Barton Model 581a Differntial Pressure Switch User Manual

BARTON® NUCLEAR MODEL 581A
DIFFERENTIAL PRESSURE
SWITCH
User Manual
Part No. 9A-C10766, Rev. 01
Model 581A-0 October 2011
Contents
Safety............................................................................................................. 2
Section 1—Introduction.................................................................................. 3
General.......................................................................................................... 3
Wiring......................................................................................................... 5
Differential Pressure Unit........................................................................... 5
Specifications . .............................................................................................. 6
General:..................................................................................................... 6
Nuclear Qualifications................................................................................ 6
Application Specifications ......................................................................... 7
Storage Specifications .............................................................................. 7
Section 2—Installation.................................................................................... 9
Mounting/Piping/DPU Installation.................................................................. 9
Electrical Connection..................................................................................... 9
Switch Use..................................................................................................... 9
Startup......................................................................................................... 10
Switch Wiring............................................................................................... 10
Section 3—Maintenance and Calibration.....................................................11
Tools.............................................................................................................11
Bezel/Lens Assembly or Cover Installation and Removal........................... 12
Pointer Installation and Removal................................................................. 13
Pointer Installation . ................................................................................. 13
Pointer Removal....................................................................................... 14
Scale Plate Installation and Removal.......................................................... 14
Indicator Calibration..................................................................................... 15
Drive Arm Tightness Test.......................................................................... 17
Drive Arm Stop Adjustment...................................................................... 17
Switch Calibration ...................................................................................... 17
Calibration Setup...................................................................................... 18
Linkage Calibration Procedure ................................................................ 18
Changing Switch Set Point ......................................................................... 20
Definitions of Terms.................................................................................. 20
Best Practices for Set Points.................................................................... 20
Changing Set Point of an In-Service Instrument...................................... 20
Changing Set Point of an Out-of-Service Instrument............................... 21
Range Changes....................................................................................... 22
Troubleshooting .......................................................................................... 22
Section 4—Assembly Drawing and Parts List............................................ 25
Section 5—Dimensional Drawings.............................................................. 33
Appendix A—Model 199 DPU......................................................................A-1
DPU Description.........................................................................................A-1
Specifications..........................................................................................A-2
DPU Components...................................................................................A-2
DPU Installation..........................................................................................A-5
Unpacking...............................................................................................A-5
Mounting.................................................................................................A-6
Piping—Standard Practices....................................................................A-6
Piping Diagrams......................................................................................A-8
Startup...................................................................................................A-14
DPU Maintenance.................................................................................A-14
Required Tools......................................................................................A-14
DPU Cleaning and Inspection...............................................................A-15
Calibration Setup...................................................................................A-16
Torque Tube Rotation Check (Replacement Units)...............................A-16
Changing the DPU Range.....................................................................A-17
Setting Bellows Travel...........................................................................A-21
Bellows Unit Assembly (BUA) Replacement.........................................A-21
Attaching Drive Arm to Torque Tube......................................................A-22
Drive Arm Tightness Test.......................................................................A-23
Adjusting Pulsation Dampener..............................................................A-23
Troubleshooting.....................................................................................A-24
DPU Assembly Drawing and Parts List.....................................................A-26
DPU Dimensional Drawings.....................................................................A-31
Safety
Before installing this product, become familiar with the installation instruc-
tions presented in Section 3, Appendix A and all safety notes throughout.
! WARNING: This symbol identifies information about practices or circum-

stances that can lead to personal injury or death, property damage, or
economic loss.
CAUTION: Indicates actions or procedures which if not performed correctly

may lead to personal injury or incorrect function of the instrument
or connected equipment.
IMPORTANT: Indicates actions or procedures which may affect instrument operation or

may lead to an instrument response that is not planned.
Model 581A Differential Pressure Switch Section 1
Section 1—Introduction
General
The 581A Differential Pressure Switch actuates single or dual signal circuits
when predetermined limits of flow or level are exceeded. The DPU is con-
nected to the process or vessel by tubing or piping. Changes in differential
pressure (DP) at the DPU produce a mechanical output which moves a pointer
and switch actuation controls.
For flow measurements, the instrument is connected to the high-pressure

and low-pressure sides of a primary device in the process run. Normally the
primary device will be an orifice plate, venturi, or flow tube.
For liquid level measurement applications, the instrument is connected to

measure changes in differential pressure caused by variations in hydrostatic
pressures of the liquid in a tank.
The 581A switch is available in three model variations:

• Indicating Switch (Model 581A-0). This model, shown on the manual
cover, has a thick tempered plate glass lens and provides a visual indica-
tion of the difference in the two monitored pressures.
• Blind Switch (Model 581A-2).This model has a solid metal cover and
provides no visual indication of differential pressure.
• Blind Switch with Internal Indicator. Unlike the indicating model with
the glass lens, there is no externally visible indicator. However, internally,
components are the same as in Model 581A-0. With the cover removed, a
user can use the internal indicator to determine DPU input pressure when
making adjustments to the switch setpoints.
The Model 581A uses two independently adjustable single-pole double-throw
(SPDT) snap-acting switches that are rated for high temperatures. Both sides
of the switches are wired, enabling the switches to serve both normally-open
and normally-closed applications. The direct-set switch contacts are adjustable
over a scale range of 10-90% nominal. Switches and all adjustments are read-
ily accessible when the cover is removed (see Figures 1.1 and 1.2, page 4).
The 581A Switches (indicating and blind) are qualified per IEEE 323-1974,
IEEE 344-1975, IEEE 381-1977and NUREG 0588, Rev. 1 for either Func-
tional and/or Pressure Boundary Integrity service in limited harsh environ-
ment applications.
The switch case is drawn stainless steel with a sealed glass header for the
electrical interface with the switches. No additional conduit seals are required
to ensure the integrity of the instrument.
3
Section 1 Model 581A Differential Pressure Switch
Left Switch Actuating Cam

Right Switch
Plunger Screw Plunger Screw
Right Switch
Left Switch
Lock Screw
Lock Screw
Drive Arm
Pointer
Stop Bracket
Switch Adjust Linkage
Movement Assembly
Left Switch
Adjustment
Assembly*
Terminal Strip
Right Switch
Adjustment
Assembly*
Range Adjust
* Switch Adjustment Assembly includes crank, index shaft, and index pointer.
Figure 1.1—581A (with indicator), internal components
Actuating Cam
Left Switch Right Switch
Plunger Screw Plunger Screw
Right Switch
Left Switch
Lock Screw
Lock Screw
Cam Actuator
Left Switch
Adjustment Switch Adjust Linkage
Assembly*
Terminal Strip
Right Switch
Adjustment
Assembly*
* Switch Adjustment Assembly includes crank, index shaft, and index pointer.
Figure 1.2—581A (without indicator), internal components
The cam rotates counterclockwise with increased pressure. In Figure 1.3, page
5, the LOW switch (typically set to alarm at decreasing pressure) is set at 25%
differential pressure while the HIGH switch (typically set to alarm at increas-
ing pressure) is set at 75% differential pressure.
4
B O T H S W I T C HES RELAX ED Mid-point DP

50
C AM 0 100
S W I T C H "A" S W I T C H "B " CLOSED OPEN

SWITCH CONTACTS CONTACTS
(LEF T ) (RI GHT )
SWITCH LOW HIGH A (LEFT) YELLOW/BLUE YELLOW/RED
PLU NGER
B (RIGHT) GREEN/WHITE GREEN/BLACK
S C REW
Y ELLO W
B LAC K
W HI T E
GREEN
B LU E
RED
T ERM I NAL
B LO C K I N
C AS E
S W I T C H "A" AC T UAT ED/S W I T C H "B " RELAX ED Zero DP

50
0 100
S W I T C H "A" S W I T C H "B " CLOSED OPEN

SWITCH CONTACTS CONTACTS
(LEF T ) (RI GHT )
A (LEFT) YELLOW/RED YELLOW/BLUE
B (RIGHT) GREEN/WHITE GREEN/BLACK
S W I T C H "A" RELAX ED/S W I T C H "B " AC T UAT ED Maximum DP

50
0 100
CLOSED OPEN
S W I T C H "A" S W I T C H "B " SWITCH CONTACTS CONTACTS
(LEF T ) (RI GHT )
A (LEFT) YELLOW/BLUE YELLOW/RED
B (RIGHT) GREEN/BLACK GREEN/WHITE
Notes:
1. CAM ROTATES COUNTER-CLOCKWISE WITH INCREASED DIFFERENTIAL PRESSURE
2. EACH SWITCH MAY BE SET AT ANY POINT FROM 10% TO 90% OF DP RANGE
3. WIRES: No. 22 AWG (Internal) and No. 18 AWG (External)
Figure 1.3—Switch wiring connections and actuation example
Wiring
Each switch is wired internally to a glass-sealed header using No. 22 AWG
ethylene tetrafluoroethylene (Tefzel®) insulated wire for radiation service per
IEEE Standard 393-1974. Externally, from the header, permanently color
coded No. 18 AWG Tefzel® wires exit through a female conduit connection.
Differential Pressure Unit

For detailed information on the Model 199 DPU, see Appendix A.
5
Specifications
General:
Actuating Unit (DPU) �� Model 199 DPU
Dial Size �� 6 inches (150 mm)
Service Conditions (Normal) �� 40°F (4.4°C) to +180°F (+57.2°C) @ <90% R.H.
Switch Repeatability �� ±1% of calibrated span
Switch Set-point Range �� 10 to 90% of calibrated span
Switch Deadband �� ±10% of calibrated span (maximum)
Switch Type �� Mechanical, Snap-Acting; both switches are SPDT
Activation �� Increasing or decreasing scale
Switch Contact Rating:
5.0 Amps @ 125 VAC
5.0 Amps @ 250 VAC
3.0 Amps @ 30 VDC (resistive)
1.0 Amp @ 30 VDC (inductive w/arc suppression)
0.4 Amp @ 125 VDC (resistive)
0.2 Amp @ 125 VDC (inductive w/arc suppression)
Input Range �� 0-10" WC to 0-115 psid

