Emerson 2625NS Instruction Manual
Contents
1. Figure 4 Volume Booster Assembly Drawing i DAO APBOO OADAPNS S S N 23 maL Lae A i AO a SNI SNE BOO S N Q D stb GO 2 A 7 TET Le zR ae Ry N M OL NH SODMOOAMOE a O j QU DV4286 B x gt B amp O A 1 Remove the six cap screws key 15 from the perimeter of the spring case assembly key 3 and lift off the assembly taking care you do not lose the upper spring key 8 or the spring seat key 9 2 Remove the upper diaphragm key 6 the diaphragm spacer key 2 the diaphragm assembly key 5 which includes the lower diaphragm and the O rings key 14 3 Unscrew the valve assembly key 7 from the body The seat ring key 7A has a 1 1 2 inch hex for removal 4 Apply lubricant key 21 to the O ring key 7D lubricant key 23 to the lower valve and stem key 7B and sealant key 20 to the thread of the seat ring key 7A 5 Install the valve assembly key 7 into the body key 1 making sure the lower valve and stem key 7B engages over the lower spring key 10 and into the bottom plug key 4 2625 and 2625NS Volume Booster Instruction Manual January 2015 D100348X012 6 Install the diaphragm assembly key 5 onto the upper valve key 7C 7 Install the diaphragm spacer key 2 onto the body key 1 8 Place a straight edge at least 5 inches 127 mm long across the diaphragm spacer2. 2625NS Volume Booster Instruction Manual January 2015 D100348X012 Table 2 Maximum Flow Coefficients PORT SIZE COMBINATIONS Supply Port 0 094 12 7 l 0 375 0 5 FIELDVUE DVC6200 DVC6200 SIS DVC6200f DVC6200p DVC6000 DVC6000 SIS DVC6000f digital valve controllers FIELDVUE DVC2000 digital valve controller Low Pressure Relay High Pressure Relay Fisher 3570 valve positioner Fisher 3582 valve positioner Fisher 3610 3610JP 3611JP 3620 3620JP 3621 P valve positioner Installation Always wear protective clothing gloves and eyewear when performing any maintenance procedures to avoid personal injury System damage may result if a volume booster is installed in a way that it can be physically damaged Personal injury or system damage may result when service conditions exceed booster or other equipment ratings Exceeding the pressure specifications in table 1 may cause leakage parts damage or personal injury due to bursting of pressure containing parts or explosion of accumulated gas Check with your process or safety engineer for any additional measures that must be taken to protect against process media Note Do not use separate pressure supplies for the volume booster and associated positioner The volume booster may not exhaust immediately upon loss of a separate pressure supply However if the system is in a transient state at the time of pressure supply loss or if changes to the booster s input signal are suf
3. boosters with 3 8 inch supply R2625V38012 12 7 mm 0 5 inch supply port For boosters with 1 2 inch supply R2625V12012 For 2625NS 9 5 mm 0 375 inch supply port 12 7 mm 0 5 inch supply port 7A Seat Ring Brass 9 5 mm 0 375 inch supply port i i 12 7 mm 0 5 inch supply port Pa rts List figure 4 7B Lower Valve and Stem Key Description For 2625 Aluminum nitrile SST For 2625NS 1 Body Aluminum 7C Upper Valve 2 Diaphragm Spacer For 2625 Aluminum nitrile Aluminum For 2625NS Aluminum with 1 2 NPT vent connection 7D Valve O Ring For 2625 nitrile 3 Spring Case Assembly Aluminum heat treated 440 stainless steel For 2625NS EPDM 4 Body Cap 7E Hex Nut steel pl Brass 316 SST 8 Upper Spring steel pl 5 Diaphragm Assembly For 2 8 bar 40 psig max supply pressure For 2625 For 10 3 bar 150 psig max supply pressure Nitrile on nylon diaphragm With brass blocked exhaust 9 Spring Seat SST With brass 2 4mm 0 094 inch exhaust With brass 9 5mm 0 375 inch exhaust 10 Lower Spring steel pl With brass 12 7mm 0 5 inch exhaust For 2 8 bar 40 psig max supply pressure For 2625NS For 10 3 bar 150 psig max supply pressure EPDM meta aramid With 9 5 mm 0 375 inch exhaust 11 Restriction SST With 12 7 mm 0 5 inch exhaust 12 Hex Nut steel pl Recommended spare parts 11 2625 and 2625NS Volume Booster January 2015 Figure 5 Volume Booster with Yoke Mounting Bracket Key 13 14 16 17 20 21 22 23 Note ATTACH
