Part Number 27-45A

INSTALLATION, OPERATION, AND MAINTENANCE

MUD FLOW SENSOR

PART NUMBERS
270700-107
270700-108
270700-109
270700-110
270700-111
270700-112

Manufacturers of Precision Instruments

Printed in U.S.A. April 20, 1981

 INSTRUCTION MANUAL 27-45A
LIST OF EFFECTIVE PAGES

Total number of pages in this publication is 38

40 consisting of the following:

PAGE ISSUE
NO. DATE

Cover . . . . . . . . . . . 20 April 1981

A........ . . . . . 20 April 1981
iii throughiv vi .
i through . . . . . . 20 April 1981
l-l through l-3 . . . . . . 20 April 1981
l-4 Blank . . . . . . . . . 20 April 1981
2-1 through 2-8 . . . . . . 20 April 1981
3-l through 3-10 . . . . . 20 April 1981
4-l through 4-4 . . . . . . 20 April 1981
Ai . . . . . . . . . . . . 20 April 1981
Aii Blank . . . . . . . . . 20 April 1981
A-l through A-3 . . . . . . 20 April 1981
A-4 Blank . . . . . . . . . 20 April 1981
B-l and B-2 . . . . . . . . 20 April 1981

01 SS 1, by TOTCO. All RiShtr Rarewed

A
 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

April 1981 iii

M/D TOTCO
 LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv April 1981
M/D TOTCO
INSTRUCTION MANUAL 27-45A

v
 INSTRUCTION MANUAL 27-45A
SI UNIT CONVERSION EACTORS

ATM&SPHERES (atm) (standard sea level pressure)

x 101.325 = Kilopascals (kPa) absolute
x 29.92 = Inches of mercury (in Hg) at O'C

KILOPASCALS (kPa)
x 0.001 = Pascals (Pa)
x 0.001 = Newtons per square metre (N/m2)

POUNDS PER SQUARE INCH GAGE (PSIG)

= Pounds-force per square inch (lbf/in2)
x 6.895 = Kilopascals (kPa)

BARRELS, PETROLElJlI (bbl)

x 0.1590 = Cubic metres (m3)
x 42 = U. S. gallons (U. S. gal) oil

BARRELS PER INCH, PETROLEUM (bbl/in)

x 0.626 = Cubic metres per centimetre (m3/cm)

INCHES (in.)
x 2.540 = Centimetres (cm)

SQUARE FEET (ft2)

x 0.0929 = Square metres (m2)

DEGREES FAHRENHEIT (OF)

('F-32) x 5/9 = "C

DEGREES CENTIGRADE ('C)

("C x 9/5) + 32 = OF

POUNDS-FORCE (lbf av.)

x 4.448 = Newtons (N)
x 0.4448 = Decanewtons (daN)

POUNDS MASS PER U. S. GALLON (lb/gal)

x 119.826 = Kilograms per cubic metre (kg/m3)

vi
 INSTRUCTION MANUAL 27-45A
TABLE OF CONTENTS

Section Page

I PURPOSE, DESCRIPTION AND OPERATION .......... ...... l-l

l-1 Introduction ................. ...... l-l
l-3 Purpose .................... ...... l-l
1-5 Description .................. ...... l-l
1-7 Operation ................... ...... 1-l
l-9 . Pneumatic Transmitter Operation ....... ...... l-2
l-11 . Electric Transmitter Operation ....... ...... l-2
l-13 Previous Models ................ ...... l-3
II INSTALLATION, CALIBRATION AND ADJUSTMENT ....... ...... 2-l
2-l Installation ................. ...... 2-l
2-2 . Base and Sensor Box Installation ...... ...... 2-l
2-4 . Pneumatic Tubing Installation ........ ...... 2-l
2-6 . Electric Cable Installation ......... ...... 2-4
2-8 Calibration .................. ...... 2-4
2-10 . Pneumatic Calibration (Sensor Box 270701-102) ...... 2-4
2-12 . Electric Calibration (Sensor Box 270701-103). ...... 2-6
2-14 Adjustment .................. ...... 2-8
III PERIODIC INSPECTION AND MAINTENANCE .......... ...... 3-l
3-l General .................... ...... 3-l
3-3 Periodic Inspection .............. ...... 3-l
3-4 .General................... ...... 3-l
3-6 . Air Supply System Inspection (Pneumatic). .. ...... 3-1
3-8 . Electrical Connections ........... ...... 3-l
3-10 Maintenance .................. ...... 3-l
3-11 .General.. ................. ...... 3-l
3-13 . Cleaning Flow Sensor ............ ...... 3-5
3-15 . Inspection and Disassembly ......... ...... 3-6
3-17 .. Pneumatic Flow Sensor ........... ...... 3-6
3-18 .. Electric Flow Sensor ........... ...... 3-6
3-19 .. Electrical Element ............ ...... 3-7
3-20 . Assembly of Flow Sensor ........... ...... 3-7
3-22 .. Pneumatic Flow Sensor Assembly ...... ...... 3-7
3-23 .. Electrical Element ............ ...... 3-9
3-24 .. Electric Flow Sensor Assembly ....... ...... 3-10
IV TROIJBLESHOOTING .................... ...... 4-l
4-l General .................... ...... 4-l
4-3 . Pneumatic Flow Sensor ............ ...... 4-l
4-5 . Electric Flow Sensor ............ ...... 4-3
APPENDICES ............................ ...... Ai

LIST OF ILLUSTRATIONS
Figure Page

l-l Pneumatic and Electric Flow Sensor ................ l-2

2-l Installation Dimensions ...................... 2-2
2-2 Configuration of Flow Sensor Installation ............. 2-3
2-3 Penumatic Flow Sensor Adjustment ................. 2-5
2-4 Electric Flow Sensor Adjustment .................. 2-7

iii
 INSTRUCTION MANUAL 27-4!5A
LIST OF ILLUSTRATIONS (Cont’d)

Figure Page

3-1 Pneumatic Sensor Box Assembly .................. 3-2

3-2 Electrical Sensor Box Assembly ................. 3-4
3-3 Electric Element. ........................ . 3-8

LIST OF TABLES

Table Page

2-l Test Point Values ........................ 2-8

4-l Pneumatic Flow Sensor Troubleshooting .............. 4-l
4-2 Electric Flow Sensor Troubleshooting .............. . 4-2

