Installation Manual
Manual PA/PG3000IM
Revision G
December 2007
PA/PG3000 SERIES
Gage and Absolute
Hermetically Sealed Adjustable
Electronic Pressure Transmitters
®
AEROSPACE AND POWER INSTRUMENTS • GULTON-STATHAM™ PRODUCTS
1644 Whittier Avenue • Costa Mesa, CA 92627
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PA/PG3000 Installation Manual
MODEL PA/PG3000
GAGE AND ABSOLUTE ELECTRONIC
PRESSURE TRANSMITTERS
CAUTION
TO AVOID POSSIBLE INVALIDATION
OF WARRANTY, PLEASE READ BEFORE
INSTALLATION AND MAINTENANCE
Ametek Gulton-Statham conducts a policy of continuous product development.
The specifications in this document may therefore be changed without formal notification.
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TABLE OF CONTENTS
SECTION
PAGE
I INTRODUCTION
5
II. SPECIFICATIONS
7
III. MECHANICAL INSTALLATION
10
IV. ELECTRICAL INSTALLATION
13
V. CALIBRATION
21
VI. MAINTENANCE, ETC.
24
VII. TROUBLESHOOTING
25
VIII. RETURN FOR REPAIR
26
IX. WARRANTY
29
X NACE COMPLIANCE & APPROVALS
30
XI INTRINSICALLY SAFE SYSTEMS
34
XII. INSTRUMENT NOTES
40
4
FIGURE
NO
PG3000 Cross Sectional Illustration
Amplifier Block Diagram
Non-Condensing Gas Installation
Liquid Or Condensing Gas Installation
Electrical Block Diagram
Multiple Transmitter Installation Diagram
Transient Protection
Factory Molded Cable
TP114 Transient Protector
C100/101 Electrical Connector
TP131 Electrical Schematic
TP131 Mechanical Installation
Wiring With TP131 Installed
Wiring Without TP131 Installed
Elevated Zero Application
Elevated Zero Examples
Suppressed Zero Application
Suppressed Zero Applications
Compound Pressure Calibration
Gage vs. Absolute Pressure
Zero Adjustment
Zero Adjustment
Product Approval - North America
Class, Division, Group - North America
Barrier Requirements - FM
Barrier Requirements - CSA
Barrier Requirements - ATEX
1.1
1.2
3.1
3.2
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
10.1
10.2
11.1
11.2
11.3
PA/PG3000 Installation Manual
SECTION I
INTRODUCTION
Sensor
The heart of the 3000 series is a strain gage
sensor that converts a mechanical force
(pressure) to an electrical signal. A Wheatstone
resistance bridge circuit is molecularly
deposited on a metal bending beam using a
technique similar to the process used to
manufacture high-density integrated circuit
chips. The deposition process is carried out in a
Class 100 clean room under direct computer
control to ensure conformance to Ametek
Gulton-Statham's specification. Each finished
beam is tested for linearity, sensitivity, thermal
stability, bridge resistance and balance before
installation in the sensor assembly. The sensing
mechanism is isolated from the process fluid by
an isolation diaphragm and silicone fill fluid.
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PA/PG3000 Installation Manual
then performance tested in an environmental
chamber at temperatures to 180°F (82°C) (or
180°F (104°C) for HT units) to verify
characteristics within the operating thermal
band.
Amplifier
The simple DC electronics provide excitation
voltage to the Wheatstone bridge, converts the
bridge output to a current (mA) signal and
provides electrical offset of zero to simulate (0)
psi (see Figure 1.2). The amplifier is packaged
in a hermetically sealed 316 stainless steel
housing to guard against moisture and
corrosion, the leading cause of electronic
component failure in competitive transmitters.
Ametek Gulton-Statham utilizes high-energy
product magnets to couple the internal
potentiometers to the external adjustment
screws. As the outside magnet is turned, the
internal magnet also turns, thereby adjusting
the zero and span potentiometers.
After
calibration is completed, the external magnets
may be removed and keepers inserted to
provide “tamper-proof” installation.
Measurement Reference
The PA/PG3000 transmitters feature a sealed
gage sensor with a fixed reference of 14.7 psi.
The sealed gage sensor allows the transmitter
to be electrically offset to simulate 0 psia for
vacuum applications. (For further installation
details see Section V, Mechanical Installation.)
Small Lightweight, Easily Mounted
The hybrid DC electronics of the 3000 series is
simple and reliable, requiring far less space
than in competitive transmitters. The small size
electronics enclosure, made of 316 stainless
steel, provides a lighter and more rugged unit,
for easy and inexpensive mounting.
In Process Verification
The transmitters are tested for accuracy,
stability
and
reliability
during
each
manufacturing phase. Sensing assemblies are
checked in an environmental chamber to verify
performance characteristics and eliminate
mechanical
stresses.
Simultaneously,
amplifiers are burned in at elevated
temperatures
to
eliminate
premature
component failures. The electronic amplifier
assembly and sensors are then matched,
assembled and welded together to form the
complete transmitter. The completed unit is
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PA/PG3000 Installation Manual
SECTION II
SPECIFICATIONS
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SECTION III
MECHANICAL INSTALLATION
Location Selection
Ametek Gulton-Statham 3000 series transmitters
have been specifically designed and constructed
to operate in hazardous environments. It is,
however, important to recognize that these are
precision
measuring
instruments
whose
accuracy, reliability and stability may have a
great influence on process efficiency and quality.
For best results, the location should be selected
with care.
GENERAL
Most problems associated with pressure
transmitters are generally the result of improper
installation. The importance of following the
instructions
and
considering
the
recommendations provided in this section cannot
be overemphasized.
Unpacking
The shipping container should be examined
carefully before unpacking. If there are visible
signs of significant damage, do not open the
container, but notify the carrier and Ametek
Gulton-Statham immediately. If no external
damage is apparent, the container should be
opened and the contents compared with the
packing list. The carrier and Ametek GultonStatham should be immediately notified if there
is equipment damage or shortage. Please do
not return goods without contacting Ametek
Gulton-Statham in advance.