Indicator Accuracy �� ±2.0% of calibrated span (for ranges to 400 psid)1
Indicator Repeatability �� ±0.5% of calibrated span
Safe Working Pressure �� 3000 psig
Maximum Overrange �� To safe working pressure
Process Connections �� 1/4" NPT top and bottom
1/2" NPT top and 1/4" NPT bottom
Electrical Connections �� Female, 3/4" NPT, 20 ft., color-coded Tefzel®
insulated 18 AWG wire (40 ft. leads available by
special order)
Torque Tube Rotation �� 8° (nominal)
Accuracy of Repeatability �� ±0.5% of calibrated span
1
Additional 2% is applicable near the switch setpoints (±10% span).
Nuclear Qualifications
The following nuclear qualification applications are based on Cameron Engi-
neering Report 9A-CR3-580A-29.
Design Basis Event (DBE) Performance Error1 (% of calibrated span):
Radiation (1 x 107 Rads) �� ±10%
Seismic (12.5 Gs):
During Event �� ±10%
Following Event �� ±5%
Harsh Environment (≤ 200°F):
During Event �� ±10%
Following Event �� ±10%
1
Includes the cumulative effect of accelerated aging.
6
Application Specifications
Model 581A switches were subjected to IEEE 323-1974/344-1975 qualifi-
cation testing, which found the devices suitable for functional service in a
limited harsh environment. The service conditions associated with the limited
qualifications are:
• 22 year qualified service life1 normal conditions of 104°F and 0 psig
• Radiation exposure to 1 x 107 Rads (TID)
• 85 days @maximum DBE conditions of 200°F, 10 psig ambient pressure
and ≥ 95% R.H.
• Seismic qualifications:
–– OBE @ 6.25 Gs (series of 5)
–– SSE @ 12.5 Gs
–– 5% critical damping
–– No resonance in frequencies below 33 Hz
• Mechanical aging included:
–– 25,000 pressure cycles during accelerated aging
–– 12,500 electrical cycles during accelerated aging
–– Vibration cycling using 0.2 G sinusoidal sweeps over the 1 to 200
Hz range at 1.0 octave/min.
1
Qualified Life: This equipment contains some organic material. The qualified life will be
governed by factors such as environmental temperature, radiation exposure, and activa-
tion energy.
Storage Specifications
Storage per ANSI N45.2.2-1978 Level B at 70°F (21°C) ±20°F (±11°C) in
factory sealed package for 2.5 years maximum will not affect installed service
life.
7
8
Section 2—Installation
The instrument should be inspected at time of unpacking to detect any dam-
age that may have occurred during shipment.
IMPORTANT: The DPU was checked for accuracy at the factory. Do not change any of
the settings during examination or accuracy could be affected.
For applications requiring special cleaning/precautions, a polyethylene bag

is used to protect the instrument from contamination. This bag should be
removed only under conditions of extreme cleanliness.
Mounting/Piping/DPU Installation
Mount the instrument with four 5/16" (8mm) bolts, Grade 5 or greater,
torqued to 17 ft/lbs (see Figure 7.1). Mounting structures should be designed
to avoid resonance and/or minimize resulting amplification below 33 Hz.
Response spectra at mounting surface of the instrument shall not exceed those
in the 9A-CR3-580A-29 Qualification Report. Interfacing process tubing and
conduit shall be supported by the same mounting as the DP instrument base
in order to minimize relative motion of the DP instrument and connections.
Dimensional drawings are provided in Section 5, page 32.
See Appendix A for Model 199 DPU installation and maintenance informa-
tion.
Electrical Connection
Units are supplied with dual alarm switches. The direct-set switch contacts
are adjustable over 10% to 90% of the scale range.
The high switch and low switch set point adjustment procedures are covered
in Changing Switch Set Point, page 20.
For physical location of switches, see Figures 1.1 and 1.2, page 4.
Switch Use
Switch contact life is influenced by various application conditions such as
temperature, humidity, airborne contamination, vibration, amount of plunger
travel, cycling rate, and rate of plunger travel (and others), as well as by the
electrical (circuit) characteristics.
IMPORTANT: Arc suppression for inductive loads will prolong the life of the switch
contacts.
9
Startup
For startup procedures, warnings, and other information, refer to Appendix A.
IMPORTANT: To ensure the unit calibration is within factory-set calibration tolerances,

perform the Calibration Check procedure on page 12.
Switch Wiring
IMPORTANT: Figure 2.1 shows switch contacts in the relaxed (shelf) condition, the low
switch set to trip at a position below the pointer scale position, and the
high switch set to trip at a position above the pointer scale position. NO
= Normally Open in (shelf) condition. NC = Normally Closed in (shelf)
condition. C= Common.
LOW & HIGH SPDT SWITCHES
NO C NC NC C NO
YELLOW
GREEN
BLACK
WHITE
BLUE
RED
1 2 3 4 5 6 7 8 9 10
YELLOW
GREEN
BLACK
WHITE
BLUE
RED
Figure 2.1—Low/high SPDT switch diagrams
Table 2.1—Switch Wire Color Coding

581A Current Configurations
NO C NC
Low Red Yellow Blue
High Black Green White
10
Section 3—Maintenance and Calibration

The following checks are recommended for preventive maintenance:
• Periodically inspect the alarm switch mechanism to verify that all mount-
ing screws are seated properly.
• Inspect linkage for wear.
• Inspect integrity of electrical circuits. Tighten as necessary.
When repairs are necesssary, review this section for maintenance procedures
such as bezel/lens installation and removal, pointer installation and removal,
indicator calibration, switch calibration, and switch set point changes. Refer
to Figure 3.1 as needed for component identification.
Figure 3.1—Model 581A adjustment controls
IMPORTANT: See Appendix A for related warning/caution notices and instructions

on DPU inspection, cleaning, service, repair, range change, and BUA
replacement. Never perform maintenance/repair on the Model 581A
differential pressure switch or DPU without first reviewing all proce-
dures and warning/caution notices in Appendix A.
11
Tools
The following tools are recommended for general maintenance of the Model
581A differential pressure switch.
Table 3.1—Tools
Equipment Purpose
Pointer Puller Pointer removal
Small Screwdriver Calibration adjustment
Medium Screwdriver Bezel removal and replacement
1/4" and 1/8" Open-end Wrenches Zero (1/4") and Range (1/8") adjustments
1/8 Hex Allen Wrench Switch set point adjustment
Bezel/Lens Assembly or Cover Installation and Removal

To remove the bezel/lens assembly or cover, loosen the screws on the front
and lift the assembly or cover from the enclosure.
To reinstall the bezel/lens assembly (581A-0 only), install the O-ring in the
groove of the case, assemble the bezel, lens, and lens gasket, and realign the
screw holes with the holes in the case. Then, reinstall the screws in the bezel
to secure all components to the case. Torque the screws per Table 4.3, page 30.
To reinstall the cover (581A-2), install the O-ring in the groove of the case
and realign the screw holes in the cover with the holes in the case. Reinstall
the screws in the cover to secure it to the case. Torque the screws per Table
4.3, page 30.
IMPORTANT: Ensure the bezel gasket is properly oriented before placing the instru-
ment back in service. Incorrect gasket orientation will cause the instru-
ment indicator to jam, resulting in inaccurate readings.
Calibration Check
To ensure the unit calibration is within factory-set calibration tolerances,

perform the following procedure.
IMPORTANT: Review all procedures and WARNINGS/NOTICES in Appendix A

BEFORE performing this procedure.
1. Mount the instrument in an approximately level position and connect to a

standard pressure source.
2. If the zero indication is incorrect, adjust it as follows:
a. Remove the bezel/lens assembly or cover.
b. Using a 1/4" open-end wrench (included in calibration toolkit, Part
12
No. 9A-0288-1032B), hold the hexagon pointer hub fixed and rotate
the pointer with fingers until the pointer indicates zero on the scale.
See Figure 3.2, page 13.
c. Replace the bezel/lens assembly.
Pointer "slipped" HUB

rotated on hub
Hub held in place

with 1/4" wrench
Figure 3.2—"Slipping" pointer
3. To test for reverse travel, connect the pressure source to the low-pressure
(LP) housing and vent the HP housing. Apply pressure to approximately
150% of the DP range. The pointer should move approximately 5% to
10% below zero.
4. To test for overtravel, connect the pressure source to the HP housing and
vent the LP housing. Apply pressure to approximately 150% of DP range.
The pointer should move approximately 5% to 10% above the full scale
mark.
5. Apply 0, 50, and 100% of full scale pressure. If the indication is within
specified limits, no adjustments are necessary. If the indication is not
within specified limits, perform a complete calibration (see Scale Plate
Installation and Removal, page 14).
6. Make sure the instrument zero indication is correct; otherwise, repeat
step 2.
7. Verify the switch set points (refer to Changing Switch Set Point, page 20).
Pointer Installation and Removal

During adjustment and calibration of the unit, it may be necessary to remove
and reinstall the pointer. See the following procedures for instructions.
Pointer Installation
1. Position the pointer on the movement shaft with the pointer set at zero
scale. Obtain 75% to 90% pointer hub engagement on the movement
pinion shaft. The pinion shaft must not extend through the pointer hub.It
may be necessary to enlarge the hub hole using a tapered broach (includ-
ed in the calibration toolkit, Part No. 9A-0288-1032B).
13
2. Lightly tap the pointer hub with a hand-set or other flat-end tool. Use
perpendicular blows to avoid bending the shaft.
3. Check the calibration of the indicating switch over its entire range (refer
to Scale Plate Installation and Removal, page 14). If the indicating switch
is correctly calibrated, secure the pointer to the movement shaft by tap-
ping the hub with a hand-set or other flat-end tool.
4. Test the pointer for tightness by moving the pointer from the zero to the
50% position manually, and then letting the pointer return freely to zero.
If the pointer indicates a shift, tap the pointer hub to tighten it to the
shaft.
Pointer Removal
The pointer is removed with a pointer puller shown in Figure 3.3. This tool is
included in the calibration toolkit, Part No. 9A-0288-1032B.
To remove the pointer, perform the following steps:

1. Slide the pointer puller along the pointer until the pin protruding from the
tip of the screw in the pointer puller is directly over the movement shaft
and the arms of the pointer puller are directly under the pointer.
2. Gently turn the knurled head of the screw clockwise, pushing the pin
against the movement shaft and lifting the pointer with the arms. Finger
pressure should be sufficient to pull the pointer free. If more pressure is
required, an Allen wrench (inserted into head of the screw) can be used.
However, care should be exercised to avoid breaking the pin.
POINTER PULLER
HUB
POINTER
HUB
MOVEMENT SHAFT
Figure 3.3—Pointer puller (Part No. 9A-0163-0005B)
Scale Plate Installation and Removal

During adjustments and calibration of the unit, it may be necessary to remove
and reinstall the scale plate. The scale plate is split to allow removal without
pulling the pointer. It is held in place by five screws (item 40 in Figure 4.1,
page 25) and two mounting tabs at 12 o'clock and 6 o'clock positions. The scale
plate halves rest against the top tab (12 o'clock), and slide beneath the bottom
tab (6 o'clock).
14
To remove the scale plate, move the pointer to the 12 o'clock position, remove
the screws from the scale plate, and gently guide the scale plate halves from
beneath the bottom mounting tab. Screws are located at 12, 3 and 9 o'clock
positions and near the center of the plate which overlays a narrow bracket.
To reinstall the scale plate, repeat the installation steps in reverse order, as
follows. Holding the pointer in the 12 o'clock position, place the scale plate
halves against the top mounting tab and guide the bottom edges behind the
bottom tab. Replace the screws in the top tab and in the center of the scale
plate. No screw is used with the bottom tab.
Indicator Calibration
If the DPU assembly is replaced on a Model 581A differential pressure switch
with indicator, the indicator must be recalibrated. This procedure does not ap-
ply to the 581A-2 blind switch without indicator.
IMPORTANT: Review all procedures and WARNINGS/NOTICES in Appendix A

