Yokogawa PK200 User Manual

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User's Manual

PK200 CURRENT-TO-PNEUMATIC CONVERTER [Style:S2]

IM 21B03D01-01E

12th Edition

CONTENTS

 INTRODUCTION.............................................................................................. iii

1. HANDLING PRECAUTIONS ......................................................................... 1-1

1.1 Checking the Model Suffix Code and Specifications .......................... 1-1

1.2 Transportation Precautions ................................................................. 1-1

1.3 Storage Precautions ............................................................................ 1-2

1.4 Precautions for Installation Area ......................................................... 1-2

1.5 Installation of Intrinsically Safe Type .................................................. 1-2

1.5.1 CSA Intrinsically Safe Type ......................................................... 1-2

1.5.2 TIIS Intrinsically Safe Type .......................................................... 1-3

1.6 Installation of Flameproof Type .......................................................... 1-3

1.6.1 TIIS Flameproof Type .................................................................. 1-3

1.6.2 FM Explosionproof Type .............................................................. 1-4

1.7 EMC Conformity Standard .................................................................. 1-4

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

2.1 Functional Description ......................................................................... 2-1

2.2 Standard Specifications ...................................................................... 2-1

2.3 Model and Suffix Codes ...................................................................... 2-2

2.4 Options ................................................................................................ 2-2

2.5 External Dimensions ........................................................................... 2-3

2.6 Part Names ......................................................................................... 2-4

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

3.1 Overview ............................................................................................. 3-1

3.2 Installation ........................................................................................... 3-1

3.2.1 Pipe Mounting .............................................................................. 3-1

3.2.2 Wall Mounting ............................................................................... 3-1

4. WIRING AND PIPING ................................................................................... 4-1

4.1 Piping .................................................................................................. 4-1

4.1.1 Supply Air ..................................................................................... 4-1

4.1.2 Air Supply Piping .......................................................................... 4-1

4.1.3 Output Piping................................................................................ 4-1

4.2 General-Use and Flameproof Type Wiring ......................................... 4-1

4.2.1 Cable Selection ............................................................................ 4-1

4.2.2 Wiring ........................................................................................... 4-2

4.2.3 Grounding ..................................................................................... 4-4

4.3 Intrinsically Safe Type Wiring ............................................................. 4-4

5. OPERATION .................................................................................................. 5-1

5.1 Auto/Manual (A/M) Transfer Mechanism ............................................ 5-1

5.2 Zero Point Adjustment ........................................................................ 5-1

5.3 Calibration ........................................................................................... 5-2

5.4 Range Adjustment ............................................................................... 5-4

5.5 4 to 20mA/10 to 50mA Selection ........................................................ 5-4

IM 21B03D01-01E

CONTENTS

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

6.1 Overview ............................................................................................. 6-1

6.2 Periodic Inspection .............................................................................. 6-1

6.2.1 Cleaning the Restrictor................................................................. 6-1

6.3 Parts Replacement .............................................................................. 6-1

6.3.1 Replacing the Screen Filter.......................................................... 6-1

6.3.2 Replacing the Controller Relay .................................................... 6-2

6.3.3 Replacing the Amplifier Assembly ............................................... 6-2

7. TROUBLESHOOTING................................................................................... 7-1

7.1 Overview ............................................................................................. 7-1

7.2 Operation Principle .............................................................................. 7-1

7.3 Troubleshooting Flow .......................................................................... 7-2

Appendix A. AIR SUPPLY SYSTEM................................................................ A-1

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS INTRINSICALLY

SAFE EQUIPMENT ............................................................................. Ex-A03E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF

EQUIPMENT ........................................................................................ Ex-B03E

Customer Maintenance Parts List

Model PK200 Current-to-Pneumatic Converter .............. CMPL 21B03D01-01E

Revision Record

IM 21B03D01-01E

 INTRODUCTION

Thank you for purchasing the Current-to-Pneumatic Converter.

The Current-to-Pneumatic Converter is correctly calibrated at the factory before shipment. To ensure correct and efficient use of the instrument, please read this manual thoroughly and fully understand how to operate the instrument before operating it.

■ Regarding This Manual

•This manual should be passed on to the end user.

• The contents of this manual are subject to change without prior notice.

• Yokogawa makes no warranty of any kind with regard to this manual, including, but not limited to, implied warranty of merchantability and fitness for a particular purpose.

• If any question arises or errors are found, or if any information is missing from this manual, please inform the nearest Yokogawa sales office.

• The specifications covered by this manual are limited to those for the standard type under the specified model number break-down and do not cover custom-made instrument.

• Please note that changes in the specifications, construction, or component parts of the instrument may not immediately be reflected in this manual at the time of change, provided that postponement of revisions will not cause difficulty to the user from a functional or performance standpoint.

■ Safety Precautions

• Yokogawa will not be liable for malfunctions or damage resulting from any modification made to this instrument by the customer.

• For the intrinsically safe equipment and explosionproof equipment, in case the instrument is not restored to its original condition after any repair or modification undertaken by the customer, intrinsically safe construction or explosionproof construction is damaged and may cause dangerous condition. Please contact Yokogawa for any repair or modification required to the instrument.

• The following safety symbol marks are used in this Manual:

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

IMPORTANT

Indicates that operating the hardware or software in this manner may damage it or lead to system failure.

• For the protection and safety of the operator and the instrument or the system including the instrument, please be sure to follow the instructions on safety described in this manual when handling this instrument. In case the instrument is handled in contradiction to these instructions, Yokogawa does not guarantee safety.

NOTE

Draws attention to information essential for understanding the operation and features.

iii

IM 21B03D01-01E

WARRANTY

•The warranty shall cover the period noted on the quotation presented to the purchaser at the time of purchase. Problems occurred during the warranty period shall basically be repaired free of charge.

•In case of problems, the customer should contact the Yokogawa representative from which the instrument was purchased, or the nearest Yokogawa office.

• If a problem arises with this instrument, please inform us of the nature of the problem and the circumstances under which it developed, including the model specification and serial number. Any diagrams, data and other information you can include in your communication will also be helpful.

• Responsible party for repair cost for the problems shall be determined by Yokogawa based on our investigation.

● The Purchaser shall bear the responsibility for

repair costs, even during the warranty period, if the malfunction is due to:

•Improper and/or inadequate maintenance by the Purchaser.

•Failure or damage due to improper handling, use or storage which is out of design conditions.

•Use of the product in question in a location not conforming to the standards specified by the Yokogawa, or due to improper maintenance of the installation location.

• Failure or damage due to modification or repair by the party except Yokogawa or who is requested by Yokogawa.

• Malfunction or damage from improper relocation of the product in question after delivery.

•Reason of force majeure such as fires, earthquakes, storms/floods, thunder/lightening, or other natural disasters, or disturbances, riots, warfare, or radioactive contamination.

 INTRODUCTION

IM 21B03D01-01E

1. HANDLING PRECAUTIONS

IMPORTANT

For installation, wiring and maintenance in hazadous areas, please follow 1.5 Installation of Intrinsically Safe Type, 1.6 Installation of Flameproof Type and “Installation and Operating Precautions for TIIS Flameproof Equipment” at the end of this manual

1. HANDLING PRECAUTIONS

The PK200 current-to-pneumatic converter is fully factory inspected before shipment. When the instrument is delivered, visually check the instrument and accessories to ensure that they are not damaged. This chapter describes the handling precautions, read them carefully before using the instrument.

For items other than those described in this chapter, see the relevant items.

If you wish to make inquiry, contact the distributor where you purchased the instrument or the nearest YOKOGAWA service station.

1.1 Checking the Model Suffix

Code and Specifications

The data plate on the side face of the instrument base shows the model suffix code and specifications. With reference to the model suffix code and specifications in section 2.3, confirm that the instrument is as specified by the order.

Figure 1.2 Data Plate for CSA Intrinsically Safe Type

Figure 1.3 Data Plate for FM Explosionproof Type

1.2 Transportation Precautions

To prevent damage occurring during transportation, transport the converter in the original shipping container (box) with all packing items and equipment in its proper position.

For inquiry, inform us of the model suffix code and instrument serial number.

Figure 1.1 Data Plate for General-Use Type

1-1

IM 21B03D01-01E

1. HANDLING PRECAUTIONS

1.3 Storage Precautions

(1) Select a storage place :

• Which is protected from rain and water.

• Which is free from vibration and impact.

•Whose temperature and humidity are as specified below. Room temperature and humidity (approx. 25°C and 65%) are more recommendable.

Temperature: -10 to 60°C Humidity: Less than 80%

(2) Store the converter in the packing condition of

shipment from YOKOGAWA whenever possible.

1.4 Precautions for Installation

Area

To use the converter stably for a long time, determine an installation place, taking into account the following.

(1) Ambient Temperature

Avoid installing the instrument in a place subject to a large temperature gradient and variations. If the instrument is subject to plant-generated heat radiation, take measures such as provision of heat protection and good ventilation.

(2) Atmospheric Conditions

Avoid installing the converter in corrosive atmosphere. Should it be used in corrosive atmosphere, make provision for maintaining good ventilation.

(3) Magnetic Field

Please contact us in the case this instrument is installed the strong Magnetic Field.

1.5 Installation of Intrinsically Safe Type

1.5.1 CSA Intrinsically Safe Type

[Intrinsically Safe]

Hazardous Location

Class I, II, III, Division 1, Groups A, B, C, D, E, F, G

–

PK200 Current-topneumatic Converter

[Nonincendive]

Hazardous Location

Class I, II, III, Division 2, Groups A, B, C, D, E, F, G Class III, Division 1.

–

PK200 Current-topneumatic Converter

Figure 1.4 Installation of CSA Intrinsically Safe Type

1. PK200 current to pneumatic converter is

applicable for use in hazardous locations:

• Intrinsically Safe for Class I, Division 1, Groups A,

B, C & D, Class II, Division 1, Groups E, F & G and Class III, Division 1 Hazardous Locations.

•Nonincendive for Class I, Division 2, Groups A, B,

C & D, Class II, Division 2, Groups F & G, and Class III, Division 1 Hazardous Locations.

• Outdoor Hazardous Locations, Encl Type 4X.

• Temperature Class: T4

• Ambient Temperature: -40 to 60°C

Non-hazardous Location

Safety Barrier

–

Non-hazardous Location

General Purpose Equipment

–

Note: Not use safety Barrier

General Purpose Equipment

–

F0105.EPS

2. Entity Parameters

• Intrinsically safe apparatus parameters

Vmax = 30V Imax = 165mA Pmax = 0.9W Ci = 2nF Li = 730µ H

• Associated apparatus parameters (CSA Certified

Barriers)

Voc ≤ 30V Isc ≤ 165mA Pmax ≤ 0.9W

1-2

IM 21B03D01-01E

1. HANDLING PRECAUTIONS

3. Installation

• Control equipment connected to barrier must not use or generate more than 250 Vrms or Vdc.

