Azbil KUX113 I/P Converter User's Manual
The KUX113 is a field installation type of instrument that converts an electric current signal of 4 to 20mA DC into a pneumatic pressure signal of 0.2 - 1.0 kgf/cm2 (or other unit of measure). It can be installed on a 2-inch pipe stanchion using a standard type of mounting bracket.
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Field-Type I/P Converter
Model : KUX113
User's Manual
OM2-5900-1130
Copyright, Notices and Trademarks
1994-2012 Azbil Corporation All Rights Reserved.
While this information is presented in good faith and believed to be accurate,
Azbil Corporation disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer.
In no event is Azbil Corporation liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.
Table of Contents
Chapter 1 : General
Chapter 2 : Specifications
Chapter 3 : Operating Principle
Chapter 4 : Installation
Chapter 5 : Operation Procedure
Chapter 6 : Calibration
Chapter 7 : Maintenance
Chapter 8 : Bypass Manifold
Chapter 9 : Handling Procedure for A/M Switch (Pipingless type)
List of Figure
Azbil Corporation
Chapter 1 : General
External view
Pilot relay (rear panel)
Casing
Accessories
Hole for U-bolt
Bracket
Mounting holes for meter body
Terminal box
Figure 1-1 External view
U-bolt
L-wrench
Nut
Bolts
Figure 1-2 Accessories
Mounting bracket (1),
U-shape bolt (1), bolts (4), nuts (2)
KUX113 - Field-Type I/P Converter 1-1
General Azbil Corporation
1-1 : Description
The model KUX113 Field-type I/P Converter is a field installation type of instrument
(to be installed on a 2-inch pipe stanchion). It converts an electric current signal of 4 -
20mA DC into a pneumatic pressure signal of 0.2 - 1.0 kgf/cm
2
(or other unit of measure).
1-2 : Structure and Features
The KUX113 I/P Converter is comprised of a casing (in which the converter mechanism is directly installed), a pilot relay and a cover. The KUX113 can be installed on a
2-inch pipe stanchion employing a standard type of mounting bracket (which is identical to those used for other DSTJ3000 filed-type instruments).
The protective feature of a water splashproof casing, a flameproof enclosure, or of an intrinsic safety barrier.
The water splashproof casing complies with of JIS F8001 Class 3 requirements.
For the flameproof type, frameproof structure consists of the terminal box and magnet unit. These structures allow you to open the cover of the casing to maintain even while the instrument is operating in a hazardous area.
The intrinsic safety barrier type of instrument employs two spark killer diodes connected in parallel to the coil in the magnet section, in conjunction with a barrier.
If a bypass manifold is provided, the Converter can use manually produced signals as its outputs.
1-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 2 : Specifications
2-1 : Performance Specifications
Table 2-1 Performance specifications
Item Specifications
Input signal
4 to 20mA DC (Maximum allowable current approx.
30mA.)
250 ohms maximum
Input resistance
Output signal
20 to 100 kPa, 3 to 15 psi, 0.2 to 1.0 bar, 0.2 to 1.0 kgf/cm
2
(Maximum allowable pressure 200kPa)
Air supply pressure
140 kPa {1.4 kgf/cm
2
} ±10%
Air consumption
4 l/min(N) (With output 50% balanced)
Maximum air supply capacity
110 l/min(N)
Maximum air exhaust capacity 110 l/min(N)
Minimum load capacity
I.D. 4 mm copper tube × 3 m + 20 cc
AIr piping connections
Rc1/4, 1/4NPT internal thread
Electrical conduit connection
G1/2 internal thread
Material of major components Aluminum alloy
Operating temperature range
Waterproof, dust proof type: -30 to +80°C
Operating humidity range
Accuracy
Linearity
(with reference to zero)
Flame-proof type explosionproof type: -10 to +70°C
Intrinsic-safety explosionproof type: -10 to +60°C
10 to 90% RH
± 0.5% F.S.
± 0.2% F.S.
Hysteresis error
Reproducibility
Dead band
Temperature effect
Mounting
Net weight
Finish and color
< 0.5% F.S.
< 0.4% F.S.
< 0.05% F.S.
