Emerson Process Management Bristol CI-9110, Bristol 9110-00A, Bristol 9110 User Manual

Instruction Manual

CI-9110
Mar. 2007

Remote Set Regulator
Model 9110-00A

Series 9110

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this device in some applications may result
in damage or injury. The user is urged to keep this book filed in a convenient location
for future reference.

These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or main­tenance. Should problems arise that are not covered sufficiently in the text, the pur­chaser is advised to contact Bristol for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for
whatever reason, may leave an operating process without protection. Depending upon
the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment
or provide alternate means of protection such as alarm devices, output limiting, fail­safe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional
in-formation is required, the purchaser is advised to contact Bristol .

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note
the following: The party sending such materials is responsible to ensure that the
materials returned to Bristol are clean to safe levels, as such levels are defined and/or
determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Bristol and save Bristol harmless from any liability or
damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic in­struments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by
exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude
and duration of the ESD, this can result in erratic operation or complete failure of the
equipment. Read supplemental document S14006 at the back of this manual for
proper care and handling of ESD-sensitive components.

Bristol Inc. 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

A. Bristol warrants that goods described herein and manufactured by Bristol are free

from defects in material and workmanship for one year from the date of shipment
unless otherwise agreed to by Bristol in writing.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from

defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited

to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part

thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written

or oral warranties beyond those set forth herein.

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or

replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Water­town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incidental or consequential

damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its employees or other parties of goods sold under said agreement.

REMEDIES

How to return material for Repair or Exchange

Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify
proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very
important since the information permits the Bristol Repair Dept. to effectively and
efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX
Completing the form (GBU 13.01) and faxing it to [phone]. A Bristol Repair

Dept. representative will return call (or other requested method) with a RA number.

B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)

and sending it via E-Mail to [e-mail]
representative will return E-Mail (or other requested method) with a RA number.

C. Mail
Mail the form (GBU 13.01) to

Bristol Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

A Bristol Repair Dept. representative will return call (or other requested method)

with a RA number.

D. Phone

Calling the Bristol Repair Department at [phone]. A Bristol Repair Depart-

ment representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in­cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.

. A Bristol Repair Dept.

Bristol Inc. Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required

to receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is

practice may be requested in the “Special Requests” section.

• Evaluate / Test / Verify Discrepancy

• Repair / Replace / etc. in accordance with this form

• Return to Customer

Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)
Bill to : Ship to:

Purchase Order: Contact Name:____________________________________
Phone: Fax: E-Mail:

Part II Please complete Parts II & III for each unit returned

Model No./Part No. Description

Please be aware of the Non warranty standard charge:

• There is a $100 minimum evaluation charge, which is

applied to the repair if applicable (√ in “returned”
B,C, or D of part III below)

Range/Calibration S/N
Reason for return

: Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________

3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due

to Bristol’s warranty clause, would you like the product:

repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,
would you like the product:

C. If product is deemed not repairable would you like your product:
D. If Bristol is unable to verify the discrepancy, would you like the product:

repaired returned replaced scrapped?

returned replaced scrapped?
returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact

that has the most knowledge of the problem is: ______________________________ phone_____________________

If we are unable to contact this person the backup person is: _________________________
Special Requests: ____________________________________________________________________________________

phone_____________________

____________________________________________________________________________________________________

Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: [phone] Fax: 860-945-

2220 Form GBU 13.01 Rev. C 04/27/06

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

• Avoid Delays and problems in getting your system on-line

• Minimize installation, start-up and maintenance costs.

• Make the most effective use of our hardware and software.

• Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at three locations: Houston, Orlando and our Watertown, CT
headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol products and realize the full
potential of your system.

For information or to enroll in any class, contact our training department in Watertown at
[phone]. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

A Few Words About Bristol Inc.

For over 100 years, Bristol® has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Inc. instruments, controllers, and systems running year-in and
year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis­tance in using this product from the following sources:

Help Files / Release Notes

Many Bristol software products incorporate help screens. In addition, the software typically
includes a ‘read me’ release notes file detailing new features in the product, as well as other
information which was available too late for inclusion in the manual.

Contacting Bristol Inc. Directly

Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.

Our main phone numbers are:

[phone]
[phone] (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.

