ABB AV1, AV2 Operating Instructions

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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION | OI/AV12 REV. E

AV1 and AV2

Characterizable pneumatic and electro-pneumatic positioners

Pneumatic and electro-pneumatic positioners built on proven performance for demanding process conditions

Measurement made easy

— Characterizable analog positioners

Introduction

AV characterizable pneumatic positioners are control devices that satisfy a wide range of applications. They provide fast, sensitive and accurate positioning of pneumatic single- or double-acting, linear or rotary motion actuators. A mechanical connection from the actuator to a position feedback cam in the positioner establishes actual position. Three characterized segments on one cam provide application flexibility by establishing various relationships between input signal and actuator position. The relationships provided by the segments are square root, linear and square.

Trademarks and Registrations

Registrations and trademarks used in this document include:

® Delrin Registered trademark of E.I. DuPont de Nemours Company, Incorporated ® Dow Corning Registered trademark of Dow Corning Corporation ® Lexan Registered trademark of General Electric Company, GE Plastics Division ® Monel Registered trademark of International Nickel Company ® Noryl Registered trademark of General Electric Company, GE Plastics Division ® PowerRac Registered trademark of DeZurik, a Unit of General Signal ® Rynite Registered trademark of E.I. DuPont de Nemours Company, Incorporated ® Teflon Registered trademark of E.I. DuPont de Nemours Company, Incorporated ® Valox Registered trademark of General Electric Company, GE Plastics Division ® Viton Registered trademark of E.I. DuPont de Nemours Company, Incorporated

WARNING notices as used in this manual apply to hazards or unsafe practices which could result in personal injury or death.

CAUTION notices apply to hazards or unsafe practices which could result in property damage. NOTES highlight procedures and contain information which assist the operator in understanding the informa-

tion contained in this manual.

All software, including design, appearance, algorithms and source codes, is copyrighted by ABB Inc. and is owned by ABB Inc. or its suppliers.

WARNING

POSSIBLE PROCESS UPSETS. Maintenance must be performed only by qualified personnel and only after

securing equipment controlled by this product. Adjusting or removing this product while it is in the system may upset the process being controlled. Some process upsets may cause injury or damage.

The information contained in this document is subject to change without notice. ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this publication specifi-

cally disclaim all liabilities and warranties, express and implied (including warranties of merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information contained herein and/or for the fitness for any particular use and/or for the performance of any material and/or equipment selected in whole or part with the user of/or in reliance upon information contained herein. Selection of materials and/or equipment is at the sole risk of the user of this publication.

NOTICE

This document contains proprietary information of ABB Inc., and is issued in strict confidence. Its use, or reproduction for use, for the reverse engineering, development or manufacture of hardware or software described herein is prohibited. No part of this document may be photocopied or reproduced without the prior written consent of ABB Inc..

Table of Contents

Page

SECTION 1 - INTRODUCTION................................................................................................... 1-1

OVERVIEW.....................................................................................................................................1-1

INTENDED USER...........................................................................................................................1-1

DESCRIPTION................................................................................................................................1-1

Performance Series Option......................................................................................................1-2

Explosionproof I/P Option.........................................................................................................1-3

NEMA 4X Option......................................................................................................................1-3

APPLICATION.................................................................................................................................1-3

FEATURES .....................................................................................................................................1-3

INSTRUCTION CONTENT..............................................................................................................1-5

REFERENCE DOCUMENTS..........................................................................................................1-6

NOMENCLATURE ..........................................................................................................................1-6

SPECIFICATIONS...........................................................................................................................1-7

SECTION 2 - DESCRIPTION AND OPERATION....................................................................... 2-1

INTRODUCTION.............................................................................................................................2-1

FUNCTIONAL OPERATION ...........................................................................................................2-2

SECTION 3 - INSTALLATION.................................................................................................... 3-1

INTRODUCTION.............................................................................................................................3-1

UNPACKING AND INSPECTION....................................................................................................3-1

ENCLOSURE CLASSIFICATION....................................................................................................3-2

MOUNTING CONSIDERATIONS....................................................................................................3-2

MOUNTING TYPE AV POSITIONERS...........................................................................................3-4

TUBING CONNECTIONS ...............................................................................................................3-8

Air Supply Pressure..................................................................................................................3-8

Air Supply Filtering...................................................................................................................3-8

Air Supply Quality (Recommended).........................................................................................3-9

Tubing Connections .................................................................................................................3-9

WIRING TYPE AV2 POSITIONER................................................................................................3-10

WIRING TYPE AV1 POSITIONER................................................................................................3-13

RADIO FREQUENCY INTERFERENCE.......................................................................................3-15

WIRING REQUIREMENTS...........................................................................................................3-15

SECTION 4 - CALIBRATION...................................................................................................... 4-1

INTRODUCTION.............................................................................................................................4-1

CALIBRATION.................................................................................................................................4-1

Zero Adjustment.......................................................................................................................4-1

Span Adjustment......................................................................................................................4-3

CALIBRATION FOR PARTICULAR APPLICATION .......................................................................4-3

Zero Adjustment.......................................................................................................................4-4

Span Adjustment......................................................................................................................4-4

GAIN AND SPEED ADJUSTMENTS ..............................................................................................4-5

Gain Adjustment.......................................................................................................................4-5

Speed Adjustment....................................................................................................................4-6

ORIFICE............................................................................................................................4-6

PILOT VALVE STROKE ADJUSTMENT..........................................................................4-6

TROUBLESHOOTING CALIBRATION ADJUSTMENTS................................................................4-8

SECTION 5 - OPERATING PROCEDURES............................................................................... 5-1

INTRODUCTION.............................................................................................................................5-1

Table of Contents (continued)

EQUALIZING AND AIR SUPPLY SHUTOFF VALVE..................................................................... 5-1

Transfer from Automatic to Manual Operation ........................................................................ 5-1

Transfer from Manual to Automatic Operation ........................................................................ 5-1

SECTION 6 - TROUBLESHOOTING...........................................................................................6-1

INTRODUCTION............................................................................................................................ 6-1

SECTION 7 - MAINTENANCE.....................................................................................................7-1

INTRODUCTION............................................................................................................................ 7-1

PREVENTIVE MAINTENANCE SCHEDULE................................................................................. 7-1

PREVENTIVE MAINTENANCE PROCEDURES ........................................................................... 7-2

MANIFOLD FILTERS ..................................................................................................................... 7-2

SECTION 8 - REPAIR AND REPLACEMENT.............................................................................8-1

INTRODUCTION............................................................................................................................ 8-1

REPLACEMENT PROCEDURES .................................................................................................. 8-1

Manifold................................................................................................................................... 8-1

Gain Hinge Spring................................................................................................................... 8-2

Pilot Valve Assembly............................................................................................................... 8-3

I/P Converter ........................................................................................................................... 8-4

Cam......................................................................................................................................... 8-5

Diaphragm Assembly .............................................................................................................. 8-5

DIAPHRAGM ASSEMBLY REMOVAL............................................................................. 8-6

DIAPHRAGM ASSEMBLY REPLACEMENT................................................................... 8-6

PILOT VALVE STROKE ADJUSTMENT........................................................................................ 8-7

Page

SECTION 9 - SUPPORT SERVICES...........................................................................................9-1

INTRODUCTION............................................................................................................................ 9-1

RECOMMENDED SPARE PARTS................................................................................................. 9-1

ADDITIONAL SPARE PARTS........................................................................................................ 9-3

APPENDIX A - POSITION TRANSMITTERS............................................................................. A-1

INTRODUCTION............................................................................................................................A-1

DESCRIPTION AND OPERATION ................................................................................................A-1

CALIBRATION................................................................................................................................A-2

Calibrating the Potentiometric Position Transmitter ................................................................A-2

POTENTIOMETRIC APPLICATION EXAMPLE ..............................................................A-3

CALIBRATING THE POTENTIOMETRIC EXAMPLE......................................................A-4

Calibrating the 4 to 20-mA Position Transmitter......................................................................A-6

APPENDIX B - QUICK START...................................................................................................B-1

INTRODUCTION............................................................................................................................B-1

PRODUCT IDENTIFICATION (NOMENCLATURE).......................................................................B-1

MOUNTING THE POSITIONER..................................................................................................... B-2

TUBING CONNECTIONS...............................................................................................................B-5

TYPE AV2 POSITIONER WIRING.................................................................................................B-8

TYPE AV1 POSITIONER WIRING...............................................................................................B-10

CALIBRATION..............................................................................................................................B-11

Table of Contents (continued)

Page

APPENDIX C - CAM CHARACTERIZATION.............................................................................C-1

INTRODUCTION............................................................................................................................C-1

CAM CHARACTERIZATION..........................................................................................................C-1

CAM SELECTION..........................................................................................................................C-3

CAM SHAPING ..............................................................................................................................C-5

APPENDIX D - TYPE AV1 PNEUMATIC POSITION TRANSMITTER.......................................D-1

INTRODUCTION............................................................................................................................D-1

DESCRIPTION...............................................................................................................................D-1

INSTALLATION..............................................................................................................................D-2

CALIBRATION................................................................................................................................D-3

List of Figures

No. Title Page

1-1. Capacity (Exhaust to Atmosphere)...........................................................................................1-9

1-2. Air Consumption.....................................................................................................................1-10

1-3. Output Air Flow vs. Error Signal — Standard and Performance Series.................................1-10

1-4. Expanded First Quadrant View ..............................................................................................1-11

2-1. Operation Diagram...................................................................................................................2-1

2-2. Block Diagram..........................................................................................................................2-1

3-1. External and Mounting Dimensions..........................................................................................3-3

3-2. Electrical Connections..............................................................................................................3-4

3-3. Drive Arm Connections.............................................................................................................3-4

3-4. Drive Shaft Variations...............................................................................................................3-5

3-5. Mounting Using Linkage (Typical)............................................................................................3-5

3-6. Mounting Using Direct Coupling (Typical)................................................................................3-6

3-7. Cam..........................................................................................................................................3-7

3-8. Cam Roller Alignment...............................................................................................................3-8

3-9. Port Locations ..........................................................................................................................3-9

3-10. Direct Acting, Top Loaded, Single Acting Tubing Example.....................................................3-11

3-11. Reverse Acting, Top Loaded, Single Acting Tubing Example.................................................3-12

3-12. Direct Acting, Bottom Loaded, Single Acting Tubing Example...............................................3-12

3-13. Reverse Acting, Bottom Loaded, Single Acting Tubing Example...........................................3-13

3-14. Double Acting Tubing Example ..............................................................................................3-14

3-15. Wiring Connections................................................................................................................3-14

4-1. Calibration Adjustments............................................................................................................4-2

4-2. Cam Roller Alignment...............................................................................................................4-3

4-3. Zero Adjustment Graph ............................................................................................................4-4

4-4. Span Adjustment Graph ...........................................................................................................4-5

4-5. Pilot Valve Adjustment..............................................................................................................4-7

4-6. Speed Adjustment Screws .......................................................................................................4-7

4-7. I/P Adjustment..........................................................................................................................4-9

7-1. Positioner with Manifold ...........................................................................................................7-3

7-2. Manifold with Filter Cover Removed ........................................................................................7-3

8-1. Positioner with Manifold ...........................................................................................................8-2

8-2. Manifold O-Rings......................................................................................................................8-3

iii

List of Figures (continued)

No. Title Page

8-3. Pilot Valve Measurement for Maximum Speed........................................................................ 8-8

8-4. Stroke Adjustment Screws....................................................................................................... 8-8

9-1. Mounting Kits........................................................................................................................... 9-6

9-2. Bypass Valve Assembly........................................................................................................... 9-8

9-3. Type AV1 Positioner ...............................................................................................................9-11

9-4. Type AV2 Positioner (Page 1 of 2)......................................................................................... 9-16

9-4. Type AV2 Positioner (Page 2 of 2)......................................................................................... 9-17

A-1. Terminal Block Connections....................................................................................................A-2

A-2. Schematic Diagram.................................................................................................................A-4

A-3. Potentiometric Position Transmitter (Exploded View)..............................................................A-5

A-4. Calibration Features for 4 to 20-mA Position Transmitter........................................................A-6

A-5. 4 to 20-mA Position Transmitter (Exploded View)...................................................................A-7

B-1. Mounting Using Linkage (Typical) ...........................................................................................B-3

B-2. Mounting Using Direct Coupling (Typical) ...............................................................................B-3

B-3. Drive Arm Connections............................................................................................................B-4

B-4. Cam Roller Alignment..............................................................................................................B-4

B-5. Port Locations..........................................................................................................................B-5

B-6. Direct Acting, Top Loaded, Single Acting Tubing Example......................................................B-6

B-7. Reverse Acting, Top Loaded, Single Acting Tubing Example..................................................B-6

B-8. Direct Acting, Bottom Loaded, Single Acting Tubing Example ................................................B-7

B-9. Reverse Acting, Bottom Loaded, Single Acting Tubing Example ............................................B-7

B-10. Double Acting Tubing Example................................................................................................B-8

