MODEL 199

DIFFERENTIAL PRESSURE UNIT (DPU)

Standard and NACE Service

User Manual
Manual No. 9A-10030, Rev. 01
January 2008

CONTENTS
Section 1 - Introduction................................................................... Page 3
Section 2 - Theory of Operation..................................................... Page 5
Section 3 - Installation/Operation ................................................. Page 9
Section 4 - Maintenance, Adjustment, & Calibration.................. Page 13
4-1. Tools Required for Maintenance and Calibration.............. Page 13
4-2. DPU Inspection and Cleaning............................................. Page 13
4-3. Calibration Setup................................................................... Page 18
4-4. Torque Tube Rotation Check (Replacement Units).......... Page 18
4-5. Range Change........................................................................ Page 19
4-6. Setting Bellows Travel........................................................... Page 22
4-7. Bellows Unit Assembly (BUA) Replacement..................... Page 22
4-8. Attaching Drive Arm to Torque Tube.................................. Page 24
4-9. Drive Arm Tightness Test..................................................... Page 24
4-10. Adjusting Pulsation Dampener.......................................... Page 25
4-11. Troubleshooting................................................................... Page 25
Section 5 - Parts Drawing/List........................................................ Page 27
Section 6 - Outline Dimension Drawings...................................... Page 30

(This manual is for the DPU only.) Refer to the appropriate (separate)
instrument manual for information on the instrument being actuated.
Barton instrument is as stated on the back (last
SECTION 1 - INTRODUCTION

1-1. General
The Barton® Model 199 Differential Pressure Unit (DPU) (see Figure 1 -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 con­
tained in a process vessel.
For process flow measurements, the DPU is connected across a primary device
(a venturi, an orifice plate or a 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.
1-2. Product Description
The Model 199 DPU is a dual
HP Housing LP Housing
bellows assembly enclosed within
pressure housings. The dual
bellows assembly consists of two
opposing internally connected liq- Venting
uid-filled bellows, a center plate, Connection
range springs, overrange valves, Torque Tube
and a torque tube assembly. Shaft
The pressure housings are con- Pressure
nected by Pipe or tubing to the Connection
primary device located in the sys- Mounting
tem piping. Variations in differen- Bracket
tial 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 mo-
tion actuates the mechanism of the process monitoring instrument.
The process monitoring instrument that is connected to the torque tube as-
sembly may be an indicator, a switch, a transmitter, a recorder, or other process
control device.
1-3. Specifications
Torque Tube Rotation (full scale DP).............8° ±10%
Torque Tube Material..................................Beryllium Copper (BeCu)
Temperature Limits ....................................-40°F/°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
Housing Materials/Ranges ..........................Refer to Table 1-1

3
4
Table 1-1. Model 199 DPU Material/Range Specifications
Available DP Ranges
SWP
psi Body Housing Material Stainless Steel Bellows Inconel Bellows
(bar)
2-1/8" (55mm) O.D. 3-3/4" (95mm) O.D. 2-1/8" (55mm) O.D. 3-3/4" (95mm) O.D.
1,000 Cast Aluminum 356T6
(69) Forged Stainless Steel 316
NACE
Forged Steel AISI C1018
2,000
(For NACE Service)
(138)
2,500
Forged Steel AISI C1018 0-15 psi to 0-100 psi 0-10" w.c. to 0-400" w.c. 0-15 psi to 0-100 psi 0-10" w.c. to 0-400" w.c.
(172)
(0-1 bar to 0-6.9 bar) (0-25 mbar to 0-993 mbar) (0-1 bar to 0-6.9 bar) (0-25 mbar to 0-993 mbar)
3,000
Forged Stainless Steel 316
(207)
4,500
Forged Alloy Steel 4142
(310)
6,000 Forged Alloy Steel 4142
(414) Forged Stainless Steel 17-4 PH
Net Low Pressure (LP) Head 35" (575 cc) 30" (490 cc) 35" (575 cc) 30" (490 cc)
Volume
High Pressure (HP) Head 31" (510 cc) 26" (425 cc) 31" (510 cc) 26" (425 cc)
in cu. in.
(cc)
Displacement in cu. in.(cc) for full-scale 0.5" (8.2 cc) 1.5" (25 cc) 0.5" (8.2 cc) 1.5" (25 cc)
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). Other sizes and types of connectui-
ons (welding stubs, MS, A.N.D., etc.) available upon request. Standard pressure connections are 1/2" (top) and 1/4" (bottom) NPT. Range springs are
not interchangeable between the different size bellows, the inconel bellows, or the 10" w.c. (25 mbar) range. 3,000, 4,500, and 6,000 SWP versions
can be specified to meet NACE MR-01-75 (Rev. 80). Metric conversions are approximate. Outline dimension drawings available upon request.
SECTION 2 - THEORY OF OPERATION

