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Summary of Contents for Azbil PREX3000
- Page 1 OM2-5220-1101 PREX3000 Pneumatic Differential Pressure Transmitter Model KDP User's Manual...
- Page 2 In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice.
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Page 3: Table Of Contents
Table of Contents Chapter 1. Scope ..............1 Chapter 2. - Page 4 Chapter 5. Installation ............27 5-1.
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Page 5: Chapter 1. Scope
Chapter 1. Scope This manual covers the operation instructions for the PREX3000 Differential Transmitter. Be sure to read this manual before using the instrument. This manual has been written for instruments with the standard specifications. Note that some items may differ for those instruments with modified specifications. -
Page 7: Chapter 2. General Precautions
Upon receiving the instrument, immediately check it for any damage which it might have sustained while being shipped. If any signs of damage to the instrument are found or if there are any missing accessories, immediately notify the transport company and your Azbil Corporation agent. -
Page 8: Place Of Installation
2-5. Place of installation To maintain the instrument’s performance and reliability for a long period, pay attention to the following points when selecting a place of installation for the instrument. 2-5-1. Ambient temperature (a) Select a place where temperature change is minimal. (b) When it is unavoidable to install the instrument in a place where it is subjected to radiation from a source of heat (such as the process plant itself), provide a heat insulator and select a well ventilated location so that the ambient temperature of the instrument is... -
Page 9: Chapter 3. Wiring
Chapter 3. General 3-1. General The PREX3000 is a pneumatic transmitter which converts a process differential-pressure or a pressure into pneumatic signals (20 to 100 kPa {0.2 to 1.0 kgf/cm }. The transmitter consists of a transmitting section and a detecting section (meter body). -
Page 10: Specifications
3-2. Specifications 3-2-1. Standard specifications Measuring range (continuously adjustable) Regular type Remote Flange High static Range seal Measuring range type pressure type type 0-25 to 0-500 kPa High ΔP KDP11 KDP81 KDP61 KDP71 {0-2500 to 0-50000 mmH 0-2.5 to 0-53.9 kPa Medium ΔP KDP22 KDP82... - Page 11 External load ID 4 mm × Length 3 m + 20 cc or over Air supply capacity 20 L/minute(N) or over, with 6.7 kPa {50 mmHg} change Air consumption 5 L/minute(N) or less (when balanced at output 100%) Accuracy KDP11; ±0.5% F.S. (For span 50 to 500 kPa {5000 to 50000 mmH ±0.75% F.S.
- Page 12 Operating pressure range Cover mate Model Carbon steel, SUS Monel -50 kPa to +10 MPa -50 kPa to +10 MPa -10 kPa to +1.5 MPa KDP11/22 {-0.5 to +100 kgf/cm {-0.5 to +100 kgf/cm {-0.1 to +15 kgf/cm -50 kPa to +3.5 MPa -50 kPa to +3.5 MPa -10 kPa to +1 MPa KDP33...
- Page 13 Materials Meter body cover -Carbon steel (SF45A), SUS316... (KDP11/22/33/44/61/62/81/82) Monel, PVC... (KDP11/22/33/61/62) Flange - Carbon steel (IF45A), SUS304... (KDP61/62/71/72) Measuring element: SUS316 (diaphragm: SUS316L), SUS316L, Monel, Tantalum Wet part gasket: Teflon Centerbody: SUS304 (KDP44 is Al) Transmitter case: Aluminum alloy Capillary tube length 2, 3, 5 m (remote seal type) SUS316 Mounting...