RELATED PUBLICATIONS

Publication
Number Title

26-58 Rig Air Filter/Instrument Air Filter Regulator, Installation,

Operation and Maintenance with Illustrated Parts Breakdown

27-44A Mud Flow Sensor, Instruction Manual, Illustrated Parts Breakdown

RELATED TOOLS AND TEST EQUIPMENT

Part Number

263681-101 Gauge, 0 to 30 pisg

991203-007 Digital Multimeter

APPROVED EXPENDABLE ITEMS LIST

Part Number Description

992405-009 Lubricant, Corrosion Resistant

991702-006 Sealant and Lubricant, Thread
991205-001 Adhesive, Light Amber
991202-003 Adhesive, Red, General Purpose

iv
 INSTRUCTION MANUAL 27-45A
SECTION I
PURPOSE, DESCRIPTION AND OPERATION

l-l INTRODUCTION

l-2 This manual contains installation, operation and maintenance instructions

with illustrated parts breakdown for the Mud Flow Sensor assemblies,
PN 270700-107, -108, -109, -110, -111, and -112 manufactured by TOTCO. This manual
provides information to set up, maintain, and repair the unit on a drilling rig
without the use of special tools or special test equipment.

l-3 PURPOSE

l-4 The sensor, designed for installation on a drilling rig mud return pipe
between the well head and mud pits, signals the percentage of mud flow in
the existing system. Continuous monitoring and recording of mud flow conditions
are available to the driller through either an electrical or pneumatic mechanism
that functions with a variety of TOTCO mud monitoring systems. Gas kicks, in-
vasion of fluid from formation, or loss of mud circulation is detected immediately.
The sensor then provides signals to a warning system or as a control for a pump
stroke counter.

l-5 DESCRIPTION

l-6 The mud flow sensor comprises a base which is welded to the return flow
pipe, a housing with cover plate, a paddle which is interconnected through
a pivot and linkage mechanism with a pneumatic position transmitter or electrical
element transmitter, and two shaft-mounted adjustable counterweights (See Figure l-l).
The counterweights, which are accessible outside the unit, provide a force on the
paddle against mud flow and ensure that the paddle returns to zero position when
there is no flow in the pipe. The sensor is easily removed as a unit from the base
without disassembly; the cover plate covers the base after the sensor is removed
from an installation. The sensor may be ordered with one of four different size
paddles to fit several pipe diameters.

l-7 OPERATION

l-8 Mud flowing through the return line from the annulus to the shale shaker
deflects the flow sensor paddle. The degree of deflection is determined
by the speed of the mud flow and quantity of mud flow as well as pipe angle and
diameter. The position of the counterweights also affects the amount of deflection.
Consequently, the paddle angle of each flow sensor will change in proportion to
these variables. Movement of the paddle links directly to the transmitter shaft.
Rotation of the transmitter shaft determines the amount of output signal from the
transmitter.

NOTE

The flow sensor is designed to withstand a

150 psig (10.5 kg/cm2) maximum pressure with-
in the flow line.

l-l
 INSTRUCTION MANUAL 27-45A

FIGURE l-l. PNEUMATIC AND ELECTRIC FLOW SENSOR

l-9 PNEUMATIC TRANSMITTER OPERATION

l-10 The pneumatic transmitter operates from a 20 psig (1.4 kg/cm2) instrument
quality air supply and delivers an output with a range of 3 to 15 psig
(0.21 to 1.1 kg/ cm2) to the monitoring system. When the flow paddle has no flow
pressure against it, the output signal from the transmitter is 3 psig (0.2 kg/cm2)
of air. The transmitter has a variable setting to produce a maximum output signal
of 15 psig (1.1 kg/cm2) indicating 100% flow. Actual mud flow may not cause a full
90° deflection of the paddle, therefore calibration of the transmitter is required.
Paddle counterweights are adjustable to normal mud flow to control the signal from
the transmitter.

l-11 ELECTRIC TRANSMITTER OPERATION

1-12 The electric transmitter operates from a 5.OV dc input and delivers an out-
put from 0.47 to 3.OV dc. When the paddle has no flow pressure against it,
the output signal is 0.47 volts. When the paddle is at full deflection (900), the
output signal is 3.0 volts. Calibration requires an adjustment of the linkage
between the transmitter shaft and the pivot shaft which operate on a 1:l ratio.
Paddle counterweights also require adjustment for proper operation of the sensor.

l-2
 INSTRUCTION MANUAL 27-45A

l-13 PREVIOUS MODELS

l-14 Some early production mud flow sensors were identified as Part Number
270700 without a dash number to indicate system range. Later production
identified these units as 270700-101, -102, -103, -104, -105, and -106. Informa-
tion for these units is included in Instruction Manual 27-11. Any of the above
units may be reworked into the latest production units at TOTCO Distribution Center.
Pneumatic units identified as Part Numbers 270700-107, -108, and -109 and electric
units identified in production as Part Numbers 270700-110, -111, and -112 capable
of withstanding a maximum of 150 psig (10.5 kg/cm2) are the subject of this in-
struction manual.

l-311-4
 INSTRUCTION MANUAL 27-45A
SECTION II
INSTALLATION, CALIBRATION AND ADJUSTMENT

2-l INSTALLATION

2-2 BASE AND SENSOR BOX INSTALLATION

2-3 Survey the mud flow return line to ensure that sufficient space is available
for proper installation and operation of the flow sensor (See Figure 2-l).
Then install the flow sensor as follows:

a. Ensure that mud pumps are shut down during installation.

b. Remove nuts (8, Figure 2-2), washers (9,10), and bolts (11)
securing the sensor box assembly (15) to base (13); remove
base carefully to avoid damage to the gasket (14).

C. Position the base (13) centrally on the mud return pipe and
weld in place. Using a cutting torch, cut a hole through the
mud return pipe along the inside edges of the base.

NOTE

The correct size paddle must be selected to

match the pipe size. An optional oversize
paddle for lo-3/4 thru 12-3/4 inch diameter
pipe may be used to correct for erratic mud
flow signal. To determine the correct paddle
size, Refer to Mud Flow Sensor Illustrated
Parts Breakdown (Refer to Related Publications).

d. Secure paddle (1, 2, or 3) to paddle support (7) with bolts (5)

and nuts (4). Select the mounting holes which position the
bottom edge of the paddle as close as possible to the inside (bottom)
of the flow line.

e. With gasket (14) in place and bonded to the sensor box (15)
assemble the sensor box to the base (13); secure with bolts (ll),
washers (9,10), and nuts (8). Make certain that bearings (12) are
installed in base (13).

f. Rotate counterweight assembly 90' to ensure free movement of

paddle in pipe.

2-4 PNEUMATIC TUBING INSTALLATION

2-5 The pneumatic transmitter is connected to the flow recorder and alarm
system and the air supply with l/4 inch nylon tubing. Before making
connections, blow out all tubing with clean, dry, instrument-quality air. Complete
the following steps:

a. Connect tubing to 20 psig (1.4 kg/cmL) air filter/regulator

(Refer to Related Publications).