BEFORE performing this procedure.
1. Securely mount the instrument in an approximately level position and

connect the DPU, as described in the Model 199 DPU user manual.
2. Remove the bezel/lens assembly or cover.
3. Align the linkage between the drive arm and the movement at 50% differ-
ential pressure (DP) as shown in Figure 3.4. Inspect parts for straightness
and pivot-fit without binding.
Figure 3.4—Range/linearity adjustment (50% DP)
4. Check the pointer for zero indication. If necessary, set the pointer to zero
by slipping the pointer on the hub, per Calibration Check, step 2, page 12.
5. Apply 100% pressure. If the pointer exceeds full-scale, adjust the range
adjust screw with a 1/8-in. open-end wrench to lengthen the movement
range arm.
15
6. Release pressure. Set the pointer to zero, by slipping the pointer on the
hub, per Calibration Check, step 2, page 12.
7. Repeat steps 4 and 5, as necessary, to obtain the correct zero/full-scale.
8. Apply 50% DP. If the pointer indicates 50%, proceed to step 9. If the
pointer does not indicate 50% scale, adjust linearity as follows.
a. Loosen the drive arm screw (Figure 3.5) and move the arm to shift
the pointer in the direction of the error a distance of about 10 times
the linearity error.
b. To prevent interference, check to see that the drive arm clears the
end of torque-tube housing by approximately 0.030 in. before re-
tightening the drive arm screw.
c. While supporting the block/shaft, tighten the clamp screw until it is
snug to the shaft.
d. Still supporting the block/shaft, tighten the clamp screw an addition-
al 1/3 to 1/2 turn. (This screw can normally turn one full revolution
before breaking.)
e. Perform the Drive Arm Tightness Test described on page 17.
LINK SINTERED
CLAMP BLOCK
.03 (approx)
DRIVE ARM
M199
SHAFT CLAMP SCREW
1/8” WRENCH
(PN 9A-0163-0044C)
TO TIGHTEN
Figure 3.5—Drive arm to torque tube connection
9. Release pressure and reset the pointer to zero. Check the span. If the gear
in the movement reaches a limit of travel as a result of linearity adjust-
ment (step 8), slip the range arm along the gear approximately 5 degrees
from the normal 37.5 degree angle to approximately 43 degrees (see
step 3). To slip the range arm, apply pressure to the range arm with the
thumb, while holding the gear firmly in place. Retest the pointer response
at 50%, 0%, and 100% of full-scale differential pressure, and adjust the
linkage until the readings are acceptable.
10. Apply 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25%, and 0% of full-scale
differential pressure consecutively to the instrument without overshoot.
16
Lightly tap the indicator to overcome friction. The pointer should accu-
rately indicate each applied pressure.
11. Test the instrument repeatability by applying 0%, 50%, 0%, 50% of full-
scale differential pressure. The indicator should accurately indicate each
applied pressure.
12. Set the drive arm stop to prevent the pointer from striking the post lock
on the scale.
13. Test the pointer for tightness per the pointer installation instructions on
page 13.
14. If the drive arm screw has been loosened, check for tightness by perform-
ing the Drive Arm Tightness Test described below.
15. Reassemble the unit per the cover installation instructions on page 12.
Drive Arm Tightness Test
This procedure tests the tightness of the drive arm's connection to the torque
tube by applying torque developed by the DPU onto a fixed drive arm. Ap-
ply pressure slowly, as torque is being applied to the connection through the
torque tube drive shaft.
1. With the pointer at normal 0% torque tube rotation position (0% on a
normal 0 to 100% scale unit), adjust the drive arm stop bracket (or use
alternate means) to prevent the pointer from moving (the stop bracket
interferes with drive arm movement).
IMPORTANT: On reverse acting/split range units, it will be necessary to pressurize the

DPU to move the pointer to the minimum scale position. On suppressed
units, it will be necessary to apply pressure to establish a reference point
to check for "zero" shift.
2. Pressurize the DPU to full scale DP (100% of full scale range) to apply 8
degrees of equivalent torque to the connection.
3. Observe the shift in the "zero" indication following DPU depressuriza-
tion (as required) and drive arm stop bracket readjusting (to allow free
movement of drive arm and pointer). A downscale (counter-clockwise)
shift in "zero" of greater than 1/2% indicates drive arm slippage, neces-
sitating further clamp block tightening.
Drive Arm Stop Adjustment
1. Apply sufficient pressure to the high-pressure housing to deflect the
pointer against the full range post lock on the scale plate.
2. Slide the upper drive arm stop bracket against the drive arm and tighten
the drive arm stop bracket screw.
3. Apply sufficient pressure to the low pressure housing to deflect the
pointer against the zero stop post lock on the scale plate.
17
4. Bend the zero drive arm stop against the drive arm.
5. Verify calibration as applicable.
Switch Calibration
Before performing a complete calibration of the switch, perform a calibration
check (See Calibration Check, page 12). If the instrument is out of calibration,
remove the bezel/lens and scale plate and inspect the switch mechanism (Fig-
ure 3.6) to verify the following:
• The roller rotates without wobble or binding.
• The cam does not touch the roller side shields.
• The actuator arm moves freely on its pivot.
• All switch mounting screws are tight.
• Linkages are straight and do not bind at the pivots.
Correct any problems that are observed. If no problems are observed, proceed
with a complete calibration.
SWITCH
CAM ROLLER
ACTUATOR ARM
STOP
SCREW
CAM
PLUNGER
SCREW
Figure 3.6—Switch mechanism
Calibration Setup
1. Connect an output device (lamp or buzzer) to the switch output leads.
2. Connect a test voltage to the switch input terminals on the terminal strip.
(A low voltage is recommended for safety.)
3. Unlock the switch plate and move the plate until the roller is positioned
at the top of the cam.
4. Advance the plunger screw until the switch actuates, then advance the
plunger screw an additional 60° (one flat).
5. Exercise the switch roller across the top of the cam to verify steady
operation. Advance the stop screw to touch the switch, then back out the
screw 1.5 turns (9 flats).
18
Linkage Calibration Procedure

The switch linkage should be calibrated whenever the Model 581A switch has
been rebuilt.
To calibrate the switch linkage, perform the following steps. Refer to Figure
3.7 as needed.
1. Loosen the three linkage screws and turn the crank to the 12 o’clock
position.
2. Use a 1/8-inch Allen wrench to hold the index shaft and slip the index
pointer to 0 on the switch index. Tighten the screw on the crank to the
mid-slot position to set the crank radius.
3. Turn the index pointer to index number "1" on the outer edge of the
switch index.
4. Apply 10% differential pressure and adjust the switch plate until the
switch actuates. Lock the two linkage screws.
5. Rotate the index pointer to index number “9.” Apply 90% differential
pressure and adjust the crank radius until the switch actuates.
6. Recheck 10% and 90% set points. Adjust the crank radius and the index
pointer until both set points are accurate within a 2% tolerance (nominal).
Figure 3.7—Linkage arrangement
7. If the switch is to be field-set at low differential pressure values (1% or

2% of pressure range), check the crank to prevent a 12 o'clock position.
Otherwise, the minimum set point position will be restricted and the set
point may become reversed.
8. Adjust the low switch to actuate at the desired pressure by applying test
pressures in a decreasing direction, in discrete steps. Allow the unit and
19
the pressure system to stabilize. Then change the pressure by a small

amount. The magnitude of the pressure change is determined by the
desired accuracy of the test. Tighten the lock screw before testing the
switch performance.
IMPORTANT: The high switch is usually set to actuate at increasing pressure. When
calibrating the high switch, apply test pressure in an increasing direction.
This amount of loading will prevent cam-runout of a similar condition.
IMPORTANT: Excessive plunger loading (more than 3 flats) may cause the roller to
drag on the cam. Cam friction will be apparent by excessive hysteresis,
erratic pointer readings, and inconsistent switch response.
9. Check the switch deadband, (actuate to reset) by applying differential

pressure, first in a decreasing direction, then in an increasing direction
(opposite for high switch direction). Observe pressures. To reduce the
deadband, advance the plunger screw by no more than two flats.
10. Adjust the high switch to actuate at the desired pressure. The procedure is
the same as for the low switch.
Changing Switch Set Point

(Tools: Screwdriver, 1/8-in. hex Allen wrench)
Definitions of Terms
Set Point. The measured pressure at which the snap-switch actuates and
thereby changes the states of the N.O. and N.C. contacts. For example, the set
point of the low switch is 24 psid with decreasing pressure.
Deadband. The difference in measured pressures between switch-actuation

and switch-reset. Deadband is usually expressed as percentage of full scale
(% of F.S.). Deadband is not adjustable. For example, the switch in the
example above was found to reset at 26.4 psid with increasing pressure. The
deadband was 2.4 psi, or 4% of the full scale for a unit calibrated 0 to 60 psid.
Best Practices for Set Points

1. Always check the set point after tightening switch lock screws.
2. Switch setpoints may be set at any point of the scale range, except in a
location that will prevent the deadband from enabling the switch to reset
itself. For example, the high switch (right side of scale) may be set at
full scale, but should not be set near zero. The low switch may be set at
zero, but should not be set near full scale. (Observe deadband values for
specific models).
3. If switch performance is unsatisfactory (set point does not repeat, dead-
band is excessive, pointer exhibits hysteresis, contacts are unstable, etc.),
20
remove the scale plate and inspect the switch and the switch mechanism.
The scale plate is split to allow for removal without pulling the pointer.
Changing Set Point of an In-Service Instrument (Not Recommended for
Nuclear Qualified Units)
Use the following procedure to set a set point for an instrument that is in ser-
vice, when calibration pressures cannot be applied. See Figure 3.8 for specific
locations denoted by items A, B, C and D.
1. Remove the bezel/lens assembly or cover. Do not remove the pointer or
scale plate.
2. Insert hex wrench in the switch adjust post.
3. Loosen the switch lock-screw (item B) 1/2 to 1 turn.
4. With the hex wrench, move the index pointer (item C) to the new set
point as indicated on the switch index (item D).
5. If possible, check the set point by varying the process pressures and ob-
serving the pointer readings when the switch actuates. (Open the mani-
fold bypass valve slowly and watch for “pointer-jump” at the set point or
by electrical signal.) Adjust the setting, if necessary, and repeat the test
several times to verify stability.
Figure 3.8—Set point adjustment
IMPORTANT: The switch index has 10 divisions, marked 0, 5, and 10. These match the
markings on the outer edge of the scale.
21
Example: Scale has range of 0-60 psid. Set point is 24 psid, with decreasing
pressure, (24/60 x 10 = 4).
1. Move the index pointer (item C) for the low switch from division 0 to
division 4 tick mark.
2. Tighten the switch lock (Item B) to a snug position, then turn an ad-
ditional 1/4 turn to place the set point within ±2% of full scale. Do not
overtighten.
Repeat steps 1 and 2 for the high switch, moving the index pointer from divi-
sion 10 to division 4.
Changing Set Point of an Out-of-Service Instrument

Use the following procedure to set a set point for an instrument that is out of
service—typically, an instrument that is disconnected from process lines or
mounted on a bench.
1. Drain and vent the housings.
2. Attach the calibration pressure source (air or N2) to the DPU HP housing.
3. Apply varying pressures in discrete steps and observe pointer readings
for accuracy. Use a pressure standard (Heise gage or equivalent) for
reference. A “bleed-pressure” method may cause errors.
4. Change the switch set point as described in Changing Set Point of an In-
Service Instruments, page 21.
5. Check the set point by changing measured pressure to actuate the switch.
For example: To verify a low-switch set point of 24 psid, apply approxi-
mately 30 psi. Reduce pressure to approximately 25 psid, hold for a few
seconds, then continue in 1/4 psid steps until the switch actuates. If the
set point is incorrect, continue instructions in Changing Set Point of an
In-Service Instruments, page 21.
6. To measure the switch deadband, reduce the pressure to zero, then in-
crease pressure until the switch resets.
7. To verify repeatability of a set point, repeat step 5 several times. For
improved accuracy, use smaller increments of pressure. Allow extra time
for gages with a slow response and for test systems that have long runs of
small-bore tubing.
High-alarm switches (right side of the scale) are adjusted in a similar manner.
Apply increasing pressure to establish the switch set point, and apply decreas-
ing pressure to measure the deadband.
Range Changes
The range of a Model 581A differential pressure switch can typically be
changed by replacing the range spring assembly inside the DPU. In some
cases, the replacement of the BUA may be required. See Changing the DPU
22
Range, page A-18, and Bellows Unit Assembly (BUA) Replacement, page A-22, for
details or contact the factory for assistance.
Troubleshooting
For switch troubleshooting tips, see Table 3.2 below. For information related
to the DPU, see Appendix A.
Table 3.2—Troubleshooting
Problem Possible Probable Cause Corrective Action
Source
Low or No Indica- Loose linkage or movement Tighten or replace
Indication tor, Alarm
Out of calibration Calibrate
Switch
Mechanism Pointer loose Tighten pointer
Dirty or corroded mechanism Clean or replace
Wiring interfering with move- Re-route wiring
ment
Dirty mechanism Clean mechanism
High Indicator, Loose linkage or movement Tighten or replace
Indication Alarm-
Switch Out of calibration Calibrate
Mechanism
Erratic Indica- Linkage dragging or dirty Adjust or clean
Indication tor, Alarm
Switch Pointer dragging on scale plate Adjust pointer position
Mechanism
Inaccurate Power Blown fuse Replace fuse
or No Supply
Broken or loose wire Repair
Electrical
Alarm Alarm Switch not properly adjusted Adjust switch
Switch
Dirty or burned contacts Replace switch
23
Table 3.2—Troubleshooting
Problem Possible Probable Cause Corrective Action
Source
Switch Process Transients or surges cause Add time delay gages or add time
Drifts Changes switches to actuate prema- circuit
(set point turely
not repeat-
Set point and/or deadband are Specify DP range as low as
able)
too wide in pressure values practical; set point repeatability
and deadband are percentage of
full range
Electrical overloads affect the Examine circuits for voltage,
spring properties of the leaf amperes
actuator in the switch
DC inductive loads cause Consider arc-suppression devices
arcing and burning of contacts or relays
Accumulation of fluids in piping Vent gas or drain liquids from
generate artificial signal signal lines
Calibration Failure to check set point after Verify set point repeatability after
Techniques locking locking switch plate
Rapid pressure change or vent- During calibration, make pressure
ing system changes in slow, discrete steps
Pressure application in reverse Test low-alarm with decreasing
pressure and high-alarm with
increasing pressure
Reference gage inaccuracy Suitable pressure standard such
as manometer, dead-weight
tester, or Heise-type gage may be
required
Damage to switch contacts Adjust plunger screws carefully
to avoid damage to internal parts
of switch
24
Section 4—Assembly Drawing and Parts List
LOCATE THE SCALE PLATE

