Industrial Controls IP500AC Manual

541-622-039 Page 1
Industrial Controls
IP500AC
I/P Transducer
Installation, Operation
and Maintenance
Instructions
Contents
Section Description Page
1.0 Description & Installation 2
2.0 Operation 3
3.0 Maintenance 5
4.0 Troubleshooting 5
Pilot Pressure
Atmospheric Pressure
Supply Pressure
Output Pressure
*Contact Industrial Controls
Note: Output shown is as calibrated at the factory. Large span
adjustment capability allows recalibration to achieve output
ranges from 3-35 psig (0.2-2.4 BAR) with 2-60 psig unit to
3-145 psig (0.2-10 BAR) with 2-120 psig unit.

541-622-039 Page 2
DANGER, WARNING, CAUTION and NOTE statements
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.
ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL
SPECIFICATIONS
Min./Max. Supply Pressure Minimum - 3 psig (0.21 BAR)
Above maximum output Maximum
- 100 psig (7 BAR)
Supply Pressure Sensitivity <± 0.1% of span per psig
(<± 0.15% of span per 1 BAR)
Linearity <± 0.75% of span
Repeatability < 0.5% of span
Hysteresis < 1.0% of span
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) supply
Maximum Air Consumption .05 scfm (1.4 Nl/min) midrange typical
Port Sizes 1/4 NPT (Pneumatic)
1/2 NPT (Electric)
1. DESCRIPTION and INSTALLATION
1.1 Description
1.1.1 The IP500AC 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.
1.2 Principle of Operation
1.2.1 The IP500AC is a force balance device in which a coil is suspended in the field of a magnet by a flex-
ure. 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 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.
.
1.3 Mounting
1.3.1 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.
NOTE
CAUTION
WARNING
DANGER

541-622-039 Page 3
1.4 Pneumatic Connections
(00( )1?@(@)@87446,@=<3@97>47>@49;>8@=;?@2=;&?3@@=<3@)@;?84?5>:*?6,@9<@>1?@-=8?@9.@>1?@7<:>0@6?=<@=66@
4:4?@6:<?8@>9@;?29*?@59<>=2:<=>:9<@-?.9;?@:<8>=66=>:9<0@'446,@4:4?@592497<3@>9@2=6?@>1;?=38@9.@>1?@=:;@6:<?@9<6,0@
'*9:3@/?>>:</@592497<3@:<@>1?@=:;@6:<?80
6?=<@3;,@:<8>;72?<>@7=6:>,@=:;@278>@-?@78?30@)9@:<87;?@94>:272@4?;.9;2=<5?@87446,@4;?887;?@819763@-?@
;?/76=>?30@)9@4;9*:3?@8>=-6?@:<6?>@4;?887;?@=<3@4;?*?<>@59<>=2:<=>:9<@9.@>1?@:<>?;<=6@8?5>:9<@9.@>1?@>;=<8375?;@>1?@
78?@9.@=<@<8>;72?<>@':;@:6>?;@?/76=>9;@:8@;?5922?<3?30
)1?@>+9@7<2=;&?3@49;>8@9<@>1?@-=8?@9.@>1?@7<:>@=;?@/=/?@49;>8@-7>@2=,@-?@78?3@=8@=6>?;<=>:*?@97>47>@49;>80@'<,@
7<78?3@49;>8@278>@-?@467//?30
The I/P transducer enclosure contains aluminum and is considered to constitute a potential risk of
ignition by impact or friction and must be taken into account during installation.
1.5 Electrical Connections
(00( 6?5>;:5=6@59<<?5>:9<8@=;?@2=3?@>9@>1?@-6=5&@=<3@+1:>?@6?=38@?#>?<3:</@97>@.;92@>1?@( @)@59<37:>@.:>>:</0@
1?<@>1?@498:>:*?@8:3?@9.@>1?@:<47>@8:/<=6@:8@59<<?5>?3@>9@>1?@-6=5&@6?=3!@>1?@97>47>@4;?887;?@+:66@:<5;?=8?@=8@>1?@
:<47>@8:/<=6@:<5;?=8?80@9;@;?*?;8?@=5>:</@293?@:<5;?=8:</@:<47>@8:/<=6@3?5;?=8?8@97>47>@4;?887;?!@59<<?5>@
498:>:*?@8:3?@9.@>1?@:<47>@8:/<=6@>9@>1?@+1:>?@6?=30
Figure 1 DIN 43650 Connector
2. OPERATION
2.1 Calibration
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297<>?3@=>@=<@=</6?!@;?=3%78>2?<>@9.@>1?@"?;9@:8@<?5?88=;,0@)9@5=6:-;=>?@78?@>1?@.9669+:</@4;95?37;?
(0 4?<@4;9>?5>:*?@59*?;8@>9@?#498?@"?;9@=<3@84=<@=3%78>2?<>@85;?+80
0 9<<?5>@>1?@;?5922?<3?3@=:;@87446,@>9@>1?@:<6?>@9.@>1?@>;=<8375?;@=<3@=<@=557;=>?@4;?887;?@/=/?@>9@>1?@97>6?>0
0 9<<?5>@>1?@?6?5>;:5=6@:<47>@=<3@8?>@>1?@:<47>@8:/<=6@>9@>1?@2:<:272@*=67?@9.@>1?@;=</?@-?:</@78?3@
?0/0@@2'@.9;@=@ $@2'@7<:>0
0 -8?;*?@>1?@97>47>@4;?887;?0@.@<?5?88=;,@=3%78>@"?;9@85;?+@7<>:6@;?=51:</@2:<:272@97>47>@4;?887;?@8?>>:</0@
)7;<@"?;9@85;?+@597<>?;@5695&+:8?@>9@:<5;?=8?@4;?887;?!@5695&+:8?@>9@3?5;?=8?@4;?887;?0
0 <5;?=8?@?6?5>;:5=6@:<47>@8:/<=6@>9@:>8@2=#:272@*=67?@?0/0@ $@2'@.9;@=@ $@2'@7<:>0
0 -8?;*?@>1?@97>47>@4;?887;?0@.@<?5?88=;,@=3%78>@>1?@84=<@85;?+@7<>:6@;?=51:</@2=#:272@97>47>@4;?887;?@8?>>:</0
For I/P (current) input models turn span screw counter clockwise to increase pressure,
clockwise to decrease pressure. For E/P (voltage) input models turn span screw clockwise
to increase pressure, counter clockwise to decrease pressure.
0 )1?@?;9@=<3@4=<@=3%78>2?<>8@=;?@:<>?;=5>:*?0@'.>?;@=3%78>:</@>1?@84=<@:>@+:66@-?@<?5?88=;,@>9@;?51?5&@>1?@"?;90@
?4?=>@8>?48@@7<>:6@-9>1@?<3@49:<>8@=;?@=>@>1?@;?7:;?3@*=67?80
Figure 2 Electrical Schematic
WARNING
NOTE
Notes:
@C 81F5DAEF?6F>9%F@EDF?6F/B7F@F>BF:8B=;=7F=9:/;C
AC 81F@ED<EF?6F-.>9,7F#5F;8F@EEF+.?BC
0C 81F@D"F'*F>9%FED@EF'*F17?87F#AF/B7F<F>BF
:8B=;=7F=9:/;C

