controlair 595XP Installation, Operation And Maintenance Instructions

Explosion Proof I/P Transducer

Type 595XP

5.16
[131.0]

.40
[10.0]

1/4 NPT SUPPLY PORT

Use this coding system to order:

Ø2.90
[73.7]

3.19
[81.0]

.65
[16.4]

UNIT WITH FLOW
BOOSTER (P)

2.25
[57.1]

.59
[15.0]

1.27
[32.1]

UNIT WITHOUT FLOW
BOOSTER (N)

(Drawing downloads available at http://www.controlair.com)

Installation, Operation and
Maintenance Instructions

1/2 NPT CONDUIT PORT
M20 X 1.5-6H "K" OPTION
1/2 NPT "K2" OPTION

1/8 NPT GAUGE PORT

0.43
[11.0]

4.80
[121.8]

0.94
[23.9]

1.89
[47.9]

3.19
[81.0]

4.23
[107.4]

1.34
[33.9]

1/2 NPT "K2" OPTION

0.43
[11.0]

1.42
[36.0]

.29 THRU

MOUNTING

1/2 NPT CONDUIT PORT

M20 X 1.5-6H "K" OPTION

1/2 NPT CONDUIT PORT
M20 X 1.5-6H "K" OPTION
1/2 NPT "K2" OPTION

.30
[7.7]

1/4 NPT OUTPUT PORT

Contents

Section Description Page

1.0 Installation & Approvals 3

8 Columbia Drive, Amherst, New Hampshire 03031 USA

2.0 Operation 7

Phone: [phone]  Fax: [phone]

3.0 Maintenance 7

[e-mail]  www.controlair.com

4.0 Troubleshooting 8

5.0 Warranty 8

2.89
[73.3]

1/16[1.6] SUPPLY PORT

3.19
[81.0]

2.90
[73.7]

1.42
[36.1]

MANIFOLD WITHOUT
FLOW BOOSTER (M)

0.34
[8.5]

1.06
[27.0]

1/16[1.6] OUTPUT PORT

1.00
[25.4]

.33
[8.4]

1.27
[32.1]

0.41
[10.5]

.48

[12.1]

1/4 NPT SUPPLY PORT

* ATEX Ex ia INTRINSICALLY SAFE, Ex nL and Ex nAnL APPROVAL ONLY
**R OPTION MUST BE COMBINED WITH “K” OR “K2” OPTION

441-622-099 Type 595XP

8 Columbia Drive, Amherst, New Hampshire 03031 USA

Phone: [phone]  Fax: [phone]

[e-mail] 

www.controlair.com

DANGER, WARNING, CAUTION and NOTE statements

DANGER

WARNING

CAUTION

Refers to conditions or hazards which could result in serious personal injury or death.

Refers to conditions or hazards which could result in personal injury.

Refers to conditions or hazards which could result in equipment or property damage.

Alerts you to facts or special instructions.

NOTE

ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL.

SPECIFICATIONS

Functional Specifications P Connection (with Flow Booster) M & N Connection (without Flow Booster)

INPUT 4-20 MA

Outputs 3-15 psig 0.20-1.0 BAR

Air Consumption

Supply Pressure

Note: Supply pressure must be a minimum of

5 psig (0.3 BAR) above maximum output

Flow Capacity 2.4 scfm (67.92 Nl/min) max. Same as Air Consumption
Temperature Limits -400F to 1580F (-400C to 700C) *Low Temperature (L) Option: -670F to 1580F (-550C to 700C)
Relative Humidity 75% average - 95% short time non-condensing
Impedance 260 Ohms @ 700F

Loop Load 5.2 Volts @ 700F

3-27 psig 0.20-1.8 BAR
6-30 psig 0.40-2.0 BAR

0.1 scfm (2.83 Nl/min) 2.00 scfh (1 Nl/min) @ 20 psig supply (1.4 BAR)

3-15: 22 psig (1.5 BAR) max
3-27, 6-30: 42 psig (2.8 BAR) max

* ATEX Ex ia INTRINSICALLY SAFE, Ex nL and Ex nAnL APPROVAL ONLY

4.94 scfh (2.47 Nl/min) @ 85 psig supply (6.0 BAR)

8.36 scfh (4.18 Nl/min) @150 psig supply (10.0 BAR)
150 psig (10.0 BAR) max.