UNDER THE MOUNTING TAB
WITHOUT A SCREW AT THE
6 O’CLOCK POSITION.
Figure 4.1—Model 581A-0 indicating switch (shown with glass lens)

25
Table 4.1 contains components for Model 581A-0 indicating switches and
Model 581A-2 blind switches with internal indicator. For parts list informa-
tion on Model 581A-2 blind switches without indicator, see Table 4.2, page A-16.
Table 4.1—Parts List, Model 581A-0 Indicating Switch and

Model 581A-2 Blind Switch with Internal Indicator
Per
Item Description Part No.
Unit
1 Low Switch Assembly (Temperature Stabilized) 9A-C0580-3008B 1
2 High Switch Assembly (Temperature Stabilized) 9A-C0580-3009B 1
3 Low Drive Plate Assembly 9A-C0288-0026B 1
4 High Drive Plate Assembly 9A-C0288-0027B 1
5 Low Switch Adjustment Index Assembly 9A-C0288-0028B 1
6 High Switch Adjustment Index Assembly 9A-C0288-0029B 1
7 Pointer Assembly (select one) 1
White 9A-C0580-1060B
Black 9A-C0580-1061B
8 Washer, Spring 9A-C0257-0019C 2
9 Lock Screw 9A-C0580-1017C 2
10 Screw, B.H. Slotted, 3-48 x 3/16 Lg. 9A-C0117-0007J 6
11 Washer, Flat, No. 3 9A-C0003-0045K 11
13 Retaining Ring 9A-C0087-0015T 2
14 Grip Ring 9A-C0087-0011T 2
15 Link Plate 9A-C0288-0016C 2
16 Set Screw, 6-32 x 1/4 Lg. 9A-C0320-1010J 1
17 Strap 9A-C0288-0017C 2
18 Washer, Flat 9A-C0317-0019C 2
19 Set Screw, Hex Socket, 6-32 x 3/8 Lg. 9A-C0320-1015J 2
20 Movement Assembly 9A-C0580-1108B 1
21 Link Assembly 9A-C0288-0036B 1
22 Drive Arm Assembly 9A-C0288-0037B 1
23 Nut, Hex, 4-40 9A-C0500-1026J 1
24 Block, Terminal (TB1) 9A-CS054-0011Z 1
25 Post, Lock 9A-C0277-0020C 1
26 Riser, Movement 9A-C0277-0035C 2
27 Bracket, Stop 9A-C0288-0028C 1
28 Bracket, Terminal Block 9A-C0288-0029C 1
29 DPU Assembly, Model 199 See Appendix A —
32 Case & Connecter Assembly 9A-C0581-1027B 1
33 Lens/Cover: Glass Lens (select one) 1
Model 581A-0 (with glass lens) 9A-C0580-1120C
Model 581A-2 (blind with indicator) 9A-C0580-1119C
34 Bezel (Model 581A-0 only) 9A-C0580-1125C 1
35 Lens Gasket (Model 581A-0 only) 9A-C0580-1126C 1
26
Table 4.1—Parts List, Model 581A-0 Indicating Switch and

Model 581A-2 Blind Switch with Internal Indicator
Per
Unit
36 Bracket (Switch to DPU) 9A-C0197-1019C 1
37 Header Assembly 9A-C0580-1018B 1
38 Screw, Cap:10-32 (select one) 8
Model 581A-0 (with glass lens), 1" long 9A-C0220-1062J
Model 581A-2 (blind with indicator), 1/2" long 9A-C0220-1031J
39 Screw, Rd. Hd., Slotted, 6-32 x 3/8 Lg. 9A-C0111-0015J 2
40 Screw, Pan. Hd., Slotted, 4-40 x 1/8 Lg. 5
9A-C0119-1116J
(Model 581A-0 only)
41 Screw, B.H., Slotted, 4-40 x 3/16 Lg. 1
9A-C0117-0012J
(Model 581A-0 only)
42 Screw, B.H., Slotted, 6-32 x 3/16 Lg. 2
9A-C0117-0013J
(Model 581A-0 only)
43 Bracket, Mounting 9A-C0199-1109B 1
44 Screw, Hex Head, 3/8-16 x 3/4 Lg. 9A-C0116-0007J 4
45 Washer, Split Lock, 3/8 9A-C0003-0093K 5
46 Plug 9A-C0224-0269C 1
47 O-ring (Torque Tube), EPT 9A-C0001-1069R 1
48 Ring, Grip 9A-C0087-1029T 1
50 O-ring (Header), EPT 9A-C0001-1066R 1
51 Nut, Hex., 3/8-16 9A-C0500-0039J 2
52 O-ring (Lens/Cover), EPT 9A-C0001-1057R 1
53 O-ring (Plug), EPT 9A-C0001-1051R 1
54 Set Screw, Socket Hex, 10-32 x 3/8 Lg. 9A-C0320-0024J 2
56 Scaleplate (select one) 1
White 9A-C0580-1109C
Black 9A-C0580-1110C
57 Bracket Spacer 9A-C0199-0003C 1
58 Screw, Socket, Flat Hd., 3/8-16 x 1 Lg. 9A-C0240-0004J 1
59 Screw, Hex Hd., 3/8-16 x 1 Lg. 9A-C0116-0006J 1
60 Washer, Split Lock, #6 9A-C0003-0038K 2
72 Case Bushing 9A-C0580-1101C 1
* Silicone Grease 9A-C0002-1003U A/R
** Thread Lubricant, Molykote 9A-C0002-0010U A/R
*** Locktite 222 9A-C0007-1033U A/R
Notes:
*Prior to installation, lubricate O-rings (Items 47, 50, 52 and 53) with silicone grease.
**Apply thread lubricant to threads of Item 16 (set screw) and Item 38 (cap screw) before installing.
***Apply Locktite 222 to Items 19 and 54 (set screws) when installing into the mounting plate.
27
Figure 4.2—Model 581A-2 blind switch without indicator

28
Table 4.2 contains components for Model 581A-2 blind switches without
indicator. For parts list information on Model 581A-0 indicating switches and
Model 581A-2 blind switches with internal indicator, see Table 4.1, page 26.
Table 4.2—Parts List, Model 581A-2 Blind Switch without Indicator

Per
Unit
1 Low Switch Assembly (Temperature Stabilized) 9A-C0580-3008B 1
2 High Switch Assembly (Temperature Stabilized) 9A-C0580-3009B 1
3 Low Drive Plate Assembly 9A-C0288-0026B 1
4 High Drive Plate Assembly 9A-C0288-0027B 1
5 Low Switch Adjustment Index Assembly 9A-C0288-0028B 1
6 High Switch Adjustment Index Assembly 9A-C0288-0029B 1
8 Washer, Spring 9A-C0257-0019C 2
9 Lock Screw 9A-C0580-1017C 2
11 Washer, Flat, No. 3 9A-C0003-0045K 10
13 Retaining Ring 9A-C0087-0015T 2
14 Grip Ring 9A-C0087-0011T 2
15 Link Plate 9A-C0288-0016C 2
16 Set Screw, 6-32 x 1/4 Lg. 9A-C0320-1010J 1
17 Strap 9A-C0288-0017C 2
18 Washer, Flat 9A-C0317-0019C 2
19 Set Screw, Hex Socket, 6-32 x 3/8 Lg. 9A-C0320-1015J 2
22 Drive Arm Assembly 9A-C0581-1008B 1
24 Block, Terminal (TB1) 9A-CS054-0011Z 1
28 Bracket, Terminal Block 9A-C0288-0029C 1
29 DPU Assembly, Model 199 See Appendix A —
32 Case & Connecter Assembly 9A-C0581-1027B 1
33 Lens/Cover: Blind Cover 9A-C0580-1119C 1
36 Bracket (Switch to DPU) 9A-C0197-1019C 1
37 Header Assembly 9A-C0580-1018B 1
38 Screw, Cap: 10-32 x 1/2 Lg. 9A-C0220-1031J 8
43 Bracket, Mounting 9A-C0199-1109B 1
44 Screw, Hex Head, 3/8-16 x 3/4 Lg. 9A-C0116-0007J 4
46 Plug 9A-C0224-0269C 1
47 O-ring (Torque Tube), EPT 9A-C0001-1069R 1
48 Ring, Grip 9A-C0087-1029T 1
50 O-ring (Header), EPT 9A-C0001-1066R 1
51 Nut, Hex., 3/8-16 9A-C0500-0039J 2
52 O-ring (Lens/Cover), EPT 9A-C0001-1057R 1
29
Table 4.2—Parts List, Model 581A-2 Blind Switch without Indicator

Per
Unit
53 O-ring (Plug), EPT 9A-C0001-1051R 1
57 Bracket Spacer 9A-C0199-0003C 1
58 Screw, Socket, Flat Hd., 3/8-16 x 1 Lg. 9A-C0240-0004J 1
59 Screw, Hex Hd., 3/8-16 x 1 Lg. 9A-C0116-0006J 1
72 Case Bushing 9A-C0580-1101C 1
* Silicone Grease 9A-C0002-1003U A/R
** Thread Lubricant, Mokykote 9A-C0002-0010U A/R
*** Locktite 222 9A-C0007-1033U A/R
Notes:
*Prior to installation, lubricate O-rings (Items 47, 50, 52 and 53) with silicone grease.
**Apply thread lubricant to threads of Item 16 (set screw) and Item 38 (cap screw) before installing.
***Apply Locktite to Item 19 (set screw) when installing into the mounting plate.
Table 4.3 presents torque requirements for the switch assembly fasteners.
Table 4.3—Torque Requirements for Switch Assembly Fasteners

