. Bailey, p9t-6 PRODUCT INSTRUCTIONS MINI-LINE* 500 HAND/AUTOMATIC STATION WITH ADJUSTABLE TIE-BACK RES. Lae PAT FE Co BAILEY METER COMPANY e WICKLIFFE, OHIO 44092PO1-6 H/A Station with Adjustable Te-Back Page 3 ee nm INDEX Page INSTALLATION 4 Pre-Service Adjustment Check 4 ‘Mounting H/A Station on Panel 4 Installing Connecting Tubing 4 Cleaning Seale Cover 4 OPERATION 6 ‘transfer from AUTO to HAND 6 ‘Transfer from HAND to AUTO 6 ROUTINE MAINTENANCE 7 fo CORRECTIVE MAINTENANCE 8 Vertical Gage Unt Adjustment 8 Hand Relay Disassembly 8 Hand Relay Adjustment ° Front Plate Disassembly 9 Shut-Off Vaive Disassembly 10 Valve Operator Lever and Shaft Disassembly 10 Drive Shaft Disassembly (Control Knob to Relay) 10 SCHEMATIC OPERATION 10 ‘Tymeal Application of Tie-Back Station 10 Hand Relay 1 REPLACEMENT PARTS 12 Spare Parts Kits 12 Ordering Individual Parts 12 EXPLANATION OF NOMENCLATURE 2pol 6 Page 4 H/A Station with Adjustable Tie Back ‘Sima eT eee ats sua Ne Se Bina i Sel ad rege les ae ) gS tg ¢ | 2 ome anger TBs I% A Ut ca | Li y 4 it FIGURE 1 Removing Vertical Gage Umt FIGURE 2. Vertical Gaye Umt from HA Station Zero Adjustinent Screw INSTALLATION , Service Adjustment Check IMPORTANT Before place H,A Station in service, check adjustment of vertical gage units as outlined below For convemence, perform this check at a test be rch before the H, A Station as installed in the panel 1 Position HA Station at angle at which st will be mounted inservice Apply pressure cor responding to 10% scale to H,A Station input connection H pointer reads correctly, proceed to step 4 2 It pointer does not read correctly, 16 nuove verucal gage unt trom HA Stationas out luned in Figure 1 3 Remove snapout cover (Figure 2) and turn zero adjustment screw unul pointer reads correctly Reinstall cover 4 Apply pressure to gage unit correspond ing to 90 and 50” scale Tt pointer readings are correct, proceed to step 5 If readings are hneorrect, refer to "Vertical Gage Umt Adjust ment’, page 8 ‘Mounting H_A Station on Panel Hand, Automatic Staons are designed tor plug in mounting in a panel mounted enclosure (Figure 3) Install enclosure as follows 5 Make panel cutout an accordance with Figure 3 6 Loosen mounting screws on tront plate which secure H/A Station to enclosure and re move station 7 Slide enclosure thru cutout {rom fi ont of panel 8 Place mounting clips (un bag tied to en closure) an posation on enclosure Tighle 1 clips securely against pa vel 9 Shde H.A Station inte enclosure and se cure with mounting screws in rot plate Installing Connecting Tubing 10 Connect externa tubing to manitold con, nections on rear of enclosure (Figure 3) Con nection posts are 1 418 NPT female Use 1,4 aneh OD copper alum inum, or plastic tubing, Cleaning Seale Cover 11 Removeprotectise tape: Clean cover with toothpaste or "Plastar , plas tie cover cleaner and polish (obtainable trom Barley Meter Company 1010 ounce jar specity Part Number 199274 1) CAUTION Do ict use a sohkeat which will scratch cover tinishor react with plastic coverFIGURE 3 - H/A Station Mounting DimensionsH/A Station with Adjustable Tie-Back OPERATION Befure transfer, conditions within the con trol system must be set so there 1s little or no variation 1 control pressure to the power unit as transfer takes place Procedures for trans terring from AUTO to HAND and from HAND te AUTO are outlined below. Refer to Figures, Fand 5. ‘Transfer from AUTO to HAND 1 Will HAND control knob, set transfer pressure (gage C) equal to control pressure (gage D) Caae & AUTO POSITION 2 Turn transfer switch to HAND ‘Transter from HAND to AUTO 1. With TIE BACK control knob, slowly set contral pressure (gage D) equal to transfer pres: sure (gage C). If relay pressure (gage A) 18 not ‘equal to hie back pressure (gage B). control sys tem set point 1s not being held. To correct, ad just set point, or, with HAND control knoh, ad Just control pressure (gage D) until gage A equals B when gage C equals gage D 2. Turn transfer switch to AUTO preceone eater FeeSoare MAE ate HAND POSITION FIGURE 5 Schematic of H/A StationH/A Station wath Adjustable Tie Back Page 7 ROUTINE MAINTENANCE 1. Maintain a clean air supply, free of ol _—_polish (obtainable from Bailey Meter Company, or moisture. 1n10 ounce jar specify Part No. 199274 1), ‘Do not use a solvent which will scratch cover 2. Check falter in supply anlet port at mani- __fimsh or react wath plastze cover. fold shortly after mstallation. If iter (Items 3b and 3c, Figure 11) must be replaced, remove wire mesh dise, felt pad, and second wire mesh dsc. Install new filter, making certan wire mesh disc 18 inserted in inlet port before insert- ing felt pad. 3. Periodically depress orifice clean out plunger (Figure 6) on rear of hand relay to in Sure that the orifice remains open and clean. PPL Ne ‘CORRELTONS CAUTION: ‘This operation should only be per formed when relay 1s beng bench tested since depressing the plunger while relay 18 in service may disrupt the process. GeaNouT GR ECE AND PLUNGER’ ReLar BDGUSTVENT ScREW 4. Whenever necessary, clean plastic scale cover as follows: a. Remove (and replace) scale cover as shown an Figure 7 b Clean cover with a soft cloth which will not seratch the plastic surface. Use tooth- ee eee paste or "Plastar", plastic cover cleaner and ee ees > REN VPP = = | se 3 R Ac tee 3 TURN GREW NFA jor oH Tesi 7 Erle east cen teemove soe (FO WiPetNe Ger seer IMONEL ee winrar “OVER SCRE an BOTT AF SCALE coves wer a4" © seweaees 1? NSTALL 3-ALE COVER esas Sp —_ — —— aye Tere "PELE IN deoaee MORSE pe RENNER wen SAS ge mews an " “ee mee ene wane FIGURE 7 - Removing and Replacing Vertical Gage Umt Scale Cover91-6 Page 8 H/A Station with Adjustable Tre Back WnMuM STOR UL Max wun scace RGHT 7 LEFT = ‘STOP, = ae Fontes “]l”Sohnren snapour \ ia, | ange, svara | oy ZERO. - 5 Stousrmen Z ete Senews i Ce 0uRooN TUBE Eo ca Eno sT0°S , Ardea S*CTON BB | Spee EOP ice t axoxasi ; BACKLASH SPR NG SPRNG / \ wert aon SECT On AA Sonne POWTER FIGURE 8 - Vertical Gage Umt Adjustments CORRECTIVE MAINTENANCE Vertical Gage Unst Adjustment It operational taults occur wmten are traced to the vertical gage units, make the following adjustment checks" 1 Remove gage unit trom H, A Station as shown in Figure 1 Pry off snapout cover and remove side cover for access to gage umt ad justments (see Figure 2) 2 Apply pressure to Bourdon t abe and check block assembly tor leakage with a 3oapsuds 50 luuion If a teak 1s found, replace entire gage umt The damaged umt may be returnedto the lactory for repair 3 Check ail Links tosee that they are prop erly connected and that they move freely with Bourdon tube movement 4 Make certain that mdicating pomter does hot rab agaist side or face 01 scale. If neces sary, bend pointer shghtly until it clears scale 5. Check pointer adjustment as outlined below a Apply pressure to gage equivalent to Lirst mayor seale division above O% scale If pointer does not read correctly, turn zero ad justment screw (Figure 8) untal desired reading 3s obtained » Apply pressure to gage equivalent to first major scale division below 100% seale If pointer does not read correctly, turn range ad justment screw (Figure 8) until desired 1 eadin 1s obtained ¢ Repeat steps Sa and 5b until pointer reads correctly at both seale divisions 4 Apply pressure to gage equivalent