Zero shift: ±3% F.S. /30°C (Maximum)
Span shift: ±2% F.S. /30°C (Maximum)
2-inch pipe (Horizontal of vertical)
Approx. 3 kg
Finish: Acrylic baked finish
Construction
Color: Case; Dark beige, Cover; Black PPS resin, Terminal box cover; Light beige
Waterproof, dust proof type: JIS C 0920 Watertight, JIS F
8001 Class 3 Splashproof
Flame-proof type explosionproof type: JIS C 0903, d2G4
(Operating temperature -10 to +70°C)
Intrinsic-safety explosionproof type: JIS C 0903, i3aG5
(Operating temperature: -10 to +60°C, signal power supply: 23 to 27.5V DC)
KUX113 - Field-Type I/P Converter 2-1
Specifications
2-2 : Model Number Table
Selections
Basic model no.
KUX113
-X
W
E
H
1
Azbil Corporation
Description
3
4
1
2
A
B
B
D
X
A
Filed-type I/P converter not necessary
Waterproof (JIS)
Flame-proof type explosionproof (JIS)
Intrinsic-safety explosionproof (JIS)
Input 4 to 20mA DC
Output 0.2 to 1.0 kgf/cm2
Output 3 to 15 psi
Output 0.2 to 1.0 bar
Output 20 to 100 kPa
Air pressure connections Rc1/4
Air pressure connections 1/4NPT
Standard
Corrosion-resistant paint
Heavy-corrosion-resistant paint
Silver finish
-X
No options
-P
With flameproof-packing-type cable connecting adapter
-G
With output air pressure gauge
-6
With by-pass set (on special order)
-7
WIth air set
-J
With elbow for flame-proof type explosionproof
2-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
2-3 : Dimension Drawings
Specifications
Figure 2-1 Dimension drawings
KUX113 - Field-Type I/P Converter 2-3
Specifications Azbil Corporation
2-4 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 3 : Operating Principle
The electrical input signal (current signal) is converted by the magnet unit into a mechanical force which causes the beam position to change. The change in beam position is converted by the nozzle/flapper mechanism into a pneumatic signal, which is boosted by the pilot relay into the pneumatic output signal. The pneumatic output signal is fed back via the feedback bellows to the beam, thereby attaining a state of equilibrium. Thus, the electrical input signal is converted into a pneumatic output signal, which is directly proportional to the input signal.
Air supply
Input
Magnet unit
Force
+
-
Beam
Position
Nozzle/ flapper
Pneumatic pressure
Bellows
Figure 3-1 Block diagram of I/P converter
Pilot relay
Pneumatic pressure
Output
KUX113 - Field-Type I/P Converter 3-1
Operating Principle Azbil Corporation
3-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 4 : Installation
4-1 : Installation Method
(1) The mounting holes are drilled through the rear panel of the casing as shown in
Figure 4-2. Fix the bracket (supplied) to the casing with the four bolts. Select an
appropriate mounting position according to the direction of the 2-inch pipe stanchion.
(2) Hook the U-shape bolt onto the 2-inch pipe stanchion and pass its ends through the bracket holes and fix the ends securely with the nuts.
.
Figure 4-1 Examples of installation positions
(3) The I/P Converter should be installed vertically as shown in Figure 2-1. Note that
the exhaust port of the pilot relay must face downward. To position the exhaust port downward, loosen the screw of the cover and rotate the cover. The location of the exhaust port is labelled on the surface of the cover.
Hole for bolt
Marking
Exhaust port
Figure 4-2 Location of exhaust port
KUX113 - Field-Type I/P Converter 4-1
Installation Azbil Corporation
4-2 : Environmental Conditions
The place of installation must be within the specified temperature and humidity range
(See Chapter 2 :Specifications) and must be reasonably free from mechanical vibra-
tion.
For an explosionproof type of instrument, fasten the terminal box cover with the lock screw after installing the cover. Install the instrument observing all applicable explosionproof instrument installation standards and recommendations.
4-3 : Customer Connections
Electrical Connections
Connect the electrical input signal to the “+” and “-” terminals in the terminal box. The terminals have binding screws (M4, 6mm). For earth grounding, connect the “-” terminal to the “E” terminal.
The instrument has no internal fuse or switch. Provide them externally (if possible a wiring block should be used).
Air Connections
Two air connectors (Rc1/4 or 1/4NPT internal thread) are provided near the pilot valve. Remove the caps and connect the air supply piping to the SUP connector and the output air pressure piping to the OUT connector.
The supply air must be clean. Provide it via an Airset (a regulator and a filter). The air supply pressure must be 140 kPa {1.4 kgf/cm
2
}
OUT
SUP
Figure 4-3 Locations of air connectors
4-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 5 : Operation Procedure
After the I/P Converter has been installed and electrical wiring and air piping have been completed, it is ready for operation. Provide the air supply.