B-11. Wiring Connections .................................................................................................................B-9

B-12. Calibration Adjustments...........................................................................................................B-9

C-1. Cam A, Square Root Relationship...........................................................................................C-1

C-2. Cam B, Linear Relationship.....................................................................................................C-2

C-3. Cam C, Square Relationship...................................................................................................C-2

C-4. Regulated Device Characteristics ...........................................................................................C-4

C-5. Desired Control........................................................................................................................C-4

C-6. Cam Characteristics................................................................................................................C-5

C-7. Graph to Cam Data Transfer...................................................................................................C-7

D-1. Pneumatic Position Transmitter Kit..........................................................................................D-2

List of Tables

No. Title Page

1-1. Reference Documents............................................................................................................. 1-6

1-2. Nomenclature.......................................................................................................................... 1-6

1-3. Type AV1/2 Positioner Specifications...................................................................................... 1-7

1-4. Type AV ____1__ Potentiometric Position Transmitter Specifications.................................. 1-11

1-5. Type AV ____2 __ 4 to 20-mA Position Transmitter Specifications ....................................... 1-11

1-6. Agency Approvals.................................................................................................................. 1-12

1-7. Accessories........................................................................................................................... 1-12

1-8. Rotary Actuator Retrofit Mounting Kits.................................................................................. 1-13

1-9. Speed Control Orifices .......................................................................................................... 1-13

1-10. Pressure Gages..................................................................................................................... 1-13

1-11. Supply Air Regulators with Gages......................................................................................... 1-13

List of Tables (continued)

No. Title Page

1-12. Supply Air Filters....................................................................................................................1-14

1-13. Component Material List ........................................................................................................1-14

3-1. Cam Characteristics.................................................................................................................3-7

4-1. Gain Hinge Springs..................................................................................................................4-5

6-1. Positioner Errors.......................................................................................................................6-1

7-1. Preventive Maintenance Schedule...........................................................................................7-1

9-1. Shutoff Valve Kit No. 258270_1...............................................................................................9-1

9-2. AV Diaphragm Assembly Kit No. 258486_1.............................................................................9-1

9-3. AV Diaphragm Assembly Kit No. 258486_ 2 ............................................................................9-2

9-4. Filter Replacement Kit No. 258487_1 ......................................................................................9-2

9-5. Pilot Valve Assembly Kit No. 258488_1...................................................................................9-2

9-6. Pilot Valve Assembly Kit No. 258488_ 2...................................................................................9-2

9-7. Pilot Valve Assembly Kit No. 258488_3...................................................................................9-2

9-8. Pilot Valve Assembly Kit No. 258488 _4...................................................................................9-3

9-9. Cam..........................................................................................................................................9-3

9-10. I/P Assembly Kit No. 258477_1................................................................................................9-3

9-11. Gain Hinge Springs..................................................................................................................9-3

9-12. Manifold Assembly Kit No. 258491_1 ......................................................................................9-3

9-13. Cam Follower Arm Kit No. 258544 _1 ......................................................................................9-4

9-14. Cover Assembly Kit No. 258545_1 ..........................................................................................9-4

9-15. Cover Assembly Kit No. 258545_1 ..........................................................................................9-4

9-16. Gage Block Assembly Kit No. 258569 _1.................................................................................9-4

9-17. Gage Block Assembly Kit No. 258569_3 .................................................................................9-4

9-18. Potentiometer...........................................................................................................................9-4

9-19. 4 to 20-mA Position Transmitter Circuit Board.........................................................................9-5

9-20. Positioner Mounting Kit Number 5327321_121........................................................................9-5

9-21. Positioner Mounting Kit Number 5327321_131........................................................................9-5

9-22. Positioner Mounting Kit Number 5327321_141 (for use on Fisher Actuators).........................9-6

9-23. Rotary Actuator Retrofit Mounting Kits.....................................................................................9-7

9-24. Bypass Valve Assembly (Optional)..........................................................................................9-7

9-25. Type AV1 Positioner Parts List.................................................................................................9-9

9-26. Input Signal Parts Reference for Type AV1 Positioners.........................................................9-10

9-27. Cam Selection and Manifold/Gage Block Parts Reference

for Type AV1 Positioners........................................................................................................9-10

9-28. Shaft Position Transmitter Parts Reference for Type AV1 Positioners..................................9-12

9-29. Drive Shaft Parts Reference for Type AV1 Positioners..........................................................9-12

9-30. Type AV2 Positioner Parts List ..............................................................................................9-12

9-31. Cam and Drive Shaft Parts Reference for Type AV2 Positioners..........................................9-13

9-32. Manifold/Gage Block Parts Reference for Type AV2 Positioners ..........................................9-15

9-33. Shaft Position Transmitter Parts Reference for Type AV2 Positioners..................................9-15

9-34. Conversion Kits......................................................................................................................9-17

A-1. Potentiometric Position Transmitter Parts List ........................................................................ A-5

A-2. 4 to 20-mA Position Transmitter Parts List.............................................................................. A-7

B-1. Nomenclature..........................................................................................................................B-1

B-2. Calibration Procedures..........................................................................................................B-11

C-1. Control Signal Pressure Conversions (AV1)...........................................................................C-3

C-2. Input to Output I/P Converter Relationships (AV2)..................................................................C-3

D-1. Pneumatic Position Transmitter Kit (258492_1)......................................................................D-2

Read First

Do not install, maintain or operate this equipment without reading,

understanding and following the proper factory-supplied instructions and

All equipment being returned to the factory for repair must be free of any hazardous materials (acids, alkalis, solvents, etc.). A Material Safety Data

Sheet (MSDS) for all process liquids must accompany returned equipment.

Contact the factory for authorization prior to returning equipment.

WARNING

INSTRUCTION MANUALS

manuals, otherwise injury or damage may result.

RETURN OF EQUIPMENT

Read these instructions before starting installation;

save these instructions for future reference.

Contacting the Factory . . .

Should assistance be required with any of the company’s products, contact the following:

Telephone:

24-Hour Call Center

1-800-HELP-365

E-Mail:

ins.techsupport@us.abb.com

Read First I

Read First II

OVERVIEW

SECTION 1 - INTRODUCTION

This section covers the following topics:

• Positioner description.

• Positioner application.

• Features of positioners.

• Instruction content.

• How to use this instruction.

• Positioner nomenclature.

• Positioner specifications.

• Position transmitter specifications.

• Agency approvals.

• Accessories.

• Mounting kits.

NOTE: Appendix B provides a quick start guide for the Type

AV positioner. It is intended for control engineers having experience in the use and application of pneumatic positioners. The quick start guide highlights the major points of installation and calibration. Detailed installation and calibration information is contained in Section 3 and Section 4 respectively.

INTENDED USER

DESCRIPTION

The information in this instruction is a guide for technical personnel responsible for installation, calibration, operation, maintenance and repair of the positioner.

The Type AV1 and Type AV2 positioners are control devices that satisfy a wide range of applications. They provide fast, sensitive and accurate positioning of pneumatic single or double acting actuators.

The Type AV1 positioner receives an external pneumatic signal and converts it to a pneumatic output. The Type AV2 positioner accepts a four to 20-milliamp current that is applied to an I/P (current to pneumatic) converter, located inside the housing, to generate an internal signal pressure.

If a loss of signal occurs, the Type AV2 positioner goes to the four-milliamp position. The Type AV1 positioner goes to the 3 psi position.

OVERVIEW

1 - 1

INTRODUCTION

A mechanical connection from the actuator (i.e., cylinder, valve, etc.) to the position feedback cam in the positioner establishes actual position. Three characterized segments on the cam provide application flexibility by establishing various relationships between the input signal and the actuator position. The characterized curves on the cam provide:

• Square root relationship.

• Linear relationship.

• Square characteristic.

Using the zero, span and gain adjustments and the cam, the actuator can respond with characteristics specific to an application.

An optional manifold assembly provides an integral shutoff and equalizing valve that can be used to isolate the positioner from an actuator, allowing manual override without removing the positioner from the process (required on double acting actuators with manual override). The manifold also provides gage ports and disposable filter cartridges that insure fast servicing and minimum downtime.

An optional gage block provides gage ports for mounting pressure gages. There are three gage ports on the block: One for instrument indication (internal input signal) and two for output indication. The gage block does not provide filters or means of isolating the positioner from the actuator. Installation of a supply gage is possible in the supply line (piping by customer).

Both positioners can be equipped with either an optional potentiometric or a four to 20-milliamp position transmitter that provides additional control features.

Performance Series Option

The Type AV positioner performance series provides a high flow gain pilot valve body by adding a P in the ninth nomenclature position. This high gain pilot valve body has square ports that provide a maximized air flow for a small motion of the pilot valve stem. A relatively small error signal can therefore cause a relatively large change in output air flow to the actuator. This feature is useful when driving larger actuators that might otherwise be insensitive or slow to respond to small signal changes.

Compared to other positioners on the market, the standard Type AV positioners have a high delivery capacity. The performance series increases this delivery capacity even more. The flow gain curves shown in Figures 1-3 and 1-4 show output air flow versus input error signal for the standard and high gain performance series positioners.

DESCRIPTION 1 - 2

Explosionproof I/P Option

INTRODUCTION

Figures 1-3 and 1-4 show that the large signal maximum air flow for both the standard and performance series positioners is about the same. The performance series positioners achieve maximum flow capacity at a much smaller error signal.

NOTE: ABB does not recommend using a performance series positioner on a small actuator, as it could cause instability.

The Type AV27 positioner employs an explosionproof I/P converter that is mounted to an adapter block manifold. The adapter block manifold is bolted to the outside of the main positioner housing. The unit is a Type AV12 positioner with the electric to pneumatic (four to 20-milliamp to 20.7 to 103.4-kilopascal (3.0 to

15.0-pounds per square inch gage)) conversion occurring within the externally mounted I/P converter.

The four to 20-milliamp input signal wires shall be connected through an explosionproof conduit entrance on the I/P converter. If no electrical connections are made within the main housing, the entire positioner can be considered suitable for application in the hazardous locations shown on the I/P label.

NEMA 4X Option

APPLICATION

FEATURES

Refer to Figure 3-1 for the external and mounting dimensions of the Type A V27 positioner.

The Type A V To maintain the NEMA 4X classification, the positioner shall be installed per drawing C258567 and suitable piping shall be attached to the vent opening and vented in a manner to preclude the entrance of water under pressure, as from a hose. Additionally, the conduit connections shall be suitable for a NEMA 4X rating.

The Type A V1 and Type A V2 Characterizable Pneumatic Positioners control the position of a pneumatic actuator.

• Trouble-Free Operation. Proven pilot valve that is quickly

removable, provides less downtime, lower maintenance costs, increased reliability and extended performance.

______N positioner comes with a NEMA 4X housing.

• Compact Rugged Design. Die cast aluminum housing,

beam, spring arm, follower arm and 303 stainless steel pilot

APPLICATION

1 - 3

INTRODUCTION

valve provide long life and maximum environmental protection. The compact housing increases mounting flexibility.

• Characterizable Output. Large positioning cam can be

shaped to provide desired relationship between the input signal and the actuator position.

• Accurate Calibration. Independent zero and span adjust-

ments eliminate interaction and provide fast and accurate calibration.

• Simplified Reverse Operation. Action can be changed in the

field by changing cams and reversing 01 and 02 connections. The reverse acting cam is conveniently located on the inside of the front cover.

• Highly Visible Position Status Indicator. A fluorescent

orange position indicator is visible through a polycarbonate window, providing fast indication of actuator position.

• Vent Design Allows Natural Gas Operation. Vent pipe

arrangement permits operation using natural gas.

• Split Range Service. Split range capability allows sequencing

of multiple actuators using a single control signal.

• Adjustable Gain. Two levels of gain are possible by changing

the hinge springs supplied with the positioner.

• Adaptable Usage. The positioner can control both single and

double acting, linear and rotary type actuators.

• High Capacity. More than 0.65 cubic meters per minute (23

standard cubic feet per minute) can be supplied or exhausted at 482.6 kilopascals (70.0 pounds per square inch gage) supply pressure (Fig. 1-1).

• Continuously Adjustable Span and Zero for Each Stroke

Level. Capable of 100-percent stroke for 50-percent signal span or 50-percent stroke for 100-percent signal span.

• Low Air Consumption. Enhanced pilot valve design and

manufacturing technique allows the Type AV positioner maximum performance with minimum air consumption (Fig. 1-2).

• Adjustable Speed Control without Additional Hardware.

Speed of actuator can be reduced to desired speed using the pilot valve stroke adjustment screws.

FEATURES 1 - 4

INSTRUCTION CONTENT

INTRODUCTION

This instruction includes the following sections:

Introduction

Description and

Operation

Installation

Calibration

Operating Procedures

Troubleshooting

Maintenance

Provides a description of this instruction; its sections and uses, along with a brief description of the Type AV1 and Type AV2 positioners. This section also provides reference documents (Table

1-2), product nomenclature (Table 1-2), specifications (Tables 1-3, 1-4 and 1-5), agency approvals (Table 1-6) and positioner acces-

sories (Table 1-7). Table 1-8 lists retrofit mounting kits, Table 1-9 lists available speed control orifices, and Table 1-10 lists the available pressure gages. Table 1-11 lists pressure regulators, Table

1-12 lists supply air filters available from ABB and Table 1-13 lists

the materials used in the positioner components. Describes the functional operation of the positioners.