• The safety barrier must be CSA certified.

• Associated apparatus manufacturer’s installation drawing must be followed when installing this apparatus.

• The maximum power delivered from the barrier must not exceed 0.9 W.

•Note a warning label worded “SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY” and “INSTALL IN ACCORDANCE WITH DOC. NO. ICS006-A12 P.1 AND 2”.

1.5.2 TIIS Intrinsically Safe Type

The model PK200/JS3 current-to-pneumatic converters, which have obtained certification according to technical criteria for explosion-protected construction of electric machinery and equipment (Standards Notification No.556 from the Japanese Ministry of Labor) conforming to IEC standards, is designed for hazardous areas where explosive gases and/or inflammable vapors may be present. (This allows installation in Division 0 , 1 and 2 areas)

To preserve the safety of flameproof equipment requires great care during mounting, wiring, and piping. Safety requirements also place restrictions on maintenance and repair activities. Users absolutely must read the following instructions and “Installation and Operating Precautions for TIIS Intrinsically Safe Equipment (EX - A03E)” at the end of this manual.

1. Installation

The PK200 Current-to-Pneumatic Converter should be used in connection with the certified safety barrier as shown below. All wiring shall comply with local installation requirements.

[Installation Diagram]

Hazardous Area

–

PK200 Current-to-pneumatic Converter

Non-hazardous Area

–

Safety barrier

–

F0107.EPS

2. Temperature

Install the PK200, So that any part of the instrument that may exposed to the inflammable gas or vapor would not exceed the temperature 60°C

3. Safety Barrier

Use the certified safety barrier that satisfies the following requirements.

• Safety Ratings Maximum output voltage: 28V or less Maximum output current: 94.3mA or less Maximum output power: 0.66W or less

• Protection type and group Protection type: ia Group: IIC

•Allowable inductance and capacitance Maximum_external inductance: More than the external wiring inductance Maximum_external capacitance: More than the sum of the external wiring capacitance and 39nF

Table 1.1 Recommended Safety Barrier

Contact each supplier for the details of the barrier.

Supplier Type Model

MTL Isolated type MTL5046

P+F Isolated type KFD2-SCD-Ex1.LK*

T0101.EPS

* To connect this barrier with PK200 converter, for

the connection between the barrier and the controller, use the terminal #7 and #9 of the barrier.

1.6 Installation of Flameproof

Type

1.6.1 TIIS Flameproof Type

The model PK200/JF3 current-to-pneumatic converters, which have obtained certification according to technical criteria for explosion-protected construction of electric machinery and equipment (Standards Notification No.556 from the Japanese Ministry of Labor) conforming to IEC standards, is designed for hazardous areas where explosive gases and/or inflammable vapors may be present. (This allows installation in Division 1 and 2 areas)

To preserve the safety of flameproof equipment requires great care during mounting, wiring, and piping. Safety requirements also place restrictions on maintenance and repair activities. Users absolutely must read “Installation and Operating Precautions for TIIS Flameproof Equipment (EX - B03E)” at the end of this manual.

1-3

IM 21B03D01-01E

1. HANDLING PRECAUTIONS

1.6.2 FM Explosionproof Type

Following items are described in the instruction documents of this instrument to ensure certified explosionproof properties.

1. PK200 Current to Pneumatic Converter is applicable for use in hazardous areas;

* Explosionproof for Class I, Division 1, Groups B, C

and D.

*Dust ignitionproof for Class I/II, Division 1, Groups

E, F and G.

* Outdoor hazardous locations, NEMA 4X.

2. Wiring

*All wiring shall comply with National Electrical

Code ANSI/NEPA70 and Local Electrical Codes.

*When installed in Division 1, “FACTORY

SEALED, CONDUIT SEAL NOT REQUIRED”. However, in case of installing a sealing fitting (option) for waterproof or other purposes, see

4.2.2(6).

3. Operation

* WARNING: OPEN CIRCUIT BEFORE REMOV-

ING COVER. FACTORY SEALED, CONDUIT SEAL NOT REQUIRED. INSTALL IN ACCORDANCE WITH THE INSTRUCTION MANUAL IM 21B3D1-01E

* Take care not to generate mechanical spark when

access to the instrument and peripheral devices in hazardous location.

1.7 EMC Conformity Standard

EN61326-1 Class A, Table 2 (For use in industrial locations)

CAUTION

To meet EMC regulations, Yokogawa recommends that customers run signal wiring through metal conduits or use shielded twisted-pair cabling when installing this instrument in a plant.

CAUTION

This instrument is a Class A product, and it is designed for use in the industrial environment. Please use this instrument in the industrial environment only.

4. Maintenance and Repair

* The instrument modification or parts replacement by

other than authorized representative of Yokogawa Electric Corporation is prohibited and will void Factory Mutual Explosionproof Certification.

1-4

IM 21B03D01-01E

2. OVERVIEW

2.1 Functional Description

The PK200 current-to-pneumatic converter is a signal converter that receives an electronic controller or DCS control signal and converts it into a pneumatic pressure signal.

I/O Action: Output pressure increases as input

increases.

Manual Operation: Available using auto/manual (A/M)

transfer switch (Optional) Zero Point Adjusting Range: Within 0 to ±10% of span Span Adjusting Range: Within 100 to 125% of span Air Consumption: 4Nl/min maximum (for a supply air

pressure of 140kPa) Max. Air Delivery: 110Nl/min maximum (for a supply

2.2 Standard Specifications

Materials: Case: Aluminum die-cast

Paint: Polyurethane resin-baked finish Paint color: Deep-sea moss-green

(Munsell 0.6GY3.1/2.0 or equivalent) Pressure Gauge Case: Stainless steel JIS SUS304

Input Signals: 4 to 20mA DC or 10 to 50mA DC Input Resistance: PK200 is not a constant resistor. Equivalent circuit of PK200 is shown in Fig. 2.1

Minimum Load Capacity:

Ambient Temperature:

Water Proof Construction:

air pressure of 140kPa)

1m copper tube with 4mm I.D. +20cc

-40 to 80°C (for general use)

-20 to 60°C (TIIS Explosionproof , TIIS Intrinsically safe type)

-40 to 60°C (for FM Explosionproof, CSA Intrinsically safe type)

IEC IP54 NEMA type 4X

Input Signal 4 to 20mA DC

Constant

Vol tage

Circuit

5V DC (8V DC for CENELEC Intrinsically safe type and TIIS Intrinsically safe type.)

Intrinsically Safe Construction:

CSA Intrinsically Safe (/CS1) : Intrinsically Safe for

Class I, Division 1, Groups A, B, C & D Class II, Division 1, Groups E, F

50Ω MAX

Fig. 2.1 Equivalent Circuit

Operating Voltage:

Input Signal Min. Max.

4 to 20mA (except /JS3) 5.2V (at 4mA) 6.0V (at 20mA)

4 to 20mA (for /JS3) 8.2V (at 4mA) 9.0V (at 20mA)

10 to 50mA 5.35V (at 10mA) 6.75V (at 50mA)

F0201.EPS

T0200.EPS

& G and Class III, Division 1 Hazardous Locations. Nonincendive for Class I, Division 2, Groups A, B, C & D, Class II, Division 2, Groups F & G, and Class III, Division 1 Hazardous Locations. Outdoor Hazardous Locations, Encl Type 4X. Temperature Class: T4

Output Signals:

Standard Output

Output Signal

Pa calibration 20 to 100kPa 0 to 200kPa 40 to 200kPa 0 to 400kPa 130 to 150kPa 0 to 200kPa

kgf/cm2 calibration 0.2 to 1.0 kgf/cm20 to 2kgf/cm20.4 to 2.0 kgf/cm20 to 4kgf/cm21.3 to 1.5kgf/cm20 to 2kgf/cm

Bar calibration 0.2 to 1.0bar 0 to 2bar 0.4 to 2.0bar 0 to 4bar 1.3 to 1.5bar 0 to 2bar

P calibration 3 to 15psi 0 to 30psi 6 to 30psi 0 to 60psi 19 to 22psi 0 to 30psi

*1: Set supply air pressure in the range given in the upper column for standard output and in the range given in the lower column for

multiplied pressure output.

Output Signal

Pressure Gauge

Scale

Doubled Output

Output Signal

3 to 27psi 33 to 37psi 0 to 60psi

Pressure Gauge

Scale

Recomended

Supply Air

Pressure *

230 to 260kPa 0 to 400kPa

2.3 to 2.6kgf/cm20 to 4kgf/cm

2.3 to 2.6bar 0 to 4bar

Supply Air

Pressure Gauge

Scale *

T0201.EPS

2-1

IM 21B03D01-01E

2. OVERVIEW

TIIS Intrinsically Safe (/JS3):

Intrinsically Safe Ex ia IIC T4 Certificate: TC18266

Explosionproof Construction:

TIIS Explosionproof (/JF3): Flameproof Exd II

B+H2 T6X

FM Explosionproof (/FF1): Explosionproof for Class

I, Division 1, Groups B, C and D. Dust ignitionproof for Class II/III, Division 1, Groups E, F and G. Temperature Class: T6. Outdoor hazardous locations, NEMA 4X.

Dustproof Construction: IEC IP54 Connections:

Air Connection: Rc1/4 or 1/4NPT female Electrical Connection: G1/2, G3/4 female or

1/2NPT, 3/4NPT female

Mounting: Vertical or horizontal 50mm (2-

INCH) pipe mounting Wall mounting

Mass (weight): 2.8kg (6.1lb) Accuracy: ±0.5% of span

Linearity: ±0.2% of span Hysteresis: 0.2% of span Repeatability: 0.1% of span

2.4 Options

• Option Code/JF3: JIS Flameproof TIIS flameproof Exd II B+H2 T6X

• Option Code/G11: Packing adapter for TIIS Flameproof Electrical connection: G1/2 female, Applicable cable O.D.: 8 to 12mm

• Option Code/G21: Packing adapter for TIIS Flameproof Electrical connection: G3/4 female, Applicable cable O.D.: 10 to 16mm

• Option Code/FF1: FM Explosionproof

• Option Code/JS3: TIIS Intrinsically Safe Applicable only with input signal code-A.

• Option Code/CS1: CSA Intrinsically Safe

• Option Code/SCF-: Special Color Finished on converter cover Allows the paint color of only a converter cover to be selectable by specifying the color in the specification item with reference to GS22D1F1.

• Option Code/X1: Epoxy Paint Epoxy resin-baked coating. Not applicable for special color finished.