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Page 14: Max. Working Pressure
3-2-2. Max. working pressure Note) 1. Max. working pressure depends on flange rating, flange materials and operating temperature. Please refer to the following data. Operating range of temperature depends on specification of transmitters. 2. In the case of the remote sealed type (KKP75, KFKB-75), max working pressure depends on the smaller value of either 1.05 MPa or following data. -
Page 15: Optional Specifications
3-2-3. Optional specifications Suppression and elevation Span Suppression (max.) Elevation (max.) Model kPa {mmH kPa {mmH kPa {mmH KDP11 25 to 500 {2,500 to 50,000} 50 {50,000} 475 {47,500} KDP22 2.5 to 53.9 {250 to 5,500} 53.9 {5,500} 51.4 {5,250} KDP33 0.5 to 6 {50 to 600} 6 {600}... -
Page 16: Model Number Table
3-3. Model number table 3-3-1. KDP11/22 Measuring Basic Pressure Cover material element material model piping unit/ Options Description connection Output 0-25 to 0-500 kPa KDP11 {0-2,500 to 0-50,000 mmH 0-2.5 to 0-53.9 kPa KDP22 {0-250 to 0-5,500 mmH Carbon steel (SF45A) SUS316 Monel Carbon steel (SF45A) -
Page 17: Kdp33
KDP33 Measuring Basic Pressure Cover material element material model piping unit/ Options Description connection Output 0-0.5 to 0-6 kPa KDP33 {0-50 to 0-600 mmH Carbon steel (SF45A) SUS316 Monel Carbon steel (SF45A) SUS316 Monel SUS316 (diaphragm: SUS316L) Monel Tantalum SUS316L SUS316 (diaphragm: SUS316) Monel Tantalum... -
Page 18: Kdp44
KDP44 Measuring Basic Pressure Cover material element material model piping unit/ Options Description connection Output 0-0.1 to 0-1.2 kPa KDP44 {0-10 to 0-120 mmH Carbon steel (SF45A) SUS316 Carbon steel (SF45A) SUS316 SUS316 (diaphragm: SUS316L) SUS316 (diaphragm: SUS316) PT1/4 internal thread 1/4NPT internal thread kgf/cm (or mmH... -
Page 19: Kdp61/62
KDP61/62 Flange & cover Measuring element Length of Basic Pressure material material Flange extended model piping unit/ Options Description rating part of Measuring Reference Measuring Reference connection Output flange side side side side 0-25 to 0-500 kPa KDP61 {0-2,500 to 0-50,000 mmH 0-2.5 to 0-53.9 kPa KDP62 {0-250 to 0-5,500 mmH... -
Page 20: Kdp71/72
KDP71/72 Measuring element Length of Flange material Basic Capillary Pressure material Flange extended model tube piping unit/ Options Description rating part of length connection Output flange 0-25 to 0-500 kPa {0-2,500 to 0-50,000 mmH 0-2.5 to 0-53.9 kPa {0-250 to 0-5,500 mmH Carbon steel (SF45A) SUS304 Carbon steel (SF45A) -
Page 21: Kdp81/82
KDP81/82 Measuring Basic Pressure Cover material element material model piping unit / Options Description connection Output 0-25 to 0-500 kPa KDP81 {0-2,500 to 0-50,000 mmH 0-2.5 to 0-53.9 kPa KDP82 {0-250 to 0-5,500 mmH Carbon steel (SF45A) SUS316 Carbon steel (SF45A) SUS316 SUS316 (diaphragm: SUS316L) Monel... -
Page 22: Structure
3-4. Structure The housing and the base plate of the transmitter itself make up the pneumatic circuit boards. As the componential blocks of the transmitter are installed in their respective positions on the base plate, air connections for them are automatically accomplished. No connections of pipes or tubes are needed. -
Page 23: Meter Bodies
3-4-4. Meter bodies External views Although external views of meter bodies differ by models as shown in Fig. 3-1, the bracket mounting section and instrument connection section are identical for models 11/22, 71/72, and for models 33/44, 81/82. [Models 11/22] [Model 33] [Model 44] Damping control... - Page 24 Overload protection mechanism Where pressure higher than the measured pressure is applied from the high-pressure or low- pressure side, the measuring bellows moves and the movement of the sealing liquid becomes zero between the inside of the bellows and the high-pressure chamber due to the O-ring seal.
- Page 25 Model 44 „ The high and low process pressures (HP and LP) are fed via the diaphragm and supports to the center section (silicone filled section) of the meter body. The HP acts on the pressure detecting diaphragm from the right hand side and the LP from the left hand side. When a state of equilibrium is reached (zero differential pressure state), identical forces are exercised on both sides of the differential pressure detecting diaphragm.
- Page 26 Models 61/62 „ The high and low process pressure (HP and LP) are fed via diaphragms and to the ⑪ center section (silicone filled section) of the meter body. Pressure which is proportional to the liquid head in the process vessel is fed via the seal diaphragm and liquid fill to the bellows ...
- Page 27 Models 71/72 „ The high and low process pressures (HP and LP) are fed via diaphragms to the center section (silicon filled section) of the meter body. The HP is fed via the seal diaphragm ⑪ and liquid fill to the bellows at the center section of the meter body. The LP is fed via the seal diaphragm ...
