controlair 500X Manual

441-622-015 Type 500X Page 2
Contents
Section Description Page
1.0 Specifications 2
2.0 Description & Installation 3
3.0 Operation 4
4.0 Maintenance 6
5.0 Troubleshooting 6
6.0 Warranty 6
Type 500X
Electro-Pneumatic Transducer (I/P, E/P)
Installation, Operation and
Maintenance Instructions
8 Columbia Drive, Amherst, New Hampshire 03031 USA
Phone: [phone] Fax: [phone]
[e-mail] www.controlair.com

441-622-015 Type 500X Page 2
WARNING
CAUTION
DANGER
ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL.
Functional Specifications
Standard Range High Output
INPUT 4-20 mA, 0-5 VDC, 1-9 VDC, 0-10 VDC 4-20 mA, 0-5 VDC, 0-10 VDC
Outputs psig
(bar)
Supply Pressure
psig (bar)
3-9
(0.2-0.6)
12-100
(0.8-6.9)
9-15
(0.6-1.0)
18-100
(1.2-6.9)
3-15, 15-3
(0.2-1.0)
18-100
(1.2-6.9)
3-27, 27-3
(0.2-1.8)
30-100
(2.1-6.9)
6-30, 30-6
(0.4-2.0)
33-100
(2.3-6.9)
1-17
(0.1-1.2)
20-100
(1.4-6.9)
2-60
(0.14-4.1)
65-150
(4.5-10.3)
3-120
(0.2-8.2)
125-150 (8.6-10.3)
Air Consumption
0.05 scfm (1.41 NL/min) midrange typical 0.07 scfm (1.98 NL/min) midrange typical
Flow Rate 4.5 scfm (127 NL/min)
at 25 psig (1.7 bar) supply
12.0 scfm (340 NL/min
at 100 psig (6.8 bar)
20.0 scfm (566 NL/min)
at 150 psig (10.5 bar)
Temperature Range
(Operating)
-200F to 1400F (-300C to 600C)
Relief Capacity 2 scfm (56.6 NL/min) at 5 psig (2.4 bar)
above 20 psig (1.3 bar) setpoint 7 scfm (198 NL/min) at 10 psig (0.7 bar) above 20 psig (1.3 bar) setpoint
Impedance 4-20 mA
90 Ohms 4-20 mA 90 Ohms 4-20 mA 180 Ohms
0-5 VDC
615 Ohms
1-9 VDC
985 Ohms
4-20 mA
220 Ohms
0-5 VDC
530 Ohms
1-9 VDC
840 Ohms
4-20 mA
220 Ohms
0-5 VDC
530 Ohms
1-9 VDC
840 Ohms
4-20 mA
250 Ohms 4-20 mA 225 Ohms
0-5 VDC
500 Ohms
4-20 mA
260 Ohms
0-10 VDC
805 Ohms
Performance Specifications
Terminal Based
Linearity
<± 0.75% of span <± 1.5% of span typical,
± 2.0% max.
Hysteresis < 1.0% of span < 0.5% of span
Repeatability < 0.5% of span < 0.5% of span
Response Time Dependent on pressure range - typically less than 0.25 sec for 3-15 psig units
Supply Pressure
Sensitivity
<± 0.1% of span per psig (<± 0.15% of span per 0.1 bar) <± 0.1% of span per psig,
± 2.0% max.
Physical Specifications
Housing NEMA 1 (standard); NEMA 4X (IP65) (optional)
DANGER, WARNING, CAUTION and NOTE statements
DANGER
NOTE
Refers to conditions or hazards which could result in serious personal injury or death.
Refers to conditions or hazards which could result in personal injury.
Refers to conditions or hazards which could result in equipment or property damage.
Alerts you to facts or special instructions.
1. SPECIFICATIONS