2.2 Dimensional Drawings :2?<8:9<8@=;? 
2.3 Intrinsically Safe Operation
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=44;9*=6@=8@=@8>=<3=;3@.?=>7;?@9<@=66@7<:>8@+:>1@=@ $@2'@:<47>@8:/<=60
:<0
22
541-622-039 Page 4
1.10
27.9
.55
14.0
(2) #18 GA. Wire Leads,
18" Long.
Black = Positive
White = Negative
(2) #10-32 UNF-2A x .38 DP.
Mounting Holes (Shown with
Bracket Screws Installed)
1.15
29.2
1.12
28.4
4.24
107.7
1.13
28.7
1.04
26.4
1.50
38.1
1.50
38.1
.55
14.0
1.13
28.7
Diameter
2.88
73.1
.21
.53
Diameter
MNTG.
Holes
1.250
31.7
2.18
55.4
1.44
36.6
SIGNAL
1/4
NPT
TYP.
Removable
Mounting
Bracket
1/2
NPT
IN OUT
Max (Square)
SPAN
ZERO
Alternate
Out/Gauge
Port
TYP. 180°Apart
Drawing No. 531-990-027
127(6
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0((77+()2//2:,1*5(48,5(0(176
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,VFRU,W,PD[/D!/L/FDEOH
(17,7<3$5$0(7(56)2502'(/IPAC
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541-622-039 REV 1/24/18 Page 5
3. MAINTENANCE
Under normal circumstances, no maintenance should be required. If clean dry air is not used the orifice can become blocked. To
clean, first turn off supply air, unscrew and remove orifice assembly. The 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. Replace
orifice assembly back into unit.
4. TROUBLESHOOTING
PROBLEM CHECK
No output or low output Zero adjustment
Supply pressure too low
Clogged orifice
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
Lead Wire
Bonnet
O-Ring
O-Ring
Body Subassembly
Circuit
Board
Bottom Plug
Spacer
Pintle Spring