to midscale division It pointer does not read cor- rectly, but does read correctly in steps 5a and 5b above. alter the shape of U Link at ree end ot Bourdon tube as follows 1) If midscale pomt- er reading 1s low, spread lnk shghtly, or 2) I mudseale pointer reading is hich, close lnk shghtly 6. Repeat steps 5a thru 54 until pomter reads correctly over tull scale 7 Apply 2 psig to Bourdon tube (puter Wall sead slightly below manim.m scale mark) Loosen mimimum stop screws (Fiyure 8) and position minimum stop nest to Bourdor tube end stop, tighten screws 8 Apply pressure to Bourdon tube cor respond: ig to maximum scale value plus 0 25 psig (pointer will read slightly above niaximuin, scale mark) Loosen matimum stop screws aud position maxsmum stopnest to Bourdon tube end stop, lighten screws 9 To return gage umt to service reverse the order of the operations outlined an step 1 Hand Relay Disassembly To disassemble the Hand Relay (Part No 5821995 D) for clea ng or replacement ol parts, proceed as tollows 1 Reler to Figue 11 Discoaneet tubing and remove tw. screns (26) heldiy. axe sup ort (13) (9 supuort bracket assembly (30)91-6 Page 9 H/A Station wath Adjustable Tie-Back Soo eee eee, 2, Remove two fillister head screws (39) holding manifold to Relay and slide manifold and support bracket rearward. 3. Remove two socket head screws (38) hold ing Relay to support bracket (30) and remove Relay. 4, Refer to Figure 12. Unscrew valve cap (7) and remove valve stem (11), inlet valve seat (13), and valve seat spring (15). CAUTION: Do not disturb setting of relay ad~ yustment serew (Figure 6) at center of valve cap, This setting 18 factory set and should not be disturbed unless control bellows has been removed or replaced (see "Hand Relay Adjustment"). 5. Unscrew orifice clean-out assembly (4) and orifice (14). 6, Relieve spring compression by rotating. center adjustment gear (27) counterclockwise until at turns easily. 7. Remove four nuts (al corners of valve housing face) and screws securing spring hous ing (28) to valve housing (9) and separate hous~ ings. 8. Pull control bellows assembly (16) from valve housing (9). Control bellows assembly 13, held by exhaust valve diaphragm which snaps anto place around valve seat. 9. If desired, unscrew loading spring as sembly (19) from adjustment shaft (left-hand thread). 10. To reassemble, reverse above proce- dure, Sbserving the following precautions: a, When replacing control bellows as sembly (16), make certain exhaust valve dia~ phragm (29) 18 properly snapped into place around exhaust valve seat. b. When replacing orifice clean-cut as- sembly (4), make certain that clean-out wire 18 not bent and passes cleanly thru the orifice. c, Make certain that all O-rings are undamaged and properly installed. Apply 1u- bricant to O-rings when reassembling relay. Hand Relay Adjustment 1. Connect output pressure line of Relay, thru a petcock, to a volume chamber equipped with a suitable pressure gage (0-30 psig) for indicating chamber pressure. Volume chamber may be any pressure tght container with vol ‘ume of about 300 cubie inches. 2, Qpen petcock and adjust H/A. Station control knob to obtain 3 psig pressure in vol ume chamber. 3, Close petcock and adjust control knob to obtain 27 psig (for 3-27 range) or 15 psig (for 3-15 range) output pressure from Relay (read ‘output pressure on H/A Station gage). 4, Open petcock and note time rate of pres sure increase in volume chamber. 8. Close petcock and adjust control knob to obtain 3 psig output pressure from Relay. 6. Open petcock and note time rate of pre: sure decrease 1n volume chamber. 