2-1. Basic Components (See Figure 2-1)

Torque Tube Center Plate
Shaft LP Bellows
Torque Tube

Range Spring

HP Bellows

HP Over- LP Housing
range Valve

Temperature
Compensator

HP Housing LP Overrange
Valve

Housing
Bolts

Pulsation Damper
Damping Valve Plug
Valve Stem
Figure 2-1. 199 BUA Cutaway
A. Pressure Housings
The two pressure housings of the Model 199 DPU are available in the vari-
ous safe working pressure ratings defined in Table 1-1 and in the Outline
Dimensional Drawings (seen in Section 6 DRAWINGS).
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.
The pressure housings may be rotated 180 degrees to facilitate connection
at the top of the housing for draining when used in gas service, or at the
bottom to provide venting when used in liquid service.
The housings enclose the bellows on each side of the center plate.
B. Bellows
The bellows of the Model 199 DPU are available in the various materials
and sizes (refer to Table 1-1) to accommodate the various safe working
pressure ratings.
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
bellows on each side).

5
 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.
C. 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 (refer to
Table 1-1), act with the bellows and torque tube to balance the differential
pressure applied to the unit. The number of springs used and their spring
rate depends on the individual differential pressure range requirement.

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
Range Nut
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
Springs Spring Nut
End Cup
3-3/4" Bellows Unit Assembly (BUA)

Figure 2-2. Bellows Unit Assemblies (BUAs)

6
D. Torque Tube Assembly
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
Ball Bearing

Minature
Precision Valve Stem
Ball Bearing

Figure 2-3. Torque Tube Assembly

As illustrated in Figure 2-3, 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.
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 differential pressure unit.
NOTE: An extended torque tube is used on electronic transmitters and
explosion-proof instruments.
E. Pulsation Dampener
The pulsation dampener (see Figure 2-1) controls the flow of fill-liquid
between the high and low-pressure bellows with an externally adjustable
pulsation 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 fullopen position.

7
 (Blank Page)

8
SECTION 3 - INSTALLATION/OPERATION

3-1. Unpacking
The 199 DPU should be inspected at time of unpacking to detect any damage
that may have occurred during shipment.
NOTICE: The instrument was checked for accuracy at the factory — do not
change any of the settings during examination or accuracy will be affected.
NOTICE: For application in critical media, requiring special cleaning pro-
cesses and precautions, a polyethylene bag is used to protect the instrument
from contamination. This protective bag should be removed only under
conditions of controlled extreme cleanliness.
NOTICE: Do not locate the instrument near vents or bleed holes that dis-
charge corrosive vapors or gases.
3-2. Mounting
A. Flush or Panel Mounting
Attach the case of the instrument (recorder, indicator etc.) to the panel.
Refer to the Installation and Operation Manual for the specific instrument
for the mounting details.
B. Pipe Mounting
Refer to the Outline Dimension Drawing in Section 6 for the pipe mount-
ing diagram. The DPU must be mounted approximately level to operate
properly.
3-3. Piping — Standard Practices
A. All Applications (flow and liquid level)
1 . Shorten the distance between the primary device and the DPU as
much as possible. Distances exceeding 100 feet are not recommended.
For distances 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 recom-
mended 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 two feet of uninsulated piping between the DPU and the pri-
mary 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 five pounds per square inch and insulation should not be
used. If pressure must exceed five 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 measure-
ment will be affected.
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.

9
3-3. Piping — Standard Practices (Cont.)
7. Rotate the housing as necessary to place the connection in the proper
position. The DPU has connections in the pressure housings to accom-
modate various pipe sizes (refer to Section 6- Drawings).
8. Install a valve manifold connecting the DPU and the source of differen-
tial pressure to facilitate operation and checking of the DPU.
9. Locate all shutoff valves and bypass valves to be readily accessible from
the front of the instrument. Locate block valves at the source of dif-
ferential pressure.
B. Flow Applications
Assure that the DPU high-pressure housing is connected to the upstream
tap of the primary device.
NOTE: To prevent overheating the DPU during blowdown, the operator
should monitor the temperature by placing his hands on the pipe between
the DPU and the manifold pipe containing the vent valves.
C. Liquid Level Applications
The process media may be used as a reference leg seal fluid when it is of a
type that will condense in the reference leg under all conditions.
If the process or process media characteristics are such that the above con-
ditions cannot be met, a special reference leg seal fluid will be required. The
special seal fluid media characteristics are such that the above conditions
cannot be met, a special reference leg seal fluid will be 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.