(See Figures 4.1 and 4.2 for part identification)
Item Description Part No. Per Torque*
Unit
9 Lock Screw 9A-C0580-1017C 2 Tight
10 Screw, B.H. Slotted, 3-48 x 3/16 9A-C0117-0007J 6 Tight
Lg.
12 Screw, B.H. Slotted, 8-32 x 3/16 9A-C0117-1001J 2 Tight
Lg.
16 Set Screw, 6-32 x 1/4 Lg. 9A-C0320-1010J 1 Snug
24 Terminal Strip Screw, 5-40 x 1/4 N/A 10 Snug
26 Movement Assembly Riser 9A-C0277-0035C 2 Tight
38 Screw, Cap: 10-32 x 1 Lg. (select one) 8 35-45 in-lb
Model 581A-0 (with glass lens) 9A-C0220-1062J
Model 581A-2 (blind) 9A-C0220-1031J
39 Screw, Rd. Hd., Slotted, 6-32 x 9A-C0111-0015J 2 Tight
3/8 Lg.
40 Screw, Pan. Hd., Slotted, 4-40 9A-C0119-0032J 4 Snug
x 3/16 Lg. (Model 581A-0 only),
bottom hole in scale plate not used
41 Screw, B.H., Slotted, 4-40 x 3/16 9A-C0117-0012J 1 Tight
Lg. (Model 581A-0 only)
30
Table 4.3—Torque Requirements for Switch Assembly Fasteners

(See Figures 4.1 and 4.2 for part identification)
Item Description Part No. Per Torque*
Unit
42 Screw, B.H., Slotted, 6-32 x 3/16 9A-C0117-0013J 2 Tight
Lg. (Model 581A-0 only)
44 Screw, Hex Head, 3/8-16 x 3/4 Lg. 9A-C0116-0007J 4 25-30 ft-lb
46 Plug 9A-C0224-0269C 1 Snug
51 Nut, Hex., 3/8-16 9A-C0500-0039J 2 22-25 ft-lb
55 Screw, Rd. Hd., Slotted, 6-32 x 9A-C0117-0013J 2 Tight
3/16 Lg.
58 Screw, Socket, Flat Hd., 3/8-16 x 9A-C0240-00004J 1 22-25 ft-lb
1 Lg.
59 Screw, Hex Hd., 3/8-16 x 1 Lg. 9A-C0116-0006J 1 25-30 ft-lb
* Snug denotes 1/16 (approx) turn past head contact.
Tight denotes 1/8 (approx) turn past head contact.
31
32
Section 5—Dimensional Drawings
Figure 5.1—Model 581A, front view
Dimension A
Model
(in., mm)
581A-0 11 7/16 (290.5)
581A-2 10 7/8 (276.2)
Figure 5.2—Model 581A, side view
33
Figure 5.3—Model 581A, rear view (mounting bracket not shown)
IMPORTANT: For DPU dimensional information, refer to DPU Dimensional Drawings,

page A-31.
34
Model 581A Differential Pressure Switch Appendix A
Appendix A—Model 199 DPU
General
The Barton Model 199 Differential Pressure Unit (DPU) (see Figure A.1) is
a mechanical device which accurately measures differential pressure relative
to a gas or liquid flowing through a process system, or to the level of a liquid
contained in a process vessel.
Figure A.1—Model 199 DPU unit
For process flow measurements, the DPU is connected across a primary

device (a venturi, orifice plate or flow tube) located in the process system.
For liquid level measurements, the DPU may be connected in a variety of

ways to measure the difference in pressure caused by variations in the level of
the liquid in the process vessel.
Product Description
The Model 199 DPU is a dual bellows assembly enclosed within pressure
housings. The dual bellows assembly (Figure. A.2) consists of two opposing
internally connected liquid-filled bellows, a center plate, range springs, over-
range valves, and a torque tube assembly.
The pressure housings are connected by pipe or tubing to the primary device
located in the system piping. Variations in differential pressure within the
pressure housings cause the bellows to expand or contract in a linear direction
towards the side having the lowest pressure.
The linear movement of the bellows is converted into angular rotation when
transmitted to the torque tube shaft by the drive arm and this mechanical
motion actuates the mechanism of the process monitoring instrument. The
process monitoring instrument that is connected to the torque tube assem-
bly may be an indicator, a switch, a transmitter, a recorder, or other process
control device.
A-1
Appendix A Model 581A Differential Pressure Switch
Specifications
Housing Material �� Forged 316 Stainless Steel
Torque Tube Rotation (full scale DP) 8° ±10%
Torque Tube Material �� Beryllium Copper (BeCu)
Temperature Limits �� -40°F (-40°C) to +180°F (+82°C)
Maximum Non-linearity: �� 0-10" w.c. to 0-400" w.c.
(0-25 mbar to 0-993 mbar)
±0.5% of full scale with appropriate linkage
�� 0-401" w.c. to 0-100 psi
(0-996 mbar to 0-6.9 bar)
±0.75% of full scale with appropriate linkage
Repeatability �� 0.20% of full scale DP
Table A.1—Model 199 DPU Specifications

SWP - psi Stainless Steel or Inconel Bellows
(bar)
2 1/8”(55 mm) O.D. 3 3/4” (95 mm) O.D.
1,000
(69) 0-15 psi to 0-115 psi 0-10" w.c. to 0-400" w.c.
3,000 (0-1 bar to 0-7.9 bar) (0-25 mbar to 0-995 mbar)
(207)
Net Volume, L.P. Head 35 cu. in. (575 cc) 30 cu. in. (490 cc)
(cu. in.)
Net Volume, H.P. Head 31 cu. in. (510 cc) 26 cu. in. (425 cc)
(cu. in.)
Displacement (cu. in.) 0.5 cu. in. (8.2 cc) 1.5 cu. in. (25 cc)
for full-scale travel
NOTES: Zero center or split ranges available on special order (e.g., 0-50" w.c. (0-124
mbar) range may be ordered 25-0-25" w.c. (62-0-62 mbar) or 10-0-40" w.c. (25-0-99 mbar).
Intermediate DP ranges available from 0-20" w.c. to 0-100 psi (0-50 mbar ot 0-6.9 bar).
Standard pressure connections are 1/2" (top) and 1/4" (bottom) NPT. Range springs are not
interchangeable between the different size bellows. Metric conversions are approximate.
Dimensional drawings available on request.
A-2
Theory of Operation
Basic Components
Torque Tube Center Plate
Shaft Low Pressure Bellows
Torque Tube
Range Spring
High Pressure
Bellows
High Pressure
Overrange Low Pressure
Valve Housing
Temperature
Compensator
HP Housing Low Pressure

Overrange
Valve
Housing
Bolts
Pulsation Dampener
Damping Valve Plug
Valve Stem
Figure A.2—199 BUA cutaway
Pressure Housings
The two pressure housings of the Model 199 DPU are available in the various
safe working pressure ratings defined in Table A.1, page A-2, and in the dimen-
sional drawings in Section 6.
Each pressure housing has two tapped connection ports: one port is located in
the top of the housing, the other port is located in the bottom of the housing.
Bellows
The bellows of the Model 199 DPU are available in various materials and
sizes (refer to Table A.1, page A-2) to accommodate various calibration ranges.
The DPU has two bellows. One end of each bellows is sealed. The open end
of each bellows is attached and sealed to a side of the center plate (one bel-
lows on each side) as shown in Figure A.2.
A-3
The bellows and center plate are filled with fill liquid via the drive arm hole
plug. An opening through the center plate provides a passageway for the
transfer of fill liquid between the two bellows. This opening also allows the
bellows to be connected internally by a valve stem.
Drive Arm
Hole Plug
(DO NOT LOOSEN)
Retainer
Torque Tube Gland Nut Screws
Range
(DO NOT LOOSEN)
Spring
Assembly
Push
Rod
Torque
Tube
Shaft Lock Nut
Range
Springs
2-1/8" Bellows Unit Assembly (BUA)
Drive Arm
Hole Plug
(DO NOT LOOSEN)
Torque Tube Gland Nut Spring Post

(DO NOT LOOSEN)
Range Spring
Assembly
Retainer Nut
Torque Push Rod

Tube
Shaft
Range Lock Nut
Springs Spring
End Cup
3-3/4" Bellows Unit Assembly (BUA)
Figure A.3—Bellows unit assemblies (BUAs)
Range Springs
The range of the dual-bellows type DPU is determined by the force required
to move the bellows through their normal range of travel.
The range springs, which are available in various ranges (see Table A.1, page
A-2), act with the bellows and torque tube to balance the differential pressure
A-4
applied to the unit. The number of springs used and their spring rate depends
on the individual differential pressure range requirement.
Torque Tube Assembly
As illustrated in Figure A.4, page A-5, the torque tube assembly consists of a
torque tube, a torque tube shaft, and the supporting members. The outboard
end of the torque tube shaft is attached to the center plate. The torque tube
shaft, located in the center of the torque tube, is welded to the inboard end of
the tube.
Needle Beaing
Center Plate
O-Ring Seal
Weld
Torque Tube
Lock Nut
Torque Tube
Torque Tube
Shaft
8° Drive Arm
Rotation
Valve Stem
Disc
Weld 0.200"
Bellows Travel
Jewel Bearing
Minature
Precision Valve Stem
Ball Bearing
Figure A.4—Torque tube assembly
Movement of the bellows is transmitted by the drive arm to the torque tube as
a rotary motion. Since the torque tube is attached to the center plate, the tube
must twist when subjected to torque. The torque tube shaft, which is freely
supported within the torque tube at its outer end, but connected to the torque
tube and drive arm at its inner end, rotates through the same angle as the dif-
ferential pressure unit.
Pulsation Dampener
The pulsation dampener (Figure A.2, page A-3) controls the flow of fill-liquid
between the high and low-pressure bellows with an externally adjustable pul-
sation dampener needle valve. Restriction of liquid flow reduces the effects of
pulsation. In applications where pulsation is not a problem, the needle valve is
set to the full-open position.
A-5
Installation/Operation
Unpacking
Inspect the instrument after unpacking it to detect any damage that may have
occurred during shipment.
IMPORTANT: The DPU was checked for accuracy at the factory. Do not change any of
the settings during examination or accuracy could be affected.
For applications requiring special cleaning/precautions, a polyethylene bag

is used to protect the instrument from contamination. Remove this bag only
under conditions of extreme cleanliness.
IMPORTANT: Do not locate the instrument near vents or bleed holes that discharge
corrosive vapors or gases.
Mounting
See Mounting/Piping/DPU Installation, page 9.
Piping—Standard Practices
Flow Applications (Flow and Liquid Level)
When installing piping, observe the following standard practices and refer to
the piping diagrams on pages A-8 through A-13.
1. Shorten the distance between the primary device and the DPU as much
as possible. Distances exceeding 100 feet are not recommended. For dis-
tances up to 50 feet, use 1/4-inch or 3/8-inch pipe or tubing. For runs of
50 to 100 feet, use 1/2-inch pipe or tubing. The recommended limitation
does not apply if an air purge or blow-back system is used.
2. Slope all piping at least one inch per linear foot to avoid liquid or gas
entrapment.
3. Provide 2 feet of non-insulated piping between the DPU and the primary
device for each 100°F (+37.8°C) in excess of +200°F (+93.3°C).
4. Assure that the temperature of the DPU never exceeds 180°F (+82°C).
When steam tracing is necessary, the steam pressure should not exceed
5 pounds per square inch and insulation should not be used. If pressure
must exceed 5 pounds per square inch, limit the length of tubing around
the DPU to two turns and do not insulate.
5. Install a suitable pulsation dampening device upstream of the DPU.
Where severe pulsation is present, the accuracy of the flow measurement
will be affected.
A-6
6. Mount the DPU on a solid support to minimize vibration. Tighten all