4. following adjustment procedure is recommended when using the actuator for throttling control Note When sizing the booster select the lowest Cg that will meet the stroking speed specifications Oversizing the booster in a closed loop may lead to stability problems thus requiring the bypass to be opened so far that the booster will never operate Prior to operation turn the bypass restriction adjusting screw figure 3 four or five turns counterclockwise from the fully closed position With the actuator in operation slowly turn the restriction clockwise until the booster operates in response to large changes in the input signal yet allows small changes to move the actuator without initiating booster operation If the actuator is to be used for on off control the restriction should be closed turned fully clockwise Principle of Operation Refer to figures 2 and 3 Because of the restriction large input signal changes register on the booster input diaphragm sooner than in the actuator A large sudden change in the input signal causes a pressure differential to exist between the input signal and the output of the booster When this occurs the diaphragms move to open either the supply port or the exhaust port whichever action is required to reduce the pressure differential The port remains open until the difference between the booster input and output pressures returns to within the deadband limits of the booster With the bypass restrictio
5. Instruction Manual 2625 and 2625NS Volume Booster D100348x012 January 2015 Fisher 2625 and 2625NS Volume Boosters Contents Figure 1 Fisher 2625 Volume Booster IMEFOGUCTION occ eecan tes we oeae ne ea 1 SCOPES Or Manual egerne no eraa o E EA 1 DESCHDUOM 255i tiene a e N A A AA 1 Specifications 0 cc cece cee ee eens 2 Educational Services 0 0 cece cece eee 3 INStAlStOM sve din hans Sandee eee ees 4 MOUNTING 4 2ietin cee E a ad eee aa 4 Pressure CONNECTIONS ce eee eee eee eee 5 Diagnostic Connections cee eee eee 6 SUD DIY PRESSURE rou vledke tava maaeedexe ead 6 EXMGUSE PORES ficu carlton tk eer re aaa 7 Operating Information 0 0 0 ce eee eee 7 Principle of Operation 0 cee eee eee 7 Maintenance sists oes bes eS dt eae eee teks 8 Diaphragm Assembly Replacement 8 Valve Assembly Replacement o on annann 9 Installation of Diagnostic Connections 10 Parts Ordering lt o os0 oeni sopii Eine E xmas 11 Pants KILS oicun tenas a a r aa 11 A Pam SLIS wrona a PRE E E E eee ees 11 Introduction Scope of Manual This instruction manual provides installation operation maintenance and parts information for Fisher 2625 and 2625NS volume boosters figure 1 Refer to separate instruction manuals for information regarding the valve body actuator and other accessories Do not install operate or maintain a 2625 or 2625NS volume booster without b
6. THIS SURFACE TO ACTUATOR YOKE YOKE MOUNTING BRACKET KEY 26 A6034 1 Description O Ring For 2625NS EPDM For 2625 nitrile O Ring 2 req d For 2625 nitrile For 2625NS EPDM Cap Screw steel pl 6 req d Standard With 1 2 NPT vent connection Nameplate stainless steel Drive Screw stainless steel 2 req d Anti seize sealant Lubricant silicone sealant Thread locking adhesive mild strength PTFE petroleum based lubricant see note immediately below PTFE petroleum based lubricant is only for use with 2625 For 2625NS use a medium grade silicone based lubricant Instruction Manual D100348X012 YOKE MOUNTING BRACKET KEY 26 Key Description 26 Mounting Bracket For yoke mounting see figure 5 For casing mounting Use two brackets stacked for seismic mounting Diagnostic Connections FlowScanner diagnostic system hook up Includes pipe tee pipe nipple pipe bushings connector body and body protector For diaphragm actuator SST fittings Brass fittings For piston actuator SST fittings Brass fittings Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher FIELDVUE and FlowScanner are marks owned by one of the companies in the Emerson Process Management busi
7. dicated These can be supplied as 10CFR Part 21 items Specifications Specifications for the 2625 and 2625NS volume booster are listed in table 1 Information for an individual unit as it comes from the factory appears on the product nameplate Instruction Manual D100348X012 Table 1 Specifications Port Diameters Supply Port Hi 9 5 mm 0 375 inch or W 12 7 mm 0 5 inch Exhaust Port W 2 4 mm 0 094 inch W 9 5 mm 0 375 inch or W 12 7 mm 0 5 inch Input Signal Positioner output Maximum Input Signal Pressure 10 3 bar 150 psig Input to Output Pressure Ratio Fixed at 1 to 1 Supply Pressure Ranges 2 When used in conjunction with a positioner or other pneumatic accessory always pipe the positioner and booster with one common supply through a Fisher 67D 67DR or 95H regulator see figure 2 A high capacity filter such as the Fisher 262K should be installed in the supply line to the regulator Supply pressure also must not exceed the maximum pressure rating of the actuator Constructions are available in two maximum supply ranges When Normally Used With Diaphragm Actuators Up to 2 8 bar 40 psig When Normally Used With Piston Actuators Up to 10 3 bar 150 psig Nominal Deadband Percent of Positioner Output Span 4 2 4 mm 0 094 inch exhaust port 2 9 5 mm 0 375 inch exhaust port 3 5 12 7 mm 0 5 inch exhaust port 5 1 May be used in any combination 2625 and 2625NS Volume Boo