3-4. General Startup Practice Considerations

Observe the following practices when starting up an instrument.
1. Always start with the block valves closed.
2. Perform a zero check on the instrument as follows.
NOTICE: For gas service, it is recommended that zero check be performed
with both block valves closed. If the gas flow is pulsating, there may be a
standing wave effect in the process 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 entrap-
ment in the lines or in the DPU (depending on the orientation of the
piping layout and service).

10
3-4. General Startup Practice Considerations (Cont.)
2. Perform a zero check on the instrument as follows (Cont.)
c. If necessary, adjust the pen or pointer by turning the zero adjust on the
instrument.
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. Any leakage will be indicated by pen or pointer movement, up or down
scale.
NOTE: Be careful not to subject the DPU to unnecessary shock or over-
range pressure during operations.

11
 (Blank Page)

12
SECTION 4 - MAINTENANCE, ADJUSTMENT, & CALIBRATION

4-1. Tools Required for Maintenance and Calibration

A calibration tool kit (P/N 0202-1005B) containing the necessary tools is avail-
able from the factory. The following tools are required for maintenance and
calibration of the DPU:
Table 4-1. Tools
Description Purpose
Screwdriver Bracket screws
7/16" Hex wrench Housing bolts
5/8" Hex wrench Housing bolts
3/4" Hex wrench Housing bolt/stud nut (6,000 PSI units)
1/8" Allen wrench Dampener Adjustment
1/2" Open end wrench Pushrod - bellows cup connection
1/2" 12-point socket Housing bolt (6,000 PSI units)
Modified Box/Open-ended Wrench Kickoff spring lock nut
(7/16")
100 ft.-lb. Torque wrench Housing bolts

4-2. DPU Inspection and Cleaning

WARNING
(High-pressure Gas Installations
with pressures greater than 200 psig)
HIGH-PRESSURE GAS HAZARD ON DISASSEMBLY OF THE DPU.
TO PREVENT POSSIBLE SEVERE PERSONAL INJURY, DEATH,
OR SUBSTANTIAL PROPERTY DAMAGE DUE TO THE RELEASE
OF INTERNAL PRESSURE, PERFORM THE PRESSURE CHECK
PROCEDURE THAT FOLLOWS (Step A) BEFORE REMOVING THE
DPU HOUSING BOLTS.
NOTICE
If accumulation of solids or semi-solids is extensive, remove the housings
carefully to prevent damaging the bellows.
WARNING
(Housing Bolts)
DO NOT REUSE HOUSING BOLTS. IF BOLTS ARE
DISTURBED, REPLACE WITH NEW BOLTS, PER TABLE 4-2
(STANDARD) or TABLES 4-3/4-4 (NACE).
REUSE OF HOUSING BOLTS, ESPECIALLY IN CRITICAL
APPLICATIONS LIKE HYDROGEN SULFIDE AND SALT WATER
EXPOSURES, CAN RESULT IN SEVERE INJURY, DEATH
OR SUBSTANTIAL PROPERTY DAMAGE DUE TO BOLT
FAILURE.

13
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 Table 4-2. Standard Bolt Torque Ratings

Torque Lb/Ft
Lube (Note 1)
Housing Bolts

Rotation
(Note 2)

(Note 3)
SWP Mat'l Mat'l Size Qty Part No.

Steel Steel 3/8-16 x 4.5 6 0199-1345C Yes 45 180°

1000 Cres Steel 3/8-16 x 4.5 12 0199-1345C Yes 40 270°
Alum Steel 3/8-16 x 4.5 6 0199-1345C Yes 40 180°
2500 Steel Steel 1/2-13 x 5.5 6 0199-0085C Yes 95 180°
3000 Cres Steel 1/2-13 x 5.5 12 0199-0085C Yes 80 180°
4500 Steel Steel 1/2-13 x 5.5 12 0199-0085C Yes 95 180°
Steel 1/2-20 x 7 12 0199-1001C
(Stud) 180°
6000 Yes 105
Steel 1/2-20 24 0199-1002C (Note 4)
(Nut)
Steel 1/2-20 x 6 12 0199-1346C
(Bolt) 180°
6000 Yes 105
Steel 1/2-20 12 0199-1002C (Note 4)
(Nut)
NOTES:
(1) Lubricants: Molykote G paste, Teflon-base pipe dope, graphite-base grease,
or similar lubricants. 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 with-
out torque wrench, use rotation values.
(4) Rotation reference for bolt with nut is the sum total of bolt head plus nut, or
total of 2 nuts.