KUX113 - Field-Type I/P Converter 5-1
Operation Procedure Azbil Corporation
5-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 6 : Calibration
Nozzle block clamping-screws
Zero control wheel
Beam
Nozzle
Flapper Magnet unit
Feedback bellows
Span control slit
Figure 6-1 Layout of components
(1) Connect an air supply to the SUP connector and a precision air pressure gauge to the OUTPUT connector.
(2) Connect a precision electrical signal source (4 - 20mA DC) to the electrical input terminals.
I/P Converter
OUT SUP
Constant-current source (4 - 20mA DC)
IN
140 kPa
Airset
Air supply
Precision pressure gauge
20 cc
Volume tank
Figure 6-2 Calibration setup
KUX113 - Field-Type I/P Converter 6-1
Calibration Azbil Corporation
(3) Feed a current signal of 4mA from the constant-current source. Adjust the ZERO control wheel so that the output pressure become 20 kPa {0.2 kgf/cm
2
}±0.25%.
The output pressure rises as you turn the wheel couterclockwise as viewed from
the top in the attitude shown in Figure 6-1.
(4) Feed a current signal of 20mA from the constant-current source. Adjust the SPAN control by inserting a screwdriver into the SPAN control slit so that the output pressure becomes 100 kPa {1.0 kgf/cm2} 0.25%. The output span becomes wider
as you move the screw driver to the right as viewed in the attitude shown in Figure
(5) Repeat step (3) and (4) until the required zero and span accuracies are obtained.
The ZERO control is also adjustable externally.
Hole for control
Hole for zero control
Screws
6-2
Figure 6-3 Location of ZERO control hole
To gain access to the ZERO control hole, loosen the two screws of the cap near the nameplate on the casing, then side it downward.
~Note
If you have removed the cap by mistake, exercise care not to misplace the
O-ring of the ZERO control hole.
KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 7 : Maintenance
Normally the I/P Converter requires no maintenance service. However, if the I/P Converter is operated in adverse conditions (such as in environments prone to dust), disassemble the pilot relay and clean the restriction hole (employing a steel wire of 0.27 mm dia.) and the port and seat (employing a soft cloth). If the output pressure has become abnormally high and cannot be lowered, clean the nozzle with a steel wire of
0.6 mm dia. To do this, remove the nozzle block. (See Figure 6-1)
7-1 : Cleaning the Pilot Relay Port and Seat
(1) Remove the pilot relay cover by loosening its screws.
Pilot relay clamping-screws
(three)
Plate
(Gasket on both sides*)
*: Mark “C” is visible at gasket indent.
Figure 7-1 Removing the pilot relay
(2) Detach the pilot relay by removing its three clamping-screws.
Remove the leaf spring from the bottom of the pilot relay by loosening its two screws, and then take out the port.
Leaf spring
Port
Leaf spring
Screws
Figure 7-2 Port and seat of pilot relay
Seat plane
(Another plane deeper inside)
Port seat plane
KUX113 - Field-Type I/P Converter 7-1
Maintenance Azbil Corporation
(3) Clean the seating planes. There are two seating planes to be cleaned - one at the front and another deeper inside the hole. To clean the deeper seat plane, use a cloth formed into a bar shape.
7-2 : Cleaning the Restriction for Nozzle Back-pressure
To gain access to the restriction for the nozzle back-pressure, proceed as follows:
Remove the pilot relay. Now the plate which is sandwiched between the two gaskets is accessible. The restriction is located in the center of the plate.
Gasket
Pilot relay
Figure 7-3 Location of the restriction
Base plate
Restriction
7-3 : Notes on Installing the Pilot Relay
Install the pilot relay by following the two guide pins and exercising care not to damage the two gaskets. Position the gasket so that its indentation is aligned with the “C” mark on the plate. A circlet mark is provided on the side of the pilot relay to facilitate positioning. Align the circlet to the position of the OUT connector.
7-4 : Cleaning the Nozzle
To clean the nozzle, detach the nozzle block by loosening its two clamping-screws
7-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 8 : Bypass Manifold
This chapter is for the Bypass Manifold which is installed on a I/P Converter. The
Bypass Manifold is comprised of an Airset and an air switching mechanism, and allows the selection between an auto (A) position, a manual (M) position, and a ser-
Figure 8-1 Bypass setup
KUX113 - Field-Type I/P Converter
Figure 8-2 Bypass mechanism
8-1
Bypass Manifold Azbil Corporation
8-1 : A/M Switching
The bypass manifold is used when it is necessary to drive the control valve manually into the full open state or fully closed state (A/M position change).