8. eing fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions regarding these instructions contact your Emerson Process Management sales office before proceeding Description The 2625 is certified for use in Safety Instrumented System SIS applications Certification is by EXIDA Consulting LLC a global provider of functional safety and control system security SIS certification is identified on the product by the EXIDA logo on the 2625 nameplate The 2625 and 2625NS volume boosters are used in conjunction with a positioner on a throttling control valve to increase stroking speed The booster has a fixed deadband controlled by the seat to seat dimension of the supply and ea EMERSON www Fisher com Process Management 2625 and 2625NS Volume Booster Instruction Manual January 2015 D100348X012 exhaust plugs which is factory set during assembly and testing In addition the booster incorporates soft seat construction and an integral bypass restriction to eliminate positioner saturation problems that can occur with volume boosters that do not have these features Adjustment of the integral bypass restriction is necessary for system stability This adjustment does not affect the deadband of t
9. eplace the diaphragm assembly key 5 diaphragm spacer key 2 and the upper diaphragm key 6 Note To ensure proper operation of the bypass restriction make certain that the holes in the diaphragm and the bypass restriction are in line with the holes in the diaphragm spacer key 2 4 Install the spring case assembly key 3 on the upper diaphragm key 6 Make sure the spring seat key 9 and the upper spring key 8 are installed in the spring case assembly key 3 Press on the bottom of the spring seat with your finger If the spring seat key 9 does not move freely in the spring case assembly key 3 remove the spring seat key 9 and apply lubricant key 23 Reinstall the spring seat key 9 in the spring case assembly key 3 CAUTION To avoid damage to the diaphragms do not overtighten the screws 5 Replace the six cap screws key 15 and tighten them in a crisscross manner Instruction Manual D100348X012 Valve Assembly Replacement 2625 and 2625NS Volume Booster January 2015 CAUTION The distance between the exhaust port seat line on the upper valve key 7C and the supply port seat line on the lower valve and stem key 7B is critical to ensure the deadband requirements of the volume booster This distance must be adjusted in accordance with the following steps before you replace the valve assembly key 7 or the upper valve key 7C and lower valve and stem key 7B For key numbers refer to figure 4
10. ficient to overcome the deadband the booster will exhaust A loss of a pressure supply either separate or common to a 3582 or 3610 positioner will cause the positioners output pressure booster s input pressure to decay Always pipe the positioner and the volume booster with one common supply See figure 2 for typical installation examples A 67D 67DR or 95H regulator is required to provide sufficient capacity to supply both components A high capacity filter such as the 262K should be installed in the supply line to the 67D 67DR or 95H regulator Mounting The volume booster is typically nipple mounted between the pneumatic supply source and the actuator and may be used with piston or diaphragm actuators Many actuators require larger casing or cylinder connections and modifications to allow the booster to deliver the higher volume output Instruction Manual 2625 and 2625NS Volume Booster D100348X012 January 2015 The booster may also be directly mounted to the actuator by using an actuator yoke mounting bracket see figure 5 or casing mounting bracket Pressure Connections The input signal connection is 1 4 NPT The supply and output connections are 3 4 NPT minimum pipe size recommended for nipple mounting is 1 2 NPT Connections to the volume booster should be made as indicated in figure 3 Connections for two typical applications are shown in figure 2 Ensure that the piping is of proper size to meet the capacity demands of