Vibration & Shock
The influences of shock and vibration should
always be minimized. Vibration often occurs in
locations at certain times and under certain
process conditions, and not at other times.
Evaluate the conditions with care. See the
specifications section for the likely errors
associated with vibration on transmitter
performance. It may be possible to reduce any
harmful influences of vibration by correct
selection of the type of mounting, as well as the
location. The stiffness and flexibility of the
mounting will have an effect as will the location
of the bracket and support structure. Close
attachment to a heavier component may well
reduce the vibration effect. Remember that
vibration forces can be transmitted through the
process piping and fluids in the system, as well
as through the structure itself.
Testing
All 3000 series transmitters are factory calibrated
and performance verified prior to shipment.
Customer testing before installation is usually
unnecessary and not recommended in most
circumstances.
Storage & Shipment
For extended storage or for shipment, the
transmitter should be kept in its shipping
container. Do not remove plugs or covers. If the
transmitter has been installed, be sure all
process fluid is completely drained from the unit.
Clean the transmitter thoroughly if it has been
exposed to corrosive conditions while in service.
Always store the transmitter in a suitable
environment (see Section II, Specifications, and
Section VI, Maintenance, Storage, Shelf Life &
Spares).
Temperature
In order to achieve optimum performance, the
transmitter should not be exposed to the high or
low temperature extremes. It is good practice to
minimize, or avoid, sudden or large variations in
temperature, which can affect performance.
Consider all the possible sources of
temperature. Heat or cold may come from the
process connections, ambient air, or by radiation
from or to nearby cold or hot objects. Extended
lengths of piping will generally provide more
surface area for cooling (or heating) of hot or
cold lines connecting to the transmitter. Use
shields to block radiant and convective heat
transfer between the transmitter and hot or cold
objects in close proximity.
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PA/PG3000 Installation Manual
Transmitter Location
Proper location of the transmitter with respect to
the process measurement is critical for accurate
gage pressure measurements.
For noncondensing gases, the transmitter should be
located above the process taps (see Figure 3.1).
For liquid or condensing gases, the transmitter
should be located below the process taps (see
Figure 3.2). Other, general considerations
should include:
Accessibility
The location should be selected to allow direct
access for adjustment or recalibration while in
service. The zero and span magnets should
always be accessible. Also, the transmitter
should be removable in the event shop servicing
is required. Consideration of optional equipment
should also be made.
For example, if a
meter/junction box is incorporated, it must be
accessible for convenient viewing and wiring.
From the model number on the ID plate,
determine the options that have been included in
the unit to be installed.
11
•
Impulse tubing should be kept as short
as possible and of sufficient diameter to
avoid friction loss.
•
Slope impulse piping at least 1 (one) inch
per foot up toward the process
connections for non-condensing gas.
•
Slope impulse piping at least 1 (one) inch
per foot down toward the process
connections for liquid or steam.
•
Ambient temperature extremes
fluctuations should be avoided.
•
Sediment should be kept from depositing
in the impulse tubing.
•
The transmitter should be isolated from
hot or corrosive process fluids.
•
In dry leg applications, possible
condensation in the impulse piping
should be avoided.
•
For steam service, impulse tubing should
be filled with water to prevent contact of
live steam with the transmitter.
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PA/PG3000 Installation Manual
NON-CONDENSING GAS INSTALLATION
• Mount the transmitter such that the
impulse piping connection is made from
below the transmitter.
• Ensure there are no low spots in the
impulse piping between the process taps
and transmitter connection.
• Slope the impulse piping at least one (1)
inch per foot down toward the process
taps.
• Install valving between the process taps
and transmitter to permit static equalization
(zero adj.) and process shut off.
FIGURE 3.1
LIQUID OR CONDENSING GAS INSTALLATION
• Mount the transmitter such that the
impulse piping connection is made from
above the transmitter.
• Ensure there are no vapor traps in the
impulse piping between the process taps
and transmitter connection.
• Slope the impulse piping at least one (1)
inch per foot upward to the process taps.
• Install valving between the process taps
and transmitter to permit static equalization
(zero adjustment) and process shut off
FIGURE 3.2
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PA/PG3000 Installation Manual
Process Connections
Process tubing should be installed so it will not
produce added mechanical stresses on the
transmitter during seismic disturbances. This is
often accomplished with the use of stress-relief
loops in the process tubing or by separately
supporting the process tubing close to the
transmitter.
SECTION IV
ELECTRICAL INSTALLATION
ELECTRICAL TERMINATIONS
The 3000 series pressure transmitters are
supplied with one of five possible electrical
terminations:
The PG/PA3000 series transmitters are
supplied with one of three possible process
connections:
CODE 4.
CODE 8.
CODE 9.
CODE 2.
½-14 NPT process connection
per ANSI B2.1.
Flange fitting for three-valve
manifold.
High
pressure
tube
port
(autoclave F250C).
CODE 6.
CODE 8.
CODE 0.
Mounting Bracket Installation
The Models EW3 and EW7 2 in. pipe mounting
bracket can be installed to provide a rigid
support for the PG/PA3000 series transmitter.
Two (2) mounting screws and U-bolt assembly
are provided for mounting the transmitter to a 2inch pipe.
CODE A.
Three-wire 16 AWG. 36 in, long
BLACK WIRE - Positive
WHITE WIRE - Negative
GREEN WIRE - Ground
Molded Submersible Service
Cable, 3-conductor, 16 AWG,
Neoprene Insulated
Electrical accessory connected
to transmitter at the factory
3-Conductor cable, 18AWG,
Teflon Insulated, 60 in. long,
Molded Submersible Service
Cable, 3-conductor, 16 AWG,
Viton Insulated
Wiring The Transmitter
The power supply requirements range from +12
VDC at no load to +55 VDC at a maximum
2150 ohms load. All power to the transmitter is
supplied over signal wiring, No additional wiring
is required. Shielded twisted pairs or shielded
cable provide the maximum noise immunity.
When using shielded cable, make sure only one
end is grounded (see Figures 4.1 and 4.2).
Under no circumstance should the transmitter
signal wiring be placed in the same conduit with
AC power circuits.