7. If mlet valve seat 18 properly aqjustea, the tame rate of pressure increase as noted in step 4 wall be equal to the time rate of pressure decrease as noted in step 6. If these rates are not equal (or af the control bellows or nozzle bellows has been replaced), it will be necessary to make the following adjustment a. If time rate of pressure increase 18 greater than the rate of pressure decrease. turn adjustment screw (Figure 6) counterclockwise. b, Hf time rate of pressure decrease 15 greater than the rate of pressure increase, turn adjustment screw clockwise. NOTE. By turning the relay adjustment screw {Figure 6) on the rear of the H/A Station, the anlet valve seat position can be changed wath re spect to the neutral position af the exhaust valve seat, an effect, controlling the relative openings of the alet valve and exhaust valve for a given position of the control bellows. Front Plate Disassembly 1, Remove vertical gage units as shown in Fagure 1. 2, Refer to Figure 11, Remove HAND con- trol knob (22) by draving out steel lockpin (28) and pulling knob off shaft Remave tie-back con trol knob by inserting a small screw driver in slot behind knob and pushing outward (from front plate) on spring holding knob on shaft.ee Page 10 SSS ‘Then slide knob oft shaft. AUTO HAND trans fer switch need not be removed Remove two screws (15) at rear of front plate (17) which secures plate to H/A Station frame. 4 To reassemble, reverse the above pro cedure, observing the following precautions. ‘When placing front plate (17) on H/A Station feame, fat pans at top and bottom of plate into corresponding slots in frame, and algn transfer swatch and valve operator lever (22) so that transfer switch pin fits into hole at top of lever (22). b. When replacing control knobs, shde knobs on respective shafts. Replace locispin in HAND control knob shaft. Shut Off Valve Disassembly 1. Refer to Figure 11. Disconnect tubing at vertical gage units and remove screws (39) at Relavs. 2. Remove four screws (12) ard (14) (two at front end of plate and two at rear end neat to nameplate) which secure shut-off valve mount ang plate (top of H/A Station) to frame. Do not disturb serews holding valves to plate 3 Set transfer switch (23) (or valve oper ator lever (22) af front plate has been removed) an vertzeal position between AUTO and HAND. 4, Shde shut off valve assembly (10) (plate, valves, and tubing) to rear to disengage valve stems from valve operaior shaft. When disen gaged, assembly can be lifted trom H/A Station. SCHEMATIC Tymeal Application of Tie Back Station Figure 9 shows a typical control application A readwsnng signal 1s applied to the 1 bellows of a Proportional Plus Integral Controller The output pressure 1s combined with the primary signal, in a Proportional Controller, and applied thru the HA Station (when in AUTO) to the power umt. H/A Station with Adjustable Tre Back 8. To disassemble individual shut off valve, unscrew plug (10e) at bottom of valve and re move sprimg (10d), stem (10b), and chaphragm (101). To reassemble, reverse the above pro cedure. Valve stems must be in alignment to engage valve operator shaft. ‘Valve Operator Lever and Shaft Disassembly 1. Remove vertical gage umits (shown in Figure 1), front plate (see above), and shut-off valve assembly (see above). 2 Refer to Figure 11. Remove hex nut (25) at front end of shaft and slide valve operator lever off shaft. 3. Unscrew hearing ‘9) which supports end of shatt. 4, Slide shaft to rear until front end clears supporting bearing. Remove shaft irom frame 5. To reassemble. reverse the above procedure. Drive Shaft Disassembly (Control Knob to Relay) 1, Remove vertical gage units (as shown an Figure 1) and front plate (see above) 2. Refer to Figure 11. Remove retaining ring (34) at rear end of shaft. 