2-l
 INSTRUCTION MANUAL 27-45A

6.03 (1

m MUD FLOW

Lr
r-l 0.25
MIN.
(6.4mm)
CLEARANCE

ELECTRIC
-22.50~
(571.5mm)

nm)
1

(173180mm)

1.510.33mm)
&EuWDELDED
ld
RETURN LINE
-1.5
(0.33mm)
-10.5 l

(2.67mm)

0.438 k5.254 *
(ll.lSmm) (133.6mm)

I
I
I T 2.12$(54.lmm)

-A-- 0.188 (4.8mm)

BASE

27L46,-3A
n6.9 (175.3 mm) FOR OVERSIZE PADDLE

FIGURE 2-l. INSTALLATION DIMENSIONS

z-2
 INSTRUCTION MANUAL 27-45A

25,

FIGURE 2-2. CONFIGURATION OF FLOW SENSOR INSTALLATION

LEGEND FOR FIGURE 2-2

1. Paddle for 8-10 in. dia pipe 15. Sensor Box

1A. Oversize Paddle for lo-3/4 to 16. Gasket
12-314 in. dia pipe 17. Pneumatic Position Transmitter
2. Paddle for 12-14 in. dia pipe 18. Male Connector
3. Paddle for 16-18 in. dia pipe 19. Electric Transmitter
4. Nut 20. Cable Assy
5. Bolt 21. Counterweight
6. Cover 22. Shaft
7. Paddle Support 23. Retainer Screw
8. Nut 24. Counterweight Support
9. Lockwasher 25. Nut
10. Flat Washer 26. Lockwasher
11. Bolt 27. Flat Washer
12. Bearing 28. Bolt
13. Base 29. Bearing
14. Gasket

2-3
 INSTRUCTION MANUAL 27-458

b. Place ferrule over the end of the tubing from the filter/
regulator and attach the tubing to the male connector marked
20 PSI SUPPLY on the transmitter (17). Tighten the connector
securely to the tubing.

C. Connect tubing to control unit, flow recorder, or alarm

mechanism (follow directions of pulbications related to
each item.

d. Place ferrule over the flow sensor end of the tubing and
attach the tubing to the male connector marked SIGNAL on
the transmitter (17).

2-6 ELECTRIC CABLE INSTALLATION

2-7 The electric transmitter (19, Figure 2-2) is connected directly to the
console or junction box of the electronic control system with the flow
sensor cable (20). If the cable has been cut away from the electric element and
is too short to splice, complete the following steps:

a. Strip protective shield back from the cable two inches and
strip the black, white, and green leads back l/4 inch. En-
sure that exposed leads are clean. Firmly crimp terminal spades
to the leads.

b. Guide the cable through the cable grip and connect the leads
to terminal strip (See schematic, Figure 2-4).

C. Ensure that cable leads have sufficient strain relief and

then tighten cable grip.

2-8 CALIBRATION

2-9 The flow sensor may be calibrated after installation or securely supported
on a bench in the shop. Ensure that connections are properly completed
(Refer to Paragraphs 2-4 through 2-7).

2-10 PNEUMATIC CALIBRATION

2-11 Complete the following steps:

a. Remove nuts (25, Figure 2-2), washers (26,27), and bolts (28)
securing cover plate (6). Remove cover plate and gasket (16)
taking care not to damage gasket.

b. Verify that the drive clamp (8, Figure 2-3) is positioned on

pivot shaft (9) at 90' to bellcrank (12). Correct for mis-
alignment by loosening nut on the bolt of the counterweight support
(7) and adjusting the support. Tighten nut when support is in
position.

C. Adjust drive clamp (8) so that it is 30° counterclockwise from

the centerline of the counterweight support (7) as shown in
Figure 2-3.

2-4
 INSTRUCTION MANUAL 27-458

/
/
/

27-451-4

FIGURE 2-3. PNEUMATIC FLOW SENSOR ADJUSTMENT

LEGEND FOR FIGURE 2-3

1. Paddle 7. Counterweight Support

2. Paddle Support 8. Drive Clamp
3. Linkage 9. Shaft
4. Transmitter Lever 10. Counterweight
5. Transmitter Input Shaft 11. Connecting Link
6. Position Transmitter 12. Bell Crank

d. Replace cover plate (6, Figure 2-2) and gasket (16). Secure
with nuts (25), washers (26,27), and bolts (28).

e. Adjust position of counterweights (10, Figure 2-3) along

counterweight supports (7) so that with no mud flow, the
sensor paddle is perpendicular to the mud return pipe.

f. Connect a 0 to 30 psig (0 to 2.1 kg/cm2) gauge (Refer to Related

Tools and Test Equipment) to the transmitter male connector
labeled SIGNAL.

g. Connect a 20 psig (1.4 kg/cm2) source of dry, instrument-quality

air to the male connector labeled SUPPLY on the flow sensor.
The test gauge should indicate 3.0 -+O.l psig (0.2 kg/cm2) which is
0% mud flow.

2-5
 INSTRUCTION MANUAL 27-45A

h. Slowly rotate paddle 90° to upper limit and verify that test
gauge reading follows paddle movement; when paddle reaches
maximum travel, test gauge shall indicate 15 + 0.1 psig (1.1 kg/cm2)
which is 100% mud flow.

1. If test pressure readings in preceding steps g. and h. are

not obtained at noted paddle positions, adjust signal span of
mud flow sensor position transmitter in accordance with Foxboro
instructions included in Appendix A.

j. If above does not correct the condition, adjust linkage between

drive clamp (8, Figure 2-3) and transmitter input shaft (5).
Loosen transmitter lever (4), adjust transmitter input shaft (5) for
3 psig + 0.1 (0.2 kg/cm2) output reading; position sensor paddle (1)
perpend&ular to mud return pipe and then tighten nut on transmitter
lever (4). Verify that O" and 90° paddle positions produce 3 + 0.1 psig
(0.2 kg/cm2) and 15 20.1 psig (1.1 kg/cm2) signals respectively from
transmitter.

k. Remove the test gauge and replace tubing. The mud flow sensor
is ready for operation.

2-12 ELECTRIC CALIBRATION

2-13 Complete the following steps:

a. Position the paddle (8, Figure 2-4) in the A position.

b. Verify that the drive clamp (7, Figure 2-4) and counter-
weight support (10) are 45 O from base (14) with paddle in
the A position (See Figure 2-4). Correct for misalignment by
loosening the nuts on the bolts of the drive clamp (7) and of the
counterweight support (10). When the drive clamp and the support
are in position, tighten nuts.

C. If no power is applied to the electrical element remove the

cover (1, Figure 2-4) of electrical element (2) and connect
the leads of a digital multimeter (Refer to Related Tools and Test
Equipment) between termals 1 and 2. Set multimeter on OHM scale.

d. With paddle (8) in the A position as shown in Figure 2-4, loosen

socket head screw (3) and rotate shaft (13) to obtain 1450 250
ohms on multimeter (shaft has 180° rotation without a mechanical stop).
Tighten socket head screw to lock lever in that position (Refer to
Table 2-l for further checks). If 4000 +30 ohms is not present at B
position, shaft is 180° out of phase. If power is supplied to the elec-
trical element, the readings should approximate those given in Table 2-l.

e. Position the counterweights (9) along the counterweight

supports (10) so that the paddle (8) returns to the A
position with no mud flow.

f. Rotate the counterweight support (10) several times to ensure

that mechanism moves freely and returns to the A position.

g- Replace cover (1).