Materials Required:
Description: 2-inch pipe mounting bracket with
carbon steel hardware
EW3 Bracket P/N: 064127-000-003
OR
Description: 2-inch pipe mounting bracket with
316 CRES hardware
EW7 Bracket P/N: 064127-316-003
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PA/PG3000 Installation Manual
A single transmitter or multiple transmitters may
be connected to a +DC power supply providing
that the type of wire, length from the transmitter,
and line resistance are taken into consideration.
Make sure the power supply used has a
minimum voltage (AC) ripple and meets your
requirements to overcome voltage drop (line
loss) and current loss in your closed loop
circuit. The negative side of the power supply
should be grounded.
Do not exceed the
specified load limitations of the transmitter for a
particular power supply voltage.
A block
diagram of a typical single transmitter
installation is shown in Figure 4.1, and a
multiple transmitter installation in Figure 4.2.
Output Damping
The 3000 series gage pressure transmitters are
supplied damped with a response time of 300
milliseconds for a 63% step to input pressure.
Optional fast response of less than 10
milliseconds is available (see Figure 4.3).
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PA/PG3000 Installation Manual
Operation
The Ametek Gulton-Statham Model TP131 (see
figures 4.7 and 4.8) and Model TP114 Transient
Suppressors (see Figure 4.5) are designed to
isolate any 3000 series two-wire pressure
transmitter
against
damaging
electrical
transients such as lightning or lightning
induced, inductive switching (EMI), and
electrostatic discharge (ESD). Each lead wire
is protected by a gas filled surge protector and
ultra-fast clamping circuit to provide a low
clamping voltage, which automatically shunts
damaging electrical transients to ground. The
circuitry is environmentally protected against
man-made or atmospheric conditions to provide
extended
reliability.
These
transient
suppressors are rated as follows:
SURGE CAPACITY
MAXIMUM VOLTAGE SURGE
ADDED LOOP RESISTANCE
Factory Molded Cables
For high moisture related or submerged
applications, the 3000 series transmitters can
be supplied with factory molded Neoprene or
Viton cabling (see Figure 4.4). The cabling
consists of three 16 AWG tin/copper
conductors, compression molded to the
electrical connection of the transmitter
electronics housing. The protective, corrosion
resistant cover provides a reliable moisture
proof seal. These cables can typically be
submerged to depths of up to 500 feet (1000
psi external pressure) without degradation of
the molded seal.
Optional Electrical Connectors
Ametek
Gulton-Statham
3000
series
transmitters can be supplied with optional
electrical connectors for moisture related,
submerged or quick connect/disconnect
requirements.
5000 amps
700 VDC
44 ohms
Installation
The TP131 is designed to install directly
beneath the terminal block of the Ametek
Gulton-Statham MA130 series, NEMA rated
electrical enclosure (see Figures 4.9 and 4.10).
Its unique packaging requires only that the
terminal block be removed from the junction
box and the TP131 be inserted. Additional
assembly screws are supplied with the TP131.
These screws must be installed in place to
maintain electrical continuity from the terminal
block, through the TP131, and to the
transmitter.
C100/101 (Quick) Electrical Connector
For applications which may require a quick
disconnect for ease of removal of the
transmitter, or require flexible electrical
terminations, the 3000 series can be factory
fitted with a Ametek Gulton-Statham C100/101
electrical connector (see Figure 4.6). The
C100/101 assembly consists of the C100
adapter, which is fitted to the electrical
connection of the transmitter electronic housing
at the factory, and the C101 electrical connector
that is fitted with the field terminations by the
user. The C100 is a four-pin adapter in which
only three pins are utilized: for the ground
(Green Pin B), the positive (Black, Pin A), and
the negative (White, Pin D) terminations to the
transmitter.
The C101 is a four-pin
MS3106F14S-12S type quick disconnect
receptacle with cable clamp.
NOTE: PIN C IS LEFT OPEN
The TP114 is factory installed into the electrical
conduit connection of any 3000 series
transmitter, or compatible electrical enclosure.
Its electronic components are identical to the
TP131 in performance characteristics, but are
housed in a stainless steel tube, internally
threaded at each end. This allows simple
installation between the conduit connection of
the TP114 and the electrical conduit.
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PA/PG3000 Installation Manual
the o-ring upon reinstallation of the
cover onto the junction box housing.
Junction Box Field Installation Procedure
The PA/PG3000 series is offered with a 3/4-14
NPT thread for the installation of the optional
junction box. Should it be necessary to reinstall
a new junction box in the field, the following
procedure will assist in doing so.
5. Reinstall new o-ring.
6. Apply a new coating of anti-seize thread
compound on the external threads of the
junction box cover.
Note: Prior to
applying compound, visually inspect
threads and sealing surfaces to ensure
no contaminants which may effect
proper thread engagement or sealing
are adhering to these areas.
1. After the existing junction box has been
removed. Clean any contaminants from
the conduit thread of the transmitter
electronics housing.
2. Apply thread sealant listed below to
conduit threads of the transmitter
electrical housing. Then, starting at
zero thread engagement, install the
junction box a minimum 5-thread axial
engagement.
7. With zero thread engagement, place the
cover unto the junction box and rotate
the cover a minimum of 8 ½ revolutions
in the clockwise direction. This will
properly secure the cover and ensure
sealing of the o-ring. Note. No tooling to
assist
for
additional
mechanical
leverage or torqueing is required.
Junction Box O-ring Field Replacement
Procedure
Scope:
During
periodic
maintenance
procedures, it may be necessary to remove the
cover from the factory installed hazardous
location qualified junction box, to access field
wiring terminations. When the cover has been
removed, it is recommended standard practice
to replace the o-ring seal to ensure proper
sealing during reinstallation.
Note: While o-ring will properly seal after 8 ½
revolutions, exceeding this until metal to metal
contact between the cover and housing is
made, will not degrade the seal. The method
for installation requires hand tightening only!
No tooling to assist for additional
mechanical leverage should be utilized.
Procedure
1. By hand, remove the junction box cover
from the housing by rotating in the
counter clockwise direction until the
threads are completely disengaged.
