USER`S MANUAL - Moore Industries International
Contents
1. 891 2816 Tel 03 448 10 18 FAX 03 440 17 97 Tel 86 21 62481120 FAX 86 21 62490635 IND USTRIES Australia e sales mooreind com au The Netherlands sales mooreind n United Kingdom e sales mooreind com Tel 02 8536 7200 FAX 02 9525 7296 Tel 0 344 617971 FAX 0 344 615920 Tel 01293 514488 FAX 01293 536852 Appendix A Instrument Air and Filtration The selection and use of a good air filtration system is essential in ensuring optimum performance of pneumatic instrumentation and devices Most users find that it is much less expensive and troublesome to design a system that includes a good air filtration than to deal with downtime and repairs later The cleaner the air the longer the time before servicing will be needed Obtaining good instrument quality air involves removing solids oil and water after compression Oversizing elements helps to avoid performance aberrations and should reduce the need for periodic maintenance Redundancy should be used where possible to avoid shutdown during maintenance The IPF is available with an optional coalescing filter regulator module the FR1 Option that combines a 0 01 micron air filter and a miniature supply line regulator The unit has a 1 4 inch NPT female port and a 4 scfm maximum flow at 90 psig inlet pressure It is furnished with an integrally mounted pressure gauge scaled in both psi 0 60 and bars 0 4 The Problems Oil Oil is the most common problem i2. Refer to Calibration Section of this manual Drain Check System filters have automatic drains which depend on the fluctuation of system pressure to induce drainage A stable system may not drain efficiently Periodically check for clogs and drain system s filters by pushing the drainage valve with a small probe or wire Troubleshooting Many components of the IPF have been thermally aged tested and selected using a computer aided design program This usually makes field repair unnecessary It is therefore recommended that any properly maintained unit found to be performing below specifications be returned to the factory in accor dance with the instructions found on the back cover of this manual Page 17 IPF If a problem is suspected with the IPF review the following steps 1 Verify that bench instruments used to take measurements have the proper range and accuracy and are within current certification period limits 2 Ifa change in the relationship between the input and output is detected attempt a re calibration of the IPF 3 Ifthe response time lengthens or if the span drops this may indicate a blockage due to air supply contamination Follow the instructions in the Maintenance Section of this manual The Zero Adjust Screw This screw has a flange to prevent its being turned too far counterclockwise during adjustment Forcing the screw past the point at which its flange comes into contact with the u
3. The IPF serial and model numbers can be found on a metal tag on the side of the unit housing The example outlines the significance of each field of information in a typical IPF model number EXAMPLE Page 3 IPF Calibration Every IPF is fully tested and calibrated at the factory prior to shipment Before installation however your IPF s should be bench checked to verify proper operating levels and to set the desired unit zero and span Calibration should be conducted in an appropriate testing environment By carrying out the procedures at a technician s bench or similar lab type setup any unit damage that may have occurred during ship ment can be discovered safely i e isolated from the intended application IPF 4 20MA 3 15PSIG 20PSI FR1 WP Unit Type Input Output Supply Pressure Options s Housing Page 4 IPF Calibration Equipment Table 2 lists the equipment required to calibrate the IPF This equipment is not supplied by Moore Industries but should be available in most labs or maintenance areas Calibration Setup To prepare the IPF for calibration disassemble the unit as shown in figure 1 and connect it to your calibration equipment as shown in figure 2 which shows the calibration setup Unit Connections and Controls The IPF has two labeled terminals on its faceplate located under the top protective cover of the housing NE ty
4. 32 in standard One 3 32 in minimum length 5 5 in Ball tipped head recommended Removeable Thread locking Compound Loctite 242 or equivalent removeable threadlocker Page 14 IPF Take the internal assemblies out of the housing by grasping plastic removal tab and pulling straight out away from housing base Apply steady pull disen gaging the pneumatic fittings from their ports in the housing base Separate sub assemblies by removing the single slotted head screw in the side of section 1 of the pneumatic block which is shown in figure 7 Cleaning the Mechanical Subassembly 1 Place subassembly on work surface with zero screw and span pot down 2 Use syringe to fill flapper air passage with trichloroethane TCE See figure 7 3 Clean nozzle air passage by gently passing cleaning wire back and forth through opening in subassembly base 4 Soak several small strips of clean paper in TCE 5 Set subassembly on its side and slide one strip between nozzle and flapper Carefully apply slight pressure to flapper until it rests against nozzle with soaked paper in between 6 Maintain pressure while pulling paper out Repeat with other strips of paper until no residue is transferred to paper 7 Inspect air passage O ring If damaged contact Moore Industries Customer Service Department for replacement 8 Use instrument air supply to dry and generally blow out subassembly Put small amount
