YOKOGAWA VigilantPlant PK200 User manual

User’s
Manual PK200
Current-to-Pneumatic Converter
[Style:S2]
IM 21B03D01-01E
IM 21B03D01-01E
13th Edition
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i
IM 21B03D01-01E
PK200
Current-to-Pneumatic Converter
[Style:S2]
IM 21B03D01-01E 13th Edition
13th Edition: July 2015 (YK)
All Rights Reserved, Copyright © 1992, Yokogawa Electric Corporation
Contents
 Introduction..................................................................................................iii
1. Handling Precautions .............................................................................. 1-1
1.1 CheckingtheModelSufxCodeandSpecications ................................... 1-1
1.2 TransportationPrecautions............................................................................. 1-1
1.3 Storage Precautions......................................................................................... 1-1
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 ................................................................1-2
1.6 InstallationofFlameproofType....................................................................... 1-3
1.6.1 TIIS Flameproof Type ........................................................................ 1-3
1.6.2 FM Explosionproof Type .................................................................... 1-3
1.7 EMC Conformity Standard............................................................................... 1-4
2. Overview.................................................................................................... 2-1
2.1 FunctionalDescription..................................................................................... 2-1
2.2 StandardSpecications................................................................................... 2-1
2.3 ModelandSufxCodes ................................................................................... 2-3
2.4 Options............................................................................................................... 2-3
2.5 ExternalDimensions ........................................................................................ 2-4
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
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IM 21B03D01-01E
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
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............................................................................................ 6-2
6.3.1 Replacing the Screen Filter................................................................6-2
6.3.2 Replacing the Controller Relay.......................................................... 6-2
6.3.3 ReplacingtheAmplier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 Information
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<Introduction> iii
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efcient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.
• Allrightsreserved.Nopartofthismanualmay
be reproduced in any form without Yokogawa’s
written permission.
• Yokogawamakesnowarrantyofanykindwith
regard to this manual, including, but not limited
to, implied warranty of merchantability and
tness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
ofce.
• Thespecicationscoveredbythismanualare
limited to those for the standard type under the
speciedmodelnumberbreak-downanddonot
cover custom-made instrument.
• Pleasenotethatchangesinthespecications,
construction, or component parts of the
instrumentmaynotimmediatelybereected
in this manual at the time of change, provided
that postponement of revisions will not cause
difcultytotheuserfromafunctionalor
performance standpoint.
Safety Precautions
• 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.
• Yokogawawillnotbeliableformalfunctionsor
damageresultingfromanymodication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modication
undertaken by the customer, intrinsically safe
construction or explosionproof construction is
damaged and may cause dangerous condition.
Please contact Yokogawa for any repair or
modication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.
NOTE
Draws attention to information essential for
understanding the operation and features.
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<Introduction> iv
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ofce.
• 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specication
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speciedbythe
Yokogawa, or due to improper maintenance of
the installation location.
• Failureordamageduetomodication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res,
earthquakes,storms/oods,thunder/lightening,
or other natural disasters, or disturbances, riots,
warfare, or radioactive contamination.
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<1. Handling Precautions> 1-1
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IntrinsicallySafeEquipment
andTIISFlameproofEquipment”attheendof
this manual.
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Sufx
CodeandSpecications
The data plate on the side face of the instrument
baseshowsthemodelsufxcodeand
specications.Withreferencetothemodelsufx
codeandspecicationsinsection2.3,conrmthat
theinstrumentisasspeciedbytheorder.
Forinquiry,informusofthemodelsufxcodeand
instrument serial number.
Figure1.1 DataPlateforGeneral-UseType
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.
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
specied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.
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<1. Handling Precautions> 1-2
IM 21B03D01-01E
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
Hazardous Location Non-hazardous Location
+
–
+
–
+
–
PK200
Current-to-
Pneumatic Converter
[Intrinsically Safe]
F0104.ai
Class I, II, III, Division 1,
Groups A, B, C, D, E, F, G Safety Barrier
General
Purpose
Equipment
+
–
Hazardous Location Non-hazardous Location
+
–
+
–
PK200
Current-to-
Pneumatic Converter
Class I, II, III, Division 2,
Groups A, B, C, D, E, F, G
Class III, Division 1.