2.3 Model and Suffix Codes

Model Suffix Code Description

PK200

Input Signal -A 4 to 20mA DC

-C 4 to 20mA/10 to 50mA DC selection type

Output Signal 1 Output signal Pa calibration 20 to 100kPa scale 0 to 200kPa

2 Output signal Pa calibration 40 to 200kPa scale 0 to 400kPa 3 Output signal kgf/cm2 calibration 0.2 to 1.0 kgf/cm2scale 0 to 2kgf/cm 4 Output signal kgf/cm2 calibration 0.4 to 2.0 kgf/cm2scale 0 to 4kgf/cm 5 Output signal bar calibration 0.2 to 1.0bar scale 0 to 2bar 6 Output signal bar calibration 0.4 to 2.0bar scale 0 to 4bar 7 Output signal P calibration 3 to 15psi scale 0 to 30Psi 8 Output signal P calibration 6 to 30psi scale 0 to 60Psi 9 Output signal P calibration 6 to 27psi scale 0 to 60Psi

Connections 1 Air connection: Rc 1/4, Electrical connection: G1/2 female

2Air connection: Rc 1/4, Electrical connection: G3/4 female 3Air connection: 1/4 NPT female, Electrical connection: 1/2NPT female 4Air connection: 1/4 NPT female, Electrical connection: 3/4NPT female

Option / See section 2.4.

T0202.EPS

2-2

IM 21B03D01-01E

2. OVERVIEW

• Option Code/L: Lightning Protector Installed in the terminal box to protect internal circuitry from high voltage surges such as those caused by lightning induced.

• Option Code/AM: AUTO/MANUAL Switch Mounted on front of housing, in manual mode, output signal is varied by adjusting the external supply pressure regulator.

• Option Code/GW: Double Scale Pressure Gauge Double scales are kPa and kgf/cm2.

2.5 External Dimensions

165.5(6.52)

Electrical Connection

74(2.91)

Zero Adjustment Screw

•Option Code/SS: Stainless Steal Screw and Bracket Screw and bracket, both are made of stainless steal.

• Option Code/RA: Reverse Action Increasing of input signal to make output pressure decrease.

Unit: mm

38(1.50)

(3.82)

153.5 (6.04)

ø111

(4.37)

137.5(5.41) Wall Mount Screw 2-M8

24(0.94)

14(0.55)

Air Supply Connection

Supply Gauge

ø81(3.19) ø111(4.37)

Nominal 50 mm (2-inch) Pipe

Figure 2.2 External Dimensions

Output Gauge

A/M Transfer Switch (optional)

Input Terminal

Ground Terminal

Output Connection

 Terminal Configuration

47(1.85)

F0202.EPS

2-3

IM 21B03D01-01E

2.6 Part Names

Terminal box cover

Converter cover

2. OVERVIEW

Supply gauge

Output gauge

Figure 2.3 Part Names (1)

Span adjustment

Electrical connection

Te rminal board

Ground terminal

Figure 2.4 Part Names (2)

Case

Zero adjustment

F0203.EPS

Zero adjustment

Amplifier

F0204.EPS

2-4

IM 21B03D01-01E

3. INSTALLATION

3.1 Overview

When installing the PK200 converter, see section 1.4 “Precautions for Installation Area.” For the ambient environmental conditions of an installation place, see section 2.2 “Standard Specifications.”

3.2 Installation

PK200 can be installed on a pipe using a mounting bracket provided or directly installed on the wall. Select either method, taking into account the installation space and service method.

3.2.1 Pipe Mounting

When this instrument is mounted on a pipe, use the mounting bracket and U-bolt provided. The pipe dia. available is 50mm (2-INCH) and the instrument can be installed on either a horizontal or vertical pipe.

3.2.2 Wall Mounting

When the instrument is installed on the wall, use the two M8 screws provided.

PK200

Figure 3.2 Wall Mounting

F0302.EPS

Figure 3.1 Pipe Mounting

PK200

Pipe

Mounting bracket

F0301.EPS

3-1

IM 21B03D01-01E

4. WIRING AND PIPING

IMPORTANT

4. WIRING AND PIPING

4.1 Piping

4.1.1 Supply Air

For easy operation and maintenance, supply air must be clean and dry.

Thoroughly study selection of an air supply system, supply air suction point, installation of the header, and air supply piping so that no water, oil, or dust is carried into the current-topneumatic converter via the piping.

Table 4.1 shows the air supply pressure for this instrument.

For air consumption, see the standard specifications.

Table 4.1 Recommended Supply Air Pressure

Output Signal Code Output Signal Supply Air Pressure

1 20 to 100kPa 130 to 150kPa

2 40 to 200kPa 230 to 260kPa

3 0.2 to 1.0kgf/cm

4 0.4 to 2.0kgf/cm

5 0.2 to 1.0bar 1.3 to 1.5bar

6 0.4 to 2.0bar 2.3 to 2.6bar

73 to 15psi 19 to 22psi

86 to 30psi 34 to 37psi

93 to 27psi 34 to 36psi

1.3 to 1.5kgf/cm

2.3 to 2.6kgf/cm

T0401.EPS

4.1.3 Output Piping

Connect output air piping to the output connection

of the converter.

OUT

Generally, use copper tubes of 6mm O.D. and 4mm I.D., air piping, and coupling to install output air piping. After installing the piping, check for leakage.

4.2 General-Use and Flameproof Type Wiring

4.2.1 Cable Selection

(1) Use twisted wires or cables with performance

equal to or better than that of 600V vinyl-insulated cables (JIS C 3307) for wiring cables.

(2) Use shielded cables for wiring in a place suscep-

tible to noise influence.

(3) For wiring in an area where high or low ambient

temperatures exist, use wires or cables that meet service environment requirements.

IMPORTANT

If the PK200 is flameproof and the ambient temperature is 50°C or more, use an external cable having a maximum allowable heat resistance of at least 70°C in consideration of the instrument’s generation of heat or the cable’s self-heating.

4.1.2 Air Supply Piping

Connect air supply piping to the supply pressure connection

Generally, use copper tubes of 6mm O.D. and 4mm I.D., air piping, and coupling to install air supply piping. After installing the piping, check for leakage.

of the converter.

SUP

(4) For use in an atmosphere where harmful gas,

liquid, oil, or solvent exists, use wires or cables with materials sufficiently durable to such substances.

4-1

IM 21B03D01-01E

4.2.2 Wiring

(1) Install wiring away from noise sources such as a

large capacity transformer, motor, or power supply.

(2) Remove terminal box cover and wiring connection

dustproof plugs, then connect wiring. Using an Allen wrench (width 3mm), unscrew the locking setscrew and remove the flameproof cover. Then, connect the wiring and when installing the cover, do not neglect to fasten shrouding metal.

(3) It is recommended that clip-on terminals R1.25-5

or R2-5 be used for wiring termination (JIS C

2805).

(4) It is also recommended that wiring be installed in

conduits and ducts to provide protection against water or external damage. For flameproof external wiring, see 1.6 Installation of Flameproof Type” and “INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF EQUIPMENT” at the end of this manual.

(5) When installing a flameproof gland packing

adapter (option code: /G11 and /G21) for cable wiring, observe the following steps. a. Release the shrouding metal and remove the

terminal box cover.

b.Measure the outside dia. of the cables to be used

in two directions in 0.1mm unit.

c. Obtain the average value of the measured values

in two directions and select a gland packing whose inner dia. is nearest to the average value from among those in Table 4.1.

d.Screw the flameproof packing adapter into the

terminal box until the O-ring touches the terminal box wiring port (at least 6 full turns), and tighten the lock nut.

e. Insert the cable through the union cover, the

union coupling, the clamp nut, the clamp ring, the gland, one washer, the rubber packing, and

the packing box, in that order. f. Insert the end of the cable into the terminal box. g.Tighten the gland to grip the cable. When

tightening the union cover, tighten approximately

one turn past the point where the cable will no

longer move up and down.

Proper tightening is important. If it is too tight, a

circuit break in the cable may occur; if not tight

enough, the flameproof effectiveness will be

compromised.

4. WIRING AND PIPING

CAUTION

Tighten the gland approximately one turn after the point where you can no longer shift the cable up and down by hand. Take great care in this step, since proper tightening is very important.

h.Fasten the cable with tightening the clamp nut. i. Tighten the lock nut on the union cover. j. Connect the cable wires to each terminal.

Table 4.2 Type of Packing and Applicable Cable O.D.

Wiring port

thread diameter

G1 / 2 8-10 16 8-10 G9601AM

G3 / 4 10-12 22 10-12 G9601AN

Appropriate

cable outer

diameter (mm)

10.1-12 16 10-12

12.1-14 22 12-14

14.1-16 22 14-16

Identifying

mark

Part Number

T0402.EPS

(6) Install a sealing fitting (option) to be used for

metal conduit lines, in the following order. a. Assemble a sealing fitting into the instrument.

Apply sealing compound to the nipple provided and screw in the nipple by seven to eight turns, then fix it with a lock nut.

b.Install wiring using insulated wires and provide a

compound filling chamber of inorganic material by using sealing dams. (See Figure 4.5.)

c. Fill sealing compound from the compound filling

port until the fitting is filled with the compound.

Example of sealing compound Shimada Electric (1kg can) For FG5: Approx. 100g/P. filling For FG6: Approx. 115g/P. filling

d.After the compound has been sufficiently

softened, screw the plug into the filling port.

e. Connect a metal conduit for piping (JIS C 8305)

or explosion-proof flexible fitting to the sealing fitting by engaging five or more threads.

f. For the details of sealing, see 3.3.2.3 in the

“Recommended Practice of Explosion-Protected Electrical Installations in General Industries” published by the Industrial Safety Institute, Ministry of Labor (Japan).

4-2

IM 21B03D01-01E

Figure 4.1 General-Use and Flameproof Type Wiring

4. WIRING AND PIPING

Figure 4.2 Flameproof Metal Conduit Wiring

Figure 4.3 Flameproof Gland Packing Installation (Option code: /G11 and /G21)

4-3

IM 21B03D01-01E

4.2.3 Grounding

(1) Provide grounding with a ground resistance of

100Ω.

(2) Grounding terminals are provided inside and

outside of the terminal box. Use either terminal.

(3) Use 600V PVC insulated wire for grounding

wiring.

4.3 Intrinsically Safe Type Wiring

The wiring of the intrinsically safe circuit between the converter and the safety barrier must be kept routed with sufficient physical separation from other circuits so as not to be affected by electromagnetic induction, etc., and should be implemented using metallic conduit or shielded cable.

Current signal

Figure 4.4 Wiring

4. WIRING AND PIPING

⫹ ⫺

Ground

F0404.EPS

Figure 4.5 Intrinsically Safe Type Wiring

4-4

IM 21B03D01-01E

5. OPERATION

5.1 Auto/Manual (A/M) Transfer Mechanism

Please refer to following instruction for the model with A/M selector switch (optional code: /AM).

For the model without A/M selector switch, please go to section 5.2.

Use of A/M transfer mechanism requires that a supply pressure adjusting reducing valve be installed.

(1) Set the A/M selector switch provided at the front

(on the supply air pressure gauge side) of the converter to “M.” (Turn the switch clockwise.)

(2) This allows supply air pressure to be output, which

is supplied to the control valve.