441-622-015 Type 500X Page 3
Port Sizes
1/4” NPT (Pneumatic)
1/2” NPT (Electric) 1/4” NPT (Pneumatic) 1/2” NPT (Electric)
Media
Clean, dry, oil-free, instrument air, filtered to 40 micron
Electrical Connections Conduit 1/2” NPT (standard); DIN 43650 (optional)
Mounting
Pipe, panel, or bracket
Weight
2.1 lbs. (0.94 kg) 2.1 lbs. (0.94 kg)
2.1 Description
2.1.1 The ControlAir Type 500X converts a current or voltage input signal to a linearly proportional
pneumatic output
pressure. This versatile instrument is designed for control applications that
require a high degree of reliability and repeatability at an economical cost.
2.2 Principle of Operation
2.2.1 The Type 500X is a force balance device in which a coil is suspended in the field of a magnet by a
flexure. Current flowing through the coil generates axial movement of the coil and flexure. The
flexure moves towards the nozzle
and creates back pressure which acts as a pilot pressure to an
integral booster relay. Input signal increases (or
decreases for reverse acting) cause proportional
output pressure increases.
Zero and Span are calibrated by turning adjust screws on the front face of the unit. Adjustment of
the zero screw repositions the nozzle relative to the flexure. The span adjustment is a
potentiometer that controls the amount of
current through the coil.
2.3 Mounting
2.3.1 Unit may be pipe, panel, or bracket mounted. Mounting may be at any angle, though may require field
adjustment. High external vibration may cause output fluctuations. Mounting in a vibration-free area is
recommended.
2.4 PneumaticConnections
2.4.1 The 1/4 NPT (1/4 BSP option) supply and output ports are marked “IN” and “OUT” respectively on
the base of the unit. Clean all
pipe lines to remove contamination before installation. Apply pipe
compound to male threads of the air line only. Avoid getting compound in the air lines.
Clean dry instrument quality air must be used. To ensure optimum performance supply pressure
should be regulated. To provide stable inlet pressure and prevent contamination of the internal
section of the transducer the use of an Instrument Air Filter Regulator is recommended.
The two unmarked ports on the base of the unit are gage ports but may be used as alternative
output ports. Any
unused ports must be plugged.
WARNING The I/P transducer enclosure contains aluminum and is considered to constitute a potential risk of
ignition by impact or friction and must be considered during installation.
2.5 Electrical Connections
2.5.1 Electrical connections are made to the black and white leads extending out from the 1/2 NPT conduit
fitting. When the side of the input signal is connected to the black lead, the output pressure will
increase as the t signal increases.
Figure 1 DIN 43650 Connector (“D” option)
2. DESCRIPTION AND INSTALLATION

441-622-015 Type 500X Page 4
3.1 Calibration
3.2.1 Zero and Span should always be checked after mounting. If unit is calibrated in a vertical position and
then mounted at an angle, readjustment of the zero is necessary. To calibrate use the following
procedure:
1. Open protective covers to expose zero and span adjustment screws.
2. Connect the recommended air supply to the inlet of the transducer and an accurate pressure
gage to the outlet.
3. Connect the electrical input and set the input signal to the minimum value of the range being
used (e.g., 4 mA for a 4-20 mA unit).
4. Observe the output pressure. If necessary, adjust zero screw until reaching minimum output
pressure setting. Turn zero screw counterclockwise to increase pressure, clockwise to
decrease pressure.
If unable to achieve output during calibration process, turn zero adjustment
screw counterclockwise for up to 30 revolutions, until output pressure rises.
5. Increase electrical input signal to its maximum value (e.g., 20 mA for a 4-20 mA unit).
6. Observe the output pressure. If necessary, adjust the span screw until reaching maximum output
pressure setting.
For I/P (current) input models turn span screw counterclockwise to increase
pressure, clockwise to decrease pressure. For E/P (voltage) input models turn
span screw clockwise to increase pressure, counterclockwise to decrease
pressure.
7. The Zero and Span adjustments are interactive. After adjusting the span, it will be necessary to
recheck the zero. Repeat steps 3-6 until both end points are at the required values.
8. For reverse acting performance interchange the black and white electrical signal leads and carry
out the same input (4mA) to get maximum output then with maximum input (20mA) to get minimum
output. Repeat as necessary. FM Approvals approved units must be ordered per specific model code.
Figure 2
Electrical Schematic (E/P) Electrical Schematic (I/P)
3. OPERATION
NOTE
NOTE