When manually operating the control valve, it is recommended to change the manifold to the service position by means of the plug, in addition to the A/M position change.
(This is recommended as this will prevent hunting which could be caused when in the
M mode).
To return to the control valve to the manual mode, set the manifold to the A position.
8-2 : Switchover Procedures and Functions
Switchover from Auto (A) to Manual (M)
(1) Turn the fixing screw counterclockwise at the head of the hex cap nut with a screwdriver.
(2) Remove the hex cap nut by turning it counterclockwise.
(3) Push the plunger shaft into the manifold in the M direction until the shaft touches the stopper.
(4) Replace the hex cap nut at the M position.
When in manual, the I/P converter remains idle. The air supply adjusted by turning the knob of the Airset is fed to the actuator, allowing you to manually drive the control valve.
Service Position
To set the manifold to the service position from the manual (M) state, drive the stopper plug into the manifold with a screwdriver, until the plug touches the stopper. The service position basically is of an M state.
When in the service position, the I/P converter air supply is shut off. The control valve, however, can be driven manually the same as when the manifold is in manual.
Switchover from Manual (M) to Auto (A)
(1) If the stop plug has been set to the service position, rotate the plug by several turns counterclockwise with a screwdriver to allow the air supply to flow.
(2) Turn couterclockwise the fixing screw at the head of the hex cap nut with a screwdriver.
(3) Remove the hex cap nut by turning it counterclockwise.
(4) Push the plunger shaft into the manifold in the A direction until the shaft touches the stopper.
(5) Replace the hex cap nut at the A position.
When in auto the actuator is driven by the output of I/P converter.
The air supply for the converter is fed through the Airset.
Adjust its output pressure to obtain the required value.
8-2 KUX113 - Field-Type I/P Converter
Azbil Corporation
Chapter 9 : Handling Procedure for A/M Switch
(Pipingless type)
9-1 : Setting the A/M Switch
To set the A/M switch to the A (auto) or M (manual) mode, proceed as follows
Figure 9-1
(1) Loosen the clamping-screw of the plate and move the plate to a position where it grants you access to the A/M switch.
(2) If you want to change the A/M switch to the A mode, turn the A/M switch in the
“A” direction (counterclockwise) until it hits the stopper screw.
(3) If you want to change the A/M switch to the M mode, turn the A/M switch in the
“M” direction (clockwise) until it hits the stopper screw.
9-2 : Verifying the A/M Switch
To verify the setting of the A/M switch, proceed as follows:
(A) Verifying the A mode
(1) Be sure that the A/M switch has been set to the A mode.
(2) Set the pressure regulator output to 140 kPa {1.4 kgf/cm
2
}.
(3) Check and adjust overall operation of the I/P converter.
(B) Verifying for the M mode
(1) Be sure that the A/M switch has been set to the M mode.
(2) Set the pressure regulator output to 140 kPa {1.4 kgf/cm
2
}
(3) Check that the I/P converter output can be adjusted between a range of 0 to 140 kPa {1.4 kgf/cm
2
} by changing the pressure regulator output.
After setting and checking for the M mode of operation has been completed, return the
A/M switch to the A mode, and replace the plate to its original position and fix it securely with the clamping-screw. Finally, reset the pressure regulator output to 140 kPa {1.4 kgf/cm
2
}
KUX113 - Field-Type I/P Converter 9-1
Handling Procedure for A/M Switch (Pipingless type) Azbil Corporation
9-2 KUX113 - Field-Type I/P Converter
Document Number:
Document Name:
Date:
Issued/Edited by:
OM2-5900-1130
Field-Type I/P Converter
Model: KUX113
User's Manual
1st edition: Jun. 1994
7th edition: Sep. 2012
Azbil Corporation
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Key Features
- Field installation type
- Converts 4-20mA DC to pneumatic pressure
- 2-inch pipe stanchion mounting
- Water splashproof casing
- Flameproof or intrinsic safety barrier options
- Bypass manifold for manual operation
- Accuracy: ±0.5% F.S.
- Linearity: ±0.2% F.S.
- Operating temperature: -30 to +80°C (waterproof type)