(3) Output air pressure can be regulated using the

pressure regulator. Because the output pressure is not same as supply pressure, it is necessary to adjust it watching an output pressure gauge attached to this instrument. Pressure gauge minimum unit is 10kPa (standard output type) or 20kPa (doubled output type).

5.2 Zero Point Adjustment

(1) For the model with A/M selector switch, please set

the A/M selector switch to A (Auto). (Turn the switch counterclockwise.)

(2) Apply supply air pressure to the current-to-

pneumatic converter. For supply air pressure, see the data plate or Table

5.1 “Supply Air Pressure.” Standard output applies for model suffix output signal code “1, 3, 5, 7” and multiplied pressure output for model suffix output signal code “2, 4, 6, 8, 9.”

Table 5.1 Recommended Supply Air Pressure

Output Signal Code Output Signal Supply Air Pressure

1 20 to 100kPa 130 to 150kPa

2 40 to 200kPa 230 to 260kPa

30.2 to 1.0kgf/cm

40.4 to 2.0kgf/cm22.3 to 2.6kgf/cm

50.2 to 1.0bar 1.3 to 1.5bar

60.4 to 2.0bar 2.3 to 2.6bar

73 to 15psi 19 to 22psi

86 to 30psi 34 to 37psi

93 to 27psi 34 to 36psi

1.3 to 1.5kgf/cm

T0501.EPS

A/M selector switch

Figure 5.1 Auto/Manual Transfer Mechanism

F0501.EPS

(3) Then input an input signal.

Input a 0% electric signal. Apply 4mA for 4 to 20mA input or 10mA for 10 to 50mA input.

(4) Make zero point adjustment so that the output air

pressure reaches the specified pressure. For output air pressure, see the data plate or Table

5.2 “Output Signals.” To increase output air pressure, turn the zero adjustment clockwise. To decrease the pressure, turn the zero adjustment counterclockwise. (See Figure 5.2.) For the model with reverse action (/RA), please turn zero adjustment counterclockwise to increase output air pressure. To decrease output air pressure, please turn zero adjustment clockwise.

5-1

IM 21B03D01-01E

5. OPERATION

<Example: 20 to 100Pa output signal for 4 to

20mA input signal>

Adjust the zero adjustment so that an output signal of 20kPa is obtained when a 4mA input signal is applied.

Table 5.2 Output Signals

Output Signal Code Output Signal

1 20 to 100kPa

2 40 to 200kPa

3 0.2 to 1.0kgf/cm

4 0.4 to 2.0kgf/cm

5 0.2 to 1.0bar

6 0.4 to 2.0bar

73 to 15psi

86 to 30psi

93 to 27psi

T0502.EPS

5.3 Calibration

CAUTION

Always perform calibration in a non-hazardous area.

(1) For the model with A/M selector switch, please set

the A/M selector switch to A (Auto). (Turn the switch counterclockwise.)

(2) Remove the converter cover.

WARNING

For flameproof specifications or intrinsically safe explosion-proof specifications, first conduct a gas detector check to confirm that there is no explosive gas in the area.

Table 5.3 Recommended Supply Air Pressure

Output Signal Code Output Signal Supply Air Pressure

1 20 to 100kPa 130 to 150kPa

2 40 to 200kPa 230 to 260kPa

30.2 to 1.0kgf/cm

40.4 to 2.0kgf/cm22.3 to 2.6kgf/cm

50.2 to 1.0bar 1.3 to 1.5bar

60.4 to 2.0bar 2.3 to 2.6bar

73 to 15psi 19 to 22psi

86 to 30psi 34 to 37psi

93 to 27psi 34 to 36psi

1.3 to 1.5kgf/cm

(4) Then input a 0% input signal.

Apply 4 mA for 4 to 20mA input or 10mA for 10 to 50mA input. Control the zero adjustment so that the output air pressure reaches the specified pressure. For 0% output air pressure, see the data plate or Table 5.4 “Output Signals.” To increase output air pressure, turn the zero adjustment clockwise. To decrease the pressure, turn the zero adjustment counterclockwise. For the model with reverse action (/RA), please turn zero adjustment counterclockwise to increase output air pressure. To decrease output air pressure, please turn zero adjustment clockwise.

Table 5.4 Output Signals

Output Signal Code Output Signal

1 20 to 100kPa

2 40 to 200kPa

3 0.2 to 1.0kgf/cm

4 0.4 to 2.0kgf/cm

5 0.2 to 1.0bar

6 0.4 to 2.0bar

73 to 15psi

86 to 30psi

93 to 27psi

T0503.EPS

T0504.EPS

(3) Apply supply air pressure to the current-to-

pneumatic converter. For supply air pressure, see the data plate or Table

5.3 “Supply Air Pressure.” Standard output applies for model suffix output signal code “1, 3, 5, 7” and multiplied pressure output for model suffix output signal code “2, 4, 6, 8, 9.”

(5) Input a 100% input signal.

Apply 20mA for 4 to 20mA input or 50mA for 10 to 50mA input. Control the zero adjustment so that the output air pressure reaches a specified pressure. For 100% output air pressure, see the data plate or Table 5.2 “Output Signals.” (See Figure 5.3.) To increase output air pressure, please turn span adjustment clockwise. To decrease output air pressure, please turn span adjustment counterclockwise. (See Figure 5.3.)

5-2

IM 21B03D01-01E

5. OPERATION

For the model with reverse action (/RA), please turn span adjustment counterclockwise to increase output air pressure. To decrease output pressure, please turn span adjustment clockwise.

Zero adjustment

Figure 5.2 Zero Point Adjustment Mechanism

(6) Input a 0% input signal.

Confirm if 0% output air pressure reaches the specified pressure. If not, make zero point adjustment.

(7) Input a 100% input signal

Confirm if 100% output air pressure reaches the specified pressure. If not, make span adjustment.

(8) Repeat steps (6) and (7) two to three times to

adjust the zero point and span.

Table 5.5 Input and Output Signals

Input Current of the model with / RA is shown in ( ).

Input

Output

Signal

4 to 20mA 4mA 8mA 12mA 16mA 20mA

10 to 50mA 10mA 20mA 30mA 40mA 50mA

Output Signal 0% 25% 50% 75% 100%

1 20kPa 40kPa 60kPa 80kPa 100kPa

2 40kPa 80kPa 120kPa 160kPa 200kPa

30.2kgf/cm

40.4kgf/cm20.8kgf/cm21.2kgf/cm

50.2bar 0.4bar 0.6bar 0.8bar 1.0bar

60.4bar 0.8bar 1.2bar 1.6bar 2.0bar

7 3psi 6psi 9psi 12psi 15psi

8 6psi 12psi 18psi 24psi 30psi

9 3psi 9psi 15psi 21psi 27psi

(20mA) (16mA) (12mA) (8mA) (4mA)

(50mA) (40mA) (30mA) (20mA) (10mA)

0.4kgf/cm20.6kgf/cm

F0502.EPS

(9) After completing adjustments, change the input

signal to 0%, 25%, 50%, 75%, and 100% and confirm if the specified output is reached at the relevant input. Confirm the accuracy with reference to the input and output signal reference values given in Table

5.5 “Input and Output Signals.”

Span adjustment

Zero adjustment

F0503.EPS

Figure 5.3 Span Adjustment Mechanism

<Example: For 20 to 100 kPa output signal at 4

to 20 mA input signal>

Calibrate the input and output signals with reference to Table 5.6. Accuracy should be within ±0.5% of span.

Table 5.6 Input and Output Signals

Input Signal Output Signal

0% 4mA 20kPa

25% 8mA 40kPa

50% 12mA 60kPa

75% 16mA 80kPa

100% 20mA 100kPa

0.8kgf/cm21.0kgf/cm

1.6kgf/cm22.0kgf/cm

T0505.EPS

T0506.EPS

5-3

IM 21B03D01-01E

5.4 Range Adjustment

Perform the following to change to an output signal other than those specified in Table 5.4 “Output Signals.”

Zero point adjustable range is ±10% of span and the span adjustable range is from 100 to 125%.

An output signal can be flexibly regulated within these ranges using the zero and span adjustments.

Table 5.7 Zero and Span Adjustable Ranges

5. OPERATION

Output Signal Code

1 12 to 28kPa 80 to 100kPa

3 0.12 to 0.28kgf/cm20.8 to 1.0kgf/cm

5 0.12 to 0.28bar 0.8 to 1.0bar

7 1.8 to 4.2psi 12 to 15psi

*1 Please set the supply air pressure at the maximum working

pressure plus 30 to 60kPa.

*2 Please set the supply air pressure at the maximum working

pressure plus 0.3 to 0.6kgf/cm

*3 Please set the supply air pressure at the maximum working

pressure plus 0.3 to 0.6bar.

*4 Please set the supply air pressure at the maximum working

pressure plus 4 to 7psi.

*5 Please set the supply air pressure at the maximum working

pressure plus 7 to 9psi.

Zero Adjustable Range

24 to 56kPa 160 to 200kPa

0.24 to 0.56kgf/cm21.6 to 2.0kgf/cm

0.24 to 0.56bar 1.6 to 2.0bar

3.6 to 8.4psi 24 to 30psi

0.6 to 5.4psi 24 to 30psi

Span Adjustable Range

T0507.EPS

5.5 4 to 20mA/10 to 50mA Selection

Figure 5.4 4 to 20mA/10 to 50mA Selection

Take the following steps to select an input signal by using 4 to 20mA/10 to 50mA selecting function.

4 to 20mA or 10 to 50mA can be selected by changing the SOCKET switch on the amplifier shown in Figure

5.4. (Input signal is calibrated at 4 to 20mA at the time

of delivery.)

For 4 to 20mA input, insert the SOCKET switch to the two right pins. For 10 to 50mA input, insert the SOCKET switch to the two left pins.

NOTE

Before switching the SOCKET switch, always cut off the input signal.

5-4

IM 21B03D01-01E

6. MAINTENANCE

6.1 Overview

The PK200 converter components are structured as units to allow easy maintenance.

This chapter describes cleaning of each component and part replacement to be conducted for PK200 maintenance.

This converter is a high-precision instrument and thus, read the following description carefully before performing maintenance.

For maintenance, also see the operation items in Chapter 5.

CAUTION

Cautions for intrinsically safe apparatus Intrinsically safe apparatus shall be repaired by the manufacturer. Cautions for flameproof type instruments (a) Flameproof type instruments must be, as a

rule, removed to a non-hazardous area for maintenance and be disassembled and reassembled to the original state. For details, see “Installation and Operating Precautions for TIIS Flameproof Equipment” later in this manual.

(b) On the flameproof type instruments the cover

is locked by a setscrew. When a setscrew is driven clockwise by an Allen wrench, it is going in and cover lock is released, and then the cover can be opened. When a cover is closed it should be locked by a setscrew without fail.

6.2 Periodic Inspection

6.2.1 Cleaning the Restrictor

Remove the restrictor shown in Figure 6.1 using a screw driver and thread a wire with 0.3mm dia. into the restrictor for cleaning.