5. For a period of thirty six 36 months from the date of shipment and under normal conditions of use and service Moore Industries The Company will at its option replace repair or refund the purchase price for any of its manu factured products found upon return to the Company transportation charges prepaid and otherwise in accordance with the return procedures established by The Company to be defective in material or workmanship This policy extends to the original Buyer only and not to Buyer s customers or the users of Buyer s products unless Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not apply if the product has been subject to alteration misuse accident ne glect or improper application installation or operation THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE QUENTIAL DAMAGES WORLDWIDE e www miinet com China e sales mooreind sh cn Tel 86 21 62491499 FAX 86 21 62490635 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 LUI MOORE v INDUSTRIES JEE 2007 Moore Industries International Inc Belgium info mooreind be Tel 03 448 10 18 FAX 03 440 17 97 The Netherlands e sales mooreind nl Tel 0 344 617971 FAX 0 344 615920 Specifications and Information subject to change without notice
6. This allows the unit to be installed on either horizontal or vertical pipes The thermoplastic polyetherimide compound used in the housing provides excellent protection from chemical exposure The housing is also unaffected by electrolytic corrosion as may be found in and around salt water and many other industrial environ ments Note however that this type of IPF is designed tested and built for installation outdoors or in well ventilated areas Refer to the WP WPM housing data sheet in the Moore Industries Product Catalog for more informa tion regarding chemical environments compatibility or contact your Moore Industries Sales Representa tive for assistance Electrical Connections Refer to figure 1 in the Calibration Setup Section of this manual for instruction on the level of disassem bly required to make the electrical connections to the IPF Figure 5 is a generic diagram showing the unit s installation hookup To complete connections route wiring through conduit port or through port in sub housing for NE type units to terminal block and use a slotted tip screwdriver with a maximum head width of 3 mm 0 125 inch to loosen the terminal screws Page 9 IPF FR1 OPTION 94 mm 69 8 mm f IP 3 68 in 2 75 in Ko eare SQUARE SQUARE f l 160 mm 6 28 in 9 14 mm 0 36 in A A DIAMETER 1 l 4 MOUNTING HOLES l 1 1 i i APPROX 145 8 mm 5 7 in 1 l WHEN 1
7. and Repair our Quick Ship Facility Introduction The field mount version of Moore Industries Current to Pressure Transmitter enclosed in an all weather thermoplastic housing is called the IPF Itisa rugged two wire transmitter whose design meets the specifications for several types of water and dust tight and corrosion resistance certifications The material used in the unit s housing makes it ideal for use under even the most arduous of environmental conditions This manual contains the descriptive and instruc tional information needed to install operate and maintain the IPF It includes a brief explanation of the unit model number a table of its performance and operational specifications instructions for calibration information on installation and mainte nance procedures and checklist of troubleshooting recommendations Appendix A consists of information on instrument quality air and filtration essential for optimum IPF performance and reliability Notes and Cautions where they appear in text or illustrations are used to call attention to practices that otherwise may result in inconveniences for the user Notes or damage to the IPF Cautions Description The IPF is used to effect changes in pneumatic throughput pressure in a process loop These changes are proportional to and based upon changes in a standard process current input to the unit There are two options for input current and eight f
8. be given to any require ment that may arise for front panel access checking the fittings or reading the FR1 Option gauge and draining its filter Closed Loop Open Loop The IPF should be installed in a closed loop A closed loop is the best way to measure a control variable to determine if a deviation from a desired value exists or to automati cally provide feedback for actuator loading pressure An open loop has inherent limitiations that are not consistent with precise control Long term drift of the loop dynamics load fluctuations that require constant adjustments of the actuator loading pressure and performance quality variations due to inconsistencies between operating personnel are all problems commonly associated with open loops A controlled variable cannot be directly measured in an open loop this prevents compensating adjustments to the system input Mounting Figure 3 gives the IPF s outline dimensions The illustration also gives the dimensions of the available FR1 Option hardware recommended for most installations and the external sub housing used for the terminal block with NE type IPF s After placing the IPF in the desired location and orientation secure the housing with the optional pipe mounting hardware or other appropriate fasteners Figure 4 illustrates IPF mounting using optional pipe mounting hardware Note that the holes in the mounting plate that comprises the base of the IPF are symmetrical