3. Bach off cone point set screw (32) n perimeter of gear (33) until gear 1s free of shalt. 4, Shde shafl out thru front of umt and remove gear 5 To reassemble, reverse the above procedure. OPERATION When operating in MANUAL. this pressure 1s cul off and the power umt 18 controlled by the Hand Relay. Tie-back pressure 18 then ap plied from connection 3 to the Proportional Pius Integral Controller Adjustment of the tre back knob then varies C chamber pressure in the Pro portional Plus Integral Controller. in turn vary ang the output pressure of the Proportional Con troller. Bumpless transfer from manual to auto matie may then be accomplished by adjustingH/A Station with Adjustable Tic Pal 6 Pane 11 \ etary = f 2PM detect eee T FIGURE 9 Typical Application of H/A Station the te back relay until gage A pressure equals gage B pressure. Hand Relay ‘Hand and te back pressures are established by identical Hand Relays (Figure 10). Compres- siun of the Iuading sping 1f opposed by pres Sure in the control bellows so that forces due to spring compression and output pressure are always equal when the umt 1s balanced. Pres Sure in the control bellows 1s regulated by the inlet exhaust valve assembly. At balance, the anlet valve 18 held closed by the difference be~ tween supply pressure and :ontrol bellows (out- put) pressure. ‘Trming the control knob (HAND or TIE BACK) sn the "increase" direction compress- es the loading spring. compressing the con trol bellows, Ulusuig the exhaust valve, upen ing the inlet valve, and admutting supply air to the control bellows. Control bellows pressure increases until bellows expansion 18 sufficient to restore the anlet exhaust mechamsm to its “original position (inlet valve closed, exhaust valve floating). Output pressure 1s then propor- tional to the increased loading spring compres ‘Turing the control knob in the "decrease" durection reverses the operation described above. sums mess Fh) Seen on roe FER CONTRO. BELLOWS Lomo Na SR NG NET Lve foures | eS ee ExXHA IST VALVE cum mesure sou (arose RE FIGURE 10 Schematic of Hand RelayH/A Station with Adjustable Tie Back —) REPLACEMENT PARTS there may be individual differences in specific units because of ‘The Spare Parts Kits shown in Figure 11, 12, and 13 should be carried in stock. Specify the a. design changes made since the print Spare Parts Kit part number to order a com- ang of this Instruction Section, or plete kit b_ special design of the Tie Back H/A Ordering Individual Parts Station to make it suitable for special applica ton, sagures 11, 12, and 18 are Parts Drawings, of the Tie-Back H/A Station. Normally, these Therefore, when ordering parts, assure the drawings apply to the umt furmshed. However, receipt of correct replacements by specifying the H/A Station Module Part Number. EXPLANATION OF NOMENCLATURE [“W/a STATION VASTATION | RANGE LEFT GAGE SCALE LEGEND oe PART NO NOMENCLATURE* (PSIG) LEFT INDICATOR | RIGHT INDICATOR (ss21a65 5 ‘Ag02D10 327 RELAY ‘TIE-BACK |___S32186s 6 30110 315 RELAY TIE BACK *NOMENCLATURE appears only on the H/A Station Specification Sheet ancluded in Instruction Books furnished on system or contract jobs. A "5" in the third position of the Nomenclature indieates that the H/A Station module 1s complete with enclosure, Part No, 5322407 2. An "X" in any Nomenclature position indicates that the instrument 38 special.SETONAA —SECTON BE Lert a da—RouT dy Gace 9 *Y Gace { = FIGURE 11 Bai Sea TRE Parts Drawing P91-12, Hand/Automatic Station wit Adjustable Tie BackH/A Station with Adjustable Tie Back POS