Provides information about installing a Type AV positioner. Provides calibration and adjustment procedures. Presents information and procedures for various applications. Provides a table containing errors, causes and corrective action. Includes preventive maintenance information and procedures.

Repair and

Replacement

Support Services

Appendix A

Appendix B

Appendix C

Appendix D

Procedures in this section give step-by-step instructions for removing and replacing components.

Provides recommended spare and replacement parts lists. Illustrations of both positioners provide part numbers for all major components.

Provides calibration information about the four to 20-milliamp position transmitter and the potentiometric position transmitter.

Quick start section for control engineers that are knowledgeable about positioners and the overall process in which the positioner is to be used.

Details cam shaping information. Covers the pneumatic position transmitter option. HOW TO USE THIS INSTRUCTION For safety reasons, read and completely understand this instruc-

tion before completing any tasks or procedures associated with installation, calibration, operation, maintenance or repair.

INSTRUCTION CONTENT

1 - 5

INTRODUCTION

The section arrangement of this instruction is sequential. After initial start-up and calibration, store this instruction in a safe place for future reference.

REFERENCE DOCUMENTS

Table 1-1. Reference Documents

Number Title

ANSI/NFPA 70 National Electrical Code CEC Canadian Electrical Code D-AAP-UP Universal Pneumatic Rotary Actuator, Type UP (specification) D-APE-AV1234 Characterizable Positioners, Type AV1, AV2, AV3 & AV4 (specification) CSA c22.1 Process Control Equipment I-E96-500 Site Planning and Preparation I-P81-20 Universal Pneumatic Rotary Actuator, Type UP (instruction) ANSI/ISA-7.0.01-1996 Quality Standards for Instrument Air ISA S75.13-1989 Method of Evaluating the Performance of Positioners with Analog Input Signals and

Pneumatic Output (Instrument Society of America)

P-P88-001 Product Application Guide, Installing a Type AV Positioner in a Hazardous Location

NOMENCLATURE

Position 1 23456789

Type A V

_______

1 2

1 20.7 to 103.4 kPa (3.0 to 15.0 psig) (Type AV1) 2 20.7 to 186.2 kPa (3.0 to 27.0 psig) (Type AV1) 3 4 to 20 mA (standard intrinsically safe Type AV2) 5 20.7 to 103.4 kPa (3.0 to 15.0 psig), high temperature applications

6 20.7 to 186.2 kPa (3.0 to 27.0 psig), high temperature applications

7 4 to 20 mA with explosionproof I/P converter (NEMA 7) (Type AV2)

1 12.7 to 50.8 mm (0.5 to 2.0 in.) or 45° rotary motion 2 25.4 to 101.6 mm (1.0 to 4.0 in.) or 90° rotary motion

Table 1-2. Nomenclature

Characterizable Positioners

Characterizable Pneumatic Positioner Characterizable 4 to 20-mA Input Positioner (actuator moves to 0%

or 100% upon loss of signal)

Input Signal

(Type AV1)

Stroke/Rotary Motion (cam selection)

REFERENCE DOCUMENTS 1 - 6

Position 1 23456789

Type A V

_______

INTRODUCTION

Table 1-2. Nomenclature (continued)

Characterizable Positioners

0 No manifold 1 Manifold with equalizing valve, filters and gage ports (required for dou-

2 Manifold with equalizing valve inoperable (includes filters and gage

3 Gage block (gage port only)

0 None (must be 0 for Types AV15, AV16 and AV27) 1 Potentiometric resistive output 2 4 to 20-mA output

0 Standard with feedback arm for linear motion 1 0.500-in. square end 2 0.342-in. square end for older DeZurik actuators 3 0.250 in. across flats (UP1 and UP2 after August, 1995) 4 0.375 in. square for DeZurik PowerRac 5 0.156 in. across flats for NAMUR rotary actuators

NOTES:

1. High temperature Type AV1 positioners are only available without manifolds or position transmitters; however, gage blocks are permitted.

2. Explosionproof Type AV2 positioners are not available with position transmitters or manifolds

3. No longer available as of October 2003..

Manifold (includes filters)/Gage Block

ble acting actuators with manual override)

ports)

Position Transmitter

Drive Shaft

actuators

Other Options

0 Standard (no other options) N NEMA 4X enclosure rating (when installed per drawing C258567) P Performance Series — high pneumatic gain for large actuators

SPECIFICATIONS

Table 1-3 provides performance specifications of the Type AV1 and Type AV2 positioners. Tables 1-4 and 1-5 provide performance specifications for the position transmitters.

Table 1-3. Type AV1/2 Positioner Specifications1

Property Characteristic/Value

Input range

AV11 and AV15 20.7 to 103.4 kPa (3.0 to 15.0 psig) AV12 and AV16 20.7 to 186.2 kPa (3.0 to 27.0 psig) AV23 and AV27 4 to 20 mA

Input impedance (Type AV2 only)

Nominal 215  at 22°C (72°F) Maximum 245 at 60°C (140°F)

SPECIFICATIONS

1 - 7

INTRODUCTION



Table 1-3. Type AV1/2 Positioner Specifications1 (continued)

Property Characteristic/Value

Standard stroke range (cam selection)

AV__1____ 12.7 to 50.8 mm (0.5 to 2.0 in.) linear, rotary input 45° AV__2____ 25.4 to 101.6 mm (1.0 to 4.0 in.) linear, rotary input 90°

Gain 2 adjustment levels by changing gain hinge spring. Refer to the flow

gain curves as shown in Figures 1-3 and 1-4 for standard and high gain units.

Accuracy

Resolution

Hysteresis

Repeatability

Deadband

Linearity Supply pressure 172 to 1034 kPa (25 to 150 psig)

Supply pressure effect 0.05% per 6.9 kPa for ±69 kPa change

Capacity (maximum capacity exhausting to atmosphere)

Air consumption Refer to Figure 1-2. Vibration effect

Pneumatic connections ¼-NPT on supply, signal and output connections

Materials of construction

Enclosure classification

AV1 0.80% of span maximum AV2 0.90% of span maximum

AV1 0.09% of span maximum AV2 0.30% of span maximum

AV1 0.45% of span maximum AV2 0.70% of span maximum

AV1 0.12% of span maximum AV2 0.50% of span maximum

AV1 0.12% of span maximum AV2 0.30% of span maximum

0.70% of span maximum

NOTE: Minimum supply pressure should be 34.4 kPa (5.0 psig) above operating pressure required by actuator.

(0.05% per 1.0 psi for ±10 psig change) Refer to Figure 1-1.

Enclosure Aluminum and <0.5% magnesium Pilot valve 303 stainless steel

Standard NEMA 3R classification when vent hole is protected from rain using

AV______N NEMA 4X when installed per drawing C258567.

<2.0% error for: 5 to 15 Hz at peak-to-peak constant displacement of 4 mm (0.16 in.) 15 to 120 Hz at accelerations to 2 Gs

-NPT on pressure gages

rain elbow (½-NPT street elbow, refer to Figure 3-1).

SPECIFICATIONS 1 - 8

INTRODUCTION

Table 1-3. Type AV1/2 Positioner Specifications1 (continued)

Property Characteristic/Value

Weight

AV1 1.84 kg (4.06 lbs) AV2 (standard) 2.32 kg (5.11 lbs) AV2 (explosionproof) 2.95 kg (6.51 lbs)

Temperature limits

Operating

AV11/2 -40°C to 82°C (-40°F to 180°F) AV15/6 -20°C to 127°C (-4°F to 250°F) AV2 -20°C to 82°C (-4°F to 180°F)

Storage

AV11/2 -40°C to 93°C (-40°F to 200°F) AV15/6 -20°C to 127°C (-4°F to 250°F) AV2 -20°C to 82°C (-4°F to 180°F)

Humidity limits

Operating 0% to 95% noncondensing Storage 0% to 95% noncondensing

NOTES:

1. Performance testing performed on a ABB Type UP10 actuator.

2. Tested according to ISA-S75.13-1989

3. For operation below 4.4°C (40°F), dew point of the supply air must be 10°C (18°F) lower than the lowest expected operating temperature.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

3 3

Figure 1-1. Capacity (Exhaust to Atmosphere)

SPECIFICATIONS

1 - 9

INTRODUCTION

Figure 1-2. Air Consumption

Figure 1-3. Output Air Flow vs. Error Signal — Standard and Performance Series

SPECIFICATIONS 1 - 10

INTRODUCTION

Figure 1-4. Expanded First Quadrant View of Figure 1-3

Table 1-4. Type AV ____1__ Potentiometric Position Transmitter Specifications

Property Characteristic/Value

Total resistance 2000  Power rating 1 W up to 70°C (158°F), 0 W at or above 125°C (257°F) Wiper rate of change 9.9  nominal per degree of cam rotation Temperature effect 0.05% (500 ppm) per °C (0.03% (278 ppm) per °F) maximum Maximum voltage 35 VDC or 30 VAC across the potentiometer ends Temperature limits

Operating -40°C to 82°C (-40°F to 180°F) Storage -40°C to 93°C (-40°F to 200°F)

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

Table 1-5. Type AV____2 __ 4 to 20-mA Position Transmitter Specifications

Property Characteristic/Value

Supply voltage 16 to 34 VDC Output signal 4 to 20 mA Output loading 500  at 24 VDC, 1000  at 34 VDC Accuracy <0.6% of span (maximum) Hysteresis <0.5% of span (maximum) Ambient temperature effect <0.063% per °C (<0.035% per °F) EMI/RFI effect <1.5% maximum at 10 V/m field strength, 20 to 450 MHz Temperature limits

Operating -40°C to 82°C (-40F° to 180°F) Storage -40°C to 93°C (-40F° to 200°F)

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

SPECIFICATIONS

1 - 11

INTRODUCTION

Table 1-6. Agency Approvals1

Nomenclature Approval/Certification

AV1 and AV23 Factory Mutual Research (FM):

Approved as nonincendive for:

Class I, Division 2, Groups A, B, C and D Class II, Division 2, Groups F and G Class III, Division 2

Approved as intrinsically safe for:

Class I, Division 1, Groups A, B, C and D Class II, Division 1, Groups E, F and G Class III, Division 1

AV27__0__ Factory Mutual Research (FM):

Canadian Standards Association (CSA): Certified as:

Class 1, Division 2, Groups A, B, C and D Class II, Division 2, Groups E, F and G Class III, Division 2

Certified as intrinsically safe for: Class I, Division 1, Groups A, B, C and D Class II, Division 1, Groups E, F and G Class III, Division 1

Canadian Standards Association (CSA):

Approved as explosionproof for:

Classes I, II; Division 1, Groups B, C, D, E, F and G

All This product complies with all applicable European Community product require-

ments, and specifically with those required to display the CE marking on the product nameplate.

NOTES:

1. Hazardous locations approvals for use in flammable atmospheres are for ambient conditions of -25°C to 40°C (-13°F to 104°F), 86 to 106 kPa (12.5 to 15.7 psig) with a maximum oxygen concentration of 21%.

2. For installing the positioner in a hazardous location, refer to Product Application Guide, Installing a Type AV Positioner in a Hazard- ous Location.

Certified as explosionproof for: Classes I, II; Division 1, Groups B, C, D, E, F and G

Table 1-7. Accessories1

Accessory Description

Mounting kits Dependent on valve stem size (Figure 9-1, kit number 5327321__). For ABB retrofit

kits, refer to Table 1-8.

Speed control orifices

Pressure gages For reading signal, supply and output pressures (refer to Table 1-10). Blank cam Used to characterize the positioner if the standard cams (square, linear, square root)

Supply air regulator Refer to Table 1-11. Pneumatic position

transmitter Air filters ABB recommends installing an air filter in the supply air line to prevent particles from

Manifold Filters For addition or replacement of secondary air filters on manifold-equipped positioners.

Bypass valve assembly

NOTE:

1. For recommended spare parts and additional spare parts, refer to Section 9.

Regulate time constant of positioner and final control device. Orifices are installed directly into positioner output ports (refer to Table 1-9). Speed adjustment can also be controlled by using the internal stroke adjustment screws (refer to PILOT VALVE

STROKE ADJUSTMENT in Section 4).

will not produce the desired relationship. Blank cam must be profiled (part number 5400277_1.

Refer to Appendix D (Type AV1__0___ positioner only).

entering the positioner that can lead to malfunctions. Refer to Table 1-12 for filter part numbers.

Kit number 258487 _1. Part number 5326945_1. Refer to Table 9-24 and Figure 9-2.