9. by Applying 25 of Rated Input Range Verify by Applying 50 of Rated Input Range Gauge 2 will Read Verify by Applying 75 of Rated Input Range 12 psi 15 3 psig 15 psi 3 psi 6 psi 0 2 1 bar 0 2 bar 1 bar 0 8 bar 1 0 2 bar 1 bar 0 2 bar 0 4 bar 3 27 psig 3 psi 27 psi 21 psi 3 16 6 psig 3 psi 16 6 psi 13 2 psi 20 100 kPa 20 kPa 100 kPa 80 kPa 100 20 kPa 100 kPa 20 kPa Verify appropriate output configuration and percentage of rated input range against unit model number 40 kPa Page 8 IPF 4 Repeat steps 1 through 3 until IPF outputs 0 of rated pressure range at 0 current input and 100 of output pressure range at 100 current input 5 Verify the accuracy of your adjustments by inputting the appropriate percent of span levels listed in table 3 Installation The installation of the IPF is carried out in three phases The first phase is the physical mounting of the unit Next is the electrical connections phase and finally pneumatic connections can be made It is strongly recommended that IPF s be installed in this order It is also strongly suggested that each unit be calibrated according to the instructions in this manual before being placed into service The IPF may be installed at any angle either sur face mounted or attached to pipe or round conduit Consideration should always
10. in the opposite direction Set zero adjustment screw fully clockwise then five turns counterclockwise Page 7 IPF Table 3 lists the values to be used during calibration Refer to the table when performing the following d Check unit zero setting Monitor reading of pressure gauge 2 output and turn zero adjust screw counterclockwise to lower output clock 10 Allow approximately 5 minutes for calibration setup to stabilize Calibration Procedure To perform the recommended bench check for the IPF first perform the setup as described in the preceding section The calibration procedure con sists of a basic check and adjustment of unit zero and span based on the reading of pressure gauge 2 accuracy of 0 1 IPF Output Configuration 3 15 psig At 0 of Rated Input Range 4 or 10 mA Adjust Zero until Gauge 2 Reads 3 psi wise to raise output Set zero adjust screw so that pressure output is at 0 of appropriate range 43 when 0 input is applied 2 Check unit span setting Increase input to 100 of rated span 20 mA for 4 20 mA units or 50 mA for 10 50 mA units 3 Monitor reading of pressure gauge 2 output and adjust span pot so that reading is at 100 of appropriate pressure range for your unit Check the values listed in Table 3 Table 3 IPF Calibration Values At 100 of Rated Input Range 20 or 50 mA Adjust Span until Gauge 2 Reads 15 psi Verify
11. o RUBBER RETAINING STRAP Page 5 INTERNAL ASSEMBLY REMOVAL TAB NE TYPE 1 TERMINAL BLOCK DETAIL Figure 1 IPF Disassembly Controls and Terminals for Calibration The Zero adjustment screw is a cone tipped ma chined screw that mechanically provides a control range for zero offsets of 3 percent of rated unit span The Span pot electronically adjusts unit full scale output to 100 percent of rated span It requires approximately 22 turns to move its wiper from one extreme to the other clockwise for maximum or counterclockwise for minimum span It is equipped with a slip clutch to prevent damage if the adjustment is turned beyond the wiper stop Always use clean dry instrument air whether calibrating or operating the IPF Refer to the appen dix of this manual for information on filtration All pneumatic lines used in calibration and operation must be blown down prior to their being connected to the IPF Any condensation or oil residue in the lines if introduced into the pneumatic chambers of the IPF may result in poor unit performance Page 6 IPF DC MILLIAMMETER ADJUSTABLE CURRENT SOURCE N I OUTPUT PORT PRESSURE GAUGE SR 2 A K ACCURACY 0 1 Wi Ka e PNEUMATIC TEST LOAD SUPPLY PORT _ PRESSURE GAUGE SE N X ACCURACY 2 Ge y i REGULATED INSTRUMENT AIR SUPPLY Figu
12. of alcohol in air passage and set subassembly aside Cleaning the Pneumatic Block Refer to figure 7 to disassemble the IPF pneumatic block and when performing the following 1 Place block on work surface with its two socket head screws facing up Use screwdriver to mark one side of block with several small scratches for use when re assembling parts 2 Dip cleaning wire in TCE and use it to clean orifice 1 the air passage between block and mechanical subassembly see figure 7 Flush orifice with alcohol after cleaning 3 Remove two socket head screws that hold the pneumatic block together Separate section 1 from block 4 Use swabs dipped in TCE to clean internal surfaces and to remove any dirt particles or oil Flush all parts with alcohol after cleaning 5 Push cleaning wire dipped in TCE through small orifices on underside of section 1 in center opening and along outside edge Use syringe filled with alcohol to flush openings Set section 1 aside 6 Remove spring disk and diaphragm from top of section 2 Inspect each for deterioration and dirt Use compressed air to blow off all parts 7 Remove diaphragm from bottom surface of section if necessary 8 Push cleaning wire dipped in TCE through brass fitting in center of section 9 Clean small orifices along edge of section top and bottom with cleaning wire and flush with alcohol syringe Page 15 IPF PNEUMATI