General
Purpose
Equipment
[Nonincendive]
Note: Not use safety Barrier
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
2. Entity Parameters
• Intrinsicallysafeapparatusparameters
Vmax = 30V
Imax = 165mA
Pmax = 0.9W
Ci = 2nF
 Li=730μH
• Associatedapparatusparameters(CSA
CertiedBarriers)
 Voc≤30V
 Isc≤165mA
 Pmax≤0.9W
3. Installation
• Controlequipmentconnectedtobarriermust
not use or generate more than 250 Vrms or
Vdc.
• ThesafetybarriermustbeCSAcertied.
• 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certication
according to technical criteria for explosion-
protected construction of electric machinery and
equipment(StandardsNoticationNo.556from
the Japanese Ministry of Labor) conforming to IEC
standards, is designed for hazardous areas where
explosivegasesand/orinammablevaporsmaybe
present. (This allows installation in Division 0, 1 and
2 areas)
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<1. Handling Precautions> 1-3
IM 21B03D01-01E
Topreservethesafetyofameproof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certied
safety barrier as shown below. All wiring shall
complywithlocalinstallationrequirements.
Hazardous Area Non-hazardous Area
+
–
+
–
+
–
PK200 Current-to-
Pneumatic Converter
Safety barrier
[Installation Diagram]
F0105.ai
2. Temperature
Install the PK200, So that any part of
the instrument that may exposed to the
inammablegasorvaporwouldnotexceedthe
temperature 60°C
3. Safety Barrier
Usethecertiedsafetybarrierthatsatises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*
* 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certication
according to technical criteria for explosion-
protected construction of electric machinery and
equipment(StandardsNoticationNo.556from
the Japanese Ministry of Labor) conforming to IEC
standards, is designed for hazardous areas where
explosivegasesand/orinammablevaporsmaybe
present. (This allows installation in Division 1 and 2
areas)
Topreservethesafetyofameproof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.
1.6.2 FMExplosionproofType
Following items are described in the instruction
documentsofthisinstrumenttoensurecertied
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tting
(option) for waterproof or other purposes, see
4.2.2(6).
3. Operation
* WARNING:OPENCIRCUITBEFORE
REMOVINGCOVER.
FACTORYSEALED,CONDUIT
SEALNOTREQUIRED.
INSTALLINACCORDANCEWITH
THEINSTRUCTIONMANUAL
IM 21B3D1-01E
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<1. Handling Precautions> 1-4
IM 21B03D01-01E
* Take care not to generate mechanical spark
when access to the instrument and peripheral
devices in hazardous location.
4. Maintenance and Repair
* Theinstrumentmodicationorparts
replacement by other than authorized
representative of Yokogawa Electric
Corporation is prohibited and will void Factory
MutualExplosionproofCertication.
1.7 EMC Conformity Standard
EN61326-1ClassA,Table2
(For use in industrial locations)
Immunityinuenceduringthetest:
Outputshiftisspeciedwithin±1%ofspan.
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.
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<2. Overview> 2-1
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.
2.2 StandardSpecications
Materials:
Case: Aluminum die-cast
Paint:Polyurethaneresin-bakednish
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Figure2.1
Constant
Voltage
Circuit
50Ω MAX
Input Signal
4 to 20mA DC
5V DC
(8V DC for TIIS Intrinsically
safe type /JS3.)
F0201.ai
Figure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)
OutputSignals:
See Table 2.1
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airpressure
of 140kPa)
MinimumLoadCapacity:
1m copper tube with 4mm I.D. +20cc
AmbientTemperature:
-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)
Water Proof Construction:
IEC IP54
NEMAtype4X
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 & 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
TIISIntrinsicallySafe(/JS3):
Intrinsically Safe Ex ia IIC T4
 Certicate:TC18266
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<2. Overview> 2-2
IM 21B03D01-01E
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
Table2.1 OutputSignals
Output
Signal
StandardOutput DoubledOutput Recomended
SupplyAir
Pressure*1
SupplyAir
Pressure
Gauge Scale*1
OutputSignal Pressure
Gauge Scale OutputSignal Pressure Gauge Scale
Pa
calibration
20 to 100kPa 0 to 200kPa 40 to 200kPa 0 to 400kPa 130 to 150kPa 0 to 200kPa
230 to 260kPa 0 to 400kPa
kgf/cm2
calibration
0.2to1.0kgf/cm20to2kgf/cm20.4to2.0kgf/cm20to4kgf/cm21.3to1.5kgf/cm20to2kgf/cm2
2.3to2.6kgf/cm20to4kgf/cm2
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
2.3 to 2.6bar 0 to 4bar
P calibration 3 to 15psi 0 to 30psi 6 to 30psi
3 to 27psi
0 to 60psi 19 to 22psi 0 to 30psi
*2 0 to 60psi
*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.