Performance Specifications

Linearity (Independent) <±0.5% of span
Hysteresis <±0.3% of span
Deadband <±0.1% of span
Repeatability
Mounting Orientation <±0.5% / 90 degree change
Air Supply Sensitivity < .3% / 1.5 psig (0.10 BAR) change <±0.6% / 25 psig (1.72 BAR) change
Vibration Effect

Temperature Effect <±0.75% / 100F change

<±0.3% of span; <±0.15% of span typical

<±1% up to 10g and 20-80 Hz

Physical Specifications

Housing NEMA 4X (IP 65)
Port Sizes Pneumatic 1/4” NPT, & 1/16 manifold mount

Media Clean, dry, oil-free, instrument air, filtered to 40 micron
Electrical Connections Terminal block
Mounting Direct (standard) or 2” pipe (optional)
Materials Housing: Chromate-treated aluminum with epoxy paint. NEMA 4X (IP65)

Weight 1.4 lb

441-622-099 Type 595XP Page 2

Electric 1/2" NPT , M20 x 1.5 (ATEX “K”) or 1/2" NPT (ATEX “K2”)

Elastomers: Buna-N
Trim: Stainless steel; brass; zinc-plated steel

1. INSTALLATION AND APPROVALS

1.1 Pre-Installation Requirements

1.1.1 Environment: Suitable for installation in the following locations:

 Intrinsically safe operation in hazardous locations outdoors (NEMA 4X, CSA. ENC. 4 & IP65)
 Explosion Proof Installation in hazardous locations outdoors (NEMA 4X, CSA. ENC. 4 & IP65)
 See section 1.5, 1.6 and 1.7 for Factory Mutual (FM), Canadian Standards (CSA) and ATEX

approvals.

WARNING

to prevent impact or friction.

All wiring must be made to all local and national codes appropriate to the area of

1.1.2 Electrical Input: 4-20 mA dc current source. It is recommended that shielded cable be used and that the

1.1.3 Air supply: Clean, dry, oil free instrument air filtered to 40 micron.

DANGER

shield be grounded to unit and earth ground. See Figure 1 on page 4 for location of ground screw.

The I/P transducer enclosure contains aluminum and is considered to constitute a potential
risk of ignition by impact or friction. Care must be taken into account during installation

installation.

NOTE

1.1.4 ATEX Specific Conditions of Use

 The user shall permanently mark the protection type chosen by adding a tick mark in the appropriate

box that corresponds to the type of hazardous area installation (i.e. Ex db, Ex tb, Ex ia, Ex nAnL or
Ex nL). See figure 2.
Once the type of protection has been marked, it shall not be changed.

 The flameproof joints of the equipment are not intended to be repaired.

Consult the manufacturer if repair of the flameproof joints is necessary.

 Refer to the manufacturer’s instructions to reduce the potential of an electrostatic charging hazard

due to impact or friction on the equipment enclosure.

1.2 Mounting

1.2.1 The Type 595XP has been designed to mount inline, to a standard valve yoke (bracket included with
unit), or to a 2” (5.1 cm) pipe (optional mounting kit 448-542-016 required).

1.3 Pneumatic Connections

1.3.1 Clean all pipe lines to remove dirt and scale prior to installation.

1.3.2 Supply air must be filtered to 40 microns and free of moisture and lubricants.

1.4 Electrical Connections

1.4.1 The Type 595XP is supplied with a 1/2" NPT electrical conduit connection as standard and “K2” option,
M20 x 1.5 for ATEX “K” option (see Figure 1).

