switching Module 48 For product technical data including materials of construction see the Swagelok Variable Area Flowmeters catalog MS 02 346 Connection to Swagelok Offered Switch Amplifier Two Limit Switches 1 Connect the minimum limit switch to slot 1 and slot 3 of the transistor relay 2 Connect the maximum limit switch to slot 4 and slot 6 3 Connect the outputs of the minimum limit switch to slot 7 and slot 8 for a signal when flow is above the limit switch setting normally open or to slot 7 and s
45. tion leaving the CAL 1 valve in the AUTO OFF position Note The system is not intended to have both manual calibration valves simultaneously placed in the MANUAL position Note Any manual or automatic calibration activity will shut off the bypass stream preventing loss of calibration fluids through the bypass stream A Swagelok Pre Engineered Subsystem Calibration and Switching Module 19 Maintenance Warning Before servicing any installed system component you must purge the system depressurize the system Follow these steps to depressurize your CSM 1 Close the isolation valves upstream of the process inlet 2 Close the calibration source flow upstream of the calibration inlets 3 Open the ball valves on all sample inlet and calibration inlets 4 Systems with a Pressure Regulator Inlet Assembly Adjust the pressure regulators to an acceptable pressure Do not leave the regulators in the closed position 5 Open the metering valves on the sample assembly outlet and the bypass outlet flow meter 6 Open the sample inlet and calibration inlet SSV valves by applying a pneumatic signal to each SSV actuator 7 Depressurize the CSM by opening a vent regulator or vent valve downstream of the CSM 8 Prior to disassembly confirm that there is no pressure in the line s downstream of the bypass or ARV check valve s Periodically check the operation of system relief valves using one of the following methods
46. w Outlet View 2 76 70 1 0 75 19 0 0 80 20 3 1 125 28 6 6 37 162 add 1 6 in 40 6 mm for additional streams 0 68 17 3 to vent port not shown 0 53 13 5 1 60 40 6 1 70 43 2 4 13 105 1 02 25 9 Outlet port Air inlet port 0 50 12 7 0 98 24 9 1 30 33 0 to vent port not shown Inlet port Air gap vent 1 50 38 1 1 05 26 7 SSV Series Assembly and Service Instructions A Swagelok Pre Engineered Subsystem Calibration and Switching Module 29 General SSV Assembly 1 Place a left end base block in a vise Note For assemblies using an ARV base block the ARV block is in place of a left end base block 2 Place a base block on the left end base block aligning the O rings 9 007 with the through ports The square end of the left end base block inserts will be located in the counterbores of the base block See Fig 1 3 Tighten the two base block insert screws to the two left end base block inserts using a 9 64 in hex torque wrench placed through the base block inserts to 35 to 45 in lb 4 0 to 5 1 N m See Fig 2 4 Continue building the base block assembly by repeating steps 2 and 3 tightening the base block insert screws to the adjacent base block inserts Place the outlet base block in the desired position within the base block assembly Caution Do not intermix standard and MPC style base blocks Note It is recommended tha
47. wagelok Pre Engineered Subsystem Calibration and Switching Module 41 Warning Factory fitted KVV series relief valves are set to zero when assembled to the regulator Venting of outlet pressure will occur until pressure setting is adjusted by user Warning Reset relief pressure to the desired value before pressurizing the system Adjusting the Pressure Setting 1 Using a 5 32 in or 4 mm hex wrench loosen the locking screw by turning counter clockwise 2 Slide the hex wrench into the adjusting screw 3 Turn the both screws clockwise to increase the relief pressure counter clockwise to decrease until the desired relief pressure is obtained 4 Slide the hex wrench back up into the locking screw and turn clockwise to lock 5 Verify relief pressure Adjusting screw Locking screw Caution Do not mix or interchange parts with those of other manufacturers Pressure Regulators User s Guide A Swagelok Pre Engineered Subsystem Calibration and Switching Module 42 Variable Area Flowmeters Installation Instructions G Series and M Series Safety Definitions 1 Safety Information 1 Installation 2 Startup 2 Reading the Flowmeter 2 Reading the Flowmeter Using a Conversion Factor 2 Limit Switches Without a Junction Box 3 With a Junction Box 3 Adjusting 4 To an Isolated Switch Amplifier With Relay Output 5 Output Signal 6 Contents Swagelok va
Download Pdf Manuals
Related Search