2-6
 INSTRUCTION MANUAL 27-45A

MUD FLOW SENSOR

------ELECTRICAL ELEMENT -----l

SJO 1813
--------SIGNAL CABLE------

--------- L ---- -- ---- ---_

I A POSITION

ELECTRICAL ELEMENT SCHEMATIC

9-
,, B ,, POSITION
7

14

“A” POSITION

FIGURE 2-4. ELECTRIC FLOW SENSORADJUSTMENT

MUD

.
FLOW

2-7
 INSTRUCTION MANUAL 27-458

LEGEND FOR FIGURE 2-4

1. Cover 9. Counterweight
2. Electric Element 10. Counterweight Support
3. Socket Head Screw 11. Linkage
4. Connector Cable 12. Transmitter Lever
5. Connector Cable Grip 13. Transmitter Shaft
6. Shaft 14. Base
7. Drive Clamp 15. Paddle Support
8. Paddle

TABLE 2-l. TEST POINT VALUES

F
PADDLE VOLTS BETWEEN TERMINALS 1
SUPPORT RESISTANCE BETWEEN AND 2 WITH 5V DC APPLIED TO
POSITION TERMINALS 1 AND 2 TERMINALS 3 AND 1
A 1450 -+50R 0.45V dc
B 4000 +3on 3.OV dc (nominal)
L

_ .~ .~ ”
2-14 ADJUSTMENT

2-15 Sensitivity of the mud flow sensor is affected by the position of the
counterweights (21, Figure 2-2). Greater sensitivity exists when the
counterweights are closest to the shaft (22) than when further away because it
takes less flow against the paddle to show a change in mud flow. Counterweights
should be positioned so that the paddle always returns to the A position (See
Figure 2-4) when there is no mud flow in the mud return pipe. Both counterweights
should be located in approximately the same relative position. Counterweight
retainer bolts (23, Figure 2-2) secure the position of the counterweights.
. CAUTION

NEVER LOCATE THE COUNTERWEIGHT SUPPORTS

(24, FIGURE 2-2) ON THE SHAFT (22) SO THAT
WITH 90° PADDLE DEFLECTION THE COUNTER-
WEIGHTS ADOPT A POSITION OVER-CENTER AND
UPSTREAM OF THE SHAFT. IF THIS HAPPENS,
THE PADDLE WILL REMAIN IN THE B POSITION
(SEE FIGURE 2-4) AND THE MUD FLOW SENSOR
WILL TRANSMIT A FALSE 100% FLOW SIGNAL
CONTINUOUSLY.

The following steps should be completed for final adjustments of the flow sensor:

a. Start and run mud pumps and circulate normal mud flow through
system.

b. Adjust the position of the counterweights (21, Figure 2-2) so

that the transmitter indicates the desired flow percent.

C. Shut down mud pumps. Check that paddle automatically returns to

0% (A position, Figure 2-4). If paddle does not return to 0%,
readjust position of the counterweights on the support until the
desired condition is obtained.

2-8
 INSTRUCTION MANUAL 27-45A
SECTION I I I
PERIODIC INSPECTION AND MAWTENANCE

3-1 GENERAL

3-2 The mud flow sensor assembly is constructed to provide long service with
a minimum of maintenance. To keep equipment functional and in best of
condition, an inspection should be carried out periodically. Maintenance personnel
should establish an inspection cycle based on length of operating time, level of
performance, and operating environment of equipment. The procedure primarily
consists of cleaning and checking parts for obvious damage and wear as well as
missing or loose items.

3-3 PERIODIC INSPECTION

3-4 GENERAL

3-5 Carry out a visual inspection of the mud flow sensor and installation
connections for damage, wear, and loose parts; replace all defective
parts or components.

3-6 AIR SUPPLY SYSTEM INSPECTION (PNEUMATIC)

---3-7 Ensure that clean, dry, instrument-quality air is used for operation of
equipment. If TOTCO rig air filter and instrument air filter-regulator
are installed, perform inspection and maintenance in accordance with the appropriate
manual (Refer to Related Publications).

3-8 ELECTRICAL CONNECTIONS

3-9 Ensure that the flow sensor cable deterioration is not sufficient to cause
a malfunction of the signal to the control system. Inspect the strain
relief provided by the cable grip to ensure that connections are not stressed.
Check connections on terminals for corrosion build up.

3-10 MAINTENANCE

3-11 GENERAL

3-12 Loose or worn parts require disassembly. Index numbers assigned to the
illustrations will aid in the sequence of disassembly. Observe the
following:

a. Do not remove bearings (7, Figure 3-l; 15, Figure 3-2), gaskets
(2 and 53, Figure 3-l; 10 and 47, Figure 3-2), gasket assemblies
(47, Figure 3-1; 39, Figure 3-2), or decals (23 and 24, Figure 3-l)
unless inspection reveals the need for replacement.

b. Do not attempt disassembly of bearing assemblies (44, Figure

3-1; 36, Figure 3-2). These assemblies should be replaced as
complete assemblies.

3-l
 INSTRUCTION MANUAL 27-458

FIGURE 3-l. PNEUMATIC SENSOR BOX ASSEMBLY

3-2
 INSTRUCTION MANUAL 27-45A

LEGEND FOR FIGURE 3-1

1. Cover 28. Stud

2. Gasket 29. Screw
3. Nut 30. Position Transmitter
4. Lockwasher 31. Connecting Link
5. Flat Washer 32. Pivot Shaft
6. Bolt 33. Retaining Ring
7. Bearing 34. Bushing
8. Support Assembly 35. Paddle Support
9. Cotter Pin 36. Pivot Shaft
10. Bolt 37. Retaining Ring
11. Nut 38. Bushing
12. Counterweight 39. Clevis Pin
13. Nut 40. Cotter Pin
14. Bolt 41. Shaft
15. Linkage 42. Bell Crank
16. Cotter Pin 43. Nylon Washer
17. Drive Clamp 44. Bearing Assy
18. Nut 45. Washer
19. Bolt 46. Bracket
20. Lever 47. Gasket Assy
21. Screw 48. Nut
22. Connector 49. Bolt
23. Decal 50. Identification Plate
24. Decal 51. Drive Screw
25. Nut 52. Sensor Box
26. Lockwasher 53. Gasket
27. Bearing