Figure 6.1 Restrictor Removal

Figure 6.2 Cleaning the Restrictor

6.3 Parts Replacement

6.3.1 Replacing the Screen Filter

If the mesh filter located at the rear of the supply pressure connection and output air pressure connection is clogged, use a sharp-edged tool such as tweezers to remove the filter and replace it with a new one.

Periodic inspection is required for maintaining normal plant operations. During periodic inspection, pay special attention to the following.

(1) Is the appearance normal? (2) Is there pressure leakage from the converter or its

peripheral piping?

(3) Is drainage present, or is there adhesion of dust or

oil, in the air supply system? Periodically clean the restrictor and nozzle flapper, which are easily subject to contamination. The following describes their cleaning.

Figure 6.3 Removing the Screen Filter (OUT Side)

6-1

Screen filter

F0603.EPS

IM 21B03D01-01E

Screen filter

F0604.EPS

6. MAINTENANCE

6.3.3 Replacing the Amplifier Assembly

An amplifier for replacement comes with a tube and four set screws.



 Removing the Amplifier



(1) Turn off the power and set the air supply pressure

to zero.

(2) Turn the amplifier cover counterclockwise to

remove it.

Figure 6.4 Removing the Screen Filter (IN Side)

6.3.2 Replacing the Controller Relay

(1) Set the air supply pressure to zero.

(2) Remove the controller relay from the bottom of the

converter. Unscrew the two mounting screws on the lower front face of the converter main body (see Figure

6.5) using a Phillips screwdriver. The relay can be removed downward.

(3) When installing a new relay, attach the relay to the

bottom of the converter, then fasten the relay using the two mounting screws at the front face of the converter.

(3) Adjust the zero adjustment control to the position

indicated in Figure 6.6.

Zero adjustment screw

Zero adjustment

Closeup of zero adjustment

Figure 6.6 Zero Adjustment

F0606.EPS

(4) Remove the silicon tube (a) from the pressure

sensor on the amplifier.

Figure 6.5 Removing the Control Relay

Control relay

F0605.EPS

(5) Remove the four set screws (b) for fixing wires on

the amplifier and then disconnect the wires.

(6) Remove the four set screws (c) for fixing the

amplifier.

(c)

(b)

(c)

Figure 6.7 Pressure Sensor and Amplifier Set Screws

6-2

(a) (a)

(c)

F0607.EPS

IM 21B03D01-01E

(c)

6. MAINTENANCE

(7) Pull out the amplifier directly, taking care not to

bend the zero adjustment control.

(8) Remove the silicon tube left in the case.



 Mounting the Amplifier



(1) Insert the accessory silicon tube into the body cap

firmly.

Tube pin on case

F0608.EPS

Figure 6.8 Silicon Tube Case Cap

NOTE

1.Do not apply undue pressure to the pressure sensor.

2.Do not bend the zero adjustment volume knob to prevent it from contacting the zero adjustment set screw.

(4) Fasten the four set screws for fixing the amplifier

(see Figure 6.7).

(5) Connect the four wires in the order of yellow

(ACT+), white (ACT-), red (IN+) and black (IN-).

(6) Insert the silicon tube into the amplifier pressure

sensor firmly.

Silicon tube

CAUTION

Be sure to use the accessory silicon tube that comes with the amplifier for replacement. Note that the tube size varies depending on the amplifier to be used. Be sure to use the proper tube to prevent air leakage and precision deterioration.

(2) Adjust the angle so that the volume knob of zero

adjustment forms a right angle with the amplifier.

Volume Knob of zero point adjustment

Figure 6.9 Zero Adjustment Control

F0609.EPS

(3) Pass the silicon tube through an amplifier hole and

mount the amplifier directly so that the sleeve of the pressure sensor leads into the hole of the case.

Pressure sensor

Figure 6.10 Pressure Sensor and Silicon Tube

F0610.EPS

(7) In a model allowing 4-20/10-50mA selection, refer

to 5.5 to set the socket switch as necessary.

(8) Mount the amplifier cover.



 Inspection after Amplifier Replacement



After replacing the amplifier, perform the insulation resistance test and withstand voltage test. Be sure to perform them according to the following procedure, referring to the corresponding tester instruction manuals.

CAUTION

(1) Overvoltage of the test voltage that is so

small that it does not cause an dielectric breakdown may in fact deteriorate insulation and lower the safety performance; to prevent this it is recommended that the amount of testing be kept to a minimum.

(2) The voltage for the insulation resistance test

must be 500V DC or lower, and the voltage for the withstand voltage test must be 500V AC or lower. Failure to heed these guidelines may cause faulty operation.

6-3

IM 21B03D01-01E

(3) Where a built-in arrester is provided (suffix

code: /A), the voltage for the insulation resistance test must be 100V DC or lower, and the voltage for the withstand voltage test must be 100V AC or lower. Failure to heed these guidelines may cause faulty operation.

Follow the steps below to perform the test, the wiring of the communication line must be removed before initiating testing.



 Insulation resistance test procedure



1. Lay transition wiring between the + terminal and the

- terminal.

2. Connect the insulation resistance meter (with the power turned OFF) between the transition wiring of Step 1 above and ground terminal. The polarity of the input terminals must be positive and that of the ground must be negative.

3. Turn the power of the insulation resistance meter ON and measure the insulation resistance. The duration of the applied voltage must be the period during which 100 MΩ or more is confirmed (or 20 MΩ if the unit is equipped with a built-in arrester).

4. Upon completion of the test, remove the insulation resistance meter, connect a 100 kΩ resistor between the transition wiring, and allow the electricity to discharge. Do not touch the terminal with your bare hands while the electricity is discharging for more than one second.

6. MAINTENANCE



 Withstand voltage test procedure



Testing between the input terminals and the grounding terminal

1. Lay the transition wiring between the + terminal and the - terminal, and connect the withstand voltage tester (with the power turned OFF) between the transition wiring and the grounding terminal. Connect the grounding side of the withstand voltage tester to the grounding terminal.

2. After setting the current limit value of the withstand voltage tester to 10 mA, turn the power ON, and gradually increase the impressed voltage from 0 V to the specified value.

3. The voltage at the specified value must remain for a duration of one minute.

4. Upon completion of the test, carefully reduce the voltage so that no voltage surge occurs.

6-4

IM 21B03D01-01E

7. TROUBLESHOOTING

7.1 Overview

If the PK200 converter does not operate normally, check the condition carefully and solve any problem in accordance with section 7.3 Troubleshooting Flow.

If problem appears difficult to correct, consult YOKOGAWA service personnel.

7.2 Operation Principle

The PK200 current-to-pneumatic converter accepts a 4 to 20mA or 10 to 50mA current signal from an electronic controller as an operating signal. This signal is input to a torque motor via an electric circuit, generating a torque proportional to the current signal.

An increase in the input signal causes the flapper at the end of the torque motor moving piece to move in the nozzle closing direction. When the nozzle is closed, back pressure increases, displacing the input diaphragm inside the control relay. This causes the control relay output air pressure to increase.

This output air pressure is output as PK200 converter output pressure and is also input to a feedback pressure sensor. The sensor then converts the pressure input into an electric signal, which is fed back to the electric circuit. The signal is then compared with the manipulated output signal, the result of which activates modification action until an output air pressure balanced with the input signal is obtained.

In this way, an output air pressure proportional to the input signal, which is a manipulated output signal, is obtained.

Voltage

4 to 20mA

input

Figure 7.1 PK200 Current-to-Pneumatic Converter Operation Principle Diagram

–

Torque

motor

Voltage

Nozzle

Position Air

flapper

pressure

Pressure

sensor

Pilot relay

Air

pressure

20 to 100 kPa

Output

F0701.EPS

7-1

IM 21B03D01-01E

7. TROUBLESHOOTING

7.3 Troubleshooting Flow

The PK200 current-to-pneumatic converter causes relatively few problems as long as it is used correctly. However, inadequate preparation such as in mounting or service conditions may result in a problem.

If the converter does not operate normally, take correct measures by following the flow chart below. Some problems include a complex cause which may not be uncovered by the following flow chart. If a problem appears difficult to correct, contact our service personnel.

Large output error.

Is air

supplied at normal supply

pressure?

YES

Supply air at normal supply pressure.

The converter does not operate even when input signal is applied.

supplied at normal supply

Is air

pressure?

YES

Is A / M selector switch

set to A?

YES

Is the restrictor clogged?

Supply air at normal supply pressure.

Select “A.”

Clean the restrictor.

YES

Is the

converter installed

in a place subject to large

temperature changes?

Is control relay defective?

Replace the converter using a spare.

Provide heat protection or good ventilation.

Replace the control relay.

YES

F0702.EPS

Is control relay defective?

Replace the converter using a spare.

Replace the control relay.

YES

F0703.EPS

7-2

IM 21B03D01-01E

Appendix A. AIR SUPPLY SYSTEM

1. Overview

Pneumatic industrial instruments are one of the most maintenance-free, highly reliable industrial instrument systems and are in wide use. Such features are fully demonstrated only when suitable service conditions where the characteristics of pneumatic instruments are sufficiently taken into account are established.

One of such service conditions includes an air supply system. Pneumatic instruments require clean, dry air and thus, an aftercooler, filter, and air drier are installed after a compressor to prevent water, oil, and other contaminants from entering into the instruments. Also, care should be exercised as described below at service points.

Air supply pipe for instrument

Shut-off value

Pressure gauge

2. Air Supply System

(1) Example of Panel-Mounting Instrument

When air is to be supplied to multiple instruments it is recommended that two reducing valves are used in parallel as shown in Figure 1. Parallel arrangement protects instruments from interference even if one reducing valve is suspended due to clogging. Also, use of a three-way cock as shown in Figure 1 allows any of air supply systems to be separated for maintenance. Generally, both air supply systems are used in parallel for operation. To supply clean and dry air to instruments, considerations should be made, such as provision of water drain, filter, and downward pitch (1/100 or more) for piping.

Regulator

Slope approximately 10 mm per meter length (1/100)

Drain valve

Figure 1 Example of Air Supply System (for Panel-Mounting Instrument)

Clean dry air supply

3-way cock

Air filter

High pressure air supply

F0A01.EPS

A-1

IM 21B03D01-01E

Appendix A. AIR SUPPLY SYSTEM

(2) Example for Field-Mounting Instru-

ments

Figure 2 shows an air-supply system for service point with respect to field-mounting instruments (individually installed instruments).

Securely install a filter and reducing valve in air supply piping that is nearest to an instrument. (These devices are not required if the instrument has a filter and reducing valve.)

Also, it is recommended that a shut-off valve be installed in the air supply pipe to allow removal of individual instruments without cutting off the entire air supply system.

Air supply pipe

Air header pipe

Samp

Unregulated air supply

It is recommended that an air supply pipe be provided with a shut-off valve so that individual instruments can be removed.