For technical questions about TeleFlow products call [phone].

For technical questions about ControlWave call [phone] or [phone].

For technical questions regarding Bristol’s OpenEnterprise product, call [phone]
or e-mail: [e-mail]

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call [phone].

For technical questions about Network 3000 hardware, call [phone].

You can e-mail the Application Support Group at: [e-mail]

The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at [phone] or [phone].

You can e-mail the Communication Technology Group at:

[e-mail]

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed on the rear cover of
this manual) or to your Bristol-authorized sales representative.

Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office
covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol’s Training Department offers a wide variety of courses in Bristol hardware and
software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at [phone] for course
information, enrollment, pricing, and scheduling.

CI-9110

MODEL 9110-00A REMOTE SET REGULATOR

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 -INTRODUCTION

1.1 PRODUCT DESCRIPTION

1.2 THEORY OF OPERATION

1.2.1 Analog Regulator Model

1.2.2 Guard Input

1.2.3 Current Output

1.2.4 Raise/Lower Regulator Model

1.3 DATA PLATE

2.1 GENERAL

2.2 MOUNTING

2.2.1 Two-Inch Pipe Mounting

2.2.2 In-Line Mounting

2.3 PRESSURE CONNECTIONS

2.3.1 General Piping

2.3.2 Moisture in Lines

2.3.3 Line Size

2.3.4 Venting

2.4 INTERNAL ACCESS

2.4.1 Body and Cover

2.4.2 Electrical Conduit Port

2.5 INSTALLATION IN HAZARDOUS LOCATIONS

..........................................................................................................................1-4

.....................................................................................................................1-4

.......................................................................................................................1-6

Section 2 - INSTALLATION

.............................................................................................................................2-1

..........................................................................................................................2-1

.................................................................................................................2-1

......................................................................................................................2-2

.................................................................................................................2-3

................................................................................................................................2-4

..................................................................................................................................2-4

...........................................................................................................2-4

....................................................................................................................2-4

Section 3 - BOARD SETUP

...............................................................................................1-1

................................................................................................1-1

.....................................................................................................1-1

.............................................................................................1-6

.....................................................................................................2-1

.............................................................................................2-2

........................................................................................................2-5

...........................................................2-5

3.1 USING OPTION SWITCHES

3.1.1 Switch Functions

3.2 ANALOG INPUT MODELS

3.3 RAISE/LOWER MODELS

3.3.1 Continuous Signal

3.3.2 Incremental Signal

3.4 INPUT FILTER

3.5 GUARD INPUT

3.5.1 Guard logic

3.5.2 Static or Dynamic Guard Input

3.6 OUTPUT RATE OF CHANGE

3.7 ANALOG FAILURE MODES (Fail Hold & Fail Zero)

4.1 GENERAL

4.2 TERMINAL BLOCK IDENTIFICATION

9110 Remote Set Regulator Contents / 0-1

..................................................................................................................3-2

................................................................................................................3-3

...............................................................................................................3-3

....................................................................................................................3-4

....................................................................................................................3-5

............................................................................................................................3-5

Section 4 - FIELD WIRING

.............................................................................................................................4-1

............................................................................................3-1

................................................................................................3-2

...................................................................................................3-2

..........................................................................................3-5

............................................................................................3-5

.....................................................3-6

..........................................................................4-1

SECTION TITLE PAGE #

Section 4 - FIELD WIRING (Continued)

4.3 ANALOG VOLTAGE INPUT (1-5 V) WITH GUARD ..................................................4-2

4.4 ANALOG CURRENT INPUT (4-20 mA) WITH GUARD............................................. 4-4

4.5 RAISE/LOWER INPUTS WITH GUARD ..................................................................... 4-4

4.6 4-20 mA CURRENT OUTPUT....................................................................................... 4-6

4.7 DC POWER ..................................................................................................................... 4-6

4.8 OPERATING NOTES..................................................................................................... 4-7

4.9 INITIAL CHECKS.......................................................................................................... 4-7

Section 5 - SERVICE

5.1 GENERAL.......................................................................................................................5-1

5.2 TROUBLESHOOTING HINTS ..................................................................................... 5-2

5.3 SETTING OUTPUT LIMITS ......................................................................................... 5-3

5.3.1 General Principles .......................................................................................................... 5-3