SPECIFICATIONS 1 - 12

INTRODUCTION

Table 1-8. Rotary Actuator Retrofit Mounting Kits

Kit Number Drive Nomenclature Retrofit Mounting Kit

5400309_1 UP1, UP2 Type AP positioner to 258493_1 UP3, UP4 258494_1 UP5, UP6 258527_1 AC0404 258528 _1 AC0608 258529 _1 AC0816 258530 _2 AC1016 258527_1 AC0404 ABB part number pilot 258528_1 AC0608 258529 _1 AC0816 258530_1 AC1016

Type AV positioner

valve positioner to Type AV positioner

Table 1-9. Speed Control Orifices

Part Number

5327327 _1 1.02 0.04 5327327_2 Blank (drill to suit) Blank (drill to suit)

NOTE:

1. Speed control can also be obtained by internal positioner adjustment. Refer to PILOT VALVE

STROKE ADJUSTMENT in Section 4.

mm in.

Size

Table 1-10. Pressure Gages

Part Number Legend

5326605 _4 Instrument 0 to 200 0 to 30 5326605 _5 Supply 5326605_6 Output 0 to 1,000 0 to 160

NOTE:

1. The optional manifold provides gage ports, one for instrument (internal input signal), and two output gages. A supply gage can be installed in the supply line (piping by customer).

kPa psig

0 to 1,000 0 to 160

Range

Table 1-11. Supply Air Regulators with Gages

Part Number

1951029 _5 125 250 ¼ NPT

Max. Outlet

Pressure (psig)

Max. Inlet

Pressure (psig)

Inlet/Outlet

Connections

Table 1-12. Supply Air Filters

Max. Inlet

Part Number

5328563 _2 250 121.0 125.0 ¼ NPT

NOTE:

1. In-line coalescing filter for removal of solid and liquid contaminants in compressed air. Filter comes with universal mounting bracket and grade 6 filter that is 99.97% efficient at 0.3 micron. Part number 5328563 _2 has a zinc bowl.

Pressure

(psig)

Max. Temperature Inlet/Outlet

°C °F

Connection

Size

SPECIFICATIONS

1 - 13

INTRODUCTION

Table 1-13. Component Material List

Component Material

Housing Aluminum Cover Aluminum

Inserts Lamond (thermoplastic elstomer)

Window Lexan

Screws Stainless steel Range spring 302 stainless steel Pilot valve (stem and body) 303 stainless steel Gain hinge spring 302 stainless steel Cam 302 stainless steel Cam shaft 303 stainless steel

Bearings Bronze Cam follower arm Aluminum

Bearing Stainless steel

Shaft 303 stainless steel Spring arm Aluminum Zero adjustment nut Aluminum Indicator Valox

terphthalate) Tubing Silicone Drive arm Aluminum

washers Teflon

Teflon Fasteners Steel/stainless steel Signal connector Nylon Diaphragms

All except Types AV15 and AV16 Buna-N with Dacron fabric Types AV15 and AV16 Fluorosilicone with Dacron fabric

Diaphragm plastic parts Rynite

Gage block (optional) Aluminum O-rings

All except Types AV15 and AV16 Buna-N Types AV15 and AV16 Viton

Manifold (optional) Aluminum

Adhesive Epoxy Handle Rynite Plate Aluminum Plug Stainless steel Valve Aluminum Valve handle Rynite

phthalate

(polycarbonate)

— unreinforced (polybutylene

(FR-530) polyethylene ter-

SPECIFICATIONS 1 - 14

Table 1-13. Component Material List

Component Material

Position transmitter (optional) (AV____1/2 __)

Gears Delrin Gear hub Brass

Additional Type AV2 components

Regulator Regulator bracket Tubing Nylon I/P converter Copper

Polysulfone 304 stainless steel

Copper clad glass laminate Monel Nickel-iron Noryl Polyethylene Polyester magnet wire Rare earth magnet Zinc

INTRODUCTION

(coolymer acetal)

405

(phenylene ether/phenylene)

NOTE:

1. Regulator not applicable for AV2s after July, 2001.

SPECIFICATIONS

1 - 15

INTRODUCTION

SECTION 2 - DESCRIPTION AND OPERATION

This section describes and explains the functional and physical operation of Type AV1 and AV2 positioners. Figure 2-1 diagrams the operating principles of the positioners. Figure 2-2 shows the placement of a positioner in a typical control system.

Figure 2-1. Operation Diagram

Figure 2-2. Block Diagram

INTRODUCTION

2 - 1

DESCRIPTION AND OPERATION

FUNCTIONAL OPERATION

Type AV positioners operate by balancing opposing forces. Figure

2-1 shows a diagram of the Type AV positioner. A balance beam,

hinged at one end and connected to the pilot valve at the other, is acted upon by two forces:

• Upward force of the signal diaphragm assembly.

• Downward force from the range spring.

The input signal pressure determines the diaphragm force. The Type AV1 positioner uses an external input pressure (either 20.7 to 103.4 kilopascals (3.0 to 15.0 pounds per square inch gage) or

20.7 to 186.2 kilopascals (3.0 to 27.0 pounds per square inch gage)). The Type AV2 positioner uses a current to pneumatic converter to generate the input signal pressure.

The range spring force is a function of the shape and position of the cam. The cam is coupled to the cam shaft that is connected through linkage (or coupling) to the actuator. Therefore, range spring tension is a function of the actuator position.

A change in input signal changes the force exerted by the signal diaphragm, moving the balance beam, in turn moving the pilot valve. The pilot valve supplies and/or exhausts air to the actuator that ultimately changes its position. The change in actuator position is fed back to the positioning cam. The positioning cam moves, changing the tension of the range spring until a balanced condition once again exists.

The positioner is normally located in a control loop (Fig. 2-2) between the controller and the actuator.

Actuator position is fed back to the positioner for comparison with the position commanded by the input control signal (direct signal pressure or a current value). For linear motion actuators, the feedback mechanism consists of:

• A drive rod that follows the motion of the actuator.

• An adjustable-length, swivel-ended connecting link that trans-

mits the motion of the drive rod to an adjustable drive arm on the positioner.

• A camshaft and cam that are rotated through an angle by the

drive arm. A function of the cam is to permit characterization of actuator position versus input signal.

FUNCTIONAL OPERATION 2 - 2

INTRODUCTION

SECTION 3 - INSTALLATION

Several applications are possible using a Type AV positioner. The steps for installing a Type AV positioner are in sequence in this section. After installation is complete, refer to Section 4 for calibration information.

• Unpack and inspect the equipment.

• Mount the positioner.

• Connect tubing to the positioner.

• Connect wiring to the positioner.

NOTES:

1. For application in a hazardous location, refer to ABB Product Application Guide, Installing a Type AV Positioner in a Hazardous Location.

2. Appendix B provides a quick start guide for the Type AV positioner. It is intended for control engineers having extensive experience in the use and application of pneumatic positioners. The quick start guide highlights the major points of installation and calibration. Detailed installation and calibration information is contained in this section and in Section 4.

Select an installation method that provides a fail safe mode upon loss of controller signal. Certain installation methods

WARNING

UNP ACKING AND INSPECTION

do not stroke the equipment to a fail safe condition upon loss of controller signal. Failure to select a fail safe installation method could cause injury to personnel and damage to equipment.

1. Check for obvious damage to the shipping carton.

2. Open the carton and remove all loose packing.

3. Carefully remove the positioner from the carton and inspect for any physical damage that may have occurred during shipping.

4. Remove the two cover screws and the positioner cover and examine the interior for any loose components such as nuts, screws, springs, etc. Check the data on the nameplate to be certain the positioner type ordered for the application was received.

INTRODUCTION

3 - 1

INSTALLATION

5. If the positioner is suitable for the application and appears undamaged, install the cover and proceed with the installation instructions.

6. If storing the positioner prior to installation, leave it in the original carton, if possible. Store in an area free from corrosive vapors and extremes in temperature and humidity.

7. Do not store the positioner in an area that would take it out of the specifications listed in Tables 1-3, 1-4 and 1-5.

ENCLOSURE CLASSIFICATION

The standard enclosure for the Type AV1 and Type AV2 positioners conform to NEMA 3R when a ½-14 NPT street elbow (Fig. 3-1) is installed into the vent hole on the housing. The elbow prevents water or other liquid from entering the enclosure. The position of the elbow is related to the mounting plane of the positioner in its service location. The elbow must be positioned to face downward. The NEMA 3R version meets the extended corrosion resistance requirements of NEMA 250.

A NEMA 4X version is available as an option (Type AV______N positioners). To maintain the NEMA 4X classification, the positioner shall be installed per drawing C258567 and suitable piping shall be attached to the vent opening and vented in a manner to preclude the entrance of water under pressure, as from a hose. Additionally, the conduit connections shall be suitable for a NEMA 4X rating.

MOUNTING CONSIDERATIONS

Choose a location for the positioner based on the following factors:

• Access to the internal positioner adjustments — the mounting

location should provide enough room to remove the cover in order to perform calibration and repair and replacement procedures inside the positioner. Refer to Figure 3-1 for positioner dimensions. Figure 3-2 shows the electrical connections, Figure 3-3 shows the dimensions of the drive arm connections and Figure 3-4 shows the drive shaft variations.

• Allow room for linkage to the actuator — the mounting position

should be such that a practical linkage arrangement can be made between the positioner and the actuator for full range travel.

ENCLOSURE CLASSIFICATION 3 - 2

INSTALLATION

Figure 3-1. External and Mounting Dimensions

MOUNTING CONSIDERATIONS

3 - 3

INSTALLATION

Figure 3-2. Electrical Connections

NOTE: For Type AV27, the 4-20 mA input signal wires shall be connected through an explosion-proof conduit entrance directly to the I/P converter.

MOUNTING TYPE AV POSITIONERS

The Type AV positioner can be used with double acting or single acting actuators. Mounting and external dimensions are shown in Figure 3-1. Figure 3-5 shows a typical mounting arrangement using a ABB mounting kit. Refer to Figure 9-23 for an exploded view and complete parts list of

Figure 3-3. Drive Arm Connections

MOUNTING TYPE AV POSITIONERS 3 - 4

INSTALLATION

the kit. If using the positioner with a rotary actuator, the positioner can be directly connected to the actuator, as shown in Figure 3-6.

NOTE: If the actuator is equipped with a Type AV positioner as ordered, verify that all the connections are secure and make any adjustments as required.

Figure 3-4. Drive Shaft Variations

Figure 3-5. Mounting Using Linkage (Typical)

MOUNTING TYPE AV POSITIONERS

3 - 5

INSTALLATION

WARNING

Figure 3-6. Mounting Using Direct Coupling (Typical)

Due to the wide range of applications that the Type AV positioner is suited for, we can only provide general information about mounting. Use the following procedure to mount the positioner.

Before mounting or installing positioner, check nameplate data to make certain positioner is suitable for application desired. DO NOT AT ANY TIME EXCEED THE RATINGS LISTED ON THE NAMEPLATE.

1. Set the actuator at the zero position. Connect the adjustable linkage to the drive arm. The drive arm holes correspond to stroke length of the actuator. Refer to Figure 3-3 for the stroke length for each drive arm hole.

2. Install the cam (black, direct acting; or red, reverse acting) that will provide the required direction of rotation.

A direct acting (black) positioning cam with segments A, B and C (Fig. 3-7) and a reverse acting cam are furnished with each positioner. The reverse acting cam has red radial lines and arcs and is stored on the inside of the positioner cover. Cam A is for a square root function, cam B is for linear motion and cam C is for a

MOUNTING TYPE AV POSITIONERS 3 - 6

INSTALLATION

square function (Table 3-1). Cam B is in place when the positioner is shipped from the factory. The cams may be shaped to conform to special applications. Refer to Appendix C for information about cam shaping.

NOTE: If the application is reverse acting, the reverse acting cam (red radial lines) must be installed and the connections to ports 01 and 02 must be reversed.

Figure 3-7. Cam

Table 3-1. Cam Characteristics

Positioning

Cam

Any Stroke

A B C

The cam, camshaft and drive arm rotate as an assembly. Cam motion is 90 degrees (Type AV__2____) or 45 degrees (Type AV__1____) depending on the positioner type specified by nomenclature (Figure 3-7).

Each cam shape (A, B or C) has its own eight-point center hole for mounting on the camshaft (Fig. 3-7). Place the cam in one of the eight 45-degree positions so that the midpoint of the cam corresponds to the mid stroke of the actuator. The drive arm should be perpendicular to the motion of the actuator with the actuator at mid stroke.

3. Adjust the connecting linkage so that the zero radial line on the cam intersects the center of the cam roller when the actuator is at its zero position (Fig. 3-8).

Piston or Valve Position (P)

Control Signal (I)

Square root Linear Square

IP=

=

Figure

Number

C-1 C-2 C-3

MOUNTING TYPE AV POSITIONERS

3 - 7

INSTALLATION

4. Lock all linkage components in place.

TUBING CONNECTIONS

Air Supply Pressure

CAUTION

Air Supply Filtering

Figure 3-8. Cam Roller Alignment

Type AV positioners are available with (Type AV___1___ and A V___2___) or without (AV___0 ___) manifolds. The following outlines supply air information and describes the piping connections.