points, using a suitable compound; leaks in piping can cause measure-
ment errors.
7. Install a valve manifold connecting the DPU and the source of differen-
tial pressure to facilitate operation and checking of the DPU.
8. Install shutoff and bypass valves so they are accessible from the front of
the instrument. Locate block valves at the source of differential pressure.
Flow Applications
Assure that the DPU high-pressure housing is connected to the upstream tap
of the primary device.
IMPORTANT: To prevent overheating the DPU during blowdown, monitor the tempera-
ture by placing hands on the pipe between the DPU and the manifold
pipe containing the vent valves.
Liquid Level Applications
The process media may be used as a reference leg seal fluid if it will condense
in the reference leg under all conditions.
If the process or process media characteristics are such that the above condi-
tions cannot be met, a special reference leg seal fluid is required. The special
seal fluid must not be volatile and must not be miscible with the process
media. Also, the difference in the densities of the special seal fluid and the
process media will require compensation in calculating the differential pres-
sure range of the DPU.
! WARNING: Explosion Hazard—Organic compounds, oil, grease, dirt, or

scale of any kind cannot be tolerated in an oxygen installation.
A-7
Piping Diagrams
Diagrams for typical and special flow applications are presented on the fol-
lowing pages. Use the diagram best suited for the application as a guide for
piping configuration.
BYPASS
DPU VALVES
SHUT-OFF
STATIC PRESSURE VALVES
CONNECTION
(USE ONLY ONE)
VENT VALVE
BLOCK VALVES
PRIMARY DEVICE
Figure A.5—Gas Flow, DPU Above Run
BLOCK VENT
VALVES VALVE
PRIMARY
DEVICE SHUT-OFF
VALVES
BYPASS
VALVES
STATIC PRESSURE
CONNECTION DPU
(USE ONLY ONE)
DRIP POTS
Figure A.6—Gas Flow, DPU Below Run
A-8
DPU
SHUT-OFF
VALVES
BYPASS
VALVE
PRIMARY
DEVICE
BLOCK VALVES
Figure A.7—Gas Flow, Hydrates Present
PRIMARY
DEVICE
PLUGS
BLOCK
VALVES
CONDENSING
RESERVOIR
SHUT-OFF
VALVES
VENT DPU
VALVES
(OPTIONAL)
Figure A.8—Steam Flow, DPU Below Run
VENT BYPASS
VALVE VALVES
STATIC PRESSURE DPU

CONNECTION
(USE ONLY ONE)
SHUT-OFF
VALVES
DRIP POTS
BLOCK
VALVES
PRIMARY DEVICE
Figure A.9— Liquid Flow, DPU Above Run

A-9
PRIMARY
DEVICE FILL TEE AND
VENT VALVE
FOR HOT OR
GASSY LIQUIDS
BLOCK
VALVES
SHUT-OFF
VALVES
BYPASS
VALVE
DPU
Figure A.100—Liquid Flow, DPU Below Run
BYPASS
VALVE
SEAL SHUT-OFF
POTS VALVES
DPU
PRIMARY
DEVICE
BLOCK
VALVES
Figure A.11—Corrosive Liquid Flow
BLOCK
VALVE
SHUT-OFF
VALVE
VENT
VALVE
BLOCK DPU
VALVE
HIGH-PRESSURE
SHUT-OFF DRAIN
VALVE VALVE
Figure A.12—Cool Non-Condensing Liquid, DPU Level with Tank Bottom
A-10
BLOCK
VALVE
SHUT-OFF
VALVE
BLOCK
VALVE
DPU
SHUT-OFF
VALVE DRAIN
VALVE
HIGH-PRESSURE
Figure A.13—Cool Non-Condensing Liquid, DPU Below Tank
2" CROSS
BLOCK REFERENCE
VALVE LEG
VENT
VALVE SHUT-OFF
VALVE
DPU
BLOCK
VALVE
HIGH-PRESSURE
BYPASS
VALVE
Figure A.14—DPU Bottom Tank with Reference Leg
A-11
BLOCK VALVE
INVERTED "U"
GAS TRAP
BLOCK
VALVE
MINIMUM LENGTH
DRAIN 6 INCHES
SHUT-OFF VALVE
VALVE
VAPOR GENERATOR
DPU
LOW-PRESSURE
Figure A.15—Liquid CO2
MINIMUM LENGTH BLOCK VALVE

12 INCHES
INVERTED "U"
GAS TRAP
VAPOR GENERATOR
FLAT TUBULAR SPIRAL
IN OUTER 1/3 OF TANK
INSULATION KEEP
SHUT-OFF DEAD LEG BETWEEN
BLOCK TANK AND SPIRAL
VALVE VALVE 5 INCHES OR LESS
HIGH-PRESSURE
DPU
LOW-PRESSURE
Figure A.16—Cryogenic Liquids
A-12
SIGHT FLOW
GAGE
BLOCK VALVES
INPUT GAS
REGULATOR
GAS
SUPPLY
SHUT-OFF VALVES
BYPASS VALVE
DPU
HIGH PRESSURE
Figure A.17—Bubbler System
SIGHT FLOW GAGES

WITH THROTTLING VALVES
INPUT GAS
REGULATOR BLOCK VALVES
GAS
SUPPLY SHUT-OFF VALVES
BYPASS VALVE
DPU
HIGH-PRESSURE
Figure A.18—Liquid Specific Gravity
A-13
General Startup Practice Considerations

Observe the following practices when starting up a process monitoring instru-
ment
1. Always start with the block valves closed.
2. Perform a zero check on the instrument as follows.
IMPORTANT: For gas service, perform a zero check with both block valves closed. If
the gas flow is pulsating, a standing wave effect may occur in the pro-
cess line which can displace the indicator and appear as a zero error.
a. Open the bypass valve(s), then open one shutoff valve. This proce-
dure equalizes the pressure between both sides of the instrument.
The instrument should indicate zero.
b. If the instrument does not indicate zero, check for gas or liquid
entrapment in the DPU piping or in the DPU (depending on the
orientation of the piping layout and service).
c. If necessary, adjust the pen or pointer by turning the zero adjust knob
on the instrument until the pointer indicates zero.
3. Check the manifold and piping for leaks as follows.
a. Open the bypass valve(s), then open one shutoff valve to pressurize
the instrument.
b. Close the shutoff valve and the bypass valve.
c. Observe the instrument for pen or pointer movement, up or down the
scale, which could indicate leakage.
IMPORTANT: Do not subject the DPU to unnecessary shock or overrange pressure
during operations.
Maintenance, Adjustment, and Calibration

Tools Required
Cameron's calibration tool kit (Part No. 9A-0202-1005B) contains the tools
necessary for calibrating the Model 199 DPU. The tools listed in Table A.2
are also recommended for performing general maintenance.
Table A.2—Tools
Description Purpose
7/16" Hex wrench Housing bolts
5/8" Hex wrench Housing bolts
1/8" Allen wrench Dampener Adjustment
1/2" Open ended wrench Push rod - bellows cup connection
Modified box/open-ended wrench (7/16") Kickoff spring lock nut
100 ft-lb Torque wrench Housing bolts
A-14
! WARNING: The unexpected release of internal pressure from a DPU can

result in severe personal injury, death or property damage. Before remov-
ing DPU housing bolts, perform a pressure check. This is especially im-
portant if the DPU is installed in a gas application with working pressures
exceeding 200 psig.
DPU Inspection and Cleaning

Instruments used in services where solids or semi-solids may accumulate
inside the pressure housings require periodic inspection and cleaning. Always
check for internal pressure using the procedure below before removing the
DPU housing bolts.
Pressure Check Procedure
! WARNING: Failure to perform this procedure can result in severe injury,

death or substantial property damage due to the release of internal
pressure. If the DPU has been installed in gas applications with working
pressures greater than 200 psig, PERFORM THIS PROCEDURE BEFORE
REMOVING THE DPU HOUSING BOLTS.
1. Back off all housing bolts 4 turns.

2. Check for internal pressure by attempting to move the housing in and out
along the bolts.
a. If the housing moves freely, no pressure is present and servicing or
repair may continue.
b. If the housing does not move freely, the bellows may be pressurized
and is potentially hazardous if further disassembled. Tighten the
bolts and return the unit to the factory or authorized Barton service
center for repair. Tag the unit and specify "Gas in Bellows".
Inspection and Cleaning Procedure
Instruments used in services where solids or semi-solids may accumulate
inside the pressure housings require periodic inspection and cleaning, as fol-
lows.
1. Remove the DPU from service and remove the pressure housings.
2. Carefully remove the pressure housings from the bellows unit assembly.
IMPORTANT: If accumulation of solids or semi-solids is extensive, rapid removal of the

pressure housings can damage the bellows.
3. Remove the accumulation from between the bellows convolutions and

from the inside of the housings. Use a solvent if possible. Do not use a
sharp instrument to clean between convolutions.
A-15
4. Look for broken range springs and replace as necessary.

5. Replace the housings and seals.
6. Install NEW pressure housing bolts and torque in accordance with Table
A.3.
! WARNING: Do not reuse housing bolts. Reuse of housing bolts, especial-

ly in critical applications like hydrogen sulfide and salt water exposures,
can result in severe injury, death or substantial property damage due to
bolt failure.
Table A.3—Standard Bolt Torque Ratings
Torque (lb/ft)
Rotation
(Note 1)
(Note 2)
(Note 3)
Housing Bolt
Lube
SWP Size Qty Part No.
Mat'l Mat'l
Stainless Steel 3/8-16 x 4.5 12 9A-C0199-1345C Yes 40 270°

1000
Steel
3000 Stainless Steel 1/2-13 x 5.5 12 9A-C0199-0085C Yes 80 180°
Steel
NOTES:
1. Lubricants: Molykote G paste, Teflon-base pipe dope, graphite-base grease, or similar lubri-
cants. Lube first 2 threads only. Do not lube bearing surface.
2. Torque on bolts is accomplished in 3 or 4 steps. Tighten UNIFORMLY.
3. Rotation of bolt head is measured after bolt is "snug," with approximately 5 lb/ft torque. DO NOT
EXCEED THIS ROTATION. To tighten bolts without torque wrench, use rotation values.
Calibration Setup
The test equipment required to calibrate the Model 199 DPU, when attached
to an indicator or switch is shown in Figure A.19, page A-17.
All Barton instruments using the Model 199 DPU as actuator are calibrated at
the factory.
All DPUs sold as replacement units or as actuators for other applications are
checked for accuracy prior to shipment.
Normally, the DPU is calibrated after installation on a specific instrument.

