IMI NORGREN 140 User manual

Read these instructions before starting work
2011-035d
Installation
and operating
instructions
Model140
failsafe series
Currenttopressure(I/P)
electronicconverter

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2011-035d
1
General Information
3
1.1
Information about these instructions
3
1.2
Explanation of safety notice
3
1.3
Liability and warranty
4
1.4
Warranty statement
4
2
Safety
5
2.1
Intended use
5
2.2
General Dangers
5
2.3
Personnel requirements
6
2.4
Personal protective equipment
7
3
Specifications
8
3.1
Technical data
8
4
Transport and storage
11
5
Brief user guide
12
6
Connections
14
7
General description
15
8
Installation
16
8.1
Pneumatic connection
17
8.2
Captured bleed version
17
8.3
Electrical connection
20
9
Calibration
22
10
Maintenance
25
11
Disposal
25
12
Control Drawings
26
12.1
Control drawing FM
26
12.2
Control drawing CSA
27
13
Instructions
28
13.1
Specific to hazardous area installation
29
13.2
Special conditions for safe use
30
14
Certifications
31
15
Declaration of conformity
32

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1 General
1.1 Information about
these instructions
These instructions will enable you to safely install, set
up and operate the Model 140 electro-pneumatic
converter.
These instructions are an integral part of the product
and must be accessible to personnel.
Personnel must carefully read through and understand
these instructions before starting work of any kind on
the valves.
Following all of the safety and handling instructions
contained in this manual is a fundamental requirement
for safe working.
1.2 Explanation of
symbols safety
notice
DANGER
This symbol and the word 'danger' indicates
an immediately dangerous situation that may
result in death or serious injury if not avoided.
WARNING!
This symbol and the word ‘warning’ indicates a
potentially dangerous situation that may result
in death or serious injury if not avoided.
CAUTION!
This combination of symbol and signal word
indicates a possibly hazardous situation that
may result in damage to property or
environmental damage if it is not avoided.
Indicates tips and other useful information.
Other symbols
The following symbols are used to emphasise instructions,
outcomes, lists, references and other elements in these
instructions.
Symbols
Meaning
1., 2., 3.,
Step-by-step instructions
•
Lists with no specific order

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1.3 Liability and
warranty
Modification to the Model 140 converter may only be
carried out by the manufacturer’s personnel. If the
converter requires repairs or servicing beyond the scope of
the activities described in these instructions, this work may
only be carried out by the manufacturer of the converter or
by persons who have been expressly authorised and
trained by the Manufacturer. Failure to observe the above
will void the warranty. The manufacturer accepts no liability
for damages incurred.
1.4 Warranty statement
Items sold by NORGREN LTD are warranted to be free
from defects in materials and workmanship for a period of
two years from the date of manufacture, provided said
items are used according to NORGREN LTD’S
recommended usages.
NORGREN LTD’S liability is limited to the repair of, refund
of purchase price paid for, or replacement in kind of, at
NORGREN LTD’S sole option, any items proved defective,
provided the allegedly defective items are returned to
NORGREN LTD prepaid. The warranties expressed above
are in lieu of and exclusive of all other warranties. There
are no other warranties, expressed or implied, except as
stated herein. There are no implied warranties of
merchantability or fitness for a particular purpose, which
are specifically disclaimed. NORGREN LTD’S liability for
breach of warranty as herein stated is the exclusive
remedy, and in no event shall NORGREN LTD be liable or
responsible for incidental or consequential damages, even
if the possibility of such incidental or consequential
damages has been made known to NORGREN LTD.
NORGREN LTD reserves the right to discontinue
manufacture of any product or change product materials,
design, or specification without notice. Our policy is one of
continuous research and development.
We therefore reserve the right to amend without notice
the specification given in this document. Customers are
responsible for ensuring that the product is used only for
the purpose of which it is intended. In case of doubt
Norgren will be pleased to advise.

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2 Safety
This section provides an overview of all major safety
aspects for the protection of people and for safe, fault-free
operation. Further task-related safety notices appear in the
sections on transportation, installation, checks before initial
operation and maintenance.
2.1 Intended use
The Model 140 converter is a precision electronic pressure
regulator which provides an output pressure that is
proportional to a given control signal. It is intended for
pneumatic applications where fine control of air pressure or
regular automated pressure changes are required.
Misuse
DANGER!
Dangerous if misused!
• Incorrect use of proportional control valves
can create dangerous situations.
• In areas where an explosive atmosphere may
be present, only use Hazardous Area Certified
equipment
2.2 General dangers
The following section lists residual risks which may be
present even if the safety valves are correctly used.
Compressed air
WARNING!
Danger of injury caused by compressed air!
Compressed air can cause injuries if not
handled correctly.
• Ensure systems are depressurised before
work begins.
• Have all work carried out by pneumatics
specialists.