15
 Table 4-3. NACE Bolt Torque Ratings
SWP
Item 2000 PSI 3000 PSI 4500 PSI
(13.8 MPa) (20.7 MPa) (31.0 MPa)
12 Pt. Head Bolt 12 Pt. Head Bolt
Fastener 12 Pt. Head Bolt
with Hex Nut with Hex Nut
Bolt Size 1/2-13 x 5.5" 1/2-20 x 6" 1/2-20 x 6"
Bolt Material B7M/L7M Steel B7M/L7M Steel B7M/L7M Steel
Nut Size N/A 1/2-20 1/2-20
Nut Material N/A 4140 Steel 4140 Steel
Quantity 6 12 12
Bolt Part Number 0220-1075J S408-0064Z S408-0064Z
Nut Part Number N/A S408-0021Z S408-0021Z
HSG. Gasket 0001-1140R S528-0001Z S528-0001Z
HSG. O-RIng 0001-1099R N/A N/A
Torque (ft/lbs) 55-60 55-60 55-60
SPECIAL NOTES:
(1) Lubricants: Molykote G paste, Teflon-base pipe dope, graphite-base grease,
or similar lubricants. Lube first 2 threads only. Do not lube bearing surface.
(2) Torque on bolts is accomplished in 3 or 4 steps. Tighten UNIFORMLY.
(3) If originally supplied with unit, re-install the "Do Not Reuse Bolts" and
"NACE" product tags.

16
 Table 4-4. Special 6,000 PSI NACE Bolt Torque Ratings
(6,000 PSI NACE Units/Bolts available from Canada Only)

SPECIAL NOTES:
(1) Lubricants: Molykote G paste, Teflon-base pipe dope, graphite-base grease, or
similar lubricants. Lube first 2 threads only. Do not lube bearing surface.
(2) Torque on bolts is accomplished in 3 or 4 steps. Tighten UNIFORMLY.
(3) For DP units marked as 1850 PSI (12.7 MPa) and 1500 PSI (10.3 MPa)
originally supplied with 12- point head bolts, Cameron has re-rated these lower
pressure DPUs to 2000 PSI (13.7 MPa). Apply the parts and use the torque
values for the 2000 PSI model (Table 4-3).
(4) For DP units marked as 1500 PSI (10.3 MPa) originally supplied with 6-point
head bolts, use a standard B7 alloy steel bolt that is suitable only for
applications where the application environment is not deemed to be sour.
WIth the exception of 0199-0085C bolts, apply the parts and use the torque
values for the 2000 PSI model (Table 4-3).
(5) If originally supplied with unit, re-install the "Do Not Reuse Bolts" and "NACE"
product tags.
All
All NuFlo
Bartoninstruments
instruments using 199 DPU
using 199 DPUas asactuator
actuatorare
are calibrated
calibrated at the
at the factory.
factory.
All DPUs
All DPUs sold
sold as
as replacement
replacementunitsunitsororasasactuators
actuatorsforfor
other applications
other are are
applications
checked for
checked for accuracy
accuracyprior
priortotoshipment.
shipment.
4-5. Range Change
Changing the range of the Model 199 DPU requires replacing the bellows unit
assembly with a unit of the desired range (see para. 4-7 Bellows Unit Assembly
(BUA) Replacement).
WARNING
(High-pressure Gas Installations
with pressures greater than 200 psig)
HIGH-PRESSURE GAS HAZARD ON DISASSEMBLY OF THE DPU.
TO PREVENT POSSIBLE SEVERE PERSONAL INJURY, DEATH,
OR SUBSTANTIAL PROPERTY DAMAGE DUE TO THE RELEASE
OF INTERNAL PRESSURE, PERFORM THE PRESSURE CHECK
PROCEDURE IN PARA. 4-2, Step A BEFORE REMOVING THE
DPU HOUSING BOLTS.
NOTICE
If accumulation of solids or semi-solids is extensive, remove the housings
carefully to prevent damaging the bellows.
WARNING
(Housing Bolts)
DO NOT REUSE HOUSING BOLTS. IF BOLTS ARE
DISTURBED, REPLACE WITH NEW BOLTS, PER TABLE 4-2
(STANDARD) or TABLES 4-3/4-4 (NACE).
REUSE OF HOUSING BOLTS, ESPECIALLY IN CRITICAL
APPLICATIONS LIKE HYDROGEN SULFIDE AND SALT WATER
EXPOSURES, CAN RESULT IN SEVERE INJURY, DEATH
OR SUBSTANTIAL PROPERTY DAMAGE DUE TO BOLT
FAILURE.
NOTICE: 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 as-
sumes that the DPU is either connected to an indicating instrument or fitted with
a scale and pointer to measure torque tube shaft movement):
A. 2-1/8-inch Dia. Bellows
1. Remove the D PU 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.
NOTE: 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.
(Continued on next page)