Conduit Installation
The PA/PG3000 series has ¾-14 NPTF conduit
threads for either the transmitter threaded
housing connection, or the optional junction box
threaded conduit connections. Apply thread
sealant to conduit threads. Then, starting at
zero thread engagement, install the conduit by
rotating 4-7 turns in the clockwise direction.
2. Remove the o-ring seal from the base of
the threads on the junction box cover
and properly dispose of it to ensure it
will not be re-used.
3. Wipe
existing
anti-seize
thread
compound and contaminants from the
external threads of the junction box
cover and the internal threads of the
junction box housing.
4. Apply a thin uniform coating of silicone
lubricant to the new o-ring surface.
Note: Silicone lubricant is utilized to aid
in sealing and prevention of damage to
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PA/PG3000 Installation Manual
Range Value, Upper -The highest value of a
measured variable that a device is adjusted to
measure.
SECTION V
CALIBRATION
Proper Range Selection
The 3000 series transmitters are factory
calibrated, either to the specified range or to the
maximum span of the transmitter. Since the
unit is hermetically sealed, provision has been
made for zero and span adjustments through
external screwdriver adjustable magnets. The
external adjustment screws are coupled to
internal zero and span potentiometers by the
use of permanent magnets, which are mounted
back to back on the transmitter housing. Zero
and span adjustments are non-interacting.
Definition Of Ametek Gulton-Statham Terms (Based On SAMA Standard PMC20-1-1973
"Process
Measurement
And
Control
Terminology")
Accuracy - Conformity of an indicated value to
an accepted standard value or true value.
Reference accuracy is the limit that errors will
not exceed when the instrument is used under
reference operating conditions.
Calibration -Adjustment of the output of a
device to bring it to a desired value, within a
specified tolerance, for a particular value of
input.
For gage pressure applications, proper range
selection is of the greatest importance in
ensuring compatibility of the transmitter to the
actual application. In most applications, the
transmitter type selected is predetermined by
the environmental and physical limitations.
Linearity - The maximum deviation of an actual
characteristic (average of upscale and
downscale readings) from a straight line
positioned so as to minimize the maximum
deviation.
Each transmitter manufacturer may specify a
unique elevation and suppression limit based
on the turndown ratio capability of the electronic
amplifier. To determine if a transmitter is
capable of the intended application, the
following formula (where LCV = lower calibrated
value) can be utilized.
Span - The algebraic difference between the
upper and lower range values.
Range - The region between the limits within
which a quantity is measured or transmitted.
%Elevation or suppression =
Elevation & Suppression of Electronic
Pressure Transmitters
(Definitions extracted from ISA STANDARD &
PRACTICES FOR INSTRUMENTATION, 9th
Edition, Volume 2, 1998.)
LCV
X 100
SPAN
The following rules apply:
The elevation of a transmitters output cannot
exceed the maximum span.
Range, Suppressed Zero - A range in which
the zero value of the measured variable is less
than the lower range value.
The suppression of a transmitters output cannot
be greater than the maximum span minus the
minimum span.
Range, Elevated Zero - A range in which the
zero value of the measured variable, measured
signal, etc., is greater than the lower range
value.
Example:
100 psi with 5:l turndown.
Maximum Span = 100 psi
Minimum Span =
Range Value, Lower - The lowest value of the
measured variable that a device is adjusted to
measure.
100
= 20 psi
5
100-20 = 80 psi
Max Suppression = 80 psi
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PA/PG3000 Installation Manual
Zero Suppression Applications
Zero suppression occurs when the transmitter
body is installed below the process connection.
Suppression of zero output may be achieved for
differential pressure, gage pressure, and
remote seal applications. The actual amount of
zero suppression is determined by multiplying
the vertical distance between the transmitter
body and process connection, times the specific
gravity of the process media or filled capillary
leg (see Figure 5.3 and 5.4).
Zero Elevation Applications
Zero elevation occurs when the transmitter is
installed above the process connection. The
actual amount of zero elevation is determined
by multiplying the vertical distance between the
transmitter body and the process connection,
times the specific gravity of the process media
or filled capillary leg (see Figure 5.1).
Elevation is treated as a negative value
because the static head created by the process
or fill fluid, acts as a negative pressure on the
transmitter. The term “suppressed span” is
often used for elevated zero applications;
however; the term “elevated zero range” is
preferred to avoid confusion for the actual
calibration required (see Figure 5.2).
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PA/PG3000 Installation Manual
Field Calibration
For Field or Shop calibration, a dummy load
resistor may be substituted for the receiving
instrument. The dummy load (generally 250
ohms) is installed in series with the loop. A
digital multimeter or VOM is connected to read
the output across the dummy load. A pressure
source of known accuracy should be connected
to the process or pressure connection of the
transmitter.
Compound Calibrations
Calibrations that require a reference (4mA)
setting below atmospheric pressure and a span
(20mA) above atmospheric pressure are
generally referred to as compound calibrations.
These types of calibrations are common in
applications in which vacuum is involved. (See
Figure 5.5)
•
Apply the desired zero reference
pressure or vacuum. Adjust zero to
indicate 4.00 mA (1 volt across 250 ohm
res.). To decrease the output, turn the
ZERO SCREW CCW; increase output,
turn the screw CW. Adjustment of the
zero output will have no interaction with
the span output.
ZERO ADJUSTMENT
Calibration for Vacuum Service
The PA/PG3000 series can be calibrated for
absolute (vacuum) service. The sensor is
sealed and is not subject to barometric
pressure influence. It therefore can be
electronically offset to simulate an absolute
pressure. With an elevated capability to full
vacuum (-14.7 psi) the zero output (4mA) can
be adjusted to 0 psia (-14.7 psi).
NOTE: For suppressed zero calibrations, a
pressure equivalent to the anticipated Zero
Suppression is applied to process connection.
For elevated zero calibrations, vacuum
equivalent to the anticipated Zero Elevation is
drawn on the process connection. Elevation
can be to full vacuum.
True or Low Gage Application
For gage pressure applications requiring very
low measurements or a zero reference which is
influenced by barometric pressure (true gage),
the model PD/PDH3000 can be utilized by
venting the reference (LP) side to atmosphere.