Refer to the separate instrument manual for specific calibration procedures.
A-16
Figure A.19—Calibration setup
Torque Tube Rotation Check (Replacement Units)

Prior to installation as a replacement unit, a DPU should be checked for
proper torque tube rotation, per the following procedure:
1. Mount DPU on a stable base and connect to a standard pressure source.
2. Adapt a scale graduated in degrees to the torque tube housing.
3. Adapt a pointer to the exposed end of the torque tube shaft.
4. Apply 100% DP to the high pressure (HP) housing of the DPU. The
pointer should indicate 8 degrees of travel.
A-17
Changing the DPU Range

Typically, the range of a Model 199 DPU can be changed by replacing the
range spring, as described below. In some cases, however, the replacement of
the BUA may be necessary to obtain the proper range of measurement. (see
Bellows Unit Assembly (BUA) Replacement, page A-22).
! WARNING: High-pressure gas hazard on disassembly of the DPU in

installations with pressures greater than 200 psig. To prevent possible
severe personal injury, death, or substantial property damage due to the
release of internal pressure, perform the pressure check before
removing DPU housing bolts.
IMPORTANT: If accumulation of solids or semi-solids is extensive, remove the hous-

ings carefully to prevent damaging the bellows.
IMPORTANT: The calibration range of the DPU was carefully set at the factory. The
following procedure maintains the original factory bellows travel setting
while the range spring change is performed. This procedure must be
strictly followed while changing the range spring assembly or altering the
adjustment.
To replace the range spring assembly with either a new assembly of the same
range or one with a different range value, proceed as follows (this procedure
assumes that the DPU is either connected to an indicating instrument or fitted
with a scale and pointer to measure torque tube shaft movement):
2-1/8-inch Diameter Bellows (15 to 115 psi)

1. Remove the DPU from service.
2. Remove the pressure housing bolts and the low-pressure housing.
3. With the pointer at zero, remove the spring retainer screw, retainer
springs, and the range spring assembly.
IMPORTANT: The pointer will shift from zero. This is a normal action and the pointer
should not be readjusted at this point.
4. Install the new range spring assembly onto the push rod, and replace the
spring retainer screw.
5. If the pointer is set above zero, rotate the spring adjustment clockwise
until the pointer is set at zero. If the pointer is below zero, rotate the
spring adjustment counterclockwise until the pointer is set at zero.
6. Replace and tighten the lock nut. If the pointer shifts from zero, loosen
the lock nut and reset the pointer as in step 5. Tighten the lock nut.
A-18
7. Replace the low-pressure housing and install NEW bolts (new gaskets
are also recommended). Torque the bolts in accordance with Table A.3,
page A-16.
! WARNING: Do not reuse housing bolts. Reuse of housing bolts, espe-

cially in critical applications like hydrogen sulfide and salt water expo-
sures, can result in severe injury, death or substantial property damage
due to bolt failure.
8. Calibrate in accordance with the manual for the actuated instrument.

3-3/4-inch Diameter Bellows Without Kickoff Spring (≥47" w.c.)
1. Remove the instrument from service.
2. Remove the pressure housing bolts and the low-pressure housing.
3. With the pointer set at zero, remove the lock nut retainer nuts, and the
range spring assembly. To remove the range spring assembly, rotate the
assembly counterclockwise while pulling outward on the assembly.
should not be readjusted at this point.
4. Thread the new assembly onto the push rod, and align the holes in the
range spring assembly with the spring posts. Replace and tighten the
retainer nuts.
5. Using a spanner wrench, rotate the spring adjustment until the pointer
is set at exact zero. Replace and tighten the lock nut. The pointer must
remain at the zero setting. If the pointer shifts from zero, loosen the lock
nut and repeat this step.
6. Replace the low-pressure housing and install NEW bolts (new gaskets
are also recommended). Torque the bolts in accordance with Table A.3,
page A-16.
WARNING: Do not reuse housing bolts. Reuse of housing bolts, especial-

! ly in critical applications like hydrogen sulfide and salt water exposures,
can result in severe injury, death or substantial property damage due to
bolt failure.
7. Calibrate in accordance with the manual for the actuated instrument.
A-19
3-3/4-inch Diameter Bellows with Kickoff Spring (≤46" w.c.)
The kickoff spring (also referred to as the "anti-stick" spring) is supplied as

standard equipment with 46" w.c. and lower range DPUs.
Figure A.20—Kickoff spring assembly
IMPORTANT: The lock nut requires a modified 7/16", 12-point box wrench for tighten-
ing (Figure A.21).
Figure A.21—Wrench modification
1. Remove the instrument from service. Set the pointer at zero using the
instrument zero adjustment.
2. Remove the pressure housing bolts and remove the low-pressure housing.
3. With the pointer set at zero, remove the lock nut, spring retainer nuts,
washer and lock nut, and range spring assembly.
should not be readjusted at this time.
A-20
4. Install the range spring assembly, using a 1/2-inch open-ended wrench to

connect the push rod to the low-pressure bellows cup.
IMPORTANT: The range spring assembly consists of the range springs, kickoff spring
assembly, and the push rod. The assembly is furnished as a complete
and assembled unit.
5. Position range spring assembly over retainer posts and replace retainer
nuts.
6. Insert the tubing between the range springs and tighten inboard lock nut.
7. Zero the pointer by adjusting the spud on the push rod. Be sure that the
kickoff spring is not engaged during this operation.
8. Position the kickoff spring to prevent interference with the coil springs
and tighten the kickoff spring lock nut. If clearance is needed for the
wrench, note the position of the spud (measure with a scale or count
threads to the end of the push rod) and move the spud for the required
clearance. After the lock nut is tightened, return the spud to its original
position.
9. Check the back-clearance between the kickoff spring and the slot. Use a
wire feeler gage or comparable measuring device. The clearance between
slots will vary, but must be at least 0.005-in. to prevent interference with
instrument zero. Add or remove washers as required to obtain the proper
clearance. Tighten the lock nut securely.
10. Install the jam nut and lock the spud to the push rod. Hold with pliers.
If the spud was moved in step 8, return the spud to the proper position
before tightening the jam nut.
11. Apply 100 percent negative pressure to the high-pressure side of the DPU
and repeat the clearance check and adjustment described in step 9.
12. Apply 100 percent positive pressure to the high-pressure side of the DPU
and repeat the clearance check and adjustment described in step 9.
13. Release all pressure from the instrument, replace the low-pressure hous-
ing and install NEW bolts (new gaskets are also recommended). Torque
the bolts in accordance with Table A.3, page A-16.

Setting Bellows Travel

The travel of the DPU bellows must be adjusted if one of the following
occurs.
1. The range spring assembly is removed without following the procedure.
2. Broken range springs are replaced.
A-21
3. The indicator pointer has excessive overtravel.

4. The indicator pointer has excessive undertravel.
Setting the bellows travel requires that the DPU be attached to the actuated
instrument and connected to a test pressure source. The procedure for this
adjustment is presented in the manual for the actuated instrument.
Bellows Unit Assembly (BUA) Replacement

Before replacing the BUA, read the following warning messages and refer-
ence Figure A.2, page A-3, to locate parts described in the following procedure.
! WARNING: High-pressure gas hazard on disassembly of the DPU in

installations with pressures greater than 200 psig. To prevent possible
severe personal injury, death, or substantial property damage due to the
release of internal pressure, perform the pressure check procedure on
page A-15 before removing the DPU housing bolts.
IMPORTANT: If accumulation of solids or semi-solids is extensive, remove the hous-

ings carefully to prevent damaging the bellows.
IMPORTANT: Component Removal—See the manual for the actuated instrument for
particular components that must be removed to gain access to DPU case
mounting screws. Support DPU during disassembly. Do not loosen the
drive arm hold plug (located in the top of the BUA center plate) when
removing the mounting bracket. If the plug is loosened, bellows fill fluid
will be lost.
1. Disconnect the DPU piping and remove the instrument from service.
2. Loosen the actuated instrument drive arm and slide off of the torque tube
shaft. Do not disconnect the instrument linkage.
3. Remove the case-retaining screws and remove the case assembly.
4. Remove the indicator bracket screws and the indicator bracket.
5. Remove the pressure housings bolts and pressure housings.
6. Place the pressure housings on the replacement bellows unit assembly
and insert and start (only) the pressure housing bolts.

7. Attach the indicator bracket to the replacement assembly, using the indi-
cator bracket screws.
8. Attach the mounting bracket using the screws provided.
A-22
9. Support the DPU and tighten and torque the pressure housing bolts in
accordance with Table A.3, page A-16.
10. Attach the case assembly using case retaining screws.
11. Slip the drive arm over the torque tube shaft as shown in Figure A.22,
page A-23; clear the end of the torque tube housing by approximately 0.030
inches before securing to prevent interference.
12. Tighten the drive arm assembly onto the torque tube shaft as follows:
a. Supporting the block and shaft, tighten the clamp screw until it is
snug to the shaft.
b. Still supporting the block/shaft, tighten the clamp screw an addi-
tional 1/3 to 1/2 turn. (The screw can normally turn one full revolu-
tion before breaking.)
LINK SINTERED
CLAMP BLOCK
.03 (approx)
DRIVE ARM
SHAFT CLAMP SCREW
1/8” WRENCH
(PN 9A-0163-0044C)
TO TIGHTEN
Figure A.22—Drive arm to torque tube connection
13. Perform the drive arm tightness test (see Drive Arm Tightness Test, page
17) to ensure that the drive arm is adjusted properly and will not slip during
operation.
14. Replace any instrument components that were removed to allow removal
of the DPU, referring to Section 3 of this document as required.
15. Calibrate the instrument before returning it to service. See Indicator
Calibration, page 15.
Adjusting Pulsation Dampener
See Figure A.2, page A-3, for the location of the pulsation dampener valve.
1. Remove the dust cover and insert a 1/8-in. hex key into the needle valve.
2. Turn the valve clockwise to the closed position, approximately 3 turns.
3. Back out the valve 1/2 turn or as required to reduce pulsations/shock
pressures.
A-23
Troubleshooting
See Table A.4 and refer to actuated instrument manual for more information.
Table A.4—Troubleshooting Chart

Trouble Possible Source Probable Cause Corrective Action
Low or No Primary Element Orifice installed backwards Replace orifice
Indication or Differential or oversized
Pressure Source
Flow blocked upstream Clean out run or
from run open valve
Loss of liquid in reference Refill reference leg
leg (liquid level)
Density changes in pro- Refill reference leg
cess media or reference with same density
leg liquid as process
media
Piping from Pressure tap holes Clean out piping
Primary Element plugged
to DPU
Bypass valve open or Close bypass
leaking valve(s) or repair
leaks
Liquids or gases trapped Vent piping
in piping
Block or shutoff valves Open block or shut-
closed off valves
Piping leaks, HP side Repair leaks
Bellows Unit Housing(s) filled up with Clean out housing(s)
solids, restricting bellows
movement
Gas trapped (liquid ser- Vent housing(s)
vice) or liquid trapped (gas
service) in housing(s)
Low or No Bellows Unit HP Housing gasket leaks Replace gasket
Indication (cont'd)
DPU tampered with Return BUA for
(cont'd)
repair
Mechanism Loose links/movements Tighten or replace
Corrosion or dirt in mecha- Clean or replace
nism
Pointer loose Tighten pointer
A-24
Table A.4—Troubleshooting Chart

Trouble Possible Source Probable Cause Corrective Action
High Primary Orifice partially restricted Clean out or replace
Indication or too small
Piping from Leak in LP side piping Repair leaks
Primary Element
to DPU
Bellows Unit Gas trapped (liquid Vent housing
service) in LP housing or
liquid trapped (gas ser-
vice) in HP housing
LP housing gasket leaks Replace gasket
Range spring broken or Return BUA for
DPU tampered with repair
Mechanism Loose links or movements Repair or replace
Erratic Primary Flow pulsating Install dampening
Indication device upstream of
DPU run
Piping from Liquid trapped in gas Remove (see
Primary Element piping or gas bubble in Startup Procedure,
to DPU liquid piping Section 3)
Vapor generator incor- Repipe
rectly installed
Reference leg gassy or See piping instruc-
liquid vaporizing tions
Bellows Unit Obstructed bellows travel Clean bellows
Gas trapped in DPU HP or Remove (see
LP housing Startup Procedure,
Section 3)
Mechanism Linkage dragging or dirty Adjust or clean
Pointer dragging on scale Adjust
plate
A-25
DPU Assembly Drawing and Parts List
Figure A.23—Model 199 DPU parts drawing (indicator and indicator switch mounting
brackets vary as shown; see 200A/289A and 581A insets)
A-26
Table A.5—Model 199 DPU Parts List