19
A. 2-1/8-inch Dia. Bellows (Cont.)
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 conterclockwise 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.
7. Replace the low-pressure housing and install NEW bolts (new gaskets
are recommended). Use the torque values listed in Tables 4-2 through
4-4. Refer to Housing Bolt WARNING, para. 4-5, page 19.
8. Calibrate in accordance with the manual for the actuated instrument.
B. 3-3/4-inch Dia. Bellows Without Kickoff Spring (>50" 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.
NOTE: The pointer will shift from zero. This is a normal action and the
pointer 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 thezerosetting. If the pointer shifts from zero, loosen the lock
nut and repeat this step.
6. Replace the low-pressure housing and bolts (new gaskets are recom-
mended). Use the toque values listed in Tables 4-2 through 4-4. Refer
to Housing Bolt WARNING, para. 4-5, page 19.
7. Calibrate in accordance with the manual for the actuated instrument.
C. 3-3/4-inch Dia. Bellows w/Kickoff* Spring (see Figure 4-2)
NOTE: The kickoff spring is supplied with the 0-40" w.c. and lower range DPUs
as standard equipment. It is optional with 0-50" w.c. DPUs.
*Also referred to as the "anti-stick" spring.
1 Remove the instrument from service. Set the pointer (or pen) 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, four spring retainer nuts,
washer and lock nut, and range spring assembly.
NOTE: The pointer will shift from zero. This is a normal action and the
pointer should not be readjusted at this time.
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.
NOTE: 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.

20
C. 3-3/4-inch Dia. Bellows w/Kickoff* Spring (Cont.) (see Figure 4-2)
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
during this operation, 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 the
original position.

Figure 4-2. Kickoff Spring Assembly

NOTE: The lock nut requires a modified 7/16", 12-point box wrench for tight-
ening (Figure 4-3).

Figure 4-3. Wrench Modification

9. Check the back-clearance between the kickoff spring and the slot. Use a
wire feeler gage or comparable measuring device. The clearance will vary
between each individual slot but must be at least 0.005-inch for any one
slot 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 9, return the spud to the proper position before
tightening the jam nut.

21
C. 3-3/4-inch Dia. Bellows w/Kickoff* Spring (Cont.)
11. Apply 100 percent negative pressure to the high-pressure side of the DPU
and repeat the clearance check and adjustment of step 9.
12. Apply 100 percent positive pressure to the high-pressure side of the DPU
and repeat the clearance check and adjustment of step 9.
13. Release all pressure from the instrument and replace the low-pressure hous-
ing. Use new gaskets.
14. Replace the housing bolts. Use the torque values listed in Tables 4-2
through 4-4. Refer to Housing Bolt WARNING, para. 4-2, page 13.
4-6. 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.
3. The indicator pointer has excessive overtravel.
4. The indicator pointer has excessive undertravel.
To set 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 of the actuated instrument.
4-7. Bellows Unit Assembly (BUA) Replacement (See Figure 2-1)
WARNING
(High-pressure Gas Installations
with pressures greater than 200 psig)
HIGH-PRESSURE GAS HAZARD ON DISASSEMBLY OF THE DPU.
TO PREVENT POSSIBLE SEVERE PERSONAL INJURY, DEATH,
OR SUBSTANTIAL PROPERTY DAMAGE DUE TO THE RELEASE
OF INTERNAL PRESSURE, PERFORM THE PRESSURE CHECK
PROCEDURE IN PARA. 4-2, Step A BEFORE REMOVING THE
DPU HOUSING BOLTS.
NOTICE
If accumulation of solids or semi-solids is extensive, remove the housings
carefully to prevent damaging the bellows.