441-622-015 Type 500X Page 5
3.2 Dimensional Drawings (Dimensions are in/mm)
3.3 Intrinsically Safe Operation
3.3.1 ControlAir LLC offers FM Approvals Intrinsically Safe/NEMA 4X
Order input option ‘A’ 4-20 mA and option ‘H’.
Voc OR Vt <V max; Ca> Ci + Ccable
Isc OR It <I max; La> Li + Lcable
ENTITY PARAMETERS FOR MODEL 500-A_H_
Vmax=30V Ci=0
Imax=125mA Li=0mH
Ci IS CAPACITANCE CONTRIBUTED BY THE TRANSDUCER
Li IS INDUCTANCE CONTRIBUTED BY THE TRANSDUCER
9. FOR NEMA 4X OPTION, ADD H TO THE MODEL NUMBER. ONLY THE STANDARD 1/2NPT CONDUIT IS SUITABLE FOR NEMA 4X INSTALLATIONS.
10. MODELS WITH NEMA 4X OPTION ARE FM APPROVALS APPROVED FOR INDOOR/OUTDOOR USE PER THE REQUIREMENTS OF NEMA 4X AS DESCRIBED IN THE
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION STANDARD NO. 250 "ENCLOSURES FOR ELECTRICAL EQUIPMENT, 1000 VOLTS MAX".
NOTES:
1. INSTALLATION TO BE IN ACCORDANCE WITH THE
NATIONAL ELECTRIC CODE, NFPA 70, ARTICLE
504, AND ANSI/ISA RP 12.6.
2. APPARATUS CONNECTED TO THE SYSTEM SHALL
NOT USE OR GENERATE VOLTAGE
GREATER THAN 250 V.
3. INSTALL INTRINSICALLY SAFE BARRIERS IN
ACCORDANCE WITH BARRIER INSTRUCTIONS.
4. FM APPROVALS APPROVED AS INTRINSICALLY
SAFE FOR CLASS I, II, AND III, DIV. 1, GROUPS C,
D, E, F AND G WHEN INSTALLED AS SHOWN.
5. FM APPROVALS APPROVED AS NONINCINDIVE
FOR CLASS I, DIV. 2 GROUPS A, B, C AND D AND
SUITABLE FOR CLASS II, DIV. 2 GROUPS F, G, AND
CLASS III DIV. 1 AND 2. BARRIERS ARE NOT
REQUIRED FOR NONINCENDIVE RATING. MAX
V=30 VDC.
6. CAUTION: SUBSTITUTION OF COMPONENTS MAY
VOID FM APPROVALS APPROVAL.
7. AMBIENT TEMPERATURE RANGE: -30°C TO 60°C.
8. FM APPROVALS APPROVED AS INTRINSICALLY
SAFE FOR CLASS I, II AND III DIV. 1 GROUPS C, D,
E, F, AND G WHEN USED ASSOCIATED
APPARATUS. THE LINEAR BARRIER PARAMETERS
MUST MEET THE FOLLOWING REQUIREMENTS:

441-622-015 rev. 02/24/2022 Type 500X Page 6
Under normal circumstances, no maintenance should be required. If clean dry air is not used the orifice can
become blocked. Toclean, first turn off supply air, unscrew and remove orifice assembly (large silver screw
head located above the out port). Then unplug orifice by using a wire that has a smaller diameter than 0.015 in.
(0.38 mm). Use compressed air to blow out any loose particles inside the orifice assembly. Screw orifice
assembly back into unit.
PROBLEM CHECK
No or low output Zero adjustment *
Clogged orifice
Supply pressure too low
Leakage Connections
Low or improper span Zero and Span adjustments
Supply pressure too low
Output leakage
Erratic operation Electrical input signal
Loose wires or connections
Liquid in air supply
*most common
If problems are not solved by troubleshooting
procedures, contact a factory application’s
engineer at [phone] for further assistance.
ControlAir LLC products are warranted to be free from defects in materials and workmanship for a period of eighteen
months from the date of sale, provided said products are used according to ControlAir LLC recommended usages.
ControlAir LLC’s liability is limited to the repair, purchase price refund, or replacement in kind, at ControlAir, Inc.’s
sole option, of any products proved defective. ControlAir LLC reserves the right to discontinue manufacture of any
products or change products materials, designs or specifications without notice. Note: ControlAir does not assume
responsibility for the selection, use, or maintenance of any product. Responsibility for the proper selection, use, and
maintenance of any ControlAir product remains solely with the purchaser and end user.
These products are intended for use in industrial compressed-air systems only. Do not use these
products where pressures and temperatures can exceed those listed under Specifications.
Before using these products with fluids other than air, for non-industrial applications, life-support systems, or other
applications not within published specifications, consult ControlAir LLC.
4. MAINTENANCE
5. TROUBLESHOOTING
NOTE
6. WARRANTY & DISCLAIMER
WARNING