13. t NSTALLED 18 6 mm N TYPE 0 72 in 24 2 mm M20 X 1 5 THREADS 0 94 in 1 2 14 NPT THREADS FOR FOR WPM AND WPMP WP AND WPP HOUSINGS HOUSINGS 36 7 mm OR 1 4 in M20 X 1 5 THREADS FOR WPM AND WPMP HOUSINGS N TYPE 1 4 NPT SUPPLY 142 2 mm PORT 5 6 in SIDE PORT FOR FR1 A OPTION 29 2 mm 31mm 1 2 in 1 4 NPT OUTPUT PORT Figure 3 IPF Outline Dimensions Page 10 Figure 4 Mounting the IPF on Vertical and Horizontal Pipe CURRENT INPUT 4 20 OR 10 50 mA SUPPLY PORT PNEUMATIC INSTRUMENT REGULATED INSTRUMENT AIR SUPPLY Figure 5 IPF Installation Hookup Page 11 IPF The terminals are comprised of compression screw sockets that accommodate 22 14 AWG wiring Connect positive lead to terminal labeled I and negative lead to terminal labeled P Tighten the terminal screws until snug Use shielded twisted pair wiring for low level input Ground the shielding wire as close as possible to the installed IPF Pneumatic Connections The final phase of IPF installation consists of con necting the pneumatic lines Figure 5 also illustrates these connections 30 cm a ft FLAT MAXIMUM WASHERS To complete the IPF pneumatic connections connect the supply line to the 1 4 in
14. type dryers Care must be taken in the selection and location of the filter because cooling downstream of the filter can cause more condensation of water Typically a coalescing filter should be installed immediately upstream of the pressure regulator In this way the filter removes most of the water before the air enters the regulator Air leaving the regulator then continues to dry due to expansion Solids Random solid dirt such as pipe scale and rust is occaisionally a problem in compressed air instrument systems A good filter will remove these solids However if there is a desiccant dryer in the line a high efficiency sub micron filter is recom mended for removing the highly abrasive sub micron particles produced by the dryer This sort of filter is desirable in any system and is often a feature of coalescing filters For systems subjected to freezing temperatures the portion of the system that runs outdoors should have a dryer installed The dryer reduces the dew point below the lowest expected outdoor temperature A desiccant dryer is used upstream from a coalesc ing filter to keep the dryer from being damaged by oil or from being overloaded with excessive condensed water Another high efficiency coalescing filter is recommended downstream of the dryer to remove desiccant particles Figures A1 and A2 illustrate typical non redundant systems with multiple branch lines They both work in any environment above freezin
15. C MECHANICAL BLOCK SUB ASSEMBLY NOZZLE FLAPPER J SECTION 1 T AIR PASSAGE Oh a Wy UPPER SPRING HEAVY GAUGE WIRE HOLE UPPER RUBBER DIAPHRAGM BRASS ROLL IS UP FITTING SECTION 2 ROLL IS DOWN MIDDLE RUBBER DIAPHRAGM HOLE HOLE RESTRICTOR SECTION 3 LOWER RUBBER DIAPHRAGM DISK HOLE e SUPPLY SCREEN Es SECTION 4 Figure 7 IPF Internal Assemblies 10 Use swabs dipped in TCE to clean all surfaces 12 Remove integrated diaphragm fitting from section 4 11 Repeat cleaning flushing procedure for orifices and surfaces of section 3 13 Clean orifices and surfaces on section as before Page 16 IPF Check to make sure that the spring is in good 3 condition 14 Locate supply port air filter screen on the pneu 4 matic block Remove filter screen with needle and flush with TCE Rinse with alcohol and set aside to dry Re assembly 5 1 Dry all parts of both the pneumatic block and the mechanical subassembly with the specified air or nitrogen supply Make sure all parts are clean and dry Line up pin on section 1 of pneumatic block with hole on base plate of mechanical subassembly Place a small amount of thread locker on the threads of the slotted head screw used to hold the pneumatic block and mechanical subassem bly together and secure two subassemblies to each other with the screw Make sure screw is as tight as possible Slide interna
16. COURSE OF DEALING OR TRADE USAGE AND ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE FECT OR BREACH AND NO ACTION FOR THE BREACH OF ANY WAR RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH RETURN POLICY