5.3.2 Test Setup ....................................................................................................................... 5-3

5.3.3 Procedure ........................................................................................................................ 5-3

5.4 CALIBRATION TEST SETUP ...................................................................................... 5-4

5.5 CALIBRATION PRECAUTION .................................................................................... 5-4

5.6 PRELIMINARY CALIBRATION CHECK .................................................................... 5-5

5.7 DETAILED CALIBRATION FOR ANALOG MODELS............................................... 5-6

5.7.1 Feedback Zero & Span.................................................................................................... 5-6

5.7.2 Current Output Span & Load ........................................................................................5-6

5.7.3 Pressure Output Check ..................................................................................................5-6

5.8 DETAILED CALIBRATION FOR RAISE/LOWER MODEL....................................... 5-7

5.8.1 Feedback Zero & Span.................................................................................................... 5-7

5.8.2 Current Output Span & Load ........................................................................................ 5-8

5.9 PCB REFERENCE DRAWINGS ................................................................................... 5-8

Section 6 - SPECIFICATIONS

6.1 ANALOG INPUT MODEL ............................................................................................. 6-1

6.2 RAISE/LOWER INPUT MODEL................................................................................... 6-1

6.3 GUARD INPUT ..............................................................................................................6-2

6.4 ANALOG OUTPUT ........................................................................................................ 6-2

6.5 ACCURACY - ANALOG MODELS................................................................................ 6-2

6.6 ACCURACY - RAISE/LOWER MODELS ..................................................................... 6-2

6.7 DC POWER ..................................................................................................................... 6-2

6.8 STEPPER DRIVE MECHANISM.................................................................................. 6-2

6.9 PRESSURE REGULATOR ASSEMBLY ......................................................................6-3

6.10 INSTRUMENT ENCLOSURE....................................................................................... 6-3

6.11 ENVIRONMENT. ........................................................................................................... 6-3

Section 7 - PARTS

7.1 MODEL 9110 MAIN PARTS.......................................................................................... 7.1

7.2 REMOTE SET REGULATOR BASIC PARTS.............................................................. 7-4

SUPPLEMENTAL INSTRUCTIONS

GUIDELINES FOR SYSTEM GROUNDING .........................................................S1400

CARE AND HANDLING OF PC BOARDS AND

ESD-SENSITIVE COMPONENTS ........................................................................S14006

0-2 / Contents 9110 Remote Set Regulator

Chapter 1

INTRODUCTION

1.1 PRODUCT DESCRIPTION

Series 9110-00A, Remote Set Regulators are transducer devices that use an electrical input
signal to set the level of a pneumatic output signal. Depending on the actual model, the
electrical input may be either an analog or a raise/lower type signal. For analog models, the
input can be configured for a 1-5 V dc or 4-20 mA dc signal. For the Raise/Lower models,
the input can be configured to accept a continuous or pulse incremental dc signal.

The pneumatic output of a Remote Set Regulator may be specified with a 3-15, 3-27 or 6-30
psi output. All models can operate from pressure supplies up to 100 psi (Max). Minimum
supply pressure must be at least 3 psi above the maximum range value.

The Regulator also provides a guard input. This signal can be used to Enable (turn ON) or
Inhibit (turn OFF) the input for telemetry and security applications. When the guard signal
is Enabled, it allows the output to respond to a change of the input signal.

The Remote Set Regulator is contained in a weatherproof, explosion-proof enclosure having
a detachable threaded cover. Removal of the cover provides access to the field wiring
terminals and the programmable option switches.

Regulators are factory-furnished for 12 Vdc or 24 Vdc supply operation. These voltage
ratings are fixed and cannot be changed in the field.

In-line or pipe mounting are offered as for installations. The former uses a 1/4 inch rigid
pressure line for support, while the latter includes a special bracket for two-inch pipe
mounting.

1.2 THEORY OF OPERATION

The Remote Set Regulator contains a CPU Board and a Termination Board. The CPU
Board contains the central processor and its associated circuitry, while the Termination
Board contains the field wiring terminals and the input protection circuitry.