• Air Filter

A filter removes moisture, oil, and other contaminants that cannot be removed by the main air supply system. In general a cock installed at the bottom of a filter is opened to discharge moisture, oil, and other contaminants. If the amount of moisture and oil is large, increase the number of draining times.

The above-noted methods and units are an example and there are other various methods and units. Use a method and units suitable for the process type to supply clean, dry air to instruments.

Supply Regulator

To instrument

Air filter

Figure 2 Example of Air Supply System (for Field-

Mounting Instruments)

Shut-off valve

F0A02.EPS

(3) Air supply System for Field-Mounted

Instruments

• Supply Air

Clean, dry air is required. An aftercooler, filter, air drier are used to eliminate water, oil, and other contaminants.

• Air Supply Header (Air Header)

The air header that supplies air to a series of instruments is installed with a minimum downward pitch of 10 mm/m (1/100) so that moisture and oil entrapped in the header can be discharged.

• Air Supply Piping

An air supply pipe connected to an instrument is branched from the upper part of an air header to prevent moisture entry. Even if this is not possible, an air supply pipe should be branched from the side of the air header, i.e., it must not be branched from the bottom part of the header.

A-2

IM 21B03D01-01E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS INTRINSICALLY SAFE EQUIPMENT

Apparatus Certified Under Technical Criteria (IEC-compatible Standards) and from “RECOMMENDED PRACTICES for Explosion-Protected Electrical Installations in General Industries,” published in 1979

1. General

The following describes precautions on electrical apparatus

of intrinsically safe construction (hereinafter referred to as

intrinsically safe apparatus).

Following the Labor Safety and Health Laws of Japan, an

intrinsically safe apparatus must undergo type tests in order

to be certified by the Technical Institute of Industrial Safety,

Inc. These tests are required to satisfy either the technical

criteria for electrical machinery and equipment in compliance

with explosionproof standards involving inflammable gases

or vapors and for machinery and equipment having

explosionproof performance (standards notification no. 556

from the Japanese Ministry of Labor) (hereinafter referred to

as technical criteria), in conformity with IEC Standards, or

the “Recommended Practice for Explosion-Protected

Electrical Installations in General Industries,” published in

1979. Such a certified apparatus can be used in hazardous

locations where inflammable gases or vapors may be present.

Certified apparatus includes a certification label and an

equipment nameplate with the specifications necessary for

explosion requirements as well as precautions on explosion

protection. Please confirm these precautionary items and use

them to meet specification requirements.

For electrical wiring and maintenance servicing, please refer

to “Internal Wiring Rules” in the Electrical Installation

Technical Standards as well as “USER’S GUIDELINES for

Electrical Installations for Explosive Gas Atmospheres in

General Industry,” published in 1994.

To meet intrinsically safe requirements, equipment that can

be termed an “intrinsically safe apparatus” must:

(1) be certified by the Technical Institute of Industrial

Safety, Inc. in accordance with the Labor Safety and

Health Laws of Japan and have the appropriate mark of

certification labeled on its case, and

(2) be used in compliance with the specifications marked on

its certification label, equipment nameplate and

precautionary information furnished.

Note: Intrinsically safe apparatus satisfy their performance under

specific conditions. They are not always absolutely safe under every operational and environmental condition. In other

words, they are not safe products involved with factors such as chemical reactions, geographical changes or the like other than affected by electric energy from the equipment itself.

2. Electrical Apparatus of Intrinsic Safety Type of Explosion-Protected Construction

The intrinsic safety type of explosion-protected construction

is a method of protection applicable to a circuit or part of a

circuit in which, under prescribed test conditions, no spark or

thermal effect, whether produced normally or accidentally, is

capable of causing a prescribed explosive gas to ignite. In

other words, electrical apparatus of this construction is

intended to suppress electrical energy thereby preventing

ignition of a given explosive gas atmosphere even though

spark or high thermal effect occurs in the electric circuitry.

Intrinsically safe electrical apparatus generally comprise

intrinsically safe apparatus installed in a hazardous location

and a safety barrier (associated apparatus), installed in a non-

hazardous location, aimed at preventing electrical energy

from flowing into the electric circuitry of intrinsically safe

apparatus.

However, battery-operated, portable intrinsically safe

apparatus or the like may be used alone.

3. Terminology

(1) Intrinsically safe apparatus: Electrical apparatus in which

all the circuits are intrinsically safe circuits.

(2) Associated apparatus: Electrical apparatus in which there

are both intrinsically safe circuits and non-intrinsically

safe circuits that can affect the safety of intrinsically safe

circuits.

(3) Safety barrier: A specific type of associated apparatus,

which consists mainly of safety barrier elements, and

serves to limit the flow of excessive electrical energy,

which is capable of causing ignition of a given explosive

gas or vapour of a non-intrinsically safe circuit into

concerned intrinsically safe circuits.

(4) Apparatus of category “ia”: Intrinsically safe electrical

apparatus and associated apparatus which are incapable

of causing ignition of a given explosive gas or vapour

with the appropriate safety factors such as:

EX-A03E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS INTRINSICALLY SAFE EQUIPMENT

— when up to two countable faults are applied and, in

addition,

— when non-countable faults produce an onerous

condition.

(5) Apparatus of category “ib”: Intrinsically safe electrical

apparatus and associated apparatus which are incapable

of causing ignition of a given explosive gas or vapour,

with the appropriate safety factors such as:

— when up to one countable fault is applied and, in

addition,

— when non-countable faults produce an onerous

condition.

(6) Safety rating: A rating to be designated to intrinsically

safe apparatus as well as associated apparatus and is the

maximum rating allowable for maintaining intrinsic

safety of concerned intrinsically safe circuits.

4. Caution on Combining Intrinsically Safe Apparatus and Safety Barriers

(1) A combination of certified intrinsically safe apparatus

and safety barriers needs to satisfy combination

requirements. If intrinsically safe apparatus specify

safety barriers for combination, safety barriers other than

specified cannot be used (see Note 1 for more details).

(2) Certified intrinsically safe systems specify specific safety

barriers in combination with intrinsically safe apparatus.

So safety barriers other than specified cannot be used

(see Note 2 for more details).

(3) Other than limitations of combining intrinsically safe

apparatus and safety barriers as given in (1) and (2)

above, two or more pieces of apparatus certified under

different standards cannot be combined with each other

(see Note 3 for more details). In addition, bear in mind

that classifications of explosion protection such as “IIA,”

“IIB” and “IIC” and category “ia” and “ib” limit a

combination of intrinsically safe apparatus and safety

barriers.

For more details, see the “Type Certificate Guide for

Explosion-Protected Constructionfor Electrical

Machinery and Equipment,” issued by the Japanese

Ministry of Labour, the Research Institute of Industrial

Safety.

Note 1: Testing Apparatus

Intrinsically safe apparatus and safety barriers are assessed individually to ensure that their safety requirements are satisfied. Tested and certified intrinsically safe apparatus and safety barriers incorporate individual certification numbers. A combination of intrinsically safe apparatus and safety barriers involves the following two limitations: (1) A safety barrier which meets the combination require-

ments by referring to its safety rating and combination parameters shall be selected.

(2) For pressure transmitters, pH transmitters, temperature

detectors and the like, safety barriers that can be combined are already specified. Other safety barriers cannot be used.

Note 2: Testing Intrinsically Safe System

An assembly (as a system) in which intrinsically safe apparatus and safety barriers are combined is assessed to ensure that its safety requirements are satisfied. A tested and certified system incorporates a certification number (intrinsically safe apparatus and safety barriers have the same certification number).

Note 3: Impossible Combinations of Apparatus Certified Under

Different Standards Intrinsically safe apparatus certified under technical criteria and safety barriers certified under the “Recommended Practice for Explosion-Protected Electrical Installations in General Industries” (1979) and vice versa cannot be combined even if their combination requirements are satisfied.

5. Installation of Intrinsically Safe Apparatus and Safety Barriers

(1) Classification of installation location

Intrinsically safe apparatus may be installed, depending upon

applicable gases, in a hazardous area in Zone 0, 1 or 2 (Note

4 below), where the specified gases are present. However,

note that apparatus certified under Technical Criteria, in

category “ib” shall be installed only in Zone 1 or 2. Safety

barriers (associated apparatus) that are combined with these

intrinsically safe apparatus shall be installed only in a non-

hazardous area. In cases where safety barriers are installed in

a hazardous area, they shall be enclosed, for example, in a

flameproof enclosure.

Note 4: Hazardous areas are classified in zones based upon the

frequency of the appearance and the duration of an explosive gas atmosphere as follows: Zone 0: An area in which an explosive gas atmosphere is

present continuously or is present for long periods.

Zone 1: An area in which an explosive gas atmosphere is

likely to occur in normal operation.

Zone 2: An area in which an explosive gas atmosphere is not

likely to occur in normal operation and if it does occur it will exist for a short period only.

(2) Ambient temperature limits for intrinsically

safe apparatus

Intrinsically safe apparatus shall be installed in a location

where the ambient temperature ranges from –20° to +40°C

(for those certified under Technical Criteria) or –10° to

+40°C (for those certified under the “Recommended Practice

for Explosion-Protected Electrical Installations in General

Industries” (1979). However, some field-mounted

EX-A03E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS INTRINSICALLY SAFE EQUIPMENT

intrinsically safe apparatus may be used at an ambient

temperature up to 60°C. So, specifications should be checked

before installing intrinsically safe apparatus.

If the intrinsically safe apparatus are exposed to direct

sunshine or radiant heat from plant facilities, appropriate

thermal protection measures shall be taken.

6. Wiring for Intrinsically Safe Circuits

In intrinsically safe construction, safety shall be maintained

as an intrinsically safe system involving intrinsically safe

apparatus and safety barriers connected thereto, and electrical

wiring (through intrinsically safe circuits) interconnected

between them. In other words, even when safety

requirements are maintained individually by intrinsically safe

apparatus and safety barriers, they shall not be affected by

electrical or magnetic energy caused by electrical wiring.

To make electrical wiring for intrinsically safe circuits, you

must:

(a) refer to the equipment configuration diagram and make

electrical wiring properly;

(b) prevent intrinsically safe wiring from being contacted

with non-intrinsically safe wiring, and separate the

intrinsically safe circuit from other electrical circuits;

electrostatically and magnetically affected by non-

intrinsically safe wiring;

(d) reduce wiring inductance and capacitance produced

between the intrinsically safe apparatus and safety

barrier where possible, and use a shorter cable between

the intrinsically safe apparatus and safety barrier than

specified if the maximum permissible inductance of the

cable is specified as operating conditions;

(e) conform to conditions of installation such as wiring

method, earthing or the like, if any; and

(f) protect the outer sheath of cables from damage with

appropriate measures.

7. Maintenance and Inspection of Intrinsically Safe Apparatus and Safety Barriers

Installations for Explosive Gas Atmospheres in General

Industry” issued in 1994 by the Japanese Ministry of Labour,

the Research Institute of Industrial Safety.