17. Lull moore INDUSTRIES January 1992 1992 by Moore Industries International Inc IPF Field Mount Current to Pressure Transmitter USER S MANUAL No 170 702 00 C Table of Contents Introduction 1 Description 1 Calibration 3 Installation 8 Operation 12 Maintenance 12 Troubleshooting 16 TRADEMARKS 1 Telfon is a registered trademark of the DuPont Corporation 2 Loctite is a registered trademark of Loctite Incorporated Moore Industries STAR Center has a wide variety of quality instrumentation in stock and ready to ship Zen ERY e Signal Transmitters e Temperature Transmitters e P I and UP Converters e Isolators and Converters e Indicators and Displays e Alarm Trips e Integrators and Totalizers e Power Transducers l 16650 Schoenborn Street e Instrument Power Supplies UnitedStatesCanada SPS aE Tie 68 1522 e Racks Rails and Enclosures TOLLFREE FAX 818 891 2816 ei L S CONNECT MacNet MIISEPULVEDA S ee Most instruments can be customized United Kingdom 1 Lloyds Court Manor Royal Crawley to meet your needs Even then you ll WS RH10 2QU United Kingd E FREEPHONE Tel EE Tix Se CH never have to wait more than a few days 0800525107 FAX 0293 536852 l Moore Industries Australia 3 18 Resolution Drive Caringbah TOLLFREE New South Wales 2229 Australia 008251928 ae ee G Tix 790 75914 Cc i Ge CENTER Ask for the STAR Center Support Technical Assistance
18. ch NPT female port on the side of the unit labeled SUPPLY Connect the output line to the 1 4 inch NPT female port labeled OUTPUT Refer to the unit front panel which identifies the IPF ports Seal all fittings with Teflon tape or equivalent Pipe dope is not recommended If your application environment prohibits the use of Teflon contact Moore Industries for assistance Always blow down purge all tubing and the controlled device before connecting the IPF Figure 6 illustrates the recommended technique for installing an IPF USE FLEXIBLE CONDUIT WHENEVER POSSIBLE AVOID STRAIGHT LINE CONNECTIONS SUPPORT AND CUSHIONING BRACKET SUPPORT HEAVY COMPONENTS INDEPENDENTLY Figure 6 An Example of a Typical IPF Installation Page 12 IPF Recommendations are e Use flexible or semi flexible plastic pneumatic tubing and plastic fittings if possible e Provide clip or bracket type support at 30 cm 1 ft intervals and provide independent support for any components or equipment installed in the lines Use cushioning brackets to dampen vibration if possible e Avoid straight line connections e Provide auxiliary support for the filter regulator if equipped especially in areas where shock and vibration are prevalent e Do not over tighten the fittings A torque of 10 to 15 Nem 7 4 to 11 1 ft lbs is adequate Filters The IPF requires filtered dry regulated
19. d effects of linearity hysteresis and repeatability For 3 27 psig output units or 10 50 mA input units error not to exceed 1 of span Linearity defined per SAMA standard PMC 20 1 1973 Ambient Temperature Effect 0 1 of span per C change within the rated ambient temperature operating range less than 0 055 of span per F change Supply Pressure Deviation Effect Maximum of 0 3 per 1 4 psig change Performance 0 3 per 0 1 bar Mounting Position Effect Negligible Unit should be calibrated in final orientation RFI EMI Effect 0 1 of span in field strengths of 10 V m at frequencies of 20 500 MHz Step Response 0 3 seconds into 100 ml 6 cu in at 90 of span Pneumatic Air Capacity 1 4 scfm approximately 2 7 kg hr Load Air Consumption 0 1 scfm approximately 0 2 kg hr dead ended Environmental Rati Recommended Ambient Temperature Operating Range 20 to 60 C 4 to 140 F atings Weight Approximately 800 g 1 Ib 12 oz NOTE Refer to Installation Section for unit outline dimensions Model Serial Number Moore Industries uses a system of individual unit model and serial numbers to keep track of factory configuration and options for IPF s shipped or serviced If service information or assistance is required for your IPF s be sure to provide the factory with the unit model and serial numbers to assist our profes sional technicians in their effort to give you prompt efficient service
20. equipment is not available your facility may not be qualified to perform the operations described in this section Contact Moore Industries Customer Service Department for more information Page 13 IPF Unit Disassembly To disassemble the IPF for maintenance cleaning remove the protective top cover in the same manner as was carried out in the calibration setup Unscrew the two Phillips head screws from the faceplate and remove it For NE type IPF S The wires from the external terminal block to the internal sub assemblies must be cut to perform the maintenance cleaning Cut the wires as close to their butt connectors as possible Table 4 IPF Maintenance Equipment Specifications Notes Instrument Quality Air or Nitrogen Supply Reduced to between 20 and 30 psig and fitted with a hose and fine tip or nozzle White Bond Paper Clean undyed and unlaminated Cotton Swabs and alcohol Clean general utility swabs for use in cleaning surfaces and absorbing excess solvent Trichloroethane TCE Rho Tron TPC 400 or equivalent Isopropyl Alcohol Clean general purpose flushing solution Syringe Or similar mechanism for injecting alcohol into small orifices Screwdriver Slotted tip Head width of 5 mm 0 1875 in maximum Probe Technician s tool for manipulation of very small parts Cleaning Wire 0 005 inch diameter maximum One A mm standard Hex Keys One 5