TON OF TEM 24 FOR PT NO 532 995 2 POSIT ON OF TEM 24 SECT ON B 8 PTNO 532 995 (ENLARGED) ese] PARI no TAME res] Parr No TAME 1 [coor tant | speciry no ow capenwuen | [as | ssvees21 | conenot auiuows Ase ‘ORDERING PARTS 1) | Settee 4s | Gomme wakes’ 2 |ssues2 | o tung camer 1 | Steer? f° | Spamve Seppo B fegitie t | RNG CAET 1 | Siete 1 | Loabie come & Jiosae 14 | Preupscatw 4 Rego a | ieeris'3) | ReTAMING RING 6 fisuae 7! | olune cashes b2 | joueeter | abgustMenT scRew 4 [idee | | vate ca B | Gast | Pane uousne 5 saws i | VALLE hovawe B | Novum | | Puparr mrp ix Wast 4 ReQD ao }esitias 20 | 6*uve exseer bs | Ssiecis 1 | Absusraenr starr i [sateen t | Vatre sre 2 | soto) 2 | AosustmenT GEAR ie |saitaaa 22 | O"RING Gasher mm |ésieins | Cone preur sew i [soar 1 | Vatve stat assy & | Seis’: | Exxacor vauve iapHraca q 1 | ORNCE AseemoLY 3 | Sted 1 | biasumacw eta is [ssicees 1 | Vatve'star spring a iota Mp MEX NUT 1 RD S¥OR MAND RELAY PT NO 5321004 2 POTATE ITEM (24) 1400 TO POSITION SHOWN BY DASHED LINES SPARE PARTS AIT NO_ 298127 1 INCLUDES PENS 4 6 19 12 15 17 19 21 a FIGURE 12 Parts Drawing, P91 7, Hand Relay. Part No 5321995Pol 6 Page 15 THEM [PART NO) ane 2 | SPEARS” | Matona'stoe” INCLUDES TrEME 5A 50, sa | seeyore | Bounbon Tube « stock assy 58 | See Nore | Fomnrny See race a | seenore | Scar atey + | fleas | Pawabstescr «Rego & | toca Si uk WASH RGD. 5 | Mee | wasnsey 2 mao. H | Susset | cover ouire aay, | sasare PAN nb EXT SEMS. 8 REQD % | Seenore | cover uo | aa EAWMD ExT seus 4.nE0D | Sides | stkurwnmow i | Seewore | case assy 18 | Suess | Taina abapren assy nego ron ew Fon Oren instmoMEN's sce APPUI EADLE PARTS DRAWING | PARE PARTE ENO aeeoee | [PORTER TAGE OMT RANGE TENT | WeNs | ee come ear Dovnee [327 0Rs 25 PAG Sersan 1 [ sass a | wits 2 : 7 SINOLE | 3 710R8 75 PIO sist [ soasair a | sams 1 SINGLE [9 ISOR TIPE PMNODEL Do | sorFvory [ sions | Saas DOUBLE | 3 "TOR TYPE PM MODET nee | Suse | waaay | Somes? SINGLE | TYPE PM wopELvowtyy | corn 1 | soiree | wai05 “RANGE PER ENGINEERING DATA GEE NOTED ~~ NOTE. SPECIFY TYPE MODEL SERIAL NUMBER AND RANGE OF INSTRUMENT ALso Fe ireas0) sPecirY WAPTHER Lert RIGHT “OR BOTH LEFT AND RIGHT ARE DESIRED x CTEM 6) SPECIEY LEGEND AND RANGE FIGURES FIGURE 13 - Parts Drawing P12 5, Vertical Gage Unit,BAILEY METER COMPANY DISTRICT OFFICES, U.S.A. CALIFORN A — NEW YORK San Franeico ffalo Code #15 Phone 989 6140 Code 716 Phone 839 3662 Los Angeles New York ‘Code 213 Phone 283 (187 ‘Code 212 Phone 986 8770 Schenectad} Denser enieds Code 518 Phone 374 7991 Code 303, Phone 757 5408 NEW JERSEY ast Orange a GEORGIA Code 201 Phone 674 6830 Manta Code 404 Phone 178 4348 a NORTH CAROLINA hartotte ce ILLINOIS: Code 704 Phone 334 9161 yeago Code 312 Phone 427 7324 - onto nena LOUISIANA Code 513 Phone 281 0132 New Orleans aa ee Caie16 Phone 851 8600 MAS HUSETTS Boston Phinepee PENNSYLVANIA Code 617 Phone 426 0465 laps oe MICHIGAN P ttsburgh Pa aa Ph 357 0440 Code 412 Phone 921 6356 ‘oe none TEXAS ‘MINNESOTA Dallas St Paul ‘Cole 214 Phone 363 6295 Code 612 Phone 645 7757 ae MISSOUR Code 713 Phone 774 9605 Kansas Cr Code 81 Phone 361 4902 ae WASHINGTON St Lous ‘Code 706 Phone 324 9300, Code 314 Phone 962 5532 WISCONSIN M iwaukee Codes Poone 461 1310 BAILEY METER COMPANY LTD., CANADA ALBERTA ONTARIO. Edmonton was Code 403 Phone 488 3436 Code 61% Phone 722 1979 H COLUMBIA Toronto ‘Vancouver ae Code 416 Phone 444 8488 ‘Code 604 Phone 731 3709 ‘QUEBEC MANITOBA Montreal Winripeg Code 514 Phone 489 9881 Code Sos Phone 943 1481 NOVA SCOTIA Hoatiax Code 902 Phone 486 0874 e Bailey Meter Company + — Wickliffe, Ohio 44092 a I ey In Canada: Bailey Meter Company Limited, Montreal, Canada ®