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2.3 Personnel
requirements
WARNING!
Danger of injury caused by lack of training!
People who lack proper training cannot assess
the risks when handling the proportional
pressure control valves and they place others at
risk of serious injury or death.
• Have all work on the pneumatic system carried
out by pneumatics specialists.
• Have all electrical installation work carried out
by qualified electricians.
Pneumatics specialist
Pneumatics specialists are trained for the specialist area they
work in, and they know the relevant standards and
regulations.
Because of their special training and experience, pneumatics
specialists can carry out work on pneumatic,
electropneumatic and mechatronic systems and identify and
avoid risks by themselves.
Qualified electrician
Because of their specialist training, knowledge and
experience, and their knowledge of the relevant standards
and regulations, qualified electricians are able to carry out
work on electrical installations and identify and avoid possible
risks by themselves.
Qualified electricians are specially trained for the area they
work in, and they know the relevant standards and
regulations.

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2.4 Personal protective
equipment
While carrying out work of various kinds on and with the
proportional valves, personnel must wear personal
protective equipment which is referred to in the individual
sections in these instructions.
For all work, always wear:
Protective Clothing
Protective clothes are heat-resistant and
close-fitting with low tear strength, close
fitting sleeves and without any parts
sticking out.
Safety Shoes
Safety shoes protect the feet from crushing,
falling parts and slipping on slippery
surfaces.
For special activities,
wear:
Protective gloves
Protective gloves protect the hands and
forearms against contact with heat and
sharp objects.
Safety goggles
Safety goggles protect the eyes from flying
objects and splashing liquids.
Ear protection
Ear protection protects the ears from
damage caused by exposure to noise.

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3 Specifications
The specifications for the proportional pressure
control valve also appear on the type plates.
3.1 Technical data
Specification
Value
Schematic
Medium:
Oil free, dry media, min filtered to
50µm; internal in-built filter
Output pressure:
0,2 … 1 bar (3 … 15psi)
0,2 … 2 bar (3 … 30psi
Supply pressure
Typical: 2 bar (30psi)
Maximum: 10.3 bar (150psi)
Minimum: 1.2 bar (18psi)
Flow capacity:
Up to 300 NL/min
Air Consumption:
< 2,5NL/min at 50% signal
Linearity
(independent):
Typically <0.1%,
guaranteed <0.2%
Hysteresis &
deadband:
Typically <0.1%,
guaranteed <0.2%
Response time:
<1 second
(from 0 … 90% or 90 … 10% of
output pressure into a 0,5 litre load)
Port size:
Main ports: G1/4 or ¼ NPT
Integral gauge ports: G1/4 or ¼ NPT
Exhaust ports: 1/8 NPT
Calibration:
Independent user adjustment
of 0 % and 100 % calibration
points. Independent adjustment of
tight shut off point. Adjustable up to
20% of output range. Factory
calibrated to within 1 % of span.
Operating
temperature:
-40 ... +85 °C (-40 ... +185 °F) Air
supply must be dry enough to
avoid ice formation at temperatures
below +2 °C (+35°F).
Temperature
sensitivity
Typically <0.06% span/oC between
-40 … +85oC (-40 … +185oF)

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Specification
Value
Electrical parameters
I.P. Rating:
IP66, NEMA Type 4X
Maintenance:
Modular electronics and in-built
filter offered as field replaceable
parts.
Mounting position:
Integral bracket allows for flat
surface or 2” (50 mm) pipe
mounting in any orientation.
Designed for mounting with
57 ... 73 mm pitch U bolts.
Vibration effect:
Output pressure changes less than
3% for vibration amplitude
4mm 5 … 15Hz,
2g 15 … 150Hz
1g 150 … 1000Hz
Materials:
Body: aluminium and zinc
diecasting.
Diaphragms: NBR
Black polyester powder coating
standard.
Input signal:
4… 20mA (two wire)
Terminal voltage < 6,5V at 20mA
Failure mode:
Pressure falls to below 15 mbar
(0.2 psi) in < 2 sec when input
signal fails
Insulation resistance:
>100MΩat 850V d.c., electrical
terminals to chassis
Connections:
½ NPT or M20; internal terminal
block with capacity up to 2,5mm2
conductor
Span/Zero:
Independently adjustable
Tight Shut Off:
Independently adjustable tight shut
off point adjustable up to 4,5mA
Input Impedance:
Approx. 1370Ω at 4mA
Approx. 470Ω at 12mA
Approx. 290Ω at 20mA

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Overload Protection:
100mA max overload current
Dimensions

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4 Transport and storage
Transport
Individual packed items are packed according to the
expected transportation conditions. Packaging is intended
to protect the individual components against
transportation damage, corrosion and other damage until
they are installed.
Only remove the packaging just before installation.
Check package on delivery to make sure it is
complete and has not been damaged in transit.
Packaging and storage
During transportation
• Do not drop packaged units.
• Do not throw packaged units.
The proportional valves are packed for immediate
installation upon delivery.
If they are going to be stored for extended periods,
please:
• Leave the packed units in the box they were shipped in.
• Do not store them outdoors.
• Store them in a dry, dust-free place.
• Don't expose to aggressive media, such as salty air.
• Protect them from direct sunlight.
• Storage temperature: -40°C to +85°C.
• Relative humidity: 90% max.