21. g and differ only in the placement of the first stage general purpose filter Page A2 IPF 5 MICRON GENERAL PURPOSE DESICCANT EXTEND BRANCH LINE S ABOVE MAIN COOLER FILTER DRYER LINE TO AVOID PASSING LIQUIDS MAIN LINE TO OTHER BRANCHES COMPRESSOR PRESSURE REGULATOR RECEIVER EFFICIENCY Ga PURIFIED AIR FILTER TO IPF S 5 MICRON GENERAL PURPOSE l i FILTER S ONE MAIN 0 01 MICRON Fees S L J OR MULTIPLE ON HIGH x BRANCH LINES EFFICIENCY KEEP COALESCING SHORT l S g PE FILTER NOTE All Filters should have automatic drains and service indicators to show when elements need changing Figure A1 Non Redundant System with Desiccant Dryer REFRIGERATION EXTEND BRANCH LINE S ABOVE MAIN COOLER DRYER X LINE TO AVOID PASSING LIQUIDS a A AX gt MAIN LINE TO Lb OTHER BRANCHES COMPRESSOR PRESSURE RECEIVER REGULATOR 5 MICRON PURIFIED AIR GENERAL PURPOSE l TO IPF S FILTER S ONE MAIN l OR MULTIPLE ON l l BRANCH LINES 0 01 MICRON Lu HIGH gt all EFFICIENCY COALESCING eee NOTE All Filters should have automatic drains and service indicators to FILTER show when elements need changing Figure A2 Non Redundant System with Refrigerator Dryer Note that not all gauges valves and differential pressure indicators for filter service monitoring are not shown It is recommended that filters with integral service life indicators or differential pressure indicators be used to help ensure
22. instrument quality air to prevent clogging and to ensure extended periods of maintenance free operation Moore Industries suggests the following levels of filtering protection e Pre filter A general purpose rough filter used to reduce particulate matter to 5 microns in size Also removes bulk liquids Although not re quired this filter is especially recommended to protect the 0 01 micron final filter when used e Final Filter A second final filter is recom mended to remove particulate matter in sizes down to 0 01 micron This filter removes virtually all condensable liquids from the air stream as well e Filter Regulator Module Option A combined filter regulator assembly the FR1 Option offered as an accessory for the IPF removes particles down to 0 01 micron supplying regulated instrument quality air to the unit This space saving module is affixed to the IPF supply port and comes with a pressure gauge scaled in both psi 0 60 and bars 0 4 Operation Once its calibration has been checked or adjusted and the unit has been installed properly the IPF operates unattended It requires only a minor periodic maintenance procedure detailed in the next section of this manual Remember that if an IPF is installed in an open loop it may appear to drift over extended periods of time due to the lack of corrective feedback If the unit is determined to be the cause of a loop irregularity carry out the
23. l assembly into housing being careful not to crimp or pinch the current wiring and mate fittings in housing with ports on pneu matic block of internal assembly Press down until locked into place NOTE for NE TYPE_IPF S 2 Use scratch markings made earlier to make sure that each section of pneumatic block is oriented properly and use small socket head screws to secure re assembled block Tighten screws to between 35 and 45 Nem of torque 26 to 33 foot pounds Refer to Figure 8 The wiring between the terminal block and the unit front panel cut during disassembly must be rejoined using an AWG 24 20 butt connector and heat shrink tubing available from Moore Industries Use of non specified connectors invalidates the group N certification N N POSITION HEAT SHRINK AS SHOWN As l Hr D gt BUTT CONNECTOR DO NOT PINCH WIRING a N 7 DETAIL XN 4 Se aaa wv 27 Z a HEAT SHRINK F A TUBING Ea SS E 2 E Esed e E eS i Figure 8 Re wiring the NE TYPE IPF To re connect current wiring in N type IPF s connect the wires with the same color black to black and red to red Use a crimping tool to secure the connection 6 Reseat IPF faceplate and secure it using the Phillips head screws and re secure the top cover of the housing 7 Calibrate unit
24. maintenance procedure in the next section of this manual If problems persist refer to the Troubleshooting Section Instrument quality Air Air from the application continuously flows through the IPF during operation Depending upon the purity of the air supply the unit s internal assembly may have to be removed and cleaned at comparatively short intervals to ensure continued optimum performance Initially random checks can help establish a satisfac tory maintenance interval geared to the user s air supply cleanliness Refer to the next section for instruction on the disassembly and cleaning of the IPF Maintenance Before beginning IPF maintenance the unit must be removed from its application It is strongly recom mended that the maintenance procedures be per formed in a clean controlled environment such as at a technicians bench in a laboratory etc Several internal parts are small and precision machined easily lost or damaged if an attempt is made to perform maintenance in the field After maintenance each IPF should be recalibrated before it is returned to service Refer to the Calibra tion Section of this manual for instructions You Will Need To perform the basic maintenance procedure for the IPF refer to table 4 which lists the equipment required These materials are not supplied by Moore Industries but should be available in maintenance areas prepared to perform this type of procedure If this