3-3
 INSTRUCTION MANUAL 27-45-4

I
I
18 I
I
I
20

'26

16

\il

Ei-4
21

4,
I'\,
b
/'
22

FIGURE 3-2. ELECTRICAL SENSOR BOX ASSEMBLY

3-4
 INSTRUCTION MANUAL 27-45A

LEGEND FOR FIGURE 3-2

1. Electrical Element 25. Retaining Ring

2. Screw 26. Bushing
3. Nut 27. Paddle Support
4. Lockwasher 28. Pivot Shaft
5. Flat Washer 29. Retaining Ring
6. Bearing 30. Bushing
7. Identification Plate 31. Cotter Pin
8. Drive Screw 32. Clevis Pin
9. Cover 33. Shaft
10. Gasket 34. Bellcrank
11. Nut 35. Nylon Washer
12. Lockwasher 36. Bearing
13. Flat Washer 37. Washer
14. Screw 38. Bracket
15. Bearing 39. Gasket
16. Support Assembly 40. Nut
17. Cotter Pin 41. Screw
18. Retainer Bolt 42. Nut
19. Nut 43. Lockwasher
20. Counterweight 44. Bearing
21. Bolt 45. Screw
22. Nut 46. Sensor Box
23. Connecting Link 47. Gasket
24. Pivot Shaft

3-13 CLEANING FLOW SENSOR

3-14' Complete the following steps:

a. Steam clean all parts EXCEPT the pneumatic position transmitter

(30, Figure 3-l) or the electrical element (1, Figure 3-2).

b. If steam cleaning equipment is not available, wash parts with

a soap solution and rinse with hot water.

C. Dry parts with clean, dry, low pressure air.

d. Clean the pneumatic position transmitter (30, Figure 3-l).

Plug the male connectors (22) labeled SIGNAL and 20 PSI
SUPPLY on position transmitter. Use a soap solution and warm water
to clean exterior of transmitter. Avoid jetting water directly
against the transmitter: the interior MUST remain dry.

e. Clean electrical element (1, Figure 3-2) with a damp cloth.

Avoid jetting water directly against the element. The
interior MUST remain dry.

3-5
 INSTRUCTION MANUAL 27-458

3-15 INSPECTION AND DISASSEMBLY

3-16 Visually inspect all parts for wear or damage that may affect the operation
of the flow sensor. Disassemble only to the extent required to replace
defective parts.

3-17 PNEUMATIC FLOW SENSOR. Disassembly of components of the pneumatic flow

sensor is accomplished by following the order of index numbers assigned
to the exploded view of Figure 3-l. Refer to Appendix A for a breakdown of the
pneumatic position transmitter. Requirements for critical areas of maintenance
are found in the following steps:

a. Inspect shaft (41, Figure 3-l) for excessive wear. A shaft

with a diameter of 0.621 inch (15.77 mm) or less in the area
of the bearing assemblies (44) should be replaced. Shaft surface
finish that is rough to the touch (32 RMS or rougher) requires
replacement of the shaft.

b. Replace bearing assemblies (44) at each overhaul regardless

of shaft wear.

C. Inspect sensor box (52) for pitting and corrosion of inner

walls and flange mating surfaces. Pitting that exceeds
0.20 inch (5.1 mm) requires that sensor box be replaced.

d. Inspect bearings (12, Figure 2-2 and 7, Figure 3-l) in position

for wear and evidence of the bolt touching the box, cover, or
base. Remove defective bearings and clean bearing mating surface
of the cover plate (1, Figure 3-l), sensor box (52), and base (13,
Figure 2-2).

3-18 ELECTRIC FLOW SENSOR. The following steps give the requirements for
critical areas of maintenance of the electric flow sensor. Disassembly
of components is accomplished by following the order of index numbers assigned
to the exploded view (See Figure 3-2) observing the following:

a. To inspect inside the sensor box (46, Figure 3-2), the

electrical element (1) must be removed from the cover plate
(.9) and the shaft (33). To remove the electrical element from the
shaft, first remove the support assembly (16) by loosening nut (22)
on bolt (21) which holds the support assembly.

b. Inspect shaft (33) for excessive wear. A shaft with a

diameter of 0.621 inch (15.77 mm) or less in the area of
the bearing assemblies (36) should be replaced. Shaft surface
finish that is rough to the touch (32 RMS or rougher) requires
replacement of the shaft.

C. Replace bearing assemblies (36) at each overhaul regardless of

shaft wear.

d. Inspect sensor box (46) for pitting and corrosion of inner

walls and flange mating surfaces. Pitting that exceeds
0.20 inch (5.1 mm) requires that sensor box be replaced.

3-6
 INSTRUCTION MANUAL 27-45A

e. Inspect bearings (12, Figure 2-2 and 6, 15, Figure 3-2) in position
for wear and evidence of the bolt touching the box, cover, or base.
Remove defective bearings and clean bearing mating surface of the cover
plate (91, sensor box (46) and base (13, Figure 2-2).

3-19 ELECTRICAL ELEMENT. The following steps give the requirements for critical
areas of maintenance of the electrical element. Disassembly of components
is accomplished by following the order of index numbers assigned to the exploded
view (See Figure 3-3) observing the following:

a. Inspect shaft assembly (Figure 3-3) for wear of shaft seal

(29) or shaft (28). The seal should fit close enough to
prevent moisture from entering the enclosure (49). Replace
shaft assembly if wear, binding, or corrosion is evident.

b. Remove cover (16) and inspect the wire connections at the

terminal barrier (46) and resistor (44). Ensure that
connections are free of corrosion and firmly secured.

c. Inspect strain relief of cable assembly (1). Loosen cable

grip connector (2) to increase strain relief and then tighten
securely.

3-20 ASSEMBLY OF FLOW SENSOR

3-21 Assemble the flow sensor in reverse order of disassembly and by following
the index numbers related to the pneumatic or electric flow sensor.

3-22 PNEUMATIC FLOW SENSOR ASSEMBLY. Complete the following steps using the
index numbers of Figure 3-1 unless otherwise noted:

a. Lubricate all threaded connections with corrosion resistant

lubricant (Refer to Approved Expendable Items List).

b. If bearings (12, Figure 2-2 and 7, Figure 3-1) were removed

from the cover plate (1, Figure 3-l), sensor box (52), or
base (13, Figure 2-2), install new bearings. Bond bearings in
place with light amber adhesive.

C. Before assembly, lubricate pivot shafts (32 and 36, Figure

3-1) and shaft (41) with thread sealant and lubricant.

d. Bond gasket (2) to cover plate (1) and gasket (53) to bottom
of sensor box (52) with light amber adhesive.

e. Shim each side of bell crank (42) with nylon washers (43) so
that shaft (41) shall have between 0.031 and 0.005 inch (0.79 mm
and 0.12 mm) end play. A minimum of one nylon washer (43) shall be
placed between the bell crank and the inside of the sensor box (52).