Do not exceed the maximum supply pressure of 1034 kilopascals (150 pounds per square inch gage). Exceeding this pressure could cause equipment damage.

The air supply pressure range is 172 to1034 kilopascals (25 to 150 pounds per square inch gage).

NOTE: The minimum supply pressure should be 34.4 kilopascals (5 pounds per square inch gage) above the operating pressure required by the actuator.

An external filter is recommended for Type AV positioners for primary filtration of the supply air. ABB provides supply air filters as accessories. Refer to Table 1-12 for part numbers.

NOTE: Primary air supply filters are recommended for positioners with a manifold (AV___1/2___), without a manifold (AV___0___) or with a gage block (AV___3___).

TUBING CONNECTIONS 3 - 8

Positioners equipped with manifolds have three secondary filters as part of the unit. If the filters become clogged, they can be cleaned (by removing and reverse flushing with air or liquid) or replaced (refer to Table 1-7 for kit number). Refer to Section 7 for manifold filter replacement procedures.

Air Supply Quality (Recommended)

For long-term, trouble free operation, it is recommended that the supply air be of instrument quality and conform to the ANSI/ ISA-7.0.01-1996 standard that includes the following:

INSTALLATION

Tubing Connections

• The pressure dew point as measured at the dryer outlet shall

be at least 10 which any part of the instrument air system is exposed. The pressure dew point shall not exceed 4 sure.

• The oil content should be as close to zero as possible and,

under no circumstances, shall it exceed one (1) ppm w/w or v/v.

• Instrument air should be free of corrosive contaminants and

hazardous gases, which could be drawn into the instrument air supply.

In addition, the particle size in the supply line should not be greater that 3.0 microns.

C (18oF) below the minimum temperature to

C (39oF) at line pres-

1. Connect the required air supply to connection S (Fig. 3-9).

NOTE: Use liquid or paste pipe sealant to seal the connection. Maximum torque for ¼-NPT fittings is 13.6 Nm (10 ft-lbs).

Figure 3-9. Port Locations

TUBING CONNECTIONS

3 - 9

INSTALLATION

2. Based on the positioner type, perform one of the following steps (Fig. 3-9):

AV11 or AV15: Connect 20.7 to 103.4-kPa (3.0 to 15.0-psig) instrument signal to connection I.

AV12 or AV16: Connect 20.7 to 186.2-kPa (3.0 to 27.0-psig) instrument signal to connection I.

AV2: Connection I is not used and should be plugged. If it is not plugged, do so at this time.

3. Connect the output ports 01 and 02 as required to provide the desired direction of rotation. Figures 3-10, 3-11, 3-12 and 3-13 show single acting tubing examples, and Figure 3-14 shows a double acting tubing example. Air pressure to the 01 port increases from zero toward full supply as the control signal (error) increases. Air pressure to the 02 port decreases from full supply toward zero as the control signal increases.

NOTE: The tubing arrangements shown in Figures 3-10, 3-11,

3-12, 3-13 and 3-14 are typical examples and may not reflect the

arrangement required for the application.

4. -NPT permanent instrument gages can be installed into the

8

gage ports for calibration requirements.

WIRING TYPE AV2 POSITIONER

Use the following procedure to wire the Type AV2 positioner:

1. Connect the four to 20-mA position demand signal wires to terminals TB1-4 (+) and TB1-5 (-) of the terminal block (Figs. 3-2 and 3-15). For Type AV27 positioners, unscrew the I/P cover and make the four to 20-mA connections to the positive (+) and negative (-) terminals. If installing a Type AV2 ___0__ positioner, go to Step 4.

NOTE: If using a twisted shielded pair for signal wiring, ground one end of the shielded pair at the source. Trim the other end of the pair, located inside the enclosure, so that bare wires are not exposed.

2. If equipped with an optional 4 to 20-mA position transmitter (AV2 ___2__), connect a 24-VDC power supply in series with the required output load (Table 1-7) to terminals TB1-1 (+) and TB1-2 (-).

3. If equipped with an optional potentiometric position transmitter (Type AV2___1__), connect a power supply (maximum 35 VDC or 30 VAC) across TB1-1 and TB1-3. Use the signal across TB1-1 and TB1-2 or TB1-2 and TB1-3 for position transmitter feedback.

WIRING TYPE AV2 POSITIONER 3 - 10

INSTALLATION

Refer to Appendix A for detailed information about position transmitters.

NOTE: Route the wiring inside the positioner so it does not become entangled with moving parts. A cable clamp (Figs. 3-1 and 4-1) is provided inside the positioner so entanglement can be avoided.

Figure 3-10. Direct Acting, Top Loaded,

Single Acting Tubing Example

4. Grounding positioners should be done in accordance with local electrical codes (in U.S, National Electrical Code, ANSI/ NFPA 70. In Canada, Canadian Electrical Code, CSA c22.1). A grounding screw is provided inside the enclosure for grounding, denoted by .

NOTES:

1. The grounding screw located inside the enclosure is a safety ground and should not be used to ground the shielded pair.

2. The positioner must be grounded to avoid ground loop conditions.

WIRING TYPE AV2 POSITIONER

3 - 11

INSTALLATION

Figure 3-11. Reverse Acting, Top Loaded,

Single Acting Tubing Example

Figure 3-12. Direct Acting, Bottom Loaded,

Single Acting Tubing Example

WIRING TYPE AV2 POSITIONER 3 - 12

INSTALLATION

WIRING TYPE AV1 POSITIONER

This section applies to the following positioners:

• Type A V1___1__ .

• Type A V1___2__.

NOTES:

1. If this is a Type AV1___0__ positioner, no electrical wiring is required.

2. If using a twisted shielded pair for signal wiring, ground one end of the shielded pair at the source. Trim the other end of the pair, located inside the enclosure, so that bare wires are not exposed.

1. If equipped with an optional 4 to 20-mA position transmitter (Type AV1___2__), connect a 24-VDC power supply in series with the required output load (Table 1-5) to terminals TB1-1 (+) and TB1-2 (-) (Figs. 3-2 information about position transmitters.

Figure 3-13. Reverse Acting, Bottom Loaded,

Single Acting Tubing Example

and 3-15). Refer to Appendix A for detailed

2. If equipped with an optional potentiometric position transmitter (Type AV1___1__), connect a power supply (maximum 35 VDC or 30 VAC) across TB1-1 and TB1-3. Use the signal across TB1-1 and TB1-2 or TB1-2 and TB1-3 for position transmitter feedback.

WIRING TYPE AV1 POSITIONER

3 - 13

INSTALLATION

Figure 3-14. Double Acting Tubing Example

Figure 3-15. Wiring Connections

WIRING TYPE AV1 POSITIONER 3 - 14

INSTALLATION

Refer to Appendix A for detailed information about position transmitters.

NOTE: Route the wiring inside the positioner so it does not become entangled with moving parts. A cable clamp (Fig. 3-1 or

4-1) is provided inside the positioner so entanglement can be

avoided.

3. Grounding positioners should be done in accordance with local electrical codes (in U.S, National Electrical Code, ANSI/ NFPA 70. In Canada, Canadian Electrical Code, CSA c22.1). A grounding screw is provided inside the enclosure for grounding, denoted by .

NOTES:

1. The grounding screw located inside the enclosure is a safety ground and should not be used to ground the shielded pair.

2. The positioner must be grounded to avoid ground loop conditions.

RADIO FREQUENCY INTERFERENCE

Most electronic equipment is influenced by radio frequency interference (RFI). Caution should be exercised with regard to the use of portable communications equipment in the area.

ABB recommends posting appropriate signs in the plant. Refer to the Site Planning and Preparation instruction for additional information on RFI.

WIRING REQUIREMENTS

Under ideal conditions, the use of conduit and shielded wire may not be required. However, to avoid noise problems, it is recommended that wiring be enclosed in conduit. Just prior to entering the housing, rigid conduit should be terminated and a short length of flexible conduit should be installed to reduce any stress.

RADIO FREQUENCY INTERFERENCE

3 - 15

INTRODUCTION

SECTION 4 - CALIBRATION

This section contains the following information:

• Calibration.

• Gain adjustment.

• Speed control.

• Troubleshooting calibration.

NOTES:

1. All procedures in this section assume direct acting operation.

2. The troubleshooting calibration procedure in this section is not required for normal operation. The procedure is used only when operating difficulties occur. The corrective action column of Table 6-1 indicates when to use the troubleshooting calibration.

3. Calibration can also involve cam shaping to achieve the required control characteristics. Refer to Appendix C for detailed information about the cam.

CALIBRATION

Tools required:

Zero Adjustment

-inch Allen wrench.

32

Mechanical linkage is performed during installation (Section 3) that normally consists of adjusting the connection between the positioner and actuator so that the mechanical zero on the positioning cam corresponds to the mechanical zero of the actuator. The calibration procedure detailed here involves fine adjustments to the zero and span such that the input signal will cause the desired travel.

Calibration consists of applying an input signal pressure to the positioner to set the zero and span. These adjustments are made with the supply air applied to the positioner.

Type AV positioners have position transmitter options that are available for feedback purposes. Refer to Appendix A for more information about the position transmitter options.

The positioner zero adjustment sets the tension on the range spring and adjusts the input signal level that causes the actuator to move off of the minimum travel stop. The zero percent radial line of the cam should align with the center of the cam roller (Fig.

4-2).

INTRODUCTION

4 - 1

CALIBRATION

Use the following steps to adjust the zero:

1. Depending on the nomenclature type, apply one of the following input signals:

T ype AV1

T ype AV2

20.7 kPa (3.0 psig) input signal pressure. The actuator should move to its fully closed position.

4.0 mA input signal. The actuator should move to its fully closed position.

2. To adjust the zero, loosen the zero adjustment set screw (Fig.

4-1) with the -inch Allen wrench.

3. Turn the zero adjustment nut (clockwise moves the actuator toward minimum span) until the zero radial line on the cam intersects with the center of the cam roller (Fig. 4-2).

NOTE: This adjustment may be biased; i.e., turning the zero adjustment nut slightly clockwise to make sure a valve or damper is firmly seated at the minimum input signal.

4. Tighten the zero adjustment set screw.

32

Figure 4-1. Calibration Adjustments

CALIBRATION 4 - 2

Span Adjustment

CALIBRATION

Figure 4-2. Cam Roller Alignment

T ypes AV1 1/5

T ype AV12/6

T ype AV2

Setting the span normally requires the alignment of the 100 percent radial line of the cam with the center of the cam roller.

Use the following steps to adjust the span:

1. Depending on the nomenclature type, apply one of the following input signals:

Apply 103.4 kPa (15.0 psig). The actuator should move to its fully opened position.

Apply 186.2 kPa (27.0 psig). The actuator should move to its fully opened position.

Apply 20 mA. The actuator should move to its fully opened position.

2. To adjust the span, loosen the span adjustment screw (Fig.

4-1) using a -inch Allen wrench.

3. Slide the span adjustment assembly (Fig. 4-1) in the appropriate direction until the actuator moves to align the 100% radial line with the center of the cam roller (toward pilot valve increases span of actuator).

32

4. Tighten the span adjustment screw.

CALIBRATION FOR PARTICULAR APPLICATION

The following positioner adjustments may be used to tailor the operation of the actuator to meet application requirements.

CALIBRATION FOR PARTICULAR APPLICATION

4 - 3

CALIBRATION

Zero Adjustment

The positioner zero adjustment can be used to set initial tension on the range spring so that the actuator will not begin to move from its minimum position until it receives an input signal between zero and 50 percent (Fig. 4-3). This application of suppression is useful when two or more actuators are to be operated in sequence; where the actuator is equipped with a minimum stop; or where the characteristics of the device that the actuator is moving must be matched with the characteristics of another regulated device.

Span Adjustment

Figure 4-3. Zero Adjustment Graph

The span adjustment affords a variation of actuator motion for a given span of input signal. For example, the span may be adjusted to allow full actuator travel to occur with a signal change as small as 50 percent of its full span (e.g., split ranging) (Fig. 4-4). At the other extreme, the span adjustment can be set to produce as little as 50 percent of the travel capability of the actuator over the full input signal pressure span (e.g., short stroking).

This flexibility in span adjustment is useful when the device being regulated is oversized, since the adjustment allows operation of the actuator or cylinder through its useful motion for desired full change in control signal pressure. It is also useful in matching the signal versus position characteristics of the actuator or cylinder with the characteristics of related power devices in the same control system.

CALIBRATION FOR PARTICULAR APPLICATION 4 - 4

GAIN AND SPEED ADJUSTMENTS

CALIBRATION

Figure 4-4. Span Adjustment Graph

Gain Adjustment

Gain and speed adjustment information applies to both the Type AV1 and Type AV2 positioners. This is the gain of the overall positioner. The factory-installed 0.25-millimeter (0.100-inch) gain hinge spring suits most applications. This adjustment is not a mandatory part of calibration.