Per
Unit
1 BUA (BELLOWS UNIT ASSEMBLY) SELECT 1
2 HOUSING, PRESSURE, TAPPED (MATCH PORTS WITH 1
ITEM 3)
HOUSING, 1 K SST, 1/4 X 1/4 NPT 9A-CS787-0071C
HOUSING, 1 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0061C
HOUSING, 1 K SST, 1/2 X 1/4 NPT (TOP/BOTTOM) 9A-C0199-1038C
HOUSING, 1 K SST, 1/2 X 1/2 NPT 9A-CS787-0025Z
HOUSING, 3 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0057Z
3 HOUSING, PRESSURE, DRILLED (MATCH PORTS 1
WITH ITEM 2)
HOUSING, 1 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0060C
HOUSING, 1 K SST, 1/2 X 1/2 NPT 9A-CS787-0026Z
HOUSING, 3 K SST, 1/4 X 1/2 NPT (TOP/BOTTOM) 9A-CS787-0056Z
4 BOLT, HOUSING, 1 K 9A-C0199-1345C 12
BOLT, HOUSING, 3 K 9A-C0199-0085C
5 PLUG, PIPE, 1/4"NPT, 316 SST 9A-C0199-0214C 2
PLUG, PIPE, 1/2"NPT, 316 SST 9A-C0199-0215C
6 GASKET, PRESSURE HOUSING, NICKEL 9A-C0199-0184C 2
7 LABEL, HIGH PRESSURE 9A-0199-0194C 1
8 LABEL, LOW PRESSURE 9A-0199-0195C 1
9 BRACKET, MOUNTING, 1 K MODEL 200A/289A 9A-C0199-1493B 1
BRACKET, MOUNTING, 3 K MODEL 200A/289A 9A-CS787-0047Z
BRACKET, MOUNTING, 3 K MODEL 581A 9A-C0199-1109B
10 BRACKET, INDICATOR - MODEL 200A/289A 9A-CS748-0006Z 1
BRACKET, INDICATOR - MODEL 581A 9A-C0197-1019C
11 SPACER, INDICATOR BRACKET - MODEL 200A/289A 9A-C0199-0006C 2
12 SCREW, HEX WASHER HEAD, 3/8-16 X 1-1/8 9A-C0002-1009T 2
13 SCREW, HEX HD, 3/8-16 X 3/4 - MODEL 581A 9A-C0116-0007J 2
14 BRACKET SPACER 9A-C0199-0003C 1
A-27

Per
Unit
15 SCREW, FL HEX SOC CAP HD 3/8-16 X 7/8, ST - 9A-C0240-0003J 1
MODEL 200A/289A
SCREW, FL HEX SOC CAP HD 3/8-16 X 1 - 9A-C0240-0004J
MODEL 581A
16 TAG, S/N, DPU MTG BRK - MODEL 200A/289A 9A-C0199-0002G 1
TAG, S/N, DPU MTG BRK - MODEL 581A 9A-C0224-0003G
17 DRIVE SCREW, RD HD, #0 X 3/16, SS - 9A-C0600-1003J 4
MODEL 200A/289A
DRIVE SCREW, RD HD, #0 X 3/16, SS - MODEL 581A 2
18 SPACER, MOUNTING BRACKET - MODEL 200A/289A 9A-CS787-0008Z 2
19 WASHER, SPLIT LOCK, 3/8, SST 9A-C0003-0093K 5
20 SCREW, CAP HEX HD 3/8-16 X 1-1/2 ST ZP - 9A-C0210-0011J 2
MODEL 200A/289A
21 SCREW, CAP HEX HD 3/8-16 X 1 ST ZP, 1 K - 9A-C0210-1007J 2
MODEL 200A/289A
SCREW, CAP HEX HD 3/8-16 X 3/4 ST ZP, 3 K - 9A-C0210-0012J
MODEL 200A/289A
SCREW, CAP HEX HD 3/8-16 X 3/4 ST ZP, 3 K - 9A-C0116-0007J
MODEL 581A
22 SCREW, CAP HEX HD 3/8-16 X 1 ST ZP - 9A-C0210-1007J 1
MODEL 200A/289A
SCREW, HEX HD, 3/8-16 X 1 - MODEL 581A 9A-C0116-0006J
23 SPACER, CENTER PLATE - MODEL 200A/289A 9A-CS787-0009Z 1
24 SPACER - BLACK EPOXY, 1 K - MODEL 200A/289A 9A-CS787-0006Z 2
25 SPRING PUSH ROD 9A-C0199-0049C 1
26 LOCK NUT, SPRING ADJUST 9A-C0199-0144C 1
27 SPRING RETAINER POST, ROUND, 10-19"WC 9A-C0199-0257C 8
SPRING RETAINER POST, HEX, 20-400"WC 9A-C0199-1337C
28 NUT, SPRING POST, 8-32, ROUND 9A-C0199-0258C 8
NUT, SPRING POST, 6-32, HEX 9A-C0500-0028J
29 SCREW, CALIBRATION SPRING RETAINER, RD HD, 9A-C0111-0049J 8
6-32 X 5/16, SST
30 CALIBRATION SPRING ASSEMBLY, 3-3/4 BELLOWS 1
SPRING ASSY, INC, 0 - 10" WC 9A-C0199-1385B
A-28

Per
Unit
30 SPRING ASSY, INC, 23 - 27" WC 9A-C0199-1391B 1
(cont.)
31 CALIBRATION SPRING ASSEMBLY, 2-1/8 BELLOWS 1
SPRING ASSY, INC, 0 - 15 PSI 9A-C0199-1400B
A-29

Per
Unit
31 SPRING ASSY, INC, 0 - 40 PSI 9A-C0199-1429B 1
(cont.)
32 SCREW, SET, 6-32 X 1/4 - MODEL 581A 9A-C0320-1010J 1
A-30
DPU Dimensional Drawings
Figure A.24—Dimensional drawing, Model 199 DPU, rear view
Figure A.25—Dimensional drawing, Model 199 DPU, side view
A-31
Table A.6—Model 199 DPU Dimensions

Pressure Rating Dim. A Dim. B Dim. C
# Bolts
psi (bar) inches (mm) inches (mm) inches (mm)
1,000 (69) 6-5/8 (168.3) 2 (50.8) 2-9/64 (54.4) 12
3,000 (207) Ø 7 (177.8) 2 (50.8) 2-9/64 (54.4) 12

All Standard pipe fittings furnished by customer.
(Metric conversions are approximate.)
A-32
Product Warranty
A. Warranty
Cameron International Corporation ("Cameron") warrants that at the time of shipment, the prod-
ucts manufactured by Cameron and sold hereunder will be free from defects in material and
workmanship, and will conform to the specifications furnished by or approved by Cameron.
B. Warranty Adjustment
(1) If any defect within this warranty appears, Buyer shall notify Cameron immediately.
(2) Cameron agrees to repair or furnish a replacement for, but not install, any product which
within one (1) year from the date of shipment by Cameron shall, upon test and examina-
tion by Cameron, prove defective within the above warranty.
(3) No product will be accepted for return or replacement without the written authorization of
Cameron. Upon such authorization, and in accordance with instructions by Cameron, the
product will be returned shipping charges prepaid by Buyer. Replacements made under
this warranty will be shipped prepaid.
C. Exclusions from Warranty
(1) THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER
EXPRESSED OR IMPLIED WARRANTIES OF MERCHANTABILITY, OR FITNESS FOR
A PARTICULAR PURPOSE, OR OTHERWISE.
(2) Components manufactured by any supplier other than Cameron shall bear only the war-
ranty made by the manufacturer of that product, and Cameron assumes no responsibility
for the performance or reliability of the unit as a whole.
(3) "In no event shall Cameron be liable for indirect, incidental, or consequential damages
nor shall the liability of Cameron arising in connection with any products sold hereunder
(whether such liability arises from a claim based on contract, warranty, tort, or otherwise)
exceed the actual amount paid by Buyer to Cameron for the products delivered hereun-
der."
(4) The warranty does not extend to any product manufactured by Cameron which has
been subjected to misuse, neglect, accident, improper installation or to use in violation of
instructions furnished by Cameron.
(5) The warranty does not extend to or apply to any unit which has been repaired or
altered at any place other than at Cameron's factory or service locations by persons not
expressly approved by Cameron.
Product Brand
Barton® is a registered trademark of Cameron International Corporation ("Cameron").
Tefzel® is a registered trademark of E.I. DuPont de Nemours & Co., Inc.
A-33
+603.5569.0501
ms-kl@c-a-m.com
RUSSIA

Barton Model 581a Differntial Pressure Switch User Manual

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Barton Model 581a Differntial Pressure Switch User Manual

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BARTON® NUCLEAR MODEL 581A

! WARNING: This symbol identifies information about practices or circum-

CAUTION: Indicates actions or procedures which if not performed correctly

IMPORTANT: Indicates actions or procedures which may affect instrument operation or

For flow measurements, the instrument is connected to the high-pressure

For liquid level measurement applications, the instrument is connected to

The 581A switch is available in three model variations:

Left Switch Actuating Cam

Plunger Screw Plunger Screw

Figure 1.1—581A (with indicator), internal components

Plunger Screw Plunger Screw

Switch Adjust Linkage

Figure 1.2—581A (without indicator), internal components

B O T H S W I T C HES RELAX ED Mid-point DP

S W I T C H "A" S W I T C H "B " CLOSED OPEN

S W I T C H "A" AC T UAT ED/S W I T C H "B " RELAX ED Zero DP

S W I T C H "A" S W I T C H "B " CLOSED OPEN

B (RIGHT) GREEN/WHITE GREEN/BLACK

S W I T C H "A" RELAX ED/S W I T C H "B " AC T UAT ED Maximum DP

Figure 1.3—Switch wiring connections and actuation example

Differential Pressure Unit

Input Range ������������������������������������ 0-10" WC to 0-115 psid

For applications requiring special cleaning/precautions, a polyethylene bag

Dimensional drawings are provided in Section 5, page 32.

IMPORTANT: To ensure the unit calibration is within factory-set calibration tolerances,

LOW & HIGH SPDT SWITCHES

Figure 2.1—Low/high SPDT switch diagrams

Table 2.1—Switch Wire Color Coding

Section 3—Maintenance and Calibration

Figure 3.1—Model 581A adjustment controls

IMPORTANT: See Appendix A for related warning/caution notices and instructions

Bezel/Lens Assembly or Cover Installation and Removal

To ensure the unit calibration is within factory-set calibration tolerances,

IMPORTANT: Review all procedures and WARNINGS/NOTICES in Appendix A

1. Mount the instrument in an approximately level position and connect to a

Pointer "slipped" HUB

Hub held in place

Figure 3.2—"Slipping" pointer

Pointer Installation and Removal

To remove the pointer, perform the following steps:

Figure 3.3—Pointer puller (Part No. 9A-0163-0005B)

Scale Plate Installation and Removal

IMPORTANT: Review all procedures and WARNINGS/NOTICES in Appendix A

1. Securely mount the instrument in an approximately level position and

Figure 3.4—Range/linearity adjustment (50% DP)

SHAFT CLAMP SCREW

Figure 3.5—Drive arm to torque tube connection

IMPORTANT: On reverse acting/split range units, it will be necessary to pressurize the

Linkage Calibration Procedure

Figure 3.7—Linkage arrangement

7. If the switch is to be field-set at low differential pressure values (1% or

the pressure system to stabilize. Then change the pressure by a small

9. Check the switch deadband, (actuate to reset) by applying differential

Changing Switch Set Point

Deadband. The difference in measured pressures between switch-actuation

Best Practices for Set Points

Figure 3.8—Set point adjustment

Changing Set Point of an Out-of-Service Instrument

Section 4—Assembly Drawing and Parts List

LOCATE THE SCALE PLATE

Figure 4.1—Model 581A-0 indicating switch (shown with glass lens)

Table 4.1—Parts List, Model 581A-0 Indicating Switch and

Table 4.1—Parts List, Model 581A-0 Indicating Switch and

Figure 4.2—Model 581A-2 blind switch without indicator

Input Range �� 0-10" WC to 0-115 psid