The Regulator is offered in Analog and Raise/Lower models. Both types use similar
circuitry but they perform different functions. A description of the Analog model follows
while the Raise/Lower model is explored later in the text.

1.2.1 Analog Regulator Model

The Analog Regulator circuitry is shown in the block diagram of Figure 1-2. In this circuit,
the Command signal (1-5 V or 4-20 mA) is applied to a buffer amplifier which drives the
plus (+) input of the Lower Comparator and the minus (-) input of the Raise Comparator.
Also note that the opposing inputs of both comparators are referenced to the same point
which is the center arm of a feedback pot.

CI-9110 1-1 Introduction

Figure 1-1 - Remote Set Regulator

The CPU, clock and reset circuitry performs the timing, measurement and decision making
functions of the Remote Set Regulator. This circuit analyzes the comparator outputs and
sends data to the stepper driver which, in turn, pulses the stepper motor in either direction.
Since the driveshaft of the stepper motor is mechanically coupled to the feedback pot and a
pressure regulator valve, both will be set in accordance with data received from the CPU.

Introduction 1-2 CI-5450

Figure 1-2 - Block Diagram of Analog Type Regulator

CI-9110 1-3 Introduction

The feedback pot connects across a regulated +5 Vdc source. The voltage at the feedback
pot’s contact corresponds to the mechanical position of the pressure regulator. This
reference voltage is applied to the Raise and Lower Comparators.

If an increase in signal level occurs at the command input, the Raise Comparator will
become unbalanced since this signal will exceed the voltage present at the center arm of the
pot. The Lower Comparator will be unaffected since the input signal will be of opposite
polarity compared to the feedback pot voltage. The CPU senses the increased output at the
Raise Comparator and outputs a signal that drives the stepper motor in an upward
direction. The upward driving action will continue until the voltage at the pot’s center arm
becomes equal to the new signal level. Once the comparator is balanced, the CPU will turn
off the stepper motor and the pressure regulator will provide a corresponding pressure out­put level. Input changes that reduce the output value will have the opposite effect.

The comparators are biased so that they include a certain amount of hysteresis. This bias
keeps the stepper motor in a stable, deenergized zone that is less affected by noise bursts
that may appear on the command input line.

The stepper motor is actuated in incremental steps. The pulse signals received from the
stepper driver will increment the motor one step at a time. The motor requires ap­proximately 22,000 steps for full rotation.

1.2.2 Guard Input

An optional signal can be applied to the guard input to Enable or Inhibit the command Sig­nal. The guard circuit consists of a non-polarized, opto-isolated circuit whose output is
applied to the CPU via a logic circuit.

Analog Regulator models include a fault detector circuit that is activated through jumper
selection. The fault detector monitors the analog input value for a value that is less than
0% of scale. This condition, which occurs when the AI command input signal fails, will stop
the stepper motor and maintain the last output value prior to the failure.

Two types of signal failure modes are provided by jumper selection as shown at the left of
Figure 1-2. Position "A" of the jumper provides fail-hold mode, while position "B" provides
fail-hold zero. Should the AI signal fail (signal < 0% of scale), fail-zero mode will drive the
output slowly to zero, while fail-hold mode will retain its last output value.

Mechanical limiting is also provided by adjustable tangs located on the main drive gear of
the stepper motor. When the input signal is of a value that causes the stepper to drive
against a limit, a mechanical clutch on the drive shaft will slip. After making several
revolutions, the software will time out and cut off power to the motor. Power will be re­applied when the signal level returns to the normal operating range.

1.2.3 Current Output

A 4-20 mA current output is obtained via an amplifier/converter circuit. The input to this
circuit is the feedback pot whose center arm adjusts the current output to track the valve
position.

Introduction 1-4 CI-5450

Figure 1-3 - Block Diagram of Raise/Lower Type Regulator

CI-9110 1-5 Introduction

1.2.4 Raise/Lower Regulator Model

A block diagram for the Raise/Lower Regulator model is shown in Figure 1-3. It will be
noted that this diagram is similar to the Analog Regulator except for the input circuit ar­rangement. This circuit contains Raise, Lower and Guard input circuits which are opto­isolated.

The outputs of all three opto-isolators are applied to a logic circuit that checks the status of
the three signals and determines whether the output will be in a Raise, Lower or Guard
mode.