*2: 6 to 30psi output signal; 34 to 37psi, 3 to 27psi output signal; 34 to 36psi.
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<2. Overview> 2-3
IM 21B03D01-01E
2.3 ModelandSufxCodes
Model SufxCode Description
PK200 . . . . . . . . . . . . .
Input Signal -A ...........
-C...........
4 to 20mA DC
4to20mA/10to50mADCselectiontype
Output Signal 1.........
2.........
3.........
4.........
5.........
6.........
7.........
8.........
9.........
Output signal Pa calibration 20 to 100kPa scale 0 to 200kPa
Output signal Pa calibration 40 to 200kPa scale 0 to 400kPa
Outputsignalkgf/cm2calibration 0.2to1.0kgf/cm2 scale0to2kgf/cm2
Outputsignalkgf/cm2calibration 0.4to2.0kgf/cm2 scale0to4kgf/cm2
Output signal bar calibration 0.2 to 1.0bar scale 0 to 2bar
Output signal bar calibration 0.4 to 2.0bar scale 0 to 4bar
Output signal P calibration 3 to 15psi scale 0 to 30Psi
Output signal P calibration 6 to 30psi scale 0 to 60Psi
Output signal P calibration 3 to 27psi scale 0 to 60Psi
Connections 1......
2......
3......
4......
Airconnection:Rc1/4,Electricalconnection:G1/2female
Airconnection:Rc1/4,Electricalconnection:G3/4female
Airconnection:1/4NPTfemale,Electricalconnection:1/2NPTfemale
Airconnection:1/4NPTfemale,Electricalconnection:3/4NPTfemale
Option /See section 2.4.
2.4 Options
• OptionCode/JF3:JISFlameproof
TIISameproof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
specicationitemwithreferencetoGS22D01F01-00EN.
• OptionCode/X1:EpoxyPaint
Epoxy resin-baked coating.
Notapplicableforspecialcolornished.
• 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.
• 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.
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<2. Overview> 2-4
IM 21B03D01-01E
2.5 ExternalDimensions
165.5(6.52) 137.5(5.41)
ø81(3.19) ø111(4.37)
Zero
Adjustment
Screw
Output Gauge
Supply Gauge
A/M Transfer Switch
(optional)
Air Supply Connection
Electrical
Connection
153.5(6.04)
97(3.82) 38
(1.50)
24
(0.94)
14(0.55)
74(2.91)
47
(1.85)
ø111(4.37)
Output
Connection
Wall Mount Screw
2-M8
Nominal 50 mm (2-inch) Pipe
● Terminal Configuration
Ground Terminal
Input Terminal
F0202.ai
Unit: mm
Figure2.2 ExternalDimensions
2.6 Part Names
Terminal box cover
Converter cover
Supply gauge
Output gauge
Zero adjustment
F0203.ai
Figure 2.3 Part Names (1)
Electrical
connection
Terminal board
Span adjustment Case
Zero
adjustment
F0204.ai
Amplifier
Ground
terminal
Figure 2.4 Part Names (2)
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<3. Installation> 3-1
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Specications.”
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.
Figure3.1 PipeMounting
3.2.2 Wall Mounting
When the instrument is installed on the wall, use the
two M8 screws provided.
Figure 3.2 Wall Mounting
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<4. WiringandPiping>4-1
IM 21B03D01-01E
4. WiringandPiping
4.1 Piping
4.1.1 SupplyAir
For easy operation and maintenance, supply air
must be clean and dry.
IMPORTANT
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-to-
pneumatic converter via the piping.
Table 4.1 shows the air supply pressure for this
instrument.
For air consumption, see the standard
specications.
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
30.2to1.0kgf/cm21.3to1.5kgf/cm2
40.4to2.0kgf/cm22.3to2.6kgf/cm2
5 0.2 to 1.0bar 1.3 to 1.5bar
6 0.4 to 2.0bar 2.3 to 2.6bar
7 3 to 15psi 19 to 22psi
8 6 to 30psi 34 to 37psi
9 3 to 27psi 34 to 36psi
4.1.2 AirSupplyPiping
Connect air supply piping to the supply pressure
connection IN of the converter.
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.
4.1.3 OutputPiping
Connect output air piping to the output connection
OUT of the converter.
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
susceptibletonoiseinuence.
(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ameproof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) For use in an atmosphere where harmful gas,
liquid,oil,orsolventexists,usewiresorcables
withmaterialssufcientlydurabletosuch
substances.