Consult factory for options.
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PA/PG3000 Installation Manual
•
SECTION VI
Pressure equivalent to the maximum
span and the span adjusted to indicate
20 mA (5 volts across 250 ohm resistor).
Turn the SPAN SCREW CW to
decrease output and CCW to increase
output. Adjustment of the span output
will have no interaction with the zero
output.
MAINTENANCE, STORAGE,
SHELF LIFE & SPARES
MAINTENANCE
Unlike most electronic pressure transmitters,
the 3000 series require very little maintenance.
The hermetically sealed design prevents
moisture intrusion into the electronics
assembly, thus eliminating frequent electronics
assembly replacement. The hermetic design
also eliminates the requirement for o-ring seals
in the electronics enclosure, which require
periodic replacement due to environmental
aging. In addition, only periodic verification of
the zero reference calibration may be required
to confirm that no process variables have
changed or altered the initial reference
calibration.
It will also ensure that the
transmitter is maintaining performance within its
published specifications.
SPAN ADJUSTMENT
NOTE: In the event of any change in the output
readings, repeat adjustments until the readings
are correct. Should an inability to adjust the
output persist, contact the factory for technical
assistance.
STORAGE, SHELF LIFE &, SPARE PARTS
RECOMMENDATIONS
The 3000 Series feature an environmentally
protected electronics amplifier.
The active
electronic components are sealed in an allwelded stainless steel enclosure.
This
enclosure is rated for 100% relative humidity,
therefore,
eliminating
special
storage
requirements and additional spare parts
inventories.
Storage & Shelf Life: Five (5) years at a
maximum temperature of 100°F (38°C) in a
warehouse type environment.
It is not
necessary to make special precautions for
storage. It is, however, suggested that the unit
be stored at, or near, room temperature and out
of contact with direct sunlight. The transmitter
is unaffected by relative humidity.
Spares Recommendations: With the greatly
reduced probability of electronics failure due to
moisture and other contaminants, no spare
parts are necessary. In the unlikely event of a
failure, it is recommended that a minimum of
one or two transmitters are maintained as
spares.
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PA/PG3000 Installation Manual
SECTION VII
TROUBLESHOOTING
GENERAL
In the event of a transmitter malfunction, the
procedures listed below will assist in isolating
the problem and its source. These procedures
will also help in determining whether the fault
can be corrected on site. The information is
intended to assist in diagnosis of 3 primary
malfunction symptoms. Under each symptom,
checking procedures are listed for conditions
most likely to result in the malfunction. To
expedite the troubleshooting process, select the
symptom most closely resembling the unit's
apparent malfunction and use the information in
this manual. Start with the most likely and
easiest to check conditions.
No Output Or Low Output Signal
• Check for shorts and multiple grounds in
loop wiring.
Check polarity of connections.
•
Check loop impedance.
•
Check for entrapped gas in liquid lines.
•
Check transient suppressor (if used) for
1 megohm or greater resistance to
ground from each lead.
•
Check for
transmitter.
adequate
voltage
to
High Output Signal
• Check output of power supply.
•
Check transmitter connections.
•
Check to see if block and bleed valves
are fully open.
Check for entrapped gas in liquid lines,
and entrapped liquid in gas lines.
•
Check for sediment, or other blockage,
in the impulse lines to the transmitter.
Erratic Output
• Check for intermittent shorts open
circuits, and multiple grounds in loop
wiring.
Detective or damaged transmitters should be
returned to Ametek Gulton-Statham per the
instructions defined in Section IX.
•
•
25
•
Check piping for entrapped gas in liquid
lines or for liquid in dry lines.
•
Check for
transmitter.
adequate
voltage
to
PA/PG3000 Installation Manual
SECTION VIII
RETURN FOR REPAIR
Authorization Number
When returning a transmitter for repair, please
call and request a Return Material Authorization
(RMA) Number from our CUSTOMER
SERVICE DEPARTMENT, Telephone (949)
642-2400, FAX (949) 642-9490. The following
information will be requested:
Please pack the transmitter and paperwork in a
box that will prevent shipping damage. Ship the
package, transportation prepaid, to the
following address:
Ametek Gulton-Statham,
1644 Whittier Ave.
Costa Mesa California 92627
ATTENTION: Repair Department.
RMA#: _____________________
1. Name, address, and telephone number
of the individual to be contacted for
further details.
2. Model number and serial number of
transmitter.
3. A brief description of the problem,
including any related circumstances.
4. A brief description of the service,
including
maximum
pressure,
temperature, and period of time in
service.
5. Purchase Order for repair.
6. Complete shipping instructions for
returning unit.
7. All transmitters returned for repair must
be accompanied by a hazardous
chemical disclosure form per OSHA
Standard 28CFR1910.1200, "Right To
Know Law". A form may be obtained
from customer service or a copy may be
made from the sample enclosed on
page 22.
NOTE: Please include the Return Material
Authorization Number (RMA) on the
Return Address.
Chemical Disclosure Requirements
"The Right To Know Law"
All transmitters returned for repair evaluation
must be accompanied by a hazardous chemical
disclosure form per OSHA Standard 28CFR1
910.1200, "Right To Know Law". Copies may
be obtained from the Customer Service
Department.
PLEASE NOTICE
If the product has been in contact with
potentially harmful chemicals or gases, it should
be thoroughly decontaminated prior to return to
Ametek Gulton-Statham.
Upon evaluation, a quotation indicating the
repairs required and applicable charges will be
forwarded to the customer.
Non-warranty
repair work will not be initiated until the
customer issues authorization to proceed.
Charges for repairs, not covered under
warranty, will be quoted from the factory.
Warranty repairs will be performed at no charge
and without customer authorization.
26
PA/PG3000 Installation Manual
TRANSMITTER HAZARDOUS CHEMICAL DISCLOSURE
“Right To Know Law” OSHA Standard (28CFR1910.1200)
Company Name
Date
Address
Phone
RMA #
Signature
Serial Number:
Model Number:
□
□
Has not been exposed to hazardous chemicals
□
□
Has not been exposed to hazardous chemicals
□
□
Has not been exposed to hazardous chemicals.