(1) Requirements for maintenance personnel

Maintenance and inspection of intrinsically safe apparatus

and safety barriers shall be conducted by maintenance

personnel skilled in intrinsically safe construction and

installation of electrical devices as well as capable of

applying associated rules.

(2) Maintenance and Inspection

(a) Visual inspection

Visually inspect the external connections of intrinsically

safe apparatus and safety barriers, and cables for damage

or corrosion as well as other mechanical and structural

defects.

(b) Adjustments

Zero, span and sensitivity adjustments shall be made

with applicable adjusting potentiometers and mechanical

adjustment screws.

These maintenance adjustments shall be made in a non-

hazardous location.

CAUTION

If intrinsically safe apparatus and safety barriers require maintenance service and checking, a gas detector shall be used to ensure that there is no explosive gas in the location (maintenance servicing shall be conducted in a nonhazardous location).

(3) Repair

Intrinsically safe apparatus and safety barriers shall be

repaired by manufacturers.

(4) Prohibition of modifications and specifica-

tion changes

Do not attempt to make modifications or change specifica-

tions which may affect safety.

Maintenance and inspection of intrinsically safe apparatus

and safety barriers shall be limited to within the instructions

described in applicable instruction manuals. If other than this

is required, contact the manufacturers. For more information,

refer to the “USER’S GUIDELINES for Electrical

EX-A03E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF EQUIPMENT

Apparatus Certified Under Technical Criteria (IEC-compatible Standards)

1. General

The following describes precautions on electrical apparatus

of flameproof construction (hereinafter referred to as

flameproof apparatus) in explosion-protected apparatus.

Following the Labour Safety and Health Laws of Japan,

flameproof apparatus is subjected to type tests to meet either

the technical criteria for explosionproof electrical machinery

and equipment (standards notification no. 556 from the

Japanese Ministry of Labour) (hereinafter referred to as

technical criteria), in conformity with the IEC Standards, or

the “Recommended Practice for Explosion-Protected

Electrical Installations in General Industries,” published in

1979. These certified apparatus can be used in hazardous

locations where explosive or inflammable gases or vapours

may be present.

Certified apparatus includes a certification label and an

equipment nameplate with the specifications necessary for

explosion requirements as well as precautions on explosion

protection. Please confirm these precautionary items and use

them to meet specification requirements.

For electrical wiring and maintenance servicing, please refer

to “Internal Wiring Rules” in the Electrical Installation

Technical Standards as well as “USER’S GUIDELINES for

Electrical Installations for Explosive Gas Atmospheres in

General Industry,” published in 1994.

construction is of completely enclosed type and its enclosure

shall endure explosive pressures in cases where explosive

gases or vapours entering the enclosure cause explosion. In

addition, the enclosure construction shall be such that flame

caused by explosion does not ignite gases or vapours outside

the enclosure.

In this manual, the word "flameproof" is applied to the

flameproof equipment combined with the types of protection

"e", "o", "i", and "d" as well as flameproof equipment.

3. Terminology

(1) Enclosure

An outer shell of an electrical apparatus, which encloses live

parts and thus is needed to configure explosion-protected

construction.

(2) Shroud

A component part which is so designed that the fastening of

joint surfaces cannot be loosened unless a special tool is

used.

(3) Enclosure internal volume

This is indicated by:— the total internal volume of the

flameproof enclosure minus the volume of the internal

components essential to equipment functions.

To meet flameproof requirements, equipment that can be

termed “flameproof” must:

(1) Be certified by a Japanese public authority in accordance

with the Labour Safety and Health Laws of Japan and

have a certification label in an appropriate location on its

case, and

(2) Be used in compliance with the specifications marked on

its certification label, equipment nameplate and

precautionary information furnished.

2. Electrical Apparatus of Flameproof Type of Explosion-Protected Construction

Electrical apparatus which is of flameproof construction is

subjected to a type test and certified by the Japanese Ministry

of Labour aiming at preventing explosion caused by electrical

apparatus in a factory or any location where inflammable

gases or vapours may be present. The flameproof

(4) Path length of joint surface

On a joint surface, the length of the shortest path through

which flame flows from the inside to outside of the

flameproof enclosure. This definition cannot be applied to

threaded joints.

(5) Gaps between joint surfaces

The physical distance between two mating surfaces, or

differences in diameters if the mating surfaces are cylindrical.

Note: The permissible sizes of gaps between joint surfaces, the path

length of a joint surface and the number of joint threads are determined by such factors as the enclosure’s internal volume, joint and mating surface construction, and the explosion classification of the specified gases and vapours.

EX-B03E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF EQUIPMENT

4. Installation of Flameproof Apparatus

(1) Installation Area

Flameproof apparatus may be installed, in accordance with

applicable gases, in a hazardous area in Zone 1 or 2, where

the specified gases are present. Those apparatus shall not be

installed in a hazardous area in Zone 0.

Note: Hazardous areas are classified in zones based upon the

frequency of the appearance and the duration of an explosive gas atmosphere as follows: Zone 0: An area in which an explosive gas atmosphere is

present continuously or is present for long periods.

Zone 1: An area in which an explosive gas atmosphere is

likely to occur in normal operation.

Zone 2: An area in which an explosive gas atmosphere is not

likely to occur in normal operation and if it does occur it will exist for a short period only.

(2) Environmental Conditions

The standard environmental condition for the installation of

flameproof apparatus is limited to an ambient temperature

range from –20°C to +40°C (for products certified under

Technical Criteria). However, some field-mounted

instruments may be certified at an ambient temperature up to

+60°C as indicated on the instrument nameplates. If the

flameproof apparatus are exposed to direct sunshine or

radiant heat from plant facilities, appropriate thermal

protection measures shall be taken.

5. External Wiring for Flameproof Apparatus

Flameproof apparatus require cable wiring or flameproof

metal conduits for their electrical connections. For cable

wiring, cable glands (cable entry devices for flameproof type)

to wiring connections shall be attached. For metal conduits,

attach sealing fittings as close to wiring connections as

possible and completely seal the apparatus. All non-live

metal parts such as the enclosure shall be securely grounded.

For details, see the “USER’S GUIDELINES for Electrical

Installations for Explosive Gas Atmospheres in General

Industry,” published in 1994.

(1) Cable Wiring

• For cable wiring, cable glands (cable entry devices for

flameproof type) specified or supplied with the apparatus

shall be directly attached to the wiring connections to

complete sealing of the apparatus.

• Screws that connect cable glands to the apparatus are

those for G-type parallel pipe threads (JIS B 0202) with

no sealing property. To protect the apparatus from

corrosive gases or moisture, apply nonhardening sealant

such as liquid gaskets to those threads for waterproofing.

• Specific cables shall be used as recommended by the

“USER’S GUIDELINES for Electrical Installations for

Explosive Gas Atmospheres in General Industry,”

published in 1994.

• In necessary, appropriate protective pipes (conduit or

flexible pipes), ducts or trays shall be used for

preventing the cable run (outside the cable glands) from

damage.

• To prevent explosive atmosphere from being propagated

form Zone 1 or 2 hazardous location to any different

location or non-hazardous location through the protective

pipe or duct, apply sealing of the protective pipes in the

vicinity of individual boundaries, or fill the ducts with

sand appropriately.

•When branch connections of cables, or cable connections

with insulated cables inside the conduit pipes are made,

a flameproof or increased-safety connection box shall be

used. In this case, flameproof or increased-safety cable

glands meeting the type of connection box must be used

for cable connections to the box.

(2) Flameproof Metal Conduit Wiring

• For the flameproof metal conduit wiring or insulated

wires shall be used as recommended by the USER’S

GUIDELINES for Electrical Installations for Explosive

Gas Atmospheres in General Industry, published in

1994.

• For conduit pipes, heavy-gauge steel conduits

conforming to JIS C 8305 Standard shall be used.

•Flameproof sealing fittings shall be used in the vicinity

of the wiring connections, and those fittings shall be

filled with sealing compounds to complete sealing of the

apparatus. In addition, to prevent explosive gases,

moisture, or flame caused by explosion form being

propagated through the conduit, always provide sealing

fittings to complete sealing of the conduit in the

following locations:

(a) In the boundaries between the hazardous and non-

hazardous locations.

(b) In the boundaries where there is a different

classification of hazardous location.

• For the connections of the apparatus with a conduit pipe

or its associated accessories, G-type parallel pipe threads

(JIS B 0202) shall be used to provide a minimum of

five-thread engagement to complete tightness. In

addition, since these parallel threads do not have sealing

property, nonhardening sealant such as liquid gaskets

shall thus be applied to those threads for ensuring

waterproofness.

• If metal conduits need flexibility, use flameproof flexible

fittings.

EX-B03E

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF EQUIPMENT

6. Maintenance of Flameproof Apparatus

To maintain the flameproof apparatus, do the following. (For

details, see Chapter 10 “MAINTENANCE OF EXPLOSION-

PROTECTED ELECTRICAL INSTALLATION” in the

USER’S GUIDELINES for Electrical Installations for

Explosive Gas Atmospheres in General Industry.)

(1) Maintenance servicing with the power on.

Flameproof apparatus shall not be maintenance-serviced with

its power turned on. However, in cases where maintenance

servicing is to be conducted with the power turned on, with

the equipment cover removed, always use a gas detector to

check that there is no explosive gas in that location. If it

cannot be checked whether an explosive gas is present or not,

maintenance servicing shall be limited to the following two

items:

(a) Visual inspection

Visually inspect the flameproof apparatus, metal

conduits, and cables for damage or corrosion, and other

mechanical and structural defects.

(b) Zero and span adjustments

These adjustments should be made only to the extent

that they can be conducted from the outside without

opening the equipment cover. In doing this, great care

must be taken not to cause mechanical sparks with tools.

(2) Repair

If the flameproof apparatus requires repair, turn off the power

and transport it to a safety (non-hazardous) location. Observe

the following points before attempting to repair the

apparatus.

(a) Make only such electrical and mechanical repairs as will

restore the apparatus to its original condition. For the

flameproof apparatus, the gaps and path lengths of joints

and mating surfaces, and mechanical strength of

enclosures are critical factors in explosion protection.

Exercise great care not to damage the joints or shock the

enclosure.

(b) If any damage occurs in threads, joints or mating

surfaces, inspection windows, connections between the

transmitter and terminal box, shrouds or clamps, or

external wiring connections which are essential in

flameproofness, contact Yokogawa Electric Corporation.

requirements for flameproof apparatus (however, bear in

mind that the apparatus must always be restored to its

original condition). If you attempt to repair the

flameproof apparatus, company-specified components

shall be used.

(d) Before starting to service the apparatus, be sure to check

all parts necessary for retaining the requirements for

flameproof apparatus. For this, check that all screws,

bolts, nuts, and threaded connections have properly been

tightened.