25. n compressed air instrument systems A coalescing filter removes sub micron liquid oil droplets from the air and is usually supplied with an automatic drain The filter works by trapping oil and water droplets in a bed of microfibers Droplets run together at fiber cross over points form large liquid drops and are forced by air flow to a drain A filter system consist ing of a general purpose first stage filter about 5 micron and a high efficiency coalescing final filter is recommended to obtain contaminant free air The exact location of the first stage filter in the loop is not important it can be located just ahead of each final filter or a single first stage filter can be located on a main line to protect a number of final filters on branch lines Each final filter coalescing should be located just ahead of each pressure regulator Page A1 IPF Water The amount of water in an air system depends on temperature pressure and the relative humidity of the air The amount of contamination therefore tends to vary widely with geographic location and weather To obtain intrument quality air sufficient water must be removed to lower the dew point of the air to a temperature below ambient The dew point at line pressure is expressed as the temperature at which any moisture in the system begins to condense Water may be removed using a number of tech niques including coalescing filters refrigeration dryers and desiccant
26. nit front panel could disengage it from the internal assembly If this happens disassemble the IPF as described in the Maintenance Section of this manual Visually inspect the screw and if serviceable hold down the flapper arm and turn the screw clockwise until its pin is in a position to hold the arm Refer to the Calibration Section of this manual and perform a unit recalibration Declaration of Conformity C EMC Directive 89 336 EEC Manufacturer s Name Moore Industries International Inc Manufacturer s Address 16650 Schoenborn Street North Hills CA 91343 6196 USA Declares that the product s Product Name IPF IPT IPX IPH MODEL INPUT OUTPUT POWER OPTIONS HOUSING Model Number s IPF x N CE IPT S k ig CE t IPX N S x CE IPH x KR CE N Indicates any input output supply pressures option and housing as stated on the product data sheet Conforms to the following EMC specifications EN61326 1 1998 Electromagnetic Compatibility requirements for electrical equipment for control use Supplemental Information None RS Date Fred Adt Robert Stockham Quality Assurance Director Moore Industries International Inc European Contact Your Local Moore Industries Sales and Service Office The Interface Solution Experts e www miinet com United States e info miinet com Belgium info mooreind be China e sales mooreind sh cn MOOR Tel 818 894 7111 FAX 818
27. or output pressure The IPF housing is constructed of rugged all weather polyetherimide thermoplastic It is designed to meet the specifications of several third party industrial certifying agencies Contact your Moore Industries Sales Representative for the most current list of IPF certifications and approvals Page 1 IPF The unit has two electrical conduit dimension op tions a 1 2 inch by 14 NPT female port WP and WPP and an M20 x 1 5 metric female port WPM and WPMP Pneumatic connection fittings are female 1 4 inch by 14 NPT standard NE Type Units IPF s equipped with the NE Option have a separate external enclosure attached to the main unit housing This enclosure contains the terminals for the connection of process current input The IPF can be installed in a surface mount configu ration WP or WPM or with the optional hardware on 2 inch pipe WPP and WPMP The symmetrical arrangement of the mounting holes in the base of the unit housing provides for mounting on either horizon tal or vertical piping The IPF housing affords the unit excellent protection against shock vibration and corrosion The unit is also inherently immune to radio frequency and electromagnetic interference RFI EMI Options There are several options available for the IPF The following list provides an overview A complete list including information on available mounting hard ware and more data on the current IPF app
28. pe units terminals are enclosed in a separate external sub housing labeled TERMINAL CONNECTIONS The terminal labeled I is for connection of the positive current input and the terminal labeled I is for negative connections The two IPF controls are also located inside the unit housing on the faceplate They consist of a me chanical adjustment screw and an electronic potenti ometer pot each accessed through holes in the unit front panel The following labels are used gt lt lt controls the setting for unit zero controls the setting for unit span Table 2 IPF Calibration Equipment Specifications Current Source Calibrated adjustable Must be capable of discrete output levels within the appropriate rated range for the unit under test 4 20 or 10 50 mA Refer to model number and table 1 DC Milliammeter Calibrated Accuracy of 0 1 optional equipment Air Supply Filtered regulated instrument quality Refer to appendix A of this manual for more detailed specifications filtration requirements Air Pressure Gauges Two calibrated gauges 1 with accuracy of 2 2 with accuracy of 0 1 Pneumatic Test Load Calibrated Volume of approximately 120 ml 75 in 3 per IEC spec 770 Screwdriver Slotted tip Head width of 5 mm 0 1875 in maximum SPAN POTENTIOMETER oo oN TERMINAL H I 1 n NS BLOCK S amp S N DETAIL D fy