Gain adjustment on the Type AV positioners is accomplished by changing the gain hinge spring (Item 7, Figs. 9-3 or 9-4) connecting the beam assembly to the positioner housing. Provided with each positioner are two different gain hinge springs. If actuator oscillation occurs, the overall positioner gain may be too high. Positioner gain is related to the thickness of the gain hinge spring. Gain decreases as the thickness of the gain hinge spring increases. Refer to Table 4-1 for hinge information.

For information on changing the gain hinge spring, refer to Gain

Hinge Spring in Section 8.

5400264 _ 1 5400264 _ 2 0.76 0.030 Medium

NOTES:

1. For small actuators, it may be necessary to combine both gain hinge springs.

2. The high gain hinge spring comes installed from the factory.

Table 4-1. Gain Hinge Springs1

Part Number

Thickness

mm in.

0.25 0.010 High

Gain

GAIN AND SPEED ADJUSTMENTS

4 - 5

CALIBRATION

Speed Adjustment

Speed adjustment is not normally required when calibrating a positioner. Type AV positioners come from the factory adjusted for maximum operating speed. However, the speed of operation can be reduced in two ways. Speed control orifices can be used to slow positioner operation or a speed adjustment can be made internal to the positioner to change operating speed.

When the system involves only a single actuator, a high positioning speed is usually an advantage. However, in a complex control system, it is generally desirable to operate all power devices at the same speed in order to avoid interaction between units and consequently undesirable process conditions.

ORIFICE

If it is necessary to reduce the speed of operation, 1.02-millimeter (0.04-inch) speed control orifices are available as an option from ABB. These orifices are installed directly into the output ports (01 and 02) of the positioner and have ¼-NPT ports for connecting tubing from the actuator. If these orifices are too small (causing the actuator to respond too slowly) they may be drilled out to obtain desired speed control. Blank orifices are also available. Refer to Table 1-9 for orifice part numbers.

PILOT VALVE STROKE ADJUSTMENT

If it is necessary to reduce the speed of operation, a pilot valve stroke adjustment can reduce the speed and does not require additional hardware. This adjustment limits the pilot valve stroke.

The pilot valve stroke is measured by the movement (displacement) of the pilot valve stem, as shown in Figure 4-5. Figure 4-5 shows the maximum stroke length that is also the maximum speed of operation and is how the positioner comes from the factory. Use the following procedure to reduce the speed of operation:

NOTE: Never adjust the pilot valve for a stroke greater than

0.762 millimeters (0.030 inches) in either direction. A greater stroke will reduce the performance of the positioners.

1. Use a -inch Allen wrench to turn the top adjustment screw clockwise -turn to reduce stroke time (Fig. 4-6). ABB suggests

8

-turn increments. Take note of the number of turns. In total, do not exceed one full turn (clockwise) from the factory setting (Fig.

4-5). This adjustment controls the amount of air going to port 01.

32

8

GAIN AND SPEED ADJUSTMENTS 4 - 6

Figure 4-5. Pilot Valve Adjustment

CALIBRATION

2. Use a -inch Allen wrench (the wrench must be at least 5-inches long) to turn the lower adjustment screw clockwise the same amount as the top adjustment screw to insure speed of operation is the same in both directions (if desired). Be careful when accessing the lower adjustment screw. Insert the Allen wrench up through the bottom of the range spring (Fig. 4-6). This adjustment controls the amount of air going to port 02.

NOTE: To adjust the pilot valve stroke to the factory setting, refer to PILOT VALVE STROKE ADJUSTMENT in Section 8.

3. Test for satisfactory stroke time and adjust as required.

32

Figure 4-6. Speed Adjustment Screws

GAIN AND SPEED ADJUSTMENTS

4 - 7

CALIBRATION

TROUBLESHOOTING CALIBRATION ADJUSTMENTS

The I/P converter of the Type AV2 positioner comes from the factory completely calibrated. Use the following procedures only when operating difficulties occur. The corrective action column of Table 6-1 indicates when to use the troubleshooting calibration.

The purpose of this procedure is to adjust the I/P converter so that a four to 20-milliamp input signal will produce a 20.7 to 103.4-kilopascal (3.0 to 15.0-pounds per square inch gage) signal. Use the following procedure to adjust the I/P converter. The supply air must be connected to the positioner for this procedure.

Tools Required:

CAUTION

• Digital voltmeter.

• Calibrated 0 to 30-psig instrument gage.

• Small screwdriver.

• Current source.

Do not exceed the maximum supply pressure of 1034 kilopascals (150 pounds per square inch gage). Exceeding this pressure could cause equipment damage.

1. Connect the calibrated zero to 30-psig instrument gage or other accurate pressure measuring device to the I port to monitor the signal pressure during calibration.

2. Turn on the supply air to the positioner.

3. Provide a four-mA signal to the I/P converter and observe the output pressure. If the pressure equals 20.7 kPa (3.0 psig) go to Step 5. If the pressure does not equal 20.7 kPa (3.0 psig) go to Step 4.

4. Adjust the zero screw 0  on the bottom of the I/P con- verter (Fig. 4-7) until the output pressure equals 20.7 kPa (3.0 psig). Clockwise rotation increases pressure.

5. Apply a 20-mA signal to the I/P converter and observe the output pressure. If the pressure equals 103.4 kPa (15.0 psig) go to Step 7. If the pressure does not equal 103.4 kPa (15.0 psig) go to Step 6.

6. Adjust the span screw ( on the bottom of the I/P con- verter (Fig. 4-7) until the output pressure equals 103.4 kPa (15.0 psig). Clockwise rotation increases pressure.

7. Repeat Steps 3 through 6 until the 20.7 kPa (3.0 psig) and

103.4 kPa (15.0 psig) outputs are attained with four and 20-mA signal inputs.

TROUBLESHOOTING CALIBRATION ADJUSTMENTS 4 - 8

CALIBRATION

Figure 4-7. I/P Adjustment

TROUBLESHOOTING CALIBRATION ADJUSTMENTS

4 - 9

SECTION 5 - OPERATING PROCEDURES

INTRODUCTION

This section details the equalizing valve of the optional manifold (Type AV___ 1___ positioner).

NOTE: This section only applies when the positioner is equipped with a manifold assembly.

EQUALIZING AND AIR SUPPLY SHUTOFF VALVE

The equalizing valve, supplied with the manifold assembly, allows the actuator to be manually or automatically operated. By turning the valve handle to MAN, supply pressure to the positioner is cut off and the 01 and 02 ports are tied together, allowing manual repositioning of the actuator.

NOTE: It is important to understand that the equalizing valve is not a bypass valve. Be aware that if the actuator is not secured before transferring the valve handle of the manifold, the actuator will move.

Lock the actuator in place or be aware of the possible move-

WARNING

ment before moving the equalizing valve to MAN or AUTO. Failure to do so could result in injury to personnel.

Transfer from Automatic to Manual Operation

1. Manually lock the actuator or final control element.

2. If equipped with a manifold and equalizing valve, push in the valve handle and turn it to the MAN position.

3. If not equipped with a manifold and equalizing valve, turn off the supply air.

NOTE: If there are no means of locking the actuator or final control element, it will move in the direction of the process or mechanical load when the supply air is turned off.

Transfer from Manual to Automatic Operation

1. Verify that the valve handle is in the MAN position.

INTRODUCTION

5 - 1

OPERATING PROCEDURES

2. If the manual operator does not lock the actuator in position:

a. The piston must be positioned from prior knowledge of the actuator position versus signal or the actuator may jump when transferred to automatic.

b. Push the valve handle in and turn it to the AUTO position.

3. If the manual operator locks the actuator in position:

a. Depress the valve handle and turn it to the AUTO position. The actuator will oppose the manual operator if the drive position and input signal do not correspond.

b. Manually operate the actuator until the load on the manual operator decreases. If the output pressure gages are installed on the positioner, the gage readings should equalize.

NOTE: If, in Step 3, it is desired that the drive stay in its initial position, the input signal must be adjusted to correspond with the drive position as indicated by the load on the manual operator, output pressure gages or prior knowledge of position versus input signal.

EQUALIZING AND AIR SUPPLY SHUTOFF VALVE 5 - 2

INTRODUCTION

WARNING

Error Probably Cause Corrective Action

Oscillation of actuator

Actuator at one end of stroke and does not respond to input change

SECTION 6 - TROUBLESHOOTING

This section provides information about the Type AV positioner when operating difficulties are encountered. A table listing errors, probably causes and corrective actions allows the operator to troubleshoot a problem pertaining to the positioner.

If a problem occurs and is traced to the positioner, check the supply pressure, input and output connections, and mechanical adjustments before removing it from service.

Disconnect the supply signal source or remove the equipment from the process before servicing. Failure to do so can cause unexpected movement posing a risk of bodily injury.

Table 6-1. Positioner Errors

Drive arm not securely attached to actuator.

Pneumatic signal leak.

Pilot valve sticking. Remove pilot valve and clean or replace. Refer to Pilot Valve

Gain too high. Change gain hinge spring to greater thickness. Refer to Gain

Air lines in wrong

ports. Incorrect cam

installed for application.

Pneumatic signal leak.

Mechanical calibration shift.

I/P converter not functioning.

Tighten or correct linkage as necessary.

Check for leaks in connectors or fittings.

Assembly in Section 8.

Hinge Spring in Section 8.

Check air line connections (Figs. 3-10, 3-11, 3-12, 3-13 and

3-14).

Determine application (reverse or direct acting) and check for correct cam (Figs. 3-10, 3-11, 3-12, 3-13 and 3-14).

AV1: Check input signal connection for leaks at I port. AV2: Check signal at I port. If pressure is between 20.7 and

103.4 kPa (3.0 and 15.0 psig) and responds to input signal change then problem exists elsewhere.

If pressure is not between 20.7 and 103.4 kPa (3.0 and

15.0 psig) or does not respond to input change, check for leaks inside positioner and check I/P converter calibration (refer to TROUBLESHOOTING CALIBRATION ADJUST-

MENTS in Section 4).

Make sure the linkage between positioner and actuator is tight and has no backlash.

Check I/P converter calibration (refer to TROUBLESHOOT-

ING CALIBRATION ADJUSTMENTS in Section 4).

INTRODUCTION

6 - 1

TROUBLESHOOTING

Table 6-1. Positioner Errors

Error Probably Cause Corrective Action

Excessive air consumption (exhaust loud)

Slow response Signal diaphragm

Full range cannot be obtained with mechanical zero and span adjustment

Leakage at the joint of the manifold assembly (if equipped).

Pilot valve body seal is leaking.

Tubing discon-

nected.

leaking. I/P converter out of

calibration or not functioning.

Signal diaphragm leaking.

I/P converter out of calibration or not functioning.

I/P converter is defective.

Remove manifold and check O-rings. Refer to Manifold in

Section 8.

Remove pilot valve body and check O-rings. Refer to Pilot

Valve Assembly in Section 8.

Check connection at pressure regulator and I/P converter.

Replace signal diaphragm. Refer to Diaphragm Assembly in

Section 8.

Calibrate I/P converter. Refer to TROUBLESHOOTING CALI-

BRA TION ADJUSTMENTS in Section 4. If unable to cali-

brate, replace I/P converter. Refer to I/P Converter in

Section 8.

Replace diaphragm. Refer to Diaphragm Assembly in

Section 8.

Calibrate I/P converter. Refer to TROUBLESHOOTING CALI-

BRA TION ADJUSTMENTS in Section 4. If unable to cali-

brate, replace I/P converter. Refer to I/P Converter in

Section 8.

Replace I/P converter. Refer to I/P Converter in Section 8.

INTRODUCTION 6 - 2

INTRODUCTION

The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB recommends that all equipment users practice a preventive maintenance program that will keep the equipment operating at an optimum level.

Maintenance personnel should be familiar with the Type AV positioner and have experience working with process control applications that use pneumatic positioners.

System maintenance must be performed only by qualified personnel and only after securing the equipment controlled

WARNING

PREVENTIVE MAINTENANCE SCHEDULE

by the circuit. Altering or removing components from an active circuit may upset the controlled process leading to personnel injury and equipment damage.

Table 7-1 is the preventive maintenance schedule and checklist for Type AV positioners. The table lists the preventive maintenance tasks in groups according to their specified maintenance interval. The maintenance intervals are recommendations and may vary depending on the location environment and the air quality of the positioner. As a minimum, these recommended maintenance tasks should be performed during an extended process shutdown.

SECTION 7 - MAINTENANCE

Some tasks in Table 7-1 are self-explanatory. Instructions for tasks that require further explanation are covered under PREVENTIVE

MAINTENANCE PROCEDURES.

Table 7-1. Preventive Maintenance Schedule

Preventive Maintenance Tasks

Check and tighten all wiring connections. Clean or replace supply air filter. Clean or replace manifold filters. Refer to procedure.

7 - 1

Interval

(months)

INTRODUCTION

MAINTENANCE

Table 7-1. Preventive Maintenance Schedule (continued)

Preventive Maintenance Tasks

Check all air connections for leakage while positioner is under pressure. Use a soapsuds solution.