Clean all pipe lines to remove dirt and scale prior to installation. Failures attributable to
instrument air supply contamination are not covered by the warranty.

1.4.2 A two (2) position terminal block that is wire ready is supplied for 22-12 AWG wire. Wire should be
stripped approximately 1/4" before insertion. The terminals are labeled “+” and “-“ on the terminal board
(see Figure 1).

1.4.3 It is recommended that shielded cable be used and that the shield be grounded at the unit (ground screw
provided) and to earth ground.

Observe polarity. Reverse polarity will not damage the unit, but unit will not operate.

Conduit should be connected to prevent condensation from collecting in the unit.

CAUTION

441-622-099 Type 595XP Page 3

A

A

ADJUSTMENT

ZERO

ADJUSTMENT

SPAN

GROUND

Figure 1 Figure 2

NEGATIVE TERMINAL (-)

POSITIVE TERMINAL (+)

TYPE 595XP

ControlAir Inc.

M20 x 1.5-6H
FOR ATEX (K)
OPTION

1/2 NPT FOR

TEX (K2)

OPTION

ND STANDARD

FM/CSA

ATEX COVER LOCK

1.5 FM Approvals (FM) & Canadian Standards Association (CSA) Approvals

Intrinsically Safe: Non-Incendive:
Class I, Div. 1, Groups A, B, C & D Class I, Div. 2, Groups A, B, C & D
Class II, Div. 1, Groups E, F & G Class II, Div. 2, Groups E, F & G
Class III, Div. 1, Fibers Class III, Div. 2, Fibers
Enclosure Nema 4X (IP65) Enclosure Nema 4X (IP65)
Rated 4-20 mA, 40 VDC Max. Temp. Code T6
Temp. Code T4 Ta = + 70

Explosion Proof: Entity Parameters:

0

C

Class I, Div. 1, Groups B, C & D Vmax = 40 VDC Ci = 0 uF

Enclosure Nema 4X (IP65)
Temp. Code T6

Dust Ignition Proof: Entity Installation Requirements:
Class II & III, Div. 1, Groups E, F & G Vmax > Vt OR Voc
Enclosure Nema 4X (IP65) Imax > It OR Isc
Temp. Code T6 Ca > Ci + Ccable
La > Li + Lcable

Note: Cable capacitance and inductance must be
considered when connecting to pressure transducer.

Imax = 150 mA Li = 0 mH

Ex ia

441-622-099 Type 595XP Page 4

1.6 ATEX Approvals (Option K)

Entity Parameters:

Ui (Vmax) = 40 VDC Ci = 0 uF
Ii (Imax) = 150 mA Li = 0 mH
Pi = .7 W Max.

II 1G
II 3G
II 2G
II 2D

1725

ATEX (FM) Flame proof
FM 08ATEX0049X II 2 G Ex db IIB + H2 T6 Gb Ta = -40

II 2 D Ex tb IIIC T85

0

C Db Ta = -400 C to +750 C

0

C to +750 C

1.7 EC Declaration of Conformity

We, ControlAir, Inc.
8 Columbia Drive
Amherst, NH 03031

Declare that the Type 595XP Transducer family to which this declaration applies, comply with these standards:

EN 60079-0:2012 + A11 :2013
EN 60079-1:2014

EN 60079-11:2012

EN 60079-15:2005
EN 60079-31:2014
EN 60529:1991 + A1:2000 + A2:2013
EN 1127-1:2011

Following the provisions of EMC directive 2014/34/EU

441-622-099 Type 595XP Page 5

1.8 INSTALLATION DRAWING
NO. 431-990-055

1. (North America) Control equipment connected to the Associ ated Appara t u s m u s t n o t u s e or
generate more tha n 250 Vrms or Vdc.