Has been exposed to hazardous chemicals and has been properly
neutralized
Chemical Name:
Neutralized With:
Serial Number:
Model Number:
Has been exposed to hazardous chemicals and has been properly
neutralized.
Chemical Name:
Neutralized With:
Serial Number:
Model Number:
Has been exposed to hazardous chemicals and has been properly
neutralized
Chemical Name:
Neutralized With:
27
PA/PG3000 Installation Manual
RETURN MATERIAL AUTHORIZATION
Shipments of returned goods may be refused unless preauthorized by
Ametek Gulton-Statham. An RMA number is obtained by calling our
Product Services Department (949) 642-2400.
Note:
Enclose form with shipment.
CALLER
Issued by:
RMA No
Date:
TECH. CONTACT
SHIPPING INFORMATION
COMPANY
UPS
AIRFREIGHT
OTHER
COMPANY (IF DIFFERENT FROM LEFT)
ADDRESS
ADDRESS
CITY
STATE
PHONE
FAX
ZIP
CITY
PURCHASE ORDER
STATE
ZIP
ATTENTION
The following material is hereby authorized to be returned:
MODEL/DESCRIPTION
S/N (s)
CUSTOMER OBSERVED MALFUNCTION
1
2
3
4
5
SERVICE CONDITIONS:
Temperature
°F to
°F,
Line pressure
VDC
Other:
ACTION REQUESTED:
1
Evaluate and repair, bill applicable charges (upon our approval) against P.O.
2
Return of loan or demo equipment. Loan Order
3
Return of Distributor stock (unused condition)
SHIP TO:
Approval:
Ametek Gulton-Statham,
1644 Whittier Ave.
Costa Mesa California 92627
Phone: (949) 642-2400
Fax: (949) 642-9490
28
Date:
PA/PG3000 Installation Manual
SECTION IX
WARRANTY
Seller warrants that the products and services
furnished hereunder will, at the time of
shipment, be free from all defects in material
and workmanship under normal use and
service, and will conform to Seller's applicable
standard published specifications for a period of
five (5) years from the original date of shipment.
Seller's sole obligation hereunder shall be
limited to, at Seller's option, either replacing or
repairing any products for which (I) written
notice of nonconformance hereunder is
received within the warranty period, and (II)
after Seller's authorization, are returned to
Seller's factory of origin, freight prepaid; and
(III) after examination are disclosed, to Seller's
satisfaction, to be nonconforming.
Any such repair or replacement shall not extend
the period within which such warranty can be
asserted. This warranty shall not apply to
products which Seller determines have, by
Buyer or another, been subjected to operating
and/or environmental conditions in excess of
the maximum values therefore in applicable
specifications or otherwise have been subjected
to misuse, neglect, improper installation, repair
alteration or damage.
This warranty may be asserted by Buyer only
and not by Buyer's customers or users of the
Buyer's products and is expressed in lieu of all
other warranties, expressed, implied, or
statutory, including any implied warranty of
fitness
for
a
particular
purpose
or
merchantability, and all other obligations or
liabilities on the Seller's part. Seller neither
assumes nor authorizes any other person to
assume for Seller any other liabilities in
connection with the sale of said products. In no
event shall Seller be liable for any special,
incidental, or consequential damages.
29
PA/PG3000 Installation Manual
SECTION X
C.
1.
NACE COMPLIANCE AND
APPROVALS
2.
NACE MR-01-75 COMPLIANCE
The NACE Standard is not a code document
and is not intended for certification of the
materials and procedures described.
This
Standard was prepared as a material
requirement for oil field equipment. The NACE
Committee, in its March 15, 1979 Atlanta
meeting, recognized the inadequacy in its
treatment of process instruments. The NACE
Standard can serve as a useful guideline in
selecting materials for hydrogen sulfide
applications.
I.
NACE
Standard
MR-01-75
(1984
Revision) per Paragraph 1.2 applies to
parts and materials exposed to sour gas
environments. As defined in Paragraph
1.3, “Fluids containing water as a liquid
and hydrogen sulfide… (which) ….may
cause sulfide stress cracking (SSC) of
susceptible materials.” The parts of the
3000 series transmitters that are normally
exposed to the process environment are
process flanges, flange adapters, isolation
diaphragm assemblies, drain/vent valves,
drain plugs, and “o” rings.
II.
Compliance of the exposed portions
(wetted parts) in relationship to the
Standard are:
A.
1.
Process Flanges and Flange Adapters
Stainless steel flanges and adapters are a
casting of 315 stainless steel and comply
with the Standard per Paragraph 3.6 and
Table 2.
Hastelloy C flanges and adapters comply
per Paragraph 4.1.5.1 and Table 3,
2.
B.
1.
D.
“O”-rings
“O”-rings are not covered by this
Standard. Teflon “O”-rings have been
provided for these types of applications in
the past with satisfactory results.
III.
Compliance of Fabrication Procedures:
A.
The Hastelloy C. diaphragms use electric
resistance welds. The heat affected zone
is extremely small and metallurgical
changes in the weld zone are minimal.
The intent of the Standard is met.
All exposed threads are cut and comply
with the Standard per Paragraph 5.5.1.1.
Bolting is non-exposed per Paragraph 1.3
and 6.3.
B.
C.
Isolation Diaphragm Assembly
Diaphragms of Hastelloy C comply per
Paragraph 4.1.5.1 and Table 3. Isolation
diaphragms of 316 SS comply per
Paragraph 3.6 and Table 2.
30
Drain/Vent Valves and Drain Plugs
Hastelloy C drain/vent valves comply per
Paragraph 4.2.5.1 and Table 3.
316 stainless steel drain/vent valves
comply per Paragraph 3.6 and Table 2.
IV.
Paragraph 1.3.1.2 defines specific areas
in which “off-the-shelf” equipment” may be
considered outside the scope of the
Standard when used on “crude oil, or two
or three phase crude, water and gas”.
Ametek Gulton-Statham has had years of
successful service in these areas.
V.