WARNING
(Housing Bolts)
DO NOT REUSE HOUSING BOLTS. IF BOLTS ARE
DISTURBED, REPLACE WITH NEW BOLTS, PER TABLE 4-2
(STANDARD) or TABLES 4-3/4-4 (NACE).
REUSE OF HOUSING BOLTS, ESPECIALLY IN CRITICAL
APPLICATIONS LIKE HYDROGEN SULFIDE AND SALT WATER
EXPOSURES, CAN RESULT IN SEVERE INJURY, DEATH
OR SUBSTANTIAL PROPERTY DAMAGE DUE TO BOLT
FAILURE.

22
4-7. Bellows Unit Assembly (BUA) Replacement (Cont.) (See Figure 2-1)
COMPONENT REMOVAL NOTICE: See (separate) actuated instrument
Manual for particular components that must be removed to gain access to DPU
case mounting screws. Support DPU during disassembly. Do not loosen drive
arm hold plug (located in the top of the BUA center plate) when removing
mounting bracket. If plug is loosened, bellows fill fluid will be lost.

NOTE: The reference designations listed relate to Parts Drawing in Section 5.

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 four case-retaining screws and remove the case assembly.
4. (Indicators only) Remove the three pipe mounting adapter bracket screws
(10, 11) and remove the adapter bracket (13).
5. Remove the three mounting bracket screws and remove the case mounting
bracket (18).
6. Remove the pressure housings bolts and pressure housings (26).
7. Place the pressure housings (26) on the replacement bellows unit assembly
(1) and insert and start (only) the pressure housing bolts.
8. Attach the case mounting bracket (18) to the replacement assembly, using
three mounting bracket screws.
9. (Indicators only) Attach the pipe mounting adapter bracket (13) using three
screws.
10. Support the DPU and tighten and torque the pressure housing bolts to the
specifications listed in Tables 4-2 through 4-4. Refer to Housing Bolt
WARNING, para. 4-7, page 22.
11. Attach the case assembly using four case retaining screws.
12. Attach drive arm and linkage.
13. Tighten drive arm to torque tube, per para. 4-8.
14. Replace any instrument components that were removed (refer to the
COMPONENT REMOVAL NOTICE above).
15. Calibrate the instrument before returning it to service.

23
4-8. Attaching Drive Arm to Torque Tube

Figure 4-4. Drive Arm to Torque Tube Connection

1. Slip drive arm over torque tube shaft; clear end of torque tube housing by
approximately 0.030 inches before securing to prevent interference.
2. To tighten the drive arm assembly onto the torque tube shaft:
a. Supporting block and shaft, tighten clamp screw until snug to shaft.
b. Still supporting block/shaft, tighten clamp screw an additional:
• Sintered: 1/3 to 1/2 turn (screw can normally turn one full revolu-
tion before breaking.)
• Slotted: 1/4 to 1/3 turn (slot in the slotted clamp block should still
be open.)
NOTICE: For Nuclear, Seismic, and High Shock Qualified Units, perform Drive
Arm Tightness Test, per para. 4-9.
4-9. Drive Arm Tightness Test
(Nuclear, Seismic, and High Shock Qualified Units Only)
This procedure tests the drive arm to torque tube attachment for tightness, by
applying torque developed by the DPU onto a fixed drive arm. Care should be
taken to apply pressure slowly, as torque is being applied to the connection
through the torque tube drive shaft and not the torque tube itself.
With pointer at normal 0% torque tube rotation position (max. minimum scale
position or 0% on a normal 0 to 100% scale unit), adjust drive arm stop bracket
(or use alternate means) to prevent pointer from moving (stop bracket interferres
with drive arm movement). Note: On reverse acting/split range units, it will be
necessary to pressurize DPU to move pointer to max. minimum scale position,
and on suppressed units, it will be necessary to apply pressure to establish a
reference point to check for "zero" shift.
Pressurize DPU as required to full calibrated scale differential pressure (100% of
the full scale range). This achieves 8-degrees of torque tube drive shaft equiva-
lent torque onto the connection.
Observe shift in the unit "zero" following DPU depressurization (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% is
indicative of drive arm slippage necessitating further clamp block tightening.
24
4-10. Adjusting Pulsation Dampener (See Figure 2-1)
1. Remove dust cover and insert 1/8 hex key into needle valve.
2. Turn valve clockwise to closed position, approx. 3 turns.
3. Back out valve 1/2 turn or as required to reduce pulsations/shock pres-
sures.
4-11. Troubleshooting
See Table 4-5 and refer to actuated instrument Manual for more information.
Table 4-5. 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 process Refill reference leg
media or reference leg with same density
liquid as process
media
Piping from Pressure tap holes plugged Clean out piping
Primary Element
Bypass valve open or Close bypass valve(s)
to DPU
leaking 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
High flapper setting Align drive arm
re-calibrate
Bellows Unit Housing(s) filled up with Clean out housing(s)
solids, restricting bellows
movement
Gas trapped (liquid service) Vent housing(s)
or liquid trapped (gas
service) in housing(s)
HP Housing gasket leaks Replace gasket
DPU tampered with Return BUA for
repair
Mechanism Loose links/movements Tighten or replace
Out of calibration Calibrate
Corrosion or dirt in mecha- Clean or replace
nism
Pointer loose Tighten pointer