2. (North America) The IS Barriers or Equipment (Associated Apparatus) must be FM Approved and
CSA certified and t h e configur ation of associated Apparatus must be FM Approved and CSA
certified under the Entity Concept. The Associated Apparatus may be installed within the
Hazardous (Classified) location for which it is certified. The Associated Apparatus and hazar d ous
location loop apparatus manufacturer's control drawings must be followed when installing this
equipment. An AEx [ib] Associated Apparatus is suitable only for connection to Class I, Zone 1,
Hazardous (Classified) Locations and is not suitable for Class I, Zo ne 0 , o r C l a s s I , D i v i s i on 1
Hazardous (Classified) Locations.

(ATEX) The IS Barriers or other Assoc i a t ed Apparatus shall comply with the ATEX directive
2014 / 34 / EU.

3. (US) Installation should be in accordance with ANSI/ISA RP12.06.01 "Installation of Intrinsically
Safe Systems for Hazardous (Classified) Locations" and Article 500 of the National Electrical Code
(ANSI/NFPA 7 0)

(Canada) Installation should be in accordance with Section 18 of the Canadian Electrical Code.

(ATEX) Installation shall be in accordance with the applicable local installation rules Energy

Limitation Parameters specified.

4. (North America ) All units suitable for Type 4X installations.

5. (North A merica) Un its are sui t able for Cl ass I, Division 2, Groups A, B, C, and D hazardous
(class i fied) locations. Transduc ers to be installe d in accorda nce with the

(US) National Electrical Code (ANSI/NFPA 70) Division 2 hazardous (classified) location wiring

techniques

(Canada) Canadian Electrical Code.

6. The Intrinsic Safety Entity concept allows the interconnection of two Intrinsically safe devices with
entity parameters not specifically examined in combi n a t i o n a s a sy stem when:

Entity Parameters for: MODELS TYPE 595 Ui or Vmax >Uo or Voc

Ui (Vmax) = 40 V Ii or Imax > Io or Isc or It
Ii (Imax) = 150 mA Ca or Co > Ci + Ccable
Ci=0 La or Lo > Li ÷ Lcable
Li=0 Pi > Po.

Pi = 0.7 watts

7. No revision to t his drawing is perm itted without prior FM Approval and CSA Certification.

T595XP
TRANSDUCER

T595XP
TRANSDUCER

T595XP
TRANSDUCER

+

(RED)

-

(BLACK)

+

(RED)

-

(BLACK)

+

(RED)

-

(BLACK)

HAZARDOUS

LOCATION LOCATION

NONHAZARDOUS

3

4

3

4

3

4

28V
SINGLE
CHANNEL
POLARIZED

28V
TWO­CHANNEL
POLARIZED

DIODE

28V
TWO­CHANNEL
POLARIZED

10V

1

2

1

2

1

2

4-20mA

4-20mA

4-20mA

4-20mA

4-20mA

0V

RAIL

CONTROLLER

1-5V

0V

RAIL

CONTROLLER

1-5V

0V

RAIL

CONTROLLER

TYPE 1
SYSTEM

TYPE 2
SYSTEM

TYPE 3
SYSTEM

431-990-055

441-622-099 Type 595XP Page 6

2. OPERATION

2.1 Calibration

2.1.1 All units are shipped from the factory calibrated, direct acting.

NOTE

check the calibration to ensure that settings and operation match the application requirements.

NOTE

NOTE

2.2 Calibration

2.2.1 In direct acting operation, the unit is calibrated so that minimum input signal corresponds to minimum
output pressure and increasing input signal results in increasing output pressure.

2.2.2 Apply the minimum input signal of the range being used (e.g. 4 mA).

2.2.3 Observe the output pressure. If necessary, adjust the zero screw until reaching minimum output
pressure setting. Turn zero screw clockwise to increase and counter clockwise to decrease.

2.2.4 Apply the maximum input signal of the range being used (e.g. 20 mA).

Factory calibration is susceptible to shift due to handling during transit. ControlAir
recommends that all units be recalibrated prior to use.