Each Raise and Lower input may be configured to accept a continuous or pulse incremental
signal. The continuous signal is a dc input that, when switched to an ON state, allows the
stepper motor to rotate in the proper direction; when switched to an OFF state, it stops the
stepper motor and maintains a corresponding output value. The pulse incremental signal
can be a single dc pulse or a pulse train input that causes stepper motor to change the out­put by an incremented amount. The amount of the output increment is determined by the
settings of the configuration switches.

The outputs of all three opto-isolators in Figure 1-3 are status signals that, when processed
by the CPU, establish a pressure output value that corresponds to the input signals. The
remainder of the circuitry shown in the illustration operates in the same manner as
described for Analog Regulators.

1.3 DATA PLATE

A data plate affixed to the Remote Set Regulator lists the instrument model, serial number
and other relevant information. The features and options present in an instrument can be
determined by comparing its model number to the model breakdown of Table 1-A.

Remote Set Regulators certified for use in hazardous areas will include the seal of the
certifying laboratory on the data plate. Certification will also be indicated as an element of
the instrument model number listed on the data plate.

Table 1A - Model Number Breakdown

- SAMPLE MODEL NUMBER -

# = BASE MODEL NUMBER

A = ELECTRICAL INPUT B = POWER

1 = Raise/lower Input 1 = 12V dc
2 = Analog Input (1-5V or 4-20 mA) 2 = 24V dc

Introduction 1-6 CI-5450

Table 1A - Model Number Breakdown (Continued)

C = PNEUMATIC OUTPUT D = MOUNTING ARRANGEMENT

1 = 3-15 psi 1 = 2 In. Pipe Mtg. Bracket
2 = 3-27 psi 2 = In-Line Pressure Pipe
3 = 6-30 psi
E = CERTIFICATION

1 = None
2 = FM-EXP/NI
3 = CSA-EXP

NOTE: This table is only provided for product identity and not for or-

dering purposes. Contact the Bristol Sales Department for
ordering information.

CI-9110 1-7 Introduction

BLANK PAGE

Chapter 2

INSTALLATION

2.1 GENERAL

Proper installation techniques will ensure highest performance and also minimize
measurement errors. The Remote Set Regulator should be mounted in a location that is not
subject to radical temperature extremes, vibration and shock. See Section 6 Specifications
for environmental operating conditions.

This section describes the mechanical mounting arrangements of the Regulator and
explains the technique of bringing in wiring via electrical conduit.

The installation procedures described herein are furnished as a guideline and cannot cover
all possible variations. All deviations from the installation procedures described herein are
at the discretion of the user.

2.2 MOUNTING

The overall mounting dimensions for the unit are given in Figure 2-1. Be sure that the
selected site has sufficient clearance to remove the Regulator cover and access internal
switches and terminals. Choose the appropriate mounting arrangement below as required

2.2.1 Two-Inch Pipe Mounting

Refer to the overall dimension of Figure 2-1 for views of the universal pipe mounting
bracket. For this type of installation, the bracket is assembled to the Regulator using three
screws. Select the desired set of bracket holes for either vertical or horizontal mounting
pipes.

Once the bracket is mounted, position the assembly next to the pipe as required and install
the u-bolts from the hardware kit into the appropriate bracket holes. Install nuts on the u­bolts and tighten them until the instrument is self-supporting.

2.2.2 In-Line Mounting

In-line mounting can be used when the pressure line and electrical conduit provide
sufficient strength to support the weight of the unit. This type of mounting should never be
attempted on lines constructed of soft or low-strength materials. In-line mounting is also
not recommended for non-secured lines subject to excessive vibration or hammering.

Once the desired location has been selected, cut the pressure pipe and install proper fittings
(1/4 in. NPT male) to mate with the two pressure connection ports on the Regulator. It is
recommended that unions and shutoff valves also be installed in each line to allow an easy
disconnect for maintenance or troubleshooting operations.

CI-9110 2-1 Installation

2.3 PRESSURE CONNECTIONS

Remote Set Regulators are furnished in models that provide 3-15, 3-27 or 6-30 psig outputs.
All models will accept 100 psig maximum on the supply side. Pressure supplies that exceed
this value will require an external pressure regulator or limiter.