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5 Brief user guide
Please read these instructions carefully BEFORE this
instrument is installed or maintained.
The Model 140 I/P converters are not intended to
be used as a Safety accessory or as a means to
isolate equipment from over-pressurisation or under
pressurisation.
The system builder has the responsibility
to provide all necessary measures to ensure safe
operation of the overall system, taking into account
all possible functional failures of this product. The
equipment has been designed and manufactured
according to the sound engineering practice as specified
by the pressure equipment Directive 2014/68/EU.
These converters are intended for use in industrial
compressed air systems only. Ensure that adequate
pressure relief provision is installed if application of
system supply pressure could cause downstream
equipment to malfunction. Installation should be in
accordance with local and national compressed air and
instrumentation codes.
Products certified for use in Potentially Explosive
Atmospheres and Hazardous Area installations MUST:
a) Be installed in accordance with local and national
codes for hazardous area installations, and in
accordance with this manual. (See section 12 for
specific guidance.)
b) Only be used in situations which comply with the
certification conditions stated in this handbook.
c) Only be maintained by qualified personnel with
adequate training on hazardous area instrumentation.
Before using these products with fluid other than air
or for non-industrial applications consult IMI Precision
Engineering, Leeds.

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This is a quick guide to connecting the instrument for the
convenience of personnel who are familiar with this type
of product.
More comprehensive instructions are contained later in
this manual:
1. Connect a clean air supply of about 2,0 bar (30 psig) to
the IN port (1/4”).
1. Connect a pressure gauge or actuator to the OUT port.
CAUTION:
DO NOT use PTFE tape or similar to seal
the ports. Use a minimum of soft setting
anaerobic compound, e.g. Loctite Hydraulic
Seal 542
2. Unscrew the lid to obtain access to the terminals
DANGER:
The cable will need to be sealed by an
approved gland for Flame-proof installation.
For suitable cable gland and blanking plug
refer to Instruction - section 12.
3. Connect a 4 ... 20 mA current source, either through
the Jack-Plug or Terminal connections. Ensure that it
can supply at least 6,5V at 20 mA. Check for correct
polarity.
CAUTION:
DO NOT use a voltage source; it will
irreversibly damage the converter.
5. Switch on the air supply and current source and allow
a few seconds stabilisation time. Adjust span and zero,
via the trimpots if necessary.
If the instrument fails to operate refer to the Simple
Functional Checks.

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6. Connections

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7 General description
These converters are precision electronic pressure
controllers designed for continuous process control
applications. The units operate a closed loop system
incorporating a feedback sensor ensuring long term
stability and high accuracy performance, with ‘fail-safe’
operation, i.e. the output falls to a low pressure upon
failure of the loop current. These instruments combine
substantial flow capacity, with the ability to give precise
control into closed volume ‘dead end’ applications.
The instrument has been designed to withstand the
rigours of industrial environments; such as shock,
vibration and positional effects. As with any other
precision instrument, dropping the unit onto a hard
surface may result in shifts in calibration or possibly
permanent damage. The unit may be mounted directly
upon a control valve. A mounting bracket is provided for
surface mounting, or the instrument may be fixed directly
to rigid pipework.
The electronics are enclosed within a watertight housing
which is suitable for outdoor use if a suitable cable gland
is used. The lid should be firmly tightened, the use of a
tool for this purpose is not recommended.

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8 Installation
Before installation,
please note
For new systems, ensure all connections and lines are
clean, free from burrs, fluid and debris. Do not remove
blanking covers from the proportional valves until just
before installation.
Mounting
The converter must be securely mounted to prevent
accidental damage from occuring during operation. The
converter can be mounted directly onto a valve, onto
any suitable flat surface, or onto 2” (50 mm) pipe. These
converters will operate in any position, with slight
recalibration adjustments, normal operation is in the
upright position, i.e. with the screwed lid horizontal. The
unit is unaffected by typical levels of shock and vibration,
but severe vibration environments are best avoided to
ensure good performance.
The instruments are protected against environmental
effects, to a level of Type 4X (IP66). Sensible positioning
should be used if the local environment is severe.
Temperature compensation is designed into these
converters which will operate over a range from
-40 ... +85°C (-40 ... +185°F). Maximum life is obtained if
extreme temperature cycling is avoided. In extreme direct
sunlight, sun-shading is advised.
The pneumatic exhaust and the bleed are routed through
the baffles.