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<4. WiringandPiping>4-2
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ameproof
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
ameproof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ameproof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ameproof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ameproofeffectiveness
will be compromised.
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
Appropriate
cable outer
diameter
(mm)
Identifying
mark
Part
Number
G1/2 8-10
10.1-12
16
16
8-10
10-12
G9601AM
G3/4 10-12
12.1-14
14.1-16
22
22
22
10-12
12-14
14-16
G9601AN
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<4. WiringandPiping>4-3
IM 21B03D01-01E
Electronic controller
Supply air
pressure
Stop valve
Air filter
Reducing
valve
Pressure
gauge
Non-
hazardous
area
Hazardous
area
+
–
PK200 current-to
pneumatic converter Control valve
F0401.ai
Figure4.1 General-UseandFlameproofTypeWiring
CAUTION
Be sure to apply non-hardening sealant
to the threads for water proofing.
Terminal box
Screw connection type
Flexible fitting
Sealing fitting
Nipple
Insulated wires
Heavy-gauge
steel conduit
Tee joint
Drain plug F0402.ai
Figure4.2 FlameproofMetalConduitWiring
CAUTION
Be sure to apply non-hardening sealant
to the threads for water proofing.
F0402.ai
Lock nut Wrench
Union coupling
Clamp nut
Clamp ring
Gland
Washer
Rubber packing
Wrench
Lock nut
O-ring
Adapter body
Packing box
Union cover
Cable
Figure4.3 FlameproofGlandPackingInstallation(Optioncode:/G11and/G21)
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<4. WiringandPiping>4-4
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sufcient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.
F0404.ai
G
Current
signal
+
–
Ground
Figure 4.4 Wiring
Single-loop controller
Supply air pressure
Stop valve
Air filter
Reducing
valve
Pressure
gauge
Non-
hazardous
area
Hazardous
area
+
–
PK200 current-to-
pneumatic converter
Control valve
F0405.ai
Safety barrier
Figure4.5 IntrinsicallySafeTypeWiring
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<5. Operation>5-1
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regurator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 regurator.
(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).
A/M selector switch
F0501.ai
Figure 5.1 Auto/Manual Transfer Mechanism
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“RecommendedSupplyAirPressure.”
 Standardoutputappliesformodelsufxoutput
signalcode“1,3,5,7”andmultipliedpressure
outputformodelsufx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 100 kPa 130 to 150 kPa
2 40 to 200 kPa 230 to 260 kPa
30.2to1.0kgf/cm21.3to1.5kgf/cm2
40.4to2.0kgf/cm22.3to2.6kgf/cm2
5 0.2 to 1.0 bar 1.3 to 1.5 bar
6 0.4 to 2.0 bar 2.3 to 2.6 bar
7 3 to 15 psi 19 to 22 psi
8 6 to 30 psi 34 to 37 psi
9 3 to 27 psi 34 to 36 psi
(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specied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.
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<5. Operation>5-2
IM 21B03D01-01E
<Example:20to100kPaoutputsignalfor4to
20mA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 100 kPa
2 40 to 200 kPa
30.2to1.0kgf/cm2
40.4to2.0kgf/cm2
5 0.2 to 1.0 bar
6 0.4 to 2.0 bar
7 3 to 15 psi
8 6 to 30 psi
9 3 to 27 psi
Zero adjustment
F0502.ai
Figure 5.2 Zero Point Adjustment Mechanism
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ameproofspecicationsorintrinsicallysafe
explosion-proofspecications,rstconducta
gasdetectorchecktoconrmthatthereisno
explosive gas in the area.
(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sufxoutput
signalcode“1,3,5,7”andmultipliedpressure
outputformodelsufxoutputsignalcode“2,4,
6,8,9.”
Table5.3 RecommendedSupplyAirPressure
Output
Signal Code OutputSignal SupplyAir Pressure
1 20 to 100 kPa 130 to 150 kPa
2 40 to 200 kPa 230 to 260 kPa
30.2to1.0kgf/cm21.3to1.5kgf/cm2
40.4to2.0kgf/cm22.3to2.6kgf/cm2
5 0.2 to 1.0 bar 1.3 to 1.5 bar
6 0.4 to 2.0 bar 2.3 to 2.6 bar
7 3 to 15 psi 19 to 22 psi
8 6 to 30 psi 34 to 37 psi
9 3 to 27 psi 34 to 36 psi
(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specied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.
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www.cv3000.com