25
 Table 4-5. Troubleshooting Chart (Continued)

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 service) Vent housing
in LP housing or liquid
trapped (gas service) 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
Out of calibration Calibrate
Erratic Primary Flow pulsating Install dampening
Indication device upstream of
DPU run
Piping from Liquid trapped in gas Remove (see Startup
Primary Element piping or gas bubble in Procedure-Section 3)
to DPU liquid piping
Vapor generator incorrectly Repipe
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 Startup
LP housing Procedure-Section 3)
Mechanism Linkage dragging or dirty Adjust or clean
Pointer dragging on scale Adjust
plate

26
SECTION 5 - PARTS DRAWING/LIST

5-1. General
The parts list and parts identification drawing(s) for the DPU are presented in
the separate DPU Manual.

Figure 5-1. 199 DPU Parts Drawing

27
 WARNING
(NACE SERVICE)
HAZARDOUS GAS AND PRESSURE HAZARD IN NACE QUALIFIED
SERVICE. USE ONLY NACE QUALIFIED REPLACEMENT PARTS
FOR HOUSINGS, BOLTS, AND BUA. FOR NACE BOLT PART
NUMBERS, REFER TO TABLES 4-3 & 4-4.
ANY DEVIATION FROM USE OF QUALIFIED NACE PARTS IN
NACE SERVICE WILL VOID THE INSTRUMENT/DPU NACE
RATING(s).

Table 5-1. 199 Parts List

PER
ITEM DESCRIPTION PART NO.
UNIT
1 BELLOWS UNIT ASSEMBLY (BUA) (SPECIFY) 1
*2 POST, CALIBRATION SPRING RETAINER
0199-0019C 4
(FOR 3-3/4" BELLOWS)
3 ROD, SPRING PUSH 0199-0049C 1
*4 SCREW, RETAINER, 6-32 x 5/16" 0111-0049J 8
*5 SPRING ASSEMBLY, CALIBRATION TENSION
(SPECIFY) 1
(FOR 2-1/8" BELLOWS)
6 NUT, LOCK - SPRING ADJUST 0199-0144C 1
7 PLUG, PIPE, 1/4" NPT, STEEL 0199-0191C 2
8 PLUG, PIPE, 1/2" NPT, STEEL 0199-0192C 2
9 BOLT, HOUSING (STANDARD UNITS):** A/R
STAINLESS STEEL, 1000 PSI UNITS 0199-1345C
STEEL, 2500/3000/4500 PSI UNITS 0199-0085C

STUD, ALLOY STEEL, 1/2-20 X 7 FOR 6000

PSI UNITS (NOT SHOWN) 0199-1001C

BOLT FOR 6000 PSI UNITS (NOT SHOWN) 0199-1346C

*10 SCREW, PIPE MOUNT ADAPTER, 3/8-16 X 3/4" 0210-0012J 1
11 SCREW, SCH CAP, STEEL, 3/8-16 X 1-1/2" LG. 0220-1102J 2
*12 SCREW, 3/8-16 X 5/8", STEEL (FOR ITEM 13) 0310-0013J 3
13 ADAPTER, PIPE MOUNTING 0199-0988C 1
*14 NUT, SPRING RETAINER, HEX, 6-32,
0500-0028J 8
SM PATTERN, SST (FOR 3-3/4" BELLOWS)
*15 ASSEMBLY, RANGE SPRING 1
(SPECIFY)
(FOR 3-3/4" BELLOWS)
16 SPACER, INDICATOR BRACKET 0199-0006C 2
17 SCREW, INDICATOR BRACKET 1
0240-0003J
(SOC. FLAT, 3/8-16 X7/8", ST)
18 BRACKET (SPECIFY) 1
19 SCREW, INDICATOR BRACKET, HEX, WASHER 2
0002-1009T
HD., 3/8 X 1-1/8
20 SCREW, RECORDER BRACKET, HEX, WASHER 1
0002-0034T
HD., 3/8-16 X 1/2