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8.1 Pneumatic
connection
Improper
pneumatic connection
DANGER!
Danger of injury caused by improper
connection!
Faulty pneumatic connections can impair the safe
operation of the converter and may cause injuries during
operation.
• Do not install any additional components between the
load and the converter.
• Connect pipe-work using 6mm or ¼” OD, 4mm ID pipe,
assembled with suitably rated pipe connections in
accordance with manufacturers guidelines.
WARNING
Care should be taken to prevent blocking of
the exhaust port. Failure to do so may result
in unwanted effects within the surrounding
system.
8.2 Captured bleed
version
The baffles and the baffle cover are fitted to maintain the
adequate Ingress Protection (IP) rating of the instrument.
Removal of these protective parts will invalidate the IP and
NEMA 4X rating of the instrument.
For captured bleed installation, remove the baffle cover and
unscrew both the baffles, fit 1/8“ NPT fittings to two seperate
lengths of pipe, to exhaust and bleed gas to a safe area.
Vented gas from the enclosure through bleed port must not be
re-circulated and introduced back into the process stream.
Exhaust port installation must not have any restriction to
create back-pressure that would cause instrument
malfunction. Instrument installation for the captured bleed
version must be under the installer’s discretion.
Note: Exhaust Port is nearer the conduit entry (LH side).
Enclosure Bleed Port is on the RH side.

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Pneumatic installation
These instruments are recommended for use with clean, dry, oil
free instrument grade air to BS 6739 or ISA-7.0.01-1996
Dew Point: At least 10°C (18°F) below anticipated ambient
temperature.
Dust: Filtered to below 50 microns
Oil Content: Not to exceed 1ppm mass.
The instrument is factory calibrated with a supply pressure of 30
psig (2 bar) ±10%. Operation is possible at any pressure
between 18 and 150 psig (1.3 ... 10.3 bar), though recalibration
may be necessary towards these limits to maintain specified
accuracy.
The inlet and outlet ports are threaded G1/4 or 1/4”NPT female
and suitable fitting should be used. For most installations 1/4”
(6mm) pipe will be adequate. If a large actuator, high flow rates
or long pipework is necessary then a larger diameter should be
used.
In all cases, purge the supply pipework before connection to the
converter.
Two gauge ports are provided to facilitate direct mounting
of a pressure gauge. To use one of these ports remove the
plug in a de-pressurized state, and connect the gauge.
CAUTION:
Under no circumstances should PTFE tape be
used for sealing the fitting as this tends to shred
small particles which may contaminate the
instrument and cause malfunctions.
The use of a soft setting anaerobic hydraulic seal is
recommended, (e.g. Loctite Hydraulic Seal 542). Follow the
manufacturer’s recommendations.
CAUTION:
Do not use an excessive amount as this will not set
and could find its way into the instrument.
If the air supply is not of adequate quality this can normally be
achieved by the use of air filter regulators.

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Compressed Air
WARNING!
Danger of injury caused by compressed air!
Compressed air can cause injuries if not handled
correctly.
•Make sure the machine is depressurised
before work begins.
Personnel:
• Pneumatics specialist
Protective equipment:
• Safety goggles
• Protective gloves
Connections
CAUTION:
Avoid damaging the thread when removing the
blanking covers..
1. Carefully remove the blanking covers from the
proportional pressure control valve.
2. Connect air supply equipment for drying and filtering
before connecting the valve.
Sealing
Fit and seal pipes and hose connections to the valve and
from the valve to the load, following national standards and
regulations as applicable.
An airtight compressed air system helps to save
energy, which protects the environment.

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8.3 Electrical connection
Improper electrical
connection
DANGER!
Danger of injury caused by improper
connection!
Danger of death through contact with live
components.
When switched on, electrical components can
perform uncontrolled movements and result in
serious injury
• Isolate the electrical supply before starting
work and make sure it cannot be switched back
on.
Electrical installation
Personnel:
• Qualified electrician
Protective equipment:
• Safety goggles
• Protective gloves
The electrical connections should be made as shown in
the connection drawing in Section 6. The instrument is
protected against reverse polarity to -100mA, no operation
is possible in this condition.
The Model 140 approximates a constant load of 6,5 volts
across the loop terminals therefore it is essential that the loop
controller be capable of providing a constant current in the
range 4 ... 20mA with an output voltage of at least 6,5 volts.
CAUTION:
Voltage output controllers (e.g. variable voltage
power supplies) are entirely unsuitable for
the Model 140 and could severely damage the
electronic circuits.
IMPORTANT NOTE
The control electronics of the Model 140
incorporate precision electronics. The calibration
of the unit may be affected by very high voltage
spikes. Consequently, in environments where
static electricity may be present ESD
precautions should be used.