Other parts of the pressure transmitter,
such as sealed 316 stainless steel
electronics housing, circuit boards, bolts,
nuts, module housing, etc., are not
exposed components as defined in
Paragraphs 1.3.1 and 1.2 and are outside
the scope of the Standard.
VI.
Transmitters
used
in
a
closed
environment (per Paragraph 6.2.1.2) are
required to use B7M bolts, which will meet
NACE specifications.
PA/PG3000 Installation Manual
For further information, see Flammable and
Combustible Liquids Code, NFPA30-1977;
Storage and Handling of Liquified Petroleum
Gases, NFPA 58-1979; Storage and Handling
of Liquified Petroleum Gases at Utility Gas
Plants, NFPA 59-1979; and Classification of a
Class I Hazardous Locations for Electrical
Installations in Chemical Plants, NFPA
497-1975 (ANSI).
Ametek Gulton-Statham Transmitters for
Hazardous Locations
Ametek Gulton-Statham transmitters have been
approved for use in hazardous locations in USA
by Factory Mutual Research (FM); in Canada
by Canadian Standards Association (CSA) and
in Europe to ATEX certification to IEC 60079.
Hazardous locations are classified according to
the properties of the flammable vapors, gases,
dust and fibers that may be present, and the
likelihood that a combustible concentration is
present.
For protection against static electricity hazards,
see Recommended Practice on Static
Electricity, NFPA 77-1977 (ANSI).
In USA and Canada hazardous locations have
been divided into class, division and group as
described below.
Class I, Division II,
Groups A, B, C & D
Class I, Division II, locations are those in which
ignitable concentrations of flammable gases or
vapors may exist only under abnormal
operating conditions, failure of ventilating
equipment or areas adjacent to Class I, Division
I, locations where vapors might occasionally
accumulate.
Class I, Division 1, equipment
may be used for this service.
Class I, Division I,
Groups A, B, C & D
Class I, Division I, locations are those in which
ignitable concentrations of flammable gases or
vapors may exist under normal operating
conditions. Electrical equipment for this class
of
service
may
be
“explosion-proof”,
“intrinsically safe”, “purged”, or otherwise
protected to meet the intent of Article 500 and
501 of the National Electrical Code.
Class II, Division I,
Groups E, F & G
Class II, Division I, locations are those areas
where combustible dust is normally present in
the atmosphere in such quantities that would
support ignition or explosion. Equipment listed
as suitable for Class II locations is “dustignition-proof” or otherwise designed and
installed to meet the intent of Article 500
through 503 of the national Electrical Code
(NEC).
“Explosion-proof” refers to the ability of a device
to withstand an internal explosion of a specified
gas or vapor and prevent the ignition of external
gages or vapors when sparking, flashing or
explosions occur within the enclosure.
In
addition, the external temperature of the device
will not ignite the surrounding atmosphere.
“Intrinsically safe” equipment and wiring are
incapable of releasing sufficient electrical or
thermal energy to cause ignition of specified
gases or vapors in their most ignitable
concentrations.
“Dust-ignition-proof” as used in the preceding
paragraph means that the enclosure of the
device will exclude ignitable quantities of the
dust that may affect the performance or rating,
or where installed per code, will not allow
sparks, arcs or heat to ignite materials external
to the enclosure.
“Purged” systems are designed to provide a
continuous source of clean air or inert gas
under a positive pressure with effective
safeguards against failure, thus providing a
non-hazardous atmosphere.
Equipment suitable for Class I locations is not
necessarily suitable for Class II or III locations
unless specifically identified as such.
31
PA/PG3000 Installation Manual
Class II, Division II,
Groups E, F & G
Class II, Division II, locations are areas in which
combustible dust will not normally be present in
sufficient quantities to support combustion, or
infrequently present in combustible quantities
only by the failure of electrical equipment or
apparatus. Class II, Division I, equipment may
be used for this service.
In addition to meeting the requirements for
hazardous (classified) locations as defined by
the National Electrical Code (NEC), the 3000
series transmitters meet the requirements of the
National Electrical Manufacturers Association
(NEMA) for Classes 3, 4, 6, 7 & 9 as defined
below:
NEMA 3
NEMA 3 enclosures are dust tight, rain tight and
sleet (ice) resistant suitable for outdoor service.
Class III, Divisions I & II
Class III, Divisions I and II, locations are
hazardous due to presence of combustible
fibers or flyings which are not normally present
in the atmosphere in quantities that would
support combustion.
NEMA 4
NEMA 4 enclosures are watertight, dust tight
and designed to prevent seepage from a direct
stream of water.
The preceding classification definitions have
been taken from the 1981 edition of the
National Electrical Code (NEC). Please consult
this reference for complete information
regarding the selection and installation of
devices for hazardous location service.
NEMA 6
NEMA 6 enclosures are watertight, dust tight,
submersible and ice resistant suitable for use in
either indoor or outdoor applications.
It is the user’s responsibility to select equipment
suitable for the hazardous (classified) location
and install such equipment in accordance with
published standards and approved codes.
NEMA 7
NEMA 7 enclosures are designed for Class
hazardous (classified) locations. See NEC
Article 502 for complete information.
Various equipment approved for hazardous
(classified) locations may be combined in a
system and approved as a system by arranging
for site inspection by the applicable agency.
NEMA 9
NEMA 9 enclosures are designed for Class II
hazardous (classified locations.
See NEC
Article 502 for complete information.
32
PA/PG3000 Installation Manual
EXPLOSION PROOF
X - Approved
Class I, Division I
INTRINSICALLY SAFE
Class I, Div II
Class I, Division I
GROUPS
A
B
C
D
E
F
G
A
B
C
D
PA/PG3000
X
X
X
X
X
X
X
X
X
X
X
MA134, 5, 6
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
C100/101
TP114/131
X
X
X
X
X
X
X
FIGURE 10.1
PRODUCT APPROVAL - NORTH AMERICAN
33
PA/PG3000 Installation Manual
SECTION XII
INTRISICALLY SAFE SYSTEMS
Scope
This document is intended as a guide to the
user for the proper installation of Ametek
Gulton-Statham transmitters in intrinsically safe
loop configurations.