Figure 2-1 - Overall Mounting Dimensions

2.3.1 General Piping

A basic piping diagram is shown in Figure 2-3. The pressure supply line may include a
pressure gauge, external regulator, filter and a shutoff valve as shown. Union type
connections are recommended for pressure lines to allow an easy disconnect. A pressure

Installation 2-2 CI-9110

shutoff valve allows the supply source to be closed down during maintenance checks
without disturbing other equipment operating on the line.

Figure 2-2 - Regulator Assembly

2.3.2 Moisture in Lines

The Regulator should be installed so that the supply and output lines slope downward and
away. This arrangement allows any condensate trapped in the lines to drain away from the
instrument.

CI-9110 2-3 Installation

2.3.3 Line Size

For most installations 1/4 inch pipe or tubing is satisfactory. However, if the input or
output lines run a great distance, the response lag time may become objectionable. In these
instances the use of 3/8 inch tubing is recommended.

2.3.4 Venting

The user should note that the Remote Set Regulator bleeds a small amount of pressure into
the atmosphere during operation. A 1/4 inch NPT vent is provided on the pressure regulator
body for this purpose. The vent location is shown in Figure 2-3.

When air is used as the pressure source, the vent fitting may be allowed to bleed into the
atmosphere. If fuel gas or other hazardous type gases are used as the pressure source for a
Remote Set Regulator, the VENT port must be piped to a safe location.

** Warning **

Covers of Remote Set Regulators operating in hazardous
areas should not be removed. If servicing is required, the
environment should first be made safe or the supply power
should be turned off, allowing the instrument to be discon­nected and removed to a safe area.

Figure 2-3 - Typical Pressure Connections

2.4 INTERNAL ACCESS

The subtopics that follow discuss the main mechanical and electrical assemblies that will
be accessed during installation. They describe the method of removing and installing the
cover, the use of the electrical conduit ports, and the installation precautions to be
observed.

2.4.1 Body and Cover

The Remote Set Regulator is contained in a aluminum body with a gasketed screw-on cover
as shown in Figure 2-2. Four raised lugs on the cover permit it to be loosened or tightened

Installation 2-4 CI-9110

using a flat metal bar or similar tool. When replacing the cover, it should be snugged in and
not over-tightened. The threads of the cover should also be coated with a layer of anti-seize
compound to prevent lockup.

When the cover is removed, the PC board assemblies become accessible (see right view of
Figure 2-3). The Termination Board contains the field wiring terminals while the CPU
Board contains the option switches. The gear mechanism and feedback potentiometer are
also accessible.

2.4.2 Electrical Conduit Port

Two 3/4 in. NPT electrical ports are provided at the lower part of the housing. Either or
both ports may be used to bring in signal and supply wiring (left of Figure 2-3). These ports
accommodate a standard 3/4 inch NPT pipe thread connection. If a port is not used, it must
have a conduit plug installed to maintain the explosion-proof integrity of the unit.

2.5 INSTALLATION IN HAZARDOUS LOCATIONS

Instruments that operate in hazardous locations must adhere to the following rules of
safety:

A. All instrument wiring that runs through a hazardous area must be enclosed in metal

conduit. The point where the conduit connection meets the unit's housing should be
properly tightened to prevent entry of gas or other ignitable substances. Explosion-proof
wiring practices must be followed to prevent flashback through the conduit.

B. The cover of the installed unit must be screwed in hand tight and fully seated. The cover

must not be damaged and no threads should be stripped.

C. The cover of the unit must never be removed during operation unless the atmosphere is

made safe or all electrical power is removed from the instrument.

** Warning **

No maintenance procedures should be performed while the
unit is powered and operating in a combustible or
explosive environment. If on-site maintenance is a
necessity, steps must be taken to make the environment
safe (non-hazardous). Otherwise, the instrument must be
powered down, unwired, and brought into a safe area. A
failure to observe these precautions could result in fire or
explosion and injury to persons.

** Safety Note **

For certified instruments, all installation and operating
practices must conform to area classification and safety
codes as specified by the certifying laboratory. The seal of
the certifying laboratory will appear on the instrument
data plate along with the model and serial number.

CI-9110 2-5 Installation