3-7
 INSTRUCTION MANUAL 27-458

18'

1A
I

14-

FIGURE 3-3. ELECTRIC ELEMENT

3-8
 INSTRUCTION MANUAL 27-4511

LEGEND FOR FIGURE 3-3

1. Cable Assembly 25. Retaining Ring
1A. Terminal Crimp 26. Washer
2. Cable Grip Connector 27. Spacer
3. Identification Plate 28. Shaft
4. Drive Screw 29. Shaft Seal
5. Hex Screw 30. Bearing Housing
6. Mounting Strap 31. Screw
7. Nut 32. Lockwasher
8. Lockwasher 33. Flat Washer
9. Flat Washer 33A. Flat Washer
10. Screw 34. Yellow Wire
11. Drive Clamp 35. Black Wire
12. Nut 36. Green Wire
13. Screw 37. Terminal
14. Linkage 38. Fixed Resistor
15. Cotter Pin 39. Clamp
16. Cover 40. Spring Pin
17. Screw 41. Plastic Tubing
18. Gasket 42. Set Screw
19. Wiring Decal 43. Coupling
19A. Corrosion Inhibitor 44. Variable Resistor
:
20. Screw 45. Screw
21. Lockwasher 46. Terminal Barrier
22. Flat Washer 47. Terminal Marker Strip
23. Lever 48. Bracket
24. Screw 49. Enclosure

f. Install washer (45) between bearing assembly (44) and

sensor box (52) as required to reduce frictional drag of
shaft (41) and to ensure that bearing assembly does not damage
bell crank (42). An equal number of washers should be on either
side. Lubricate threads of bearing assemblies (44) before in-
stallation. Frictional drag shall not prevent return of the
paddle support assembly (35) to a neutral position with one
counterweight support assembly (8) and one counterweight (12)
acting on the shaft (41).

g- After assembly is complete, perform calibration procedure

(Refer to Paragraph 2-8).

3-23 ELECTRICAL ELEMENT. Complete the following steps for assembling the
electrical element using the index numbers of Figure 3-3 unless other-
wise noted:

To ensure proper alignment of the variable resistor coupling

a* (43) with the shaft (28) of the shaft assembly, shim between
the terminal marker strip (47) and the enclosure (49) with flat
washers (33A)until proper mating is achieved without binding.
Cement the washers to the enclosure with red, general purpose
adhesive, then complete the installation of the variable resis-
tor (44).

3-9
 INSTRUCTION MANUAL 27-458

b. Apply red, general purpose adhesive on mating surface of bearing

housing (30) and on mating surface of enclosure (49).

C. Clean the inside area of cover (16) with suitable cleaner

before applying wiring diagram decal (19).

d. Adjust position of lever (23) on shaft (28) so that 0.005

to 0.20 inch (0.127 to 5.08 mm) end play exists between
washer (26) and lever (23).

e. Replace corrosion inhibitor (19A) at the end of two years use.

Write the installation date on the inhibitor.

f. After the electrical element is assembled, position lever (23)

horizontally and allow the weight of clamp drive (11) and
linkage (14) to move lever (23) to a vertical position. Shaft (28)
must move free enough for movement by the gravitational force of
the combined weight of the clamp drive and linkage.

3-24 ELECTRIC FLOW SENSOR ASSEMBLY. Complete the following steps for assembling
the electric flow sensor using the index numbers of Figure 3-2 unless
otherwise noted:

a. Lubricate all threaded connections with corrosion resistant

lubricant.

b. If bearings (6 and 15, Figure 3-2 and 12, Figure 2-2) were
removed from the cover plate (9, Figure 3-2), sensor box
(461, or base (13, Figure 2-2), install new bearings. Bond
bearings in place with light amber adhesive.

C. Before assembly, lubricate pivot shafts (24 and 28, Figure

3-2) and shaft (33) with thread sealant and lubricant.

d. Bond gasket (10) to cover plate (9) and gasket (47) to bottom
of sensor box (46) with light amber adhesive.

e. Shim each side of bell crank (34) with nylon washers (35)
so that shaft (33) shall have between 0.031 and 0.005 inch
(0.79 mm and 0.13 mm) end play. A minimum of one nylon washer
shall be placed between the bell crank and the inside of the
sensor box (46).

f. Install washers (37) between bearing assembly (36) and sensor

box (47) as required to reduce frictional drag of shaft (33)
and to ensure that bearing assembly does not damage bell crank (34).
An equal number of washers (35) should be on either side. Lubricate
threads of bearing assemblies (36) before installation. Frictional
drag shall not prevent return of the paddle support assembly (27)
to a neutral position with one counterweight support (16) and one
counterweight (20) acting on the shaft (33).

g* After assembly is complete, perform calibration procedure

(Refer to Paragraph 2-12).

3-10
 INSTRUCTION MANUAL 27-45A
SECTION IV
TROUBLESHOOTING

4-l GENERAL

4-2 This section contains instructions for correction of troubles which may
be encountered during adjustment or operation of the mud flow sensor assembly.
Where trouble is experienced, locate the probable cause and rectify the trouble
using the troubleshooting tables. This data assumes that all readout equipment is
operating correctly. After corrective action has been taken, appropriate calibra-
tion and adjustment of units must be performed before placing them back into
service.

4-3 PNEUMATIC FLOW SENSOR

4-4 Use Table 4-l for pneumatic flow sensor troubleshooting. Parenthetical
numbers refer to Figure 3-l unless otherwise indicated.

TABLE 4-l. PNEUMATIC FLOW SENSOR TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Leakage occurs between Bearing assemblies or Disassemble unit, inspect

bearing assemblies (44, shaft worn or damaged. parts (Paragraph 3-17,
Figure 3-l) and shaft a. and b.), and replace
(41). worn parts.

Pressure in mud return Mud flow sensor is de-

line exceeds design limit signed for a maximum of
of bearing assemblies 150 psig (10.55 kg/cm2>.
(seals). Replace sensor and over-
haul damaged unit. Re-
place damaged parts.

Readout of mud flow in- Counterweights (12) in- Readjust position of

sensitive to actual correctly positioned on counterweights (Para-
changes in mud flow or counterweight support graph 2-15).
shows constant reading. assembly (8).

Bearing assemblies (44) Disassemble unit, inspeci

and shaft (41) worn or parts (paragraph 3-7, a.
damaged. and b.), and replace won:
parts.

Lever (20) loose on trans- Tighten lever screw (21):

mitter (30) or drive clamp tighten bolt (19) and nui
(17) loose on shaft (41). (18). If necessary cali-
brate and adjust mud flol
sensor (Paragraph 2-10).

4-l
 INSTRUCTION MANUAL 27-458

TABLE 4-l. PNEUMATIC FLOW SENSOR TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Readout of mud flow in- Sensor paddle (l,lA, 2, or Determine cause of

sensitive to actual 3, Figure 2-2) stuck in one sticking paddle and
changes in mud flow or position. correct. Check for cor-
shows constant reading. rosion. Check build-up
(continued) of caked mud in flow line

Defective transmitter (30, Replace transmitter;

Figure 3-l). calibrate and adjust unit
(Paragraph 2-10).