Check the signal diaphragm for leaks. use a soapsuds solution.

Clean pilot valve and stem with low residue solvent. Refer to REP AIR AND REPLACEMENT in Section 8.

Check calibration of positioner and actuator. Refer to

Section 4.

Check and verify that there is no backlash in the linkage/connections between the positioner and the actuator. Refer to Section 3.

PREVENTIVE MAINTENANCE PROCEDURES

This section covers instructions for cleaning and replacing the manifold filters.

MANIFOLD FILTERS

Tools Required:

• Torque screw driver.

Interval

(months)

WARNING

Lock the actuator in place or be aware of the possible movement before moving the equalizing valve to MAN or AUTO. Failure to do so could result in injury to personnel.

1. Transfer the positioner from automatic to manual operation (Section 5).

2. After allowing the pressure to bleed off, remove the cover screw securing the filter cover (Fig. 7-1) and set the cover screw and cover aside.

3. Clean or replace the filters.

a. To clean the filters, soak them in a low residue solvent. After soaking, spray the filters thoroughly using compressed air until they are free of particles and solvents.

b. Insert the clean or new filters, using the filter kit identified in Table 1-7, into the filter wells.

4. Replace and lubricate the three O-rings (Fig. 7-2) using the lubricant supplied in the kit (Dow Corning

No. 4).

5. Clean and place the cover over the filters and replace the cover screw. Torque the cover screw to two Nm (18 in-lbs).

PREVENTIVE MAINTENANCE PROCEDURES 7 - 2

MAINTENANCE

6. Transfer the positioner back to automatic operation (Section 5).

Figure 7-1. Positioner with Manifold

Figure 7-2. Manifold with Filter

Cover Removed

MANIFOLD FILTERS

7 - 3

SECTION 8 - REPAIR AND REPLACEMENT

INTRODUCTION

This section provides procedures that detail removal and replacement of positioner components.

Disconnect the supply signal source or remove the equip-

WARNING

REPLACEMENT PROCEDURES

ment from the process before servicing. Failure to do so can cause unexpected movement posing a risk of bodily injury.

This section contains replacement procedures for:

• Manifold.

• Gain hinge spring.

• Pilot valve assembly.

• I/P converter.

• Cam.

• Diaphragm assembly.

Manifold

Tools Required:

• Torque screwdriver.

• -inch Allen wrench.

32

1. Secure (lock) the actuator and remove the supply air.

2. If equipped with an equalizing valve, push in on the valve handle and move it to the MAN position (Fig. 8-1).

3. Remove the four Allen screws that secure the manifold (Fig.

8-1).

4. Lift the manifold off the positioner.

5. Before replacing the manifold, make sure there are no deposits on the bosses of the positioner or on the back of the manifold. If there are, remove the deposits.

6. Replace the O-rings or clean them if they are in good condition (Fig. 8-2).

7. Clean the O-ring grooves and apply Dow Corning No. 4 or equivalent lubricant to the O-rings.

INTRODUCTION

8 - 1

REPAIR AND REPLACEMENT

8. Place the manifold in place on the positioner so it properly seats on the bosses.

9. Insert the Allen screws and torque them to 3.5 Nm (31 in.-lbs). Not all of the Allen screws are the same length. Be sure each screw mates correctly.

10. To replace the filters and filter cover, refer to MANIFOLD FIL-

TERS in Section 7.

Gain Hinge Spring

Tools Required:

Figure 8-1. Positioner with Manifold

NOTES:

1. Refer to Table 4-1 for gain hinge spring part numbers.

2. Item numbers in this procedure reference Figure 9-3 or 9-4.

• Flat-tip screwdriver.

• -inch Allen wrench.

64

1. Transfer the positioner from automatic to manual operation (Section 5).

2. Remove the positioner cover by removing the two cover screws.

3. Remove the plug button (Item 29) from the positioner housing. This opening provides access to the screws.

REPLACEMENT PROCEDURES 8 - 2

REPAIR AND REPLACEMENT

Pilot Valve Assembly

Figure 8-2. Manifold O-Rings

4. Remove the four hinge screws (Item 42) while holding the beam assembly steady (Item 6). Remove the two screws that connect the beam to the hinge first.

5. Remove the gain hinge spring.

6. Insert the new gain hinge spring.

NOTE: When installing the gain hinge spring, be sure it properly seats (flush) between the steps. If the gain hinge spring hangs up, remove and rotate the hinge 90. Check for proper seating.

7. Insert and torque the screws to 2.6, 0.2 Nm (23, 2 in.-lbs) while holding the beam assembly steady (Item 6). Insert the two screws that secure the hinge to the housing first.

8. Transfer the positioner back to automatic operation (Section 5).

9. Perform the procedure outlined in PILOT VALVE STROKE

ADJUSTMENT.

NOTES:

1. Refer to Section 9 for pilot valve assembly kit numbers.

2. Item numbers in this procedure reference Figure 9-3 or 9-4.

REPLACEMENT PROCEDURES

8 - 3

REPAIR AND REPLACEMENT

Tools Required:

Flat-tip screwdriver.

1. Transfer the positioner from automatic to manual operation (Section 5).

2. Remove the positioner cover by removing the two cover screws.

3. Carefully unhook the ends of the valve clip (Item 5). Remove the valve clip from the valve body. Remove the valve stem (Item 3) from the lower end of the valve body.

4. Remove the two pilot valve screws (Item 52) securing the valve body and lift the valve body off the housing.

5. Replace the O-rings. Clean the O-ring grooves and apply Dow Corning No. 4 or equivalent lubricant to the O-rings.

6. Set the (replacement or clean) valve body in place.

7. Secure the valve body by replacing and tightening the pilot valve screws to 2.6, 0.2 Nm (23, 2 in.-lbs).

8. Make certain the valve stem is clean. Install the valve stem.

9. Install the valve clip.

I/P Converter

Tools Required:

10. Transfer the positioner back to automatic operation (Section 5).

11. Perform the procedure outlined in PILOT VALVE STROKE

ADJUSTMENT.

NOTES:

1. Refer to Section 9 for I/P converter part numbers.

2. Item numbers in this procedure reference Figure 9-4.

3. This procedure only applies to Type AV2 positioners.

• Flat-tip screwdriver.

• T15 Torx.

• Pliers.

1. Transfer the positioner from automatic to manual operation (Section 5).

2. Remove the positioner cover by removing the two cover screws.

3. Remove the two wires that connect the I/P converter (Item 80) to the termination assembly (Item 59).

4. Loosen the three screws (Item 58) securing the I/P bracket.

REPLACEMENT PROCEDURES 8 - 4

Cam

REPAIR AND REPLACEMENT

5. Slide the I/P converter out from under the screws and remove it from the housing.

6. Disconnect the two air lines from the I/P converter. When replacing the I/P converter, remove the portion of the air line tubing that was connected to the I/P converter or replace the tubing. If this is not done, particles from the tubing can cause a blockage.

7. Reverse the preceding steps to install the new I/P converter.

NOTE: Item numbers reference Figure 9-3.

Tools Required:

• Flat-tip screwdriver.

• Adjustable wrench.

• Pliers.

1. Transfer the positioner from automatic to manual operation (Section 5).

2. Remove the positioner cover by removing the two cover screws.

3. Remove the indicator screw (Item 51) and indicator (Item 19).

4. Hold and stop the cam shaft from rotating if it is not secured by linkage or coupling. Using the adjustable wrench, remove the cam nut (Item 30) and washer (Item 55).

5. Lift the cam from the cam shaft.

6. To replace the cam, determine which cam mounting hole (A, B or C) is appropriate for the application, and set the cam on the shaft. Make certain the star-shaped hole engages squarely on the shaft. Refer to Figure 3-8 to align the cam.

7. Replace the cam washer and nut and tighten.

8. Set the indicator on the cam shaft and insert and tighten the screw.

9. Transfer the positioner back to automatic operation (Section 5).

Diaphragm Assembly

NOTES:

1. Refer to Section 9 for diaphragm assembly kit numbers.

2. Item numbers in this procedure reference Figure 9-3 or 9-4.

REPLACEMENT PROCEDURES

8 - 5

REPAIR AND REPLACEMENT

DIAPHRAGM ASSEMBL Y REMOV AL

Tools Required:

• Allen wrench.

• Adjustable wrench.

1. Transfer the positioner from automatic to manual operation (Section 5).

2. Using an Allen wrench, remove the four diaphragm cover screws (Item 45) and remove the diaphragm cover.

3. Remove the diaphragm support screw (Item 53) and washer (Item 54).

NOTE: When removing the diaphragm support screw, do not allow the diaphragm support (Item 23) to rotate.

NOTE: Item 53 is replaced by SEM screw NBMHA13006A as of November 23, 2009/Serial Number 3K620000029936 & Item 54 is no longer used.

4. Remove the diaphragm support (Item 23).

5. Carefully remove the large diaphragm (Item 73) from assembly.

6. Remove the diaphragm spacer (Item 22).

7. Remove the diaphragm ring (Item 24).

8. Carefully remove the small diaphragm.

DIAPHRAGM ASSEMBL Y REPLACEMENT

1. Place the small diaphragm (Item 20) in the diaphragm housing with the concave side facing up. Check for correct alignment of the tabs relative to the diaphragm housing.

2. Place the diaphragm ring (Item 24) over the small diaphragm (Item 20). Make sure the alignment pins on the diaphragm ring properly engage the other mating parts.

3. Set the diaphragm spacer in place (Item 22).

4. Place the large diaphragm (Item 73) in place with the convex side up. Check for correct alignment of the tabs relative to the diaphragm housing.

5. Place the diaphragm support (Item 23) on the large diaphragm.

REPLACEMENT PROCEDURES 8 - 6

REPAIR AND REPLACEMENT

6. Replace the washer (Item 54) and screw (Item 53). Torque the screw to 0.35 Nm (50 in.-oz.) while securing the diaphragm support (Item 23) so it does not rotate.

NOTE: Item 53 is replaced by SEM screw NBMHA13006A as of November 23, 2009/Serial Number 3K620000029936 & Item 54 is no longer used.

7. Inspect the diaphragm assembly for distortion. If distortion occurs loosen the screw (Item 53), straighten the diaphragm and tighten while holding Item 23 still.

8. Replace the diaphragm cover (Item 25) and screws (Item 45). Make certain the diaphragm cover is properly seated. Torque the cover screws uniformly to 0.9 Nm (8 in.-lbs).

9. Transfer the positioner back to automatic operation (Section 5).

10. Apply the input signal pressure and check for leaks around the diaphragm assembly using soapsuds solution.

11. Perform the procedure outlined in PILOT VALVE STROKE

ADJUSTMENT.

PILOT VALVE STROKE ADJUSTMENT

The purpose of this adjustment is to keep the valve stem in the proper operating range. This procedure should be used in conjunction with the following procedures:

• Gain Hinge Spring.

• Pilot Valve Assembly.

• Diaphragm Assembly.

NOTE: For internal speed adjustment refer to PILOT VALVE

STROKE ADJUSTMENT in Section 4.

When the valve stem is in the balance position, as shown in Figure 8-3, the stem is flush with both ends of the valve body. There are two adjustment screws to adjust. Use the following procedure to check and adjust the travel of the valve stem:

Tools required:

• -inch Allen wrench (standard length).

32

• -inch Allen wrench (long length — at least five inches).

32

1. With the positioner cam at approximately 50%, manually lock the actuator in position by:

a. Using manual override if available.

- or -

PILOT VALVE STROKE ADJUSTMENT

8 - 7

REPAIR AND REPLACEMENT

b. If manual override is not available, disconnect (and secure) the linkage. Plug ports 01 and 02 if necessary.

2. Apply the supply pressure.

3. Apply the maximum input signal to the positioner:

• AV11: 103.4 kPa (15.0 psig).

• AV12:186.2 kPa (27.0 psig).

• AV23: 20 mA.

4. Use the long -inch Allen wrench, adjust the top adjustment screw (Fig. 8-4) appropriately until the measurement matches the value shown in Figure 8-3. Figure 8-3 also shows the way the measurement is taken.

5. Apply the minimum input span to the positioner:

• AV11: 20.7 kPa (3.0 psig).

• AV12: 20.7 kPa (3.0 psig).

• AV23: 4 mA.

6. Use the long -inch Allen wrench to adjust the lower stroke adjustment screw (Fig. 8-4). Adjust the screw until the measurement matches the value shown in Figure 8-3.



32

Figure 8-3. Pilot Valve Measurement for Maximum Speed

PILOT VALVE STROKE ADJUSTMENT 8 - 8

REPAIR AND REPLACEMENT

Figure 8-4. Stroke Adjustment Screws

PILOT VALVE STROKE ADJUSTMENT

8 - 9

REPAIR AND REPLACEMENT

PILOT VALVE STROKE ADJUSTMENT 8 - 10

INTRODUCTION

SECTION 9 - SUPPORT SERVICES

This section provides:

Recommended spare

parts

Additional spare parts

Positioner illustrations

RECOMMENDED SPARE PARTS

A list of the parts that should be kept on hand so that if malfunctions occur, replacements are quickly accessible.