The configurations
contained in the document are to be utilized
with approved barriers only. Certified barriers
are listed in the list of Certified Electrical
Equipment.
Hazardous Area Requirements
Wiring connected to the hazardous area
terminals must be separated from nonintrinsically safe wiring.
All wiring has distributed inductance and
capacitance. The maximum permitted cable
parameters for the particular barrier must not be
exceeded. If the capacitance and inductance of
the cable used are not known, values of to
PF/FT, and 0.2 uH/FT, may be used as
conservative criteria for cable.
Factory Mutual Barrier Application
Rules & Diagram
Installation
Different intrinsically safe systems shall not be
run in the same multi-conductor cable.
Different intrinsically safe circuits of the same
intrinsically safe system shall not be run in the
same cable, unless at least 0.25 mm thickness
insulation is used on each conductor, or unless
no hazard results from interconnection., If in
doubt contact the local inspection authority.
The barrier must be located in a non-hazardous
area, and be mounted in an appropriate
enclosure or other protected space.
The barrier must be grounded, via two
independent connections, to a ground electrode
in the non-hazardous area.
Grounding
practices should conform to NEC Article 250.
The resistance from the barrier to the ground
electrode must not exceed one (1) ohm.
Hazardous area equipment shall not have
exposed any surfaces that operate at a
temperature in excess of ignition temperate of
the specific gas, vapor, or dust. Refer to
NFPA 325 for ignition listings.
Barrier installation must be in accordance with
the Ametek Gulton-Statham Intrinsically Safe
loop diagram shown on Drawing No. 64706
(See Figure 11.1).
Safe Area Requirements
Equipment connected to the non-hazardous
area terminals must not be supplied from, nor
contain, a source of potential with respect to
ground under normal or fault conditions
exceeding 250 V RMS.
Mains powered equipment connected to the
non-hazardous area terminals must be isolated
from the mains supply by a double wound
transformer, unless the applicable electrical
code permits multiple grounding of the neutral
lead.
34
PA/PG3000 Installation Manual
35
PA/PG3000 Installation Manual
Canadian Standards Association
Barrier Application Rules & Diagram
Barrier Application Rules
Hazardous Area Requirements
Installation
Wiring connected to the hazardous area
terminals must be separated from nonintrinsically safe wiring
The barrier must be located in a non-hazardous
(safe) area, and be mounted in an appropriate
enclosure or other protected space.
All wiring has distributed inductance and
capacitance. The maximum permitted cable
parameters for the particular barrier must not be
exceeded. If the capacitance and inductance of
the cable used are not known, values of 60
PF/FT, and 0.1 UH/FT, may be used as a
conservative criteria for cable.
The barrier must be grounded, via two
independent connections, to a ground electrode
in the non-hazardous area.
Grounding
practices should conform to C22.1-1k975,
Section 10. The resistance from the barrier to
the ground electrode MUST NOT EXCEED
ONE (1) OHM.
Different intrinsically safe systems shall not be
run in the same multi-conductor cable.
Different intrinsically safe circuits of the same
intrinsically safe system shall not be run in the
same cable, unless at least 0,15 mm thickness
insulation is used on each conductor, or unless
no hazard results from interconnection. If in
doubt, contact the local inspection authority.
Barrier installation must be in accordance with
Ametek Gulton-Statham intrinsically safe loop
diagrams shown on Drawing No. 64915 (See
Figure 11.2).
Safe Area Requirements
Equipment connected to the non-hazardous
area terminals must not be supplied from, nor
contain, a source of potential with respect to
ground under normal or fault conditions
exceeding 250 V RMS.
Hazardous area equipment shall not have
exposed any surface that operates at a
temperature in excess of the ignition
temperature of the specific gas, vapor, or dust.
Refer to C22.2 No. 30-1970 for ignition listings.
Mains powered equipment connected to the
non-hazardous area terminals must be isolated
from the mains power supply by a double
wound transformer, unless the applicable
electrical code permits multiple grounding of the
neutral lead.
36
PA/PG3000 Installation Manual
37
PA/PG3000 Installation Manual
ATEX Barrier Application
Rules and Diagram
Barrier Application Rules
Installation
Hazardous Area Requirements
The barrier must be located in a non-hazardous
(safe) area, and be mounted in an appropriate
enclosure or other protected space.
Wiring connected to the hazardous area
terminals must be separated from nonintrinsically safe wiring
The barrier must be grounded, via two
independent connections, to a ground electrode
in the non-hazardous area.
Grounding
practices should conform to ATEX.
The
resistance from the barrier to the ground
electrode MUST NOT EXCEED ONE (1) OHM.
All wiring has distributed inductance and
capacitance. The maximum permitted cable
parameters for the particular barrier must not be
exceeded. If the capacitance and inductance of
the cable used are not known, values of 60
PF/FT, and 0.1 UH/FT, may be used as a
conservative criteria for cable.
Barrier installation must be in accordance with
Ametek Gulton-Statham intrinsically safe loop
diagrams shown on Drawing No. 40716 (See
Figure 11.3).
Different intrinsically safe systems shall not be
run in the same multi-conductor cable.
Different intrinsically safe circuits of the same
intrinsically safe system shall not be run in the
same cable, unless at least 0,15 mm thickness
insulation is used on each conductor, or unless
no hazard results from interconnection. If in
doubt, contact the local inspection authority.
Safe Area Requirements
Equipment connected to the non-hazardous
area terminals must not be supplied from, nor
contain, a source of potential with respect to
ground under normal or fault conditions
exceeding 250 V RMS.
Hazardous area equipment shall not have
exposed any surface that operates at a
temperature in excess of the ignition
temperature of the specific gas, vapor, or
dust. Refer to ATEX for ignition listings.
Mains powered equipment connected to the
non-hazardous area terminals must be isolated
from the mains power supply by a double
wound transformer, unless the applicable
electrical code permits multiple grounding of the
neutral lead.
38
PA/PG3000 Installation Manual
39
PA/PG3000 Installation Manual
INSTRUMENT NOTES
40