No readout of mud flow. 20 psig instrument air Apply air pressure to

supply to transmitter transmitter.
turned off.

Lever (20) loose on trans- Tighten lever socket

mitter (30) or drive clamp screw (21); tighten bolt
(17) loose on shaft (41). (19) and nut (18). If
necessary,calibrate unit
(Paragraph 2-10). Re-
place transmitter; cali-
brate and adjust unit
(Paragraph 2-10).

Defective transmitter (30). Replace transmitter;

calibrate unit (Para-
graph 2-10).

With normal mud flow, Counterweights (12) and Adjust counterweights.

mud flow sensor readout counterweight support as- Check for corrosion.
improperly indicates sembly (8) are stuck in
100% reading (15 psig; overcenter position.
1.1 kg/cm2).
Counterweights (12) require Adjust counterweights.
adjustment.

Defective transmitter (30). Replace transmitter;

calibrate unit (Para-
graph 2-10).

4-2
 INSTRUCTION MANUAL 27-45A

4-5 ELECTRIC FLOW SENSOR

4-6 Use Table 4-2 for electric flow sensor troubleshooting. Parenthetical
numbers refer to Figure 3-2 unless otherwise indicated.

TABLE 4-2. ELECTRIC FLOW SENSOR TROUBLESHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Leakage occurs between Bearing assemblies or shaft Disassemble unit, inspect

bearing assemblies (36) worn or damaged. parts (Paragraph 3-18, a.
and shaft (31). and b.), and replace worn
or damaged parts.

Pressure in mud return Mud flow sensor is de-

line exceeds design limit signed for a maximum of
of bearing assemblies 150 psig (10.55 kg/cm2).
(.seals). Replace sensor and over-
haul damaged unit. Re-
place damaged parts.

Readout of mud flow Counterweights (20) in- Readjust position of

system insensitive to correctly positioned on counterweights (Para-
actual change in mud counterweight support graph 2-15).
flow or shows constant assembly (16).
reading.
Bearing assemblies (36) Disassemble unit, in-
and shaft (33) worn or spect parts (Paragraph
damaged. 3-18, a. and b.).

Lever (23, Figure 3-3) on Tighten socket screw

electric element (1, Figure (24, Figure 3-3); tighten
3-2) loose or drive clamp nut and bolt (12 and 13,
(11, Figure 3-3) loose on Figure 3-3) on drive
shaft (33, Figure 3-2). clamp (11, Figure 3-3).
Calibrate flow sensor
(Paragraph 2-12).

Paddle (1, 2, or 3, Figure Determine cause of stick-

2-2) stuck in one position. ing paddle and. correct.

Defective electrical el- Replace electrical el-

ement (1, Figure 3-2). ement and calibrate unit
(Paragraph 2-12).

Defective cable assembly Check cable for damage.

(1, Figure 3-3) on terminal Splice or replace cable
barrier (46, Figure 3-3) if necessary. Check for
connections. loose connections or
corrosion on terminals
(37) and clean and
tighten connections.

Defective resistor (44, Replace resistor.

Figure 3-3).

4-3
 INSTRUCTION MANUAL 27-458

TABLE 4-2. ELECTRIC FLOW SENSOR TROUBLESHOOTING (Cont'd)

TROUBLE PROBABLE CAUSE REMEDY

With normal mud flow, Counterweights (20, Figure Adjust counterweight

readout of mud flow 3-2) and counterweight (Paragraph 2-15). Check
system indicates 100% support assemblies (16) for corrosion.
reading (3.0 50.5V dc). are stuck in overcenter
position.

Wear or corrosion build up Rotate counterweight

on bearing assemblies (36, supports (16, Figure 3-2)
Figure 3-2) or shaft (32). from O" to 90° to free
paddle movement.

Disassemble unit, inspect

parts (Paragraph 3-18, a.
and b.). Replace worn
parts and calibrate
(Paragraph 2-11).

With normal mud flow, Wear or corrosion build Rotate counterweight

readout of mud flow up on bearing assemblies supports (16, Figure 3-2)
system indicates 0% (36, Figure 3-2) and shaft from 0' to 90° to free
(0.45V dc). (33). paddle movement.

Disassemble unit and in-

spect parts (Paragraph
3-18, a. and b.) Replace
worn parts and calibrate
flow sensor (Paragraph
2-12).

Counterweights (20) re- Calibrate and adjust unit

quire adjustment. (Paragraph 2-11).

4-4
 INSTRUCTION MANUAL 27-45A
APPENDICES
VENDOR DATA

Title Page

Foxboro Service Instructions Type CP Position Transmitter A-l

Foxboro Model 40C Control Relay B-l

Ai/Aii
 14-132
Feb. ‘
Page 1

TYPE CP POSITION TRANSMI

General versa1 lever specifically designed for these con-
trol valves.
The Type CP Position Transmitter produces a
definite output air pressure for each position of Principle of Operation
its actuating lever (K), Flg. B3082. The actu- When the actuating lever (K) is not in mo-
ating lever may be connected t.q any moving tion the system is in balance and the feedback
mechanism either directly or through a suitable bellows (A) opposes flexure assembly (B). With
linkage. A 3-15 psi output can be obtalned for the flapper-nozzle in the position shown in Fig.
any span of rotational motion from a minimum B3082 (orange sector), clockwise rotation of the
of 5 to a maximum of 30 By repositioning actuating lever rotates the flexure assembly (B)
the actuating lever on the transmitter input and the ball tip in such a direction that the
shaft (Cl, this span of rotational motion may flapper (El tends to cover the nozzle (F). Pres-
be shifted anywhere in a plane perpendicular sure established by the flapper-nozzle is ampli-
to the input shaft. Lever travel ls restricted by fled by the relay (G) and led to the feedback
a stop pin at the end of the input shaft. bellows (A) and to the output. Bellows (A) ex-
pands pushing the ball tip in such a direction as
Description of Transmitter
to restore the flapper to its detector position. For
The Type CP Position Transmitter Is housed in any given position of disc (J), the amount of re-
a die-cast aluminum case, flnlshed in a corroslon- balancing motion in direction (1) is exactly pro-
resistant vinyl paint. A gasketed cover insures a portional to the amount of unbalancing motion
vapor and dustproof interior. All moving parts in direction (2). Thus the pressure in bellows (A),
are stainless steel, beryllium copper, bronze, or and hence the output pressure, is directly pro-
Nylon. Transmitters are supplied with an actu- portional to the rotation of the actuating lever.
ating lever l/4 in diameter and approximately The output pressure is transmitted to a re-
1Q long, except those transmitters to be tised ceiving instrument which converts it to a read-
with Foxboro control valves. The latter us-e a unl- ing of posltlon.