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Page 29: Chapter 4. Operating Principle
Chapter 4. Operating Principle The input for the transmitter is applied as a torque through the torque tube. The torque causes the gap between the nozzle and flapper to change. This movement causes the back pressure of the nozzle to change. The back pressure is boosted in both pressure and capacity by the pilot relay in order to be used as an output air pressure. -
Page 31: Chapter 5. Installation
Chapter 5. Installation 5-1. Place of installation When selecting a place for installation for the instrument, take into consideration these matters related to instrument inspection, maintenance, longevity, and operation safety. (1) Select a place where temperature change is minimal (within the limits of -30°C to +80°C). Avoid a place where the instrument may be exposed to high temperature by radiation from a source of heat. -
Page 32: Installation Of Regular-Type Meter Body
5-4. Installation of regular-type meter body The meter body, together with the transmitter coupled to it, can be installed using either one of the following methods: „ Pipe stanchion mount „ Process pipe mount In either case, fix the meter body to a 2 in. vertical or horizontal pipe using the mounting bracket and U-shape bolt. -
Page 33: Installation Of Model 61/62 And 71/72
5-5. Installation of model 61/62 and 71/72 Connect the detector flange to a process flange. Tighten the bolts uniformly. The center of the flange represents the zero point of the liquid level. (See Fig. 5-5.) If the zero point is raised, the head increases by a corresponding amount. -
Page 34: Mounting Attitude
5-7. Mounting attitude When the meter body is incorporated with a vent provision, install it in such attitude so that the vent is not obstructed. Entrapped drainage or other foreign matter remaining in the meter body will adversely affect measurement. It is ideal to install the meter body so that its diaphragm or bellows planes are made vertical. -
Page 35: Air Supply Connection
5-8. Air supply connection If no Airset (a combination of regulator and filter) is used, connect the air supply to the air supply connection port (internal thread) which is marked “SUP”. The port marked “OUT” is the output air connection port. If an Airset is used, connect the output port of the Airset to the air supply connection port of the transmitter. -
Page 36: Pressure Piping
5-9. Pressure piping 5-9-1. Model 11/22/33/44/81/82 (1) Piping methods (tapping pressure connection method) may differ depending on the position in which the instrument was installed and the conditions of the process pipe line. In general, the manifold piping method or the manifold valve method is used. (A manifold valve is available as an option.) Fig. - Page 37 (5) For the pipes for pressure tapping from the process pipe, use pressure pipes of an appropriate schedule number and a nominal thickness. A typical example is 1/2 in. schedule 80 steel pipe. For the measurement of water or steam, copper pipes are generally used.
- Page 38 (7) Pressure tapping methods: For the tapping methods of process pressures, refer to the illustrations given in this section. “H” is the high pressure side of the meter body and “L” is the low pressure side. They are both marked on the meter body. Low pressure side in the case of open tank Muximum...
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Page 39: Connection Of Flange Type Meter Body To Process
5-9-2. Connection of flange type meter body to process Stop valve Stop valve Blow valve Blow valve Drain pot Drain Tank Tank Tank Release to atmosphere Fig. 5-11. process connections of model 61/62 for liquid level measurement Maximum liquid level Minimum liquid level Atmosphere... - Page 40 2.5D 8.0D To meter body To meter body (High pressure chamber) (Low pressure chamber) Static pressure distribution curve Pressure range Pressure range for for upstream-side downstream-side diaphragm diaphragm Pipe diameter : 3 in. or over Differential pressure : 1000mH O or over DIameter ratio : 0.30 to 0.70 For flow measurement with orifice plate To transmitter...
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Page 41: Elevation And Suppression
(3) For flow measurement, tapping for the differential pressure must be done in the “pipe tap” system. Therefore, install the high-pressure-side tap at a position of 2.5D (D denotes the inside diameter of the process pipe) from the upstream side of orifice and position the low-pressure-side tap at a distance of 8D from the downstream side of the orifice. - Page 42 Table 5-1: Closed tank Closed tank Model Open tank (without seal liquid) (with seal liquid) Provide suppression that corresponds to 11/22/ differential level between zero liquid level and center of the pressure receiver multiplied by the 33/44/ Provide suppression by an specific-gravity of the measured liquid.