28
 Table 5-1. 199 Parts List (Continued)
PER
ITEM DESCRIPTION PART NO.
UNIT
*21 O-RING, 2-127, NITRILE N3 ** 0001-1178R 1
*22 GASKET, TORQUE TUBE 0199-0209C 1
23 NOT USED
24 SCREW, RECORDER BRACKET, HEX, WASHER 2
0002-0033T
HD., 3/8-16 X 5/8
*25 GASKET, PRESSURE HOUSING: ** 2
0199-0027C
1000 PSI ALUMINUM UNITS
0199-0027C
2500/3000/4500 PSI STEEL UNITS
0199-0184C
1000/3000/6000 PSI SST & MONEL UNITS
26 HOUSING, PRESSURE (SPECIFY) 2
27 WASHER, LOCK, 3/8" 1
0275-0049C
(USED WITH ITEMS 10 AND 11)
28 NOT USED
29 NUT, 1/2-20, 6000/3000 PSI MONEL UNITS A/R
0199-1002C
(USED WITH ITEM 9)
*30 PLUG, DAMPENER VALVE (NOT SHOWN) 1
0199-0036C
BD HD., 1/4-28 X 1/4, SST
31 NOT USED
*32 WRENCH, RANGE SPRING ADJUSTMENT 0199-0142C 1
33 KEYS, SET OF HEX (NOT SHOWN) 0016-0013T 1
NOTES: * INDICATES RECOMMENDED SPARE PART; A/R INDICATES AS
REQUIRED; WHEN ORDERING PARTS, SPECIFY INSTRUMENT SERIAL NUMBER.
** FOR NACE SPECIFIC PART NUMBERS, REFER TO TABLES 4-3 AND 4-4.

29
SECTION 6 - OUTLINE DIMENSION DRAWINGS

Figure 6-1. 199 DPU Dimension Drawing (Part 1 of 2)

30
 Figure 6-1. 199 DPU Dimension Drawing (Part 2 of 2)

Table 6-1. 199 DPU Dimensions

PRESSURE
# BOLTS
PRESSURE CONNECTION DIM. A DIM. B DIM. C
HOUSING
RATING INCHES INCHES INCHES
MATERIAL
PSI (MPa) TOP BOTTOM (mm) (mm) (mm)

1,000 1/2 NPT 1/4 NPT 6-5/8 2 2-9/64

CAST ALUM. 356T6 6
(6.9) (Note 1) (Note 1) (168.3) (50.8) (54.4)
NACE
FORGED ST. AISI C1018 1/2 NPT 1/4 NPT Ø7 2 2-9/64
2,000 6
(For NACE Service) (Note 1) (Note 1) (177.8) (50.8) (54.4)
(13.8)
2,500 1/2 NPT 1/4 NPT Ø7 2 2-9/64
FORGED ST. AISI C1018 6
(17.2) (Note 1) (Note 1) (177.8) (50.8) (54.4)
3,000 1/2 NPT 1/4 NPT Ø7 2 2-9/64
FORGED STNL. ST. 316 12
(20.7) (Note 1) (Note 1) (177.8) (50.8) (54.4)
4,500 1/2 NPT 1/4 NPT Ø7 2 2-9/64
FORGED ALLOY ST. 4142 12
(31.0) (Note 1) (Note 1) (177.8) (50.8) (54.4)
9/16-18 9/16-18
FORGED ALLOY ST. 4142 Ø7 2 2
UNF UNF 12
6,000 FORGED STNL. ST. 17-4 PH (177.8) (50.8) (50.8)
(Note 2) (Note 2)
(41.4)
FORGED ALLOY ST. 4142 1/2 NPT 1/4 NPT Ø7 2 2-9/64
12
FORGED STNL. ST. 17-4 PH (Note 1) (Note 1) (177.8) (50.8) (54.4)
Note 1: Can be reversed when ordered or can be rotated 180° in the field.
Note 2: Suitable for use with Aminko fittings (American Inst. Co., Silver Springs, MD.) or equiv..
Note 3: All Standard pipe fittings furnished by customer.
(Metric conversions are approximate.)

31
Product Warranty
A. Warranty
Cameron International Corporation ("Cameron") warrants that at the time of ship-
ment, the products 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 immedi-
ately.
(2) Cameron agrees to repair or furnish a replacement for, but not install, any prod-
uct which within one (1) year from the date of shipment by Cameron shall, upon
test and examination 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 warranty 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 dam-
ages 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 hereunder."
(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").
MEASUREMENT SYSTEMS
Formerly: NuFlo Measurement Systems • Barton Instrument Systems • Caldon, Inc.

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