OUTPUT

SUPPLY I.tI,

RELAY

”
Fig. B3082 mmd

TOTCO Reprint
The Foxboro Company hx
Fo.bomMa,,aC!l ” s A 02035
A-l
14-132 ‘

Tranemitter Action orange colored sector to the front. If it Is de-

Remove the front cover of the Type CP Po- sired that counterclockwise rotation of the actu-
sition Transmitter and check the poslticn of the ating lever result in increasing transmitter out-
control disc (3). Fig. B3088. If it is desired that put pressure, rotate the blue colored sector to the
clockwise rotation of the actuating lever result in front. The control disc can be rotated to the
increasing transmitter output pressure, rotate the correct quadrant by means of the wrench (1).

SUP

OUT

BLUE SECTOR ORANGE SECTOR

’ ‘

BALL TIP
MOTION W E TO
COUNTERCLOCKWISE CLOCKWISE ROTATION OF
ROTATION OF L ROTATION OF
ACTUATING LEVER 2t ACTUATlNG LEVER
ACTUATING LEVER

OUTPUT P R E S S U R E OUTPUT P R E S S U R E 1 MOTION W E TO

INCREASES INCREASES FEEDBACK BELLOWS

Fig. B3588

Transmitter Operating Adjustments the slot in the instruction plate. Use MAX po-
There are three operating adjustments on the sition on the orange scale if the orange
Type CP Position Transmitter: Two of them sector is employed; MAX position on the blue
align the ball tip (2) over the center of the con- scale if the blue sector is employed.
trol disc to produce 9 psi output pressure at mid- 3. Adjust the threaded bearing (5) with a =!
stroke of the actuating lever; and the third ad- wrench until the output pressure is 9 psi.
justs the transmitter output pressures to the pro- 4. Rotate the control disc (3) beyond the MIN
cess stroke. Standard adjustments will produce 3 position until the wrench (1) hits the end of the
to 15 psi output as the actuating lever revolves slot in the instruction plate.
throughout its stroke. 5. Adjust the micrometer screw (6) until the
When the transmitter is furnished on a valve output pressure is 9 psi.
motor, these adjustments are properly set at the 6. Repeat steps 2 through 5 until 9 psi output
Factory and should require no further attention. pressure is maintained in any position of the
Otherwise, these adjustments must be made at disc within the sector chosen.
the time of installation.
To check these adjustments, connect a 20-psi
air supply to the “ (supply) connection.
Connect a O-20 psi mercury manometer (or test NOTE : If during adjustment it is necessary to
gauge) to the “ connection, turn the threaded bearing until the stop screw
(7) hits the casting, loosen stop screw (71, slide
out the collar on the shaft, and retighten screw
(7). Similarly, if excessive travel of-the micro-
Centering Adjustments
meter screw (6) is reauired. turn the micrometer
1. Rotate the actuating lever to its midstroke screw to midtravel, lo&en t stop screw ( and
position. the actuating lever clamp screw (9), and rotate
2. Select the correctly-colored quadrant as dis- the shaft as follows: With the flexure spring (8)
cussed under Transmitter Action, and rotate the vertical, stop screw (7) should be at midtravel
control disc (3) beyond the MAX position using and the actuating lever should be at Its mid-
the wrench (1) until the wrench hits the end of stroke position.

The Foxboro Company TOTCO Reprint

Foxboro. Massachusells. US A 02035

A-2
 14-132

Fig. B3088

Stroke Adjustment Reducing Tube

1. Set the actuating lever at zero travel. The reducing tube (10) consists of an orifice
2. With the wrench (11, position control disc approximately 0.008 in diameter. It can be un-
(3) until the output pressure is either 3 or 15 screwed from the Type CP Position Transmitter
psi, depending on the transmitter action. and replaced. Occasionally, a particle of dirt or
3. Check output pressures at zero, midtravel, moisture will plug the reducing tube and cause
and full travel of the actuating lever. It may be the output pressure to drop to zero. If this oc-
necessary to trim centering and stroke adjust- curs, turn off the air supply to the transmitter,
ments slightly. unscrew the reducing tube, and clean by insert-
ing a wire not larger than 0.007 (B & S Gauge
#33 or higher) through the orifice. Foxboro
Maintenance cleaning wire, Part 42527, may be used,
. The only regular maintenance necessary is the Filters
periodic blowing of the dripwell petcock to re-
move moisture from the air supply system. This Fine wire mesh filters are provided in the air
should be done often enough so less than one connections. If ‘ become clogged with dirt,
pint of liquid is removed at each blowdown. remove them with a thin pointed tool and re-
place with new Alters.

The Foxboro Company ~OXBORd TOTCO Reprint

A-3/A-4
MI 11-490
Page 2

Cleaning the Relay

Should the relay require cleaning, remove the cover and adjacent loose parts, clean
with a suitable solvent (such as trichlorethylene), and dry carefully with compressed air.
In reassembling the relay, all corresponding holes must line up and all outside edges must
coincide with those of the relay body casting.
Should further cleaning be required, remove the
large screw holding the snring,assembly to the relay
body, and clean the spring and ball. It should not be
necessary to change the setting of the tension screw.
When reinstalling the spring assembly, make sure
that the spring holds the ball in position in its seat.

Calibration Procedure
Calibration of the relay is required if the diaphragm or spring is replaced, or if
the setting of the tension adjustment screw is changed.
This procedure requires a calibrating fixture, Part C013OLB (English) or CO13OlX (SI),
obtainable from The Foxboro Company.
NOZZLE
(INPUT)
PRESSURE
OUTPUT
PRESSURE
1. Position relay as shown (with re-
cessed rectangle on cover toward
left) and mount relay on fixture.
”
Seal opening in nozzle valve with
Not used in finger until nozzle pressure (on
left gauge) is 15 psi or 100 kPa,
then release finger. Repeat.
CAUTION: Do not exceed this pres-
sure or gauge may be damaged.
Adjust nozzle valve (use l/4 inch
open-end wrench) so that nozzle
pressure is 2.2 psi or 14.7 kPa.
Note output pressure (on right
gauge). If reading is 2.5-3.0
psi or 17-20 kPa, relay is in
Connect 17 psi (120 kPa) calibration. If not proceed
air supply. Use l/8 NPT to Step 5.
fitting.

5. Remove plug from rear of fixture (use Rear of

3/16 hex-key wrench) and carefully Fixture
insert a narrow, thin-blade screwdriver
into opening to engage slotted head of
tension adjustment screw. (Note that \
air will escape through opening when
plug is removed.)
Turn screw a small anout (clockwise to
decrease output). Change in output can-
not be determined until the plug opening
is sealed with finger.
6. Repeat Step 5 until output pressure is
2.5-3.0 psi or 17-20 kPa. Relay is now
in calibration.

TOTCO Reprint

B-2