11. he booster but does permit the control valve to respond to small input signal changes from the positioner without sacrificing steady state accuracy It also allows the booster to deliver high volume output for fast stroking when large rapid input signal changes occur The volume booster is used to improve stroking speed If precision valve control is required the use of a positioner is recommended If you use the volume booster only with an actuator for on off control the integral bypass restriction on the volume booster must be closed turned fully clockwise To facilitate diagnostic testing you can install connectors and piping with each 2625 and 2625NS volume booster The 2625NS volume booster is designed for nuclear power applications The 2625NS construction includes materials that provide superior performance at elevated temperature and radiation levels The O rings in the 2625NS are EPDM ethylene propylene and the diaphragms are EPDM meta aramid EPDM demonstrates superior temperature capability and shelf life over nitrile The meta aramid diaphragm fabric demonstrates improved strength retention at elevated temperature and radiation conditions CAUTION Use a clean dry oil free air supply with instruments containing EPDM components EPDM is subject to degradation when exposed to petroleum based lubricants Under the 10CFR50 Appendix B quality assurance program the 2625NS volume booster is qualified commercial grade de
12. key 2 The upper surface of the diaphragm assembly key 5 should coincide with the upper surface of the diaphragm spacer key 2 If not loosen the hex nut key 7E and raise or lower the upper valve key 7C accordingly Remove the valve assembly key 7 to loosen the hex nut key 7E 9 Repeat steps 4 through 8 until the upper surface of the diaphragm assembly key 5 coincides with the upper surface of the diaphragm spacer key 2 Note To ensure proper operation of the bypass restriction make certain that the holes in the diaphragm and the bypass restriction are in line with the holes in the diaphragm spacer key 2 10 Make sure the O rings key 14 are installed in the diaphragm spacer key 2 and coated with lubricant key 21 11 Install the upper diaphragm key 6 12 Install the spring case assembly key 3 on the upper diaphragm key 6 Make sure the spring seat key 9 and upper spring key 8 are installed in the spring case assembly Press on the bottom of the spring seat with your finger If the spring seat does not move freely in the spring case assembly remove the spring seat apply lubricant key 23 and reinstall in the spring case assembly CAUTION To avoid damage to the diaphragms do not overtighten the screws 13 Replace the six cap screws key 15 and tighten them in a crisscross manner Installation of Diagnostic Connections See figure 2 for part names and order of installation 1 Before you a
13. n adjusted for stable operation signals having small magnitude and rate changes pass through the bypass restriction and into the actuator without initiating booster operation Both the supply and exhaust ports remain closed preventing unnecessary air consumption and possible saturation of positioner relays 2625 and 2625NS Volume Booster Instruction Manual January 2015 D100348X012 Maintenance A WARNING Always wear protective clothing gloves and eyewear when performing any maintenance procedures to avoid personal injury Maintenance requires taking the volume booster out of service periodically To avoid personal injury or equipment damage disconnect or bypass any pressure lines to the booster and vent any pressure locked in the unit before you begin maintenance Check with your process or safety engineer for any additional measures that must be taken to protect against process media Diaphragm Assembly Replacement Key numbers refer to figure 4 1 Remove the six cap screws key 15 from the perimeter of the spring case assembly key 3 and lift off the assembly taking care you do not lose the input spring key 8 or the spring seat key 9 2 Remove the upper diaphragm key 6 diaphragm spacer key 2 diaphragm assembly key 5 which includes the lower diaphragm and the O rings key 14 Inspect these parts for damage and replace if necessary 3 Replace the O rings key 14 after coating with lubricant key 21 Then r
14. ness unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fisher com 1997 2015 Fisher Controls International LLC All rights reserved gt aF EMERSON