(3) Prohibition of specification changes and

modifications

Do not attempt to change specifications or make

modifications involving addition of or changes in external

wiring connections.

7. Selection of Cable Entry Devices for Flameproof Type

IMPORTANT

The cable glands (cable entry devices for flameproof type) conforming to IEC Standards are certified in combination with the flameproof apparatus. So, Yokogawa-specified cable entry devices for flameproof type shall be used to meet this demand.

References:

(1) Type Certificate Guide for Explosion-Protected

Construction Electrical Machinery and Equipment

(relating to Technical Standards Conforming to Interna-

tional Standards), issued by the Technical Institution of

Industrial Safety, Japan

(2) USER’S GUIDELINES for Electrical Installations for

Explosive Gas Atmospheres in General Industry (1994),

issued by the Japanese Ministry of Labour, the Research

Institute of Industrial Safet

CAUTION

Do not attempt to re-process threaded connections or refinish joints or mating surfaces.

internal mechanisms may be repaired by component

replacement, as this will not directly affect the

EX-B03E

Customer Maintenance Parts List

Model PK200 Current-to-Pneumatic Converter

Item Part No. Description

F9172BS

Y9210XA

F9174VA

G9303LK

F9515AZ

F9270SA

—

F9270SA

—

U0103FP

Qty

Cover

O-Ring

Cover

O-Ring

Tag Plate

Self-tapping Screw

Nameplate (Dataplate)

Self-tapping Screw

Nameplate

for TIIS Flameproof option code: /JF3

Screen

CMPL 21B03D01-01E

10th Edition: Aug. 2012

Apr. 2001

CMPL 21B03D01-01E

Qty

/RA



/RA



/RA



Item Part No. Description

See Table 1

Y9430JB

G9339AA

Y9408ZU

—

See Table 2

F9174HA F9174HB

13A

F9172FB

Y9425JY

F9172ST F9172TC

—

Y9512JU

F9172DK

F9174HL

G9307MQ

F9275MK

Y9306JU

Y9820NS

Y9820NU

Y9800SS Y9800SU

F9174HM F9174FW

D0117XL-A

Below

PK200-A

PK200-C

PK200-A

PK200-C

2 1

G9601AM G9601AN

E9135GY

G9625BA

PK200-A

PK200-C

PK200-A

1 4 2 2 1

2 1

1 2

1 1 1 2 1

1 2 2 2 2

2 2 2 1 1

1 1

PK200-C

1 4 2 2 1

Amplifier Assembly

Machine Screw, M4⫻30

Bracket

Hex soc. H.Cap Screw, M4⫻8

Case Assembly

Pressure Gauge (see page 4) Pilot Relay Assembly

1 1 2

1 1 1 2 1

1 2 2 2 2

2 2 2 1 1

1 1

Pilot Relay Assembly

Screw Assembly

Pan H.Screw, M4⫻25

Terminal Assembly

Terminal Assembly (For /FF1)

Terminal Assembly (For /CS1)

Pan H.Screw, M5⫻12

O-Ring

Cover

Pan H.Screw, M4⫻8

Clip

Pan H.Screw

Bolt

Bolt (When option code is /SS)

Spring Washer

Spring Washer (When option code is /SS)

Bracket

Bracket (When option code is /SS)

U-Bolt/Nut Assembly

Cable Grand Assembly

For Electrical connection: G1/2 female (option code: /G11) For Electrical connection: G3/4 female (option code: /G21)

Wrench (M4)

Wrench (M3)

Dec. 2007

*1: Suffix code of output signal: 1, 3, 5, 7, A *2: Suffix code of output signal: 2, 4, 6, 8, 9, B, C *3: For suffix code details (indicated by ), refer to YOKOGAWA GS sheet. *4: When optional code is /L, Part No. is F9172SU. *5: When optional code is /L, Part No. is F9172TD. *6: Consult Yokogawa local office. *7: For TIIS Flameproof (option code: /JF3)

CMPL 21B03D01-01E

Table 1. Amplifier Assembly Part No. (Item 1)

Model

Part No.

(S2.06)

PK200-A*1*3

PK200-C*1*3

PK200-A*2*3

PK200-C*2*3

PK200-A*1*3/RA

PK200-C*1*3/RA

PK200-A*2*3/RA

PK200-C*2*3/RA

PK200-A*1*3/CS1

PK200-A*2*3/CS1

PK200-A*1*3/RA/CS1

PK200-A*2*3/RA/CS1

PK200-A*1*3/JS3

PK200-A*2*3/JS3

PK200-A*1*3/RA/JS3

PK200-A*2*3/RA/JS3

*1: Suffix code of output signal: 1, 3, 5, 7, A *2: Suffix code of output signal: 2, 4, 6, 8, 9, B, C *3: For suffix code details, refer to GS sheet. *4: Consult Yokogawa local office.

F9174XA

F9174XB

F9174XC

F9174XD

F9174XE

F9174XF

F9174XG

F9174XH

⫺

Part No.

(S2.05)

F9174MA

F9174MG

F9174MH

F9174MJ

F9174MK

F9174ML

F9174MM

F9174MN

⫺

Table 2. Pressure Gauge Part No. (Item 12)

Part No.

G9615AT

G9615AR

G9615EA

G9615ED

G9615EC

G9615EF

G9615EB

G9615EE

Output signal code

1, A

2, B, C

8, 9

Air Connection

R 1/8

1/8-27 NPT

Aug. 2012 Subject to change without notice. Printed in Japan.

CMPL 21B03D01-01E

Revision Record

● Manual No.: PK200 CURRENT - TO - PNEUMATIC CONVERTER

● Title: IM 21B03D01-01E

Edition Date Revision(s)

4th Feb. 1996 Style change (Style: S1→Style: S2) other correction.

Note CMPL 21B3D1-01E Amplifier Assembly of S2 is not compatible with S1.

5th Sep. 1996 Installation and Operating Precautions for JIS Flameproof Equipment (B0006)

updated and moved to the end of the manual. Due to Terminal box shape modification, Figure 2.2, 2.4, 4.1, 4.4 are changed.

1.1 Data plates for FM Explosionproof Type and CSA Intrinsically Safe Type added.

1.5 Installation of Intrinsically Safe Type added.

1.5.1 CSA Intrinsically Safe (/CS1) added.

1.6 Installation of Flameproof Type added.

1.6.1 JIS Flameproof Type added.

1.6.2 FM Explosionproof Type revised. NEMA 4 → NEMA 4X

CMPL Figure of terminal box changed.

Item 17, 19 revised. Item 18, 20 deleted. Note *4 revised. *5, *6 added.

6th July 1997 2.4 Option Code/B added.s

CMPL Option Code/B added. Item 1 revised.

7th Mar. 1998 1.1 Add precaution for safety

4.1 Add precaution for safety

4.4 Add precaution for safety

5.4 Add precaution for safety

5.8 Add precaution for safety

8th June 1999 Format change

Add ‘INTRODUCTION’ Update Installation and Operating Precautions for JIS Flameproof Equipment (Ex-B02)

2.2 Change ‘Exd II B+H2 T6’ to ‘Exd II B+H2 T6X’

2.4 Add optional code /JF3, /G11, and /G21 and delete /JF1 and /JF2

4.2 Add warning Change part number in Table 4.2 and Figure 4.3

CMPL Update CMPL 21B3D1-01E

9th Jan. 2000 1.2 Add Figure 1.3

Add 1.5.2 CENELEC (KEMA) Intrinsically Safe Type Add 1.5.3 JIS Intrinsically Safe Type

2.2 Add information for /KS1 and /JS3

2.4 Add codes /KS1 and /JS3, and delete code /B

Add 4.3 Intrinsically Safe Type Wiring Add Ex-A03E Ex-B03E: Change name (from EX-B02E) and format CMPL Update CMPL 21B3D1-01E

10th Apr. 2001 1.5.3 Move Table from page 4.6.

2.5 Correct terminal configuration diagram.

CMPL Table.1 Change parts number.

Edition Date Revision(s)

11th Dec. 2007 INTRODUCTION Add caution for prohibition of modification

1-1 JIS → TIIS 1-3 JIS → TIIS 1-4 Add “1.7 EMC Conformity standard” 2-1 JIS → TIIS, Delete CENELEC intrinsically safe type

Change Span Adjusting Range

Change Water Proof Construction 2-2 JIS → TIIS, Delete CENELEC intrinsically safe type 2-3 Add note for /X1 2-4 Change Figure 2.4 4-2 JIS → TIIS 5-1 Change pressure gauge minimum unit 5-3 Change Figure 5.3 5-4 Change Table 5.7 and Figure 5.4 6-1 Add caution for explosion type 6-2 Add “6.3.3 Replacing the Amplifier Assembly” CMPL P.1: Item 3 change Parts No.

P.3: Item 17 delete F9172TE

Item 30 change Parts No. and note

P.4: Change Table 1 and Table 2.

12th Aug. 2012 1-4 Change EMC conformity standard

2-1 Change operating voltage 2-2 Add certificate No.

Change water proof construction 5-1 Change description (3) CMPL Revise *1 and *2

Yokogawa PK200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

 INTRODUCTION

1. HANDLING PRECAUTIONS

1.2 Transportation Precautions

1.3 Storage Precautions

1.5 Installation of Intrinsically Safe Type

1.5.1 CSA Intrinsically Safe Type

1.5.2 TIIS Intrinsically Safe Type

1.6.1 TIIS Flameproof Type

1.6.2 FM Explosionproof Type

1.7 EMC Conformity Standard

2. OVERVIEW

2.1 Functional Description

2.2 Standard Specifications

2.4 Options

2.3 Model and Suffix Codes

2.5 External Dimensions

2.6 Part Names

3. INSTALLATION

3.1 Overview

3.2 Installation

3.2.1 Pipe Mounting

3.2.2 Wall Mounting

4. WIRING AND PIPING

4.1 Piping

4.1.1 Supply Air

4.1.3 Output Piping

4.2 General-Use and Flameproof Type Wiring

4.2.1 Cable Selection

4.1.2 Air Supply Piping

4.2.2 Wiring

4.2.3 Grounding

4.3 Intrinsically Safe Type Wiring

5. OPERATION

5.1 Auto/Manual (A/M) Transfer Mechanism

5.2 Zero Point Adjustment

5.3 Calibration

5.4 Range Adjustment

6. MAINTENANCE

6.1 Overview

6.2 Periodic Inspection

6.2.1 Cleaning the Restrictor

6.3 Parts Replacement

6.3.1 Replacing the Screen Filter

6.3.3 Replacing the Amplifier Assembly

6.3.2 Replacing the Controller Relay

7. TROUBLESHOOTING

7.1 Overview

7.2 Operation Principle

7.3 Troubleshooting Flow

Appendix A. AIR SUPPLY SYSTEM

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS INTRINSICALLY SAFE EQUIPMENT

INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF EQUIPMENT

Customer Maintenance Parts List

Revision Record