29. proper servicing Use redundancy in a filtering scheme to preclude any necessity for shutdown during servicing Note that the systems depicted in the figures differ in the method used to remove water The use of a desiccant dryer as in figure A2 requires both upstream and downstream filtration to prevent oil contamination of the desiccant as well as to prevent desiccant fines from introducing new contamination Page A3 IPF ISA Specifications The Instrument Society of America standard ISA S73 1975 ANSI MC11 1 1975 comprises the air quality requirements for instrument grade air for use in pneumatic applications Although ISA specifications call for particle size not to exceed 3 microns and oil content not to exceed 1 ppm coalescing filters are readily available that remove particles down to sub micron sizes as small as 0 01 micron while also removing oil to below 0 01 ppm Moore Industries filters that exceed ISA specifica tions provide very inexpensive protection Contact your Sales Representative for more information RETURN PROCEDURES To return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Returned Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documen
30. re 2 IPF Calibration Setup Orient IPF as it will be positioned in the applica tion That is if unit is to be oriented vertically when installed orient vertically to calibrate With zero air input supply off connect 1 4 inch pneumatic tubing between appropriate output port of regulated instrument air supply and calibrated pressure gauge 1 accuracy of 2 of span Connect another hose from gauge to port labeled SUPPLY on IPF Connect 1 4 inch pneumatic tubing between IPF port labeled OUTPUT and appropriate port of pressure gauge 2 accuracy of 0 1 of span and from that gauge to appropriate pneumatic load Run current source wiring through conduit opening in housing and to front panel of IPF For NE type units Route wiring through conduit opening in external sub housing terminal block assembly Connect positive lead of adjustable current source to I terminal of IPF Connect negative source lead to I IPF terminal A dc milliammeter may also be connected to verify level of current input When connections are complete apply 0 of appropriate input current 4 mA for 4 20 mA units or 10 mA for 10 50 mA units Apply appropriate filtered instrument quality air to supply line 20 or 35 psi 40 kPa or 1 4 bar Verify appropriate supply pressure by checking Supply Pressure field of unit model number Set span pot to approximate mid scale 22 turns in either direction then approximately 11 turns
31. rovals and certifications is available from your Moore Industries Sales Representative or directly from the factory ERT Option Coalescing Filter Regulator w Integral Gauge Maximum 4 scfm flow at 90 psig inlet pressure Removes particulate matter down to 0 01 micron in size Scaled in 0 60 pounds per square inch psi and 0 4 bars TF1 Option Plastic Tube Fitting For use with 1 4 inch O D tubing Option not available with FR1 Table 1 lists the performance and operational specifications for the IPF Page 2 IPF Table 1 IPF Performance and Operational Specifications Characteristic Specifications Factory configured 4 20 mA into 200 nominal 10 50 mA into 75 nominal available with 3 15 psig output units only Factory configured 0 2 1 bar 20 100 kPa 1 0 2 bar 100 20 kPa 3 15 psig 15 3 psig 3 16 6 psig 3 27 psig Factory configured 20 psi approximately 140 kPa 1 4 bar nominal Suppl EE 35 psi approximately 241 kPa 2 41 bar nominal 35 psi required for 3 27 psig output units Pressure Filtered regulated instrument quality air only 20 psi units accommodate up to 30 psi without damage 35 psi units accommodate up to 40 psi without damage Span Multiturn pot electronically adjusts full scale output to 100 of rated span Zero Multiturn adjustment screw mechanically provides offsets of 3 of span Controls Accuracy Error less than 0 5 of span including the combine
32. tation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following documentation a A note listing the symptoms that indicate the unit needs repair b Complete shipping information for return of the equipment after repair c Thename and phone number of the person to contact if questions arise at the factory Use sufficient packing material and carefully pack the equipment in a sturdy shipping container 4 Ship the equipment to the Moore Industries location nearest you The returned equipment will be inspected and tested at the factory A Moore Industries representative will contact the person designated on your documentation if more information is needed The repaired equipment or its replacement will be returned to you in accordance with the shipping instructions furnished in your documentation WARRANTY DISCLAIMER THE COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRAN TIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SER VICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRAN TIES ARISING FROM ANY
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