15. pipe tee and pipe bushings with an 1 8 NPT pipe bushing for the connector The connector consists of an 1 8 NPT body and body protector See separate instructions for diagnostic connections to the positioner Supply Pressure Supply pressure must be clean dry air or noncorrosive gas and it should be filtered CAUTION Use a clean dry oil free air supply with instruments containing EPDM components EPDM is subject to degradation when exposed to petroleum based lubricants Instruction Manual 2625 and 2625NS Volume Booster D100348X012 January 2015 A WARNING If a flammable or hazardous gas is to be used as the supply pressure medium personal injury property damage or equipment damage could result from fire or explosion of accumulated gas or from contact with hazardous gas The volume booster has no provision for piping away the vented exhaust gas Therefore do not use flammable or otherwise hazardous gas as a Supply medium unless the unit is in a well ventilated area and all ignition sources have been removed Exhaust Ports Exhaust to the atmosphere is through exhaust ports in the side of the unit Keep the exhaust ports free of any obstructions or foreign materials that might clog them Operating Information The only operating requirement of the volume booster is the adjustment of the bypass restriction for stable actuator performance Although systems with different characteristics may require different adjusting techniques the
16. ssemble the pipe nipple pipe tee pipe bushings actuator piping and connector body apply sealant to all threads 2 Turn the pipe tee to position the connector body and body protector for easy access when doing diagnostic testing Instruction Manual 2625 and 2625NS Volume Booster D100348X012 January 2015 Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment mention the serial number of the volume booster This serial number can be found on the nameplate key 16 figure 4 A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher instrument The use of components not manufactured by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage Parts Kits Description Part Number Key Description Repair kits for diaphragms for 2625 only Kit contains keys 5 6 13 14 6 Upper Diaphragm For boosters with 3 32 inch exhaust R2625D33212 For 2625 nitrile on nylon For boosters with 3 8 inch exhaust R2625D38012 For 2625NS EPDM meta aramid For boosters with 1 2 inch exhaust R2625D12012 7 Valve Assembly includes keys 7A 7B 7C 7D and 7E Repair kits for valve assemblies for 2625 only For 2625 Brass nitrile Kit contains key 7 9 5 mm 0 375 inch supply port For
17. ster January 2015 Operative Temperature Limits 2 3 2625 40 to 71 C 40 to 160 F 2625NS 40 to 93 C 40 to 200 F Maximum Flow Coefficients See table 2 Connections Input Signal 1 4 NPT Supply and Output Signal 3 4 NPT Hazardous Area Classification Complies with the requirements of ATEX Group Il Category 2 Gas and Dust C x 26D Safety Instrumented System Classification SIL3 capable certified by exida Consulting LLC Approximate Weight 2 3 kg 5 pounds Declaration of SEP Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph 3 of the Pressure Equipment Directive PED 97 23 EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot bear the CE marking related to PED compliance However the product may bear the CE marking to indicate compliance with other applicable EC Directives 2 The pressure temperature limits in this document and any applicable code or standard limitation should not be exceeded 3 This term T in ISA Standard 51 1 4 Zero psig to maximum supply Educational Services For information on available courses for 2625 and 2625NS volume boosters as well as a variety of other products contact Emerson Process Management Educational Services Registration Phone 1 641 754 3771 or 1 800 338 8158 e mail education emerson com http www emersonprocess com education 2625 and
18. the booster and that you equip the actuator with properly sized input connections Figure 2 Typical Installations POSITIONER OUTPUT aues OPTIONAL DIAGNOSTIC POSITIONER eRe IT CONNECTION J 2625 OR 2625NS a VOLUME BOOSTER INPUT SIGNAL Ee o CF l e AMi JO F supPLy ey E aE 67D 67DR OR 95H PIPE TEE PIPE BUSHING BODY BODY PROTECTOR 2625 OR 2625NS ACTUATOR VOLUME BOOSTER POSITIONER OUTPUT WITH A PISTON ACTUATOR BOTTOM CYL 2625 OR 2625NS VOLUME BOOSTER PIPE TEE PIPE BUSHING i BODY BODY PROTECTOR lt SSs a PIPE NIPPLE MCAT ie eee E r OPTIONAL POSITIONER OUTPUT DIAGNOSTIC CONNECTION Sp Qaa ie O _ f 5 p POSITIONER lo SUPPLY ACTUATOR 67D 67DR OR 95H WITH A DIAPHRAGM ACTUATOR B2372 1 2625 and 2625NS Volume Booster Instruction Manual January 2015 D100348x012 Figure 3 Volume Booster Sectional View BYPASS RESTRICTION INPUT SIGNAL DIAPHRAGMS ADJUSTING SCREW KEYSAND6 N i EXHAUST PORT xg i BYPASS RESTRICTION KEY 11 7 aS e EXHAUST oA j re a i Wi is om OUTPUT TO ACTUATOR SUPPLY W0679 1 Diagnostic Connections To support diagnostic testing of valve actuator positioner packages install connectors and hardware between the 2625 or 2625NS volume booster and the actuator Typical connector installations are shown in figure 2 The hardware used includes a 3 4 NPT pipe nipple
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