2.1.2 Though the units are shipped fully calibrated it is suggested that the user

ATEX option units come with a factory installed cover lock screw. Screw must be
removed before removing cover. Screw must be replaced upon replacing cover.
See Figure 1, Section 1.4

It is not necessary to remove the plastic cover of the unit for calibration.

2.2.5 Observe the output pressure. If necessary, adjust the span screw until reaching maximum output
pressure setting. Turn span screw clockwise to increase pressure, counter clockwise to decrease
pressure.

2.2.6 After setting the span it will be necessary to recheck the zero. Repeat steps 1-4 until both end points
are at required values.

3. MAINTENANCE AND REPAIRS

NOTE

Under normal circumstances, no maintenance should be required.

3.1 Instrument Air Filtration

3.1.1 Failures due to instrument supply air contamination are not covered by warranty.

3.1.2 Use of oil and/or water saturated instrument air can cause erratic operation.

3.1.3 Poor quality instrument air can result in unit failure. It is recommended that a filter regulator (such as
ControlAir Type 300) be placed upstream of each unit where oil and/or water laded instrument air is
suspected.

3.2 Factory Repairs

3.2.1 In the event of unit failure, the Type 595XP can be returned to the factory through point of purchase for

warranty repair if the warranty period has not expired.

3.2.2 All units returned for repair must be authorized prior to receipt at the factory. Contact a representative
at the point of purchase to receive a Return Authorization Number.

441-622-099 Type 595XP Page 7

p

3.3 Filter Replacement

3.3.1 Supply pressure can become obstructed should the felt filter element become clogged. To replace

filter (P/N: 445-777-018), remove slotted plug and carefully remove filter using tweezers. Insure no
dust or dirt particles remain in filter chamber. Insert new filter into chamber in orientation as shown in
figure 3. Replace slotted plug, insuring o-ring is properly seated. For N-connection, remove Nema cap
screw using a 5/64 hex key.

Figure 3 – Replacing Filter

4. TROUBLESHOOTING

PROBLEM LOOK FOR SOLUTION

No or low output

Unstable / low output Electrical connection Check connection/signal (1.1.2)
Erratic operation Liquid/contamination in air supply

Output equals supply pressure Improper pneumatic connections Insure that supply is connected to “IN” port and

P - Connection N - Connection

FILTER

FILTER

Wires reversed
Zero adjustment
Clogged filter
Supply pressure too low

Supply pressure

NEMA CAP SCREW

Reverse input wires (see Figure 1)
Reset zero (2.2.3)
Replace filter (see Figure 3)
Increase supply pressure (see specs)

Clean air supply (1.1.3)
Verify supply pressure (see specs)

output is connected to “OUT” port (1.3.3, 1.3.4)

NOTE

If problems are not solved by troubleshooting procedures, contact a factory applications
engineer at [phone] for further assistance.

5. WARRANTY & DISCLAIMER

ControlAir, Inc. products are warranted to be free from defects in materials and workmanship for a period of
eighteen months from the date of sale, provided said products are used according to ControlAir, Inc.
recommended usages. ControlAir, Inc.’s liability is limited to the repair, purchase price refund, or replacement in
kind, at ControlAir, Inc.’s sole option, of any products proved defective. ControlAir, Inc. reserves the right to
discontinue manufacture of any products or change products materials, designs or specifications without notice.
Note: ControlAir does not assume responsibility for the selection, use, or maintenance of any product.
Responsibility for the proper selection, use, and maintenance of any ControlAir product remains solely with the
purchaser and end user.

WARNING

These products are intended for use in industrial compressed-air systems only. Do not use
these

roducts where pressures and temperatures can exceed those listed under

Before using these products with fluids other than air, for non-industrial application, life-support systems, or other
applications not within published specifications, consult ControlAir, Inc.

441-622-099 rev. 04/30/18 Type 595XP Page 8