- Page 43 Zero liquid level (Atmosphere) ρ, ρ Specific-gravity of the measured liquid ρ ρ ρ Specific-gravity of the seal liquid 0.935: Specific-gravity of the seal liquid Provide elevation by ρ E ρ ρ Zero liquid level ρ ρ ρ Provide elevation by ρ E Provide suppression by (ρ...
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Page 45: Chapter 6. Operation Method
Chapter 6. Operation Method The meter body, together with the transmitter coupled to it, starts operating as the air supply and process input are fed to it. (It is recommended to check that the transmitter is properly functioning before starting the running operation.) 6-1. -
Page 46: Liquid Level Transmission
6-2. Liquid level transmission The operation method (start up procedure) described here assumes that the meter body has been installed as shown in “5-9-1: Model 11/22/33/44/81/82” (6) and “5-9-2: Connection of flange type meter body to process” of “Chapter 5 : Installation”. No operation procedure is needed for the process connections with flanges (diaphragms). -
Page 47: Chapter 7. Inspection And Maintenance
Chapter 7. Inspection and Maintenance For routine inspection and maintenance, pay attention to the following: 7-1. Check for leakage from piping Verify that there is no leakage from the pressure tap points of the piping at the meter body. If any loose connections are found, tighten them securely. -
Page 48: Cleaning Of Meter Body
When blow pipes are provided (See Fig. 5-8. in “Chapter 5 : Installation”) (1) Close the stop valve on the high pressure side of the manifold valve. (2) Close the stop valve on the low pressure side of the manifold valve. (3) Slowly open the blow valves on both high and low pressure sides to drain out sediment or any other entrapped substances. -
Page 49: Notes For Use In Freezing Weather
(4) Fix the clamping-bolts of the covers with the specified tightening torque as given in the following table. Table 7-1: Tightening torque (kgf•cm) Material of clamping-bolts Model When new when gasket is Bolt Cover gasket is used re-used 11/22, 61/62 Chrome Carbon steel, SUS molybdenum steel... -
Page 51: Chapter 8. Service And Unit Replacement
If the meter body requires to be modified due to a specification change, application change or due to failure contact your Azbil Corporation agent. If it is required that modifications be done by yourself, order service tools and the service manual SM2-5220-0000 “PREX3000 KF-B Liquid Level Meters Detector Replacement Procedure”. - Page 52 Fig. 8-1. Pilot relay assembly Table 8-1: Parts for pilot relay Name Quantity Name Quantity Screw Diaphragm (lower) Valve stem Exhaust ring (outer) Housing Exhaust ring (inner) Guide pin Area plate Conical spring Washer Washer Diaphragm (upper) Spring Cover Nozzle Washer Seal...
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Page 53: Chapter 9. Calibration And Adjustment
Chapter 9. Calibration and Adjustment 9-1. General The detector (meter body) feeds a torque, which is proportional to the measured process variable, via the torque tube to the transmitting mechanism of the transmitter. Therefore, regardless of the type of the meter body, the transmitter should be adjusted so that it transmits an output signal of 20 to 100 kPa {0.2 to 1.0 kgf/cm } linearly proportional to the 0% to 100% measuring range. - Page 54 Fig. 9-1. (8) If the output pressure has shifted from 100%, adjust the SPAN ADJ boss at the bottom of the feedback bellows as follows: If the output is higher than 100%, turn the boss so that the output becomes lower than 100% by an amount of 1/4 of the shift.
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Page 55: Setting Of Elevation / Suppression
9-3. Setting of elevation / suppression Elevation / suppression can be realized by providing the actual required the zero shift which has initially been eliminated as mentioned in “9-1 : General”. After setting an elevation / suppression, apply an input corresponding to 100% of the measuring range and, if the 100% point has been shifted, perform SPAN Adjustment. - Page 58 Warranty period and warranty scope 1.1 Warranty period Azbil Corporation’s products shall be warranted for one (1) year from the date of your purchase of the said products or the delivery of the said products to a place designated by you.
- Page 59 Although acceleration of the above situation varies depending on the conditions or environment of use of the products, you are required not to use any Azbil Corporation’s products for a period exceeding ten (10) years unless otherwise stated in specifications or instruction manuals.
- Page 61 Document Number: OM2-5220-1101 Document Name: PREX3000 Pneumatic Differential Pressure Transmitters Model: KDP User's Manual Date: 1st edition: Oct. 1998 8th edition: June 2022 Issued/Edited by:...
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