A list of parts that can be ordered for replacement. Illustrations that point out all major components of the Type AV1

and AV2 positioners. A parts list is included along with part numbers.

ABB suggests that the following items be kept on hand in case replacement is necessary. To order, call your nearest ABB sales representative; supply the kit numbers or if the items are not of a kit, supply the part numbers.

NOTE: This is not a complete list of available parts; refer also to in this section and Table 1-7 in Section 1.

Table 9-1. Shutoff Valve Kit No. 258270_1

Description Part No. Quantity

Shutoff valve 5400060_1 1

(positioners equipped with optional

manifold, Type AV___ 1/2 ___ )

Table 9-2. AV Diaphragm Assembly Kit No. 258486_1 1

Item Part No. Qty Description Item Part No. Qty Description

20 5400288 _2 1 Small diaphragm 24 5400294 _1 1 Diaphragm ring 22 5400292_1 1 Diaphragm

23 5400293 _1 1 Diaphragm

23 5400293_2 1 Diaphragm

9 - 1

(for Types AV11 and AV12)

73 5400288_1 1 Large diaphragm

spacer

73 5400283_3 1 Large diaphragm

support (AV11)

support (AV12)

NOTE:

ber 2009/Serial Number 3K620000029936.

Kit contains SEM screw NBMMA13006A as of Novem-

(AV11)

(AV12)

INTRODUCTION

SUPPORT SERVICES

Table 9-3. AV Diaphragm Assembly Kit No. 258486_2

Item Part No. Qty Description Item Part No. Qty Description

20 5400288_5 1 Small diaphragm 24 5400294_1 1 Diaphragm ring 22 5400292_ 1 1 Diaphragm

23 5400293_ 1 1 Diaphragm

23 5400293_2 1 Diaphragm

(for Types AV15 and AV16)

73 5400288_4 1 Large diaphragm

spacer

73 5400283_6 1 Large diaphragm

support (AV15)

support (AV16)

NOTE: 1 Kit contains SEM screw NBMMA13006A as of Novem-

ber 2009/Serial Number 3K620000029936.

Table 9-4. Filter Replacement Kit No. 258487_1

(positioners equipped with optional manifold, Type AV ___1/2___)

Part No. Qty Description

19984 _ 1 1 O-ring lubricant 5311428_1 3 O-rings 5400057 _1 3 Filters

(AV15)

(AV16)

Table 9-5. Pilot Valve Assembly Kit No. 258488_1

Item Part No. Qty Description

3 5400259_1 1 Valve stem 4 5400260 _1 1 Valve body

5 5400261_1 1 Valve clip 35 1951398 _12 3 O-rings — 19984_1 1 O-ring lubricant

Table 9-6. Pilot Valve Assembly Kit No. 258488_ 2

Item Part No. Qty Description

3 5400259_1 1 Valve stem

4 5400260_1 1 Valve body

5 5400261_1 1 Valve clip 35 1951779_ 010 3 O-rings — 19984_1 1 O-ring lubricant

(for Types AV11, AV12 and AV2)

(for Types AV15 and AV16)

RECOMMENDED SPARE PARTS 9 - 2

SUPPORT SERVICES

Table 9-7. Pilot Valve Assembly Kit No. 258488_3

(for Types AV11 ___P, AV12 ___P and AV2___P)

Item Part No. Qty Description

3 5400259_ 1 1 Valve stem 4 5400260_2 1 Valve body

5 5400261_1 1 Valve clip 35 1951398 _12 3 O-rings — 19984_1 1 O-ring lubricant

ADDITIONAL SPARE PARTS

Table 9-8. Pilot Valve Assembly Kit No. 258488_4

Part No. Qty Description

5400281_1 1 Forward acting full rise cam, 90° rotation 5400281_2 1 Reverse acting full rise cam, 90° rotation 5400289_1 1 Forward acting half rise cam, 45° rotation 5400289_ 2 1 Reverse acting half rise cam, 45° rotation

(for Types AV15 _0/3__ P and AV16_0/3__P)

Item Part No. Qty Description

3 5400259_1 1 Valve stem

4 5400260_2 1 Valve body

5 5400261_1 1 Valve clip 35 1951779_ 010 3 O-rings — 19984 _ 1 1 O-ring lubricant

Table 9-9. Cam

(select appropriate cam type)

Table 9-10. AV2 I/P Assembly Kit No. 258651_1

Part No. Qty Application Description

258651_1 1 AV2 I/P converter kit

Table 9-11. Gain Hinge Springs1

Item Part No. Qty

7 5400264 _1

5400264 _2 1 0.76 0.030 Medium

NOTES:

1. For small actuators, it may be necessary to combine both gain hinge springs.

2. The high gain hinge spring comes installed from the factory.

1 0.25 0.010 High

Thickness

mm in.

Gain

ADDITIONAL SPARE PARTS

9 - 3

SUPPORT SERVICES

(replaces 5400282_ 1 or 5400282 _ 2 (for replacement or field addition, Type AV ___1/2 ___))

Item Part No. Qty Description Item Part No. Qty Description

17 5400282 64 5311428_207 4 Manifold O-rings — 19984_1 1 O-ring lubricant 65 NTJHA09030 4 Manifold washers — 5400066_1 1 Valve plate 66 NBAHA16020 4 Manifold screws

NOTE:

1. Used to make equalizing valve handle inoperable for Type AV___2 ___positioner applications. Discard for Type AV1__1 ___positioner applications.

Item Part No. Qty Description Item Part No. Qty Description

1 5400254 2 5400255 3 5400256

_ 1 1 Manifold assembly 67 NBAHA16024 2 Manifold screws

_1 1 Cover 4 5400257_ 1 1 Cover insert _1 1 Window 5 5400257 _ 2 1 Cover insert _ 1 1 Gasket 6 1964033 _ 1 1 Styleplate

Table 9-12. Manifold Assembly Kit No. 258491 _1

Table 9-13. Cam Follower Arm Kit No. 258544 _ 1

(replaces part no. 5400306 _ 1)

Part No. Qty Description

258544_1 1 Cam Follower- Arm Assembly

Table 9-14. Cover Assembly Kit No. 258545 _ 1

(for Types AV11, AV12 and AV2 — replaces part no. 5400258 _ 1)

Table 9-15. Cover Assembly Kit No. 258545 _1

(for Types AV15 and AV16 — replaces part no. 5400258 _ 1)

Item Part No. Qty Description Item Part No. Qty Description

1 5400254 2 5400255 4 5400257

Item Part No. Qty Description Item Part No. Qty Description

1 5400318 2 NKJHA16004 3 Set screw, socket

5 1951041_

_1 1 Cover 5 5400257 _ 2 1 Cover insert _1 1 Window 6 1964033_ 1 1 Styleplate _ 1 1 Cover insert 10 R9025-0046 1 Silicon tubing

Table 9-16. Gage Block Assembly Kit No. 258569 _1

(for replacement or field addition, Types AV11 _3 , AV12 _3 and AV2 __ 3)

_ 1 1 Manifold, gage 6 5311428_ 207 4 O-rings

hex hdlss cup pnt

4 2 Pipe plug, socket

head

7 NBAHA16020 3 Screw, hex socket

head cap

8 NTJHA09030 3 Lockwasher,

spring

ADDITIONAL SPARE PARTS 9 - 4

SUPPORT SERVICES

Table 9-17. Gage Block Assembly Kit No. 258569 _3

(for replacement or field addition, Types AV15 _ 3 and AV16 )_3 )

Item Part No. Qty Description Item Part No. Qty Description

1 5400318 2 NKJHA16004 3 Set screw, socket

5 1951041

_1 1 Manifold, gage 6 1951779 _207 4 O-rings

7 NBAHA16020 3 Screw, hex socket

hex hdlss cup pnt

_4 2 Pipe plug, socket

head

8 NTJHA09030 3 Lockwasher,

head cap

spring

(for potentiometric position transmitters (Type AV ____1__))

Part No. Qty Description

6639540_ 1 1 Potentiometer assembly

Table 9-19. 4 to 20-mA Position Transmitter Circuit Board

Table 9-18. Potentiometer

(Type AV____2 __)

Part No. Qty Description

6639479_

1 1 Circuit board

Table 9-20. Positioner Mounting Kit Number 5327321_121

Valve Stem Diameter 0.375 to 0.750 in. (Fig. 9-1)

Item Part Number Description Item Part Number Description

1 5400266_ 1 Positioner mounting bracket 12 197120_5 Nut, elastic stop (2 req) 2 0.250-20 x 0.750 Screw, socket head (3 req) 13 5311690 _1 Adjustable stud, 2.69 in. 3 0.250 Lock washer, reg spring (3 req) 14 5311690_2 Adjustable stud, 3.43 in. 5 0.312-18 x 0.625 Cap screw, hex socket head (2 req) 21 0.375 Lock washer, med spring (3 req) 6 0.312 Lock washer, reg spring (2 req) 22 0.375-24 Nut, hex jam 7 R6440-005 Type 347 stainless steel wire, 0.300

diameter, 6-in. length

19934 _ 248 Spacer 25 5311691 _ 1 Clamp plate, 0.375 - 0.750-in. dia

0.190-32 x 1.125 Screw, pan head machine 27 0.375-16 x 1.50 Screw, hex skt head cap (2 req)

9 10 5312449_ 4 Connecting link, 12-in. length (cut to

fit)

0.190-32 x 0.875 Screw, pan head machine (2 req) 29 0.125 dia x 0.750 Groove pin, type 1

NOTES:

1. Positioner mounting kits for direct or reverse acting diaphragm actuators and single or double acting piston actuators with linear (reciprocating) motion.

2. When fastening Item 10 to the drive arm at the first hole (nearest the drive shaft), use Items 8 and 9 and omit one of Item 11.

23 5311687 _ 2 Stem clamp, 0.375 - 0.750-in. dia

28 0.375-16 Nut, hex jam (2 req)

ADDITIONAL SPARE PARTS

9 - 5

SUPPORT SERVICES

Table 9-21. Positioner Mounting Kit Number 5327321_131

Valve Stem Diameter 0.750 to 1.000 in. (Fig. 9-1)

Item Part Number Description Item Part Number Description

1 5400266 _1 Positioner mounting bracket 1130.190-32 x 0.875 Screw, pan head machine (2 req) 2 0.250-20 x 0.750 Screw, socket head (3 req) 12 197120 _ 5 Nut, elastic stop (2 req) 3 0.250 Lock washer, reg spring (3 req) 14 5311690 _ 2 Adjustable stud, 3.43 in. 5 0.312-18 x 0.625 Cap screw, hex socket head (2 req) 21 0.375 Lock washer, med spring (3 req) 6 0.312 Lock washer, reg spring (2 req) 22 0.375-24 Nut, hex jam 7 R6440-005 Type 347 stainless steel wire, 0.300

diameter, 6-in. length

19934 _ 248 Spacer 26 5312471 _ 1 Clamp plate, 0.750 - 1.00-in. dia

0.190-32 x 1.125 Screw, pan head machine 27 0.375-16 x 1.50 Screw, hex skt head cap (2 req)

10 5312449 _ 4 Connecting link, 12-in. length (cut to

fit)

NOTES:

1. Positioner mounting kits for direct or reverse acting diaphragm actuators and single or double acting piston actuators with linear (reciprocating) motion.

2. When fastening Item 10 to the drive arm at the first hole (nearest the drive shaft), use Items 8 and 9 and omit one of Item 11.

Table 9-22. Positioner Mounting Kit Number 5327321 _ 141 (for use on Fisher Actuators)

Item Part Number Description Item Part Number Description

1 5400266 _ 1 Positioner mounting bracket 11 2 0.250-20 x 0.750 Screw, socket head (3 req) 12 197120 _ 5 Nut, elastic stop (2 req) 3 0.250 Lock washer, reg spring (3 req) 15 5319500 _ 11 Drive stud, 4.59 in. 5 0.312-18 x 0.625 Cap screw, hex socket head (2 req) 16 5319500 _ 1 Drive stud, 3.43 in. 6 0.312 Lock washer, reg spring (2 req) 17 5328155 _ 1 Stud bracket 7 R6440-005 Type 347 stainless steel wire, 0.300

diameter, 6-in. length

19934 _ 248 Spacer 19 1218-00 Lock washer, shakeproof (2 req)

0.190-32 x 1.125 Screw, pan head machine 20 5319524 _ 1 Lock washer, star

9 10 5312449 _ 4 Connecting link, 12-in. length (cut to

fit)

NOTES:

1. Positioner mounting kits for direct or reverse acting diaphragm actuators and single or double acting piston actuators with linear (reciprocating) motion.

2. When fastening Item 10 to the drive arm at the first hole (nearest the drive shaft), use Items 8 and 9 and omit one of Item 11.

Valve Stem Diameter 0.375 to 0.750 in. (Fig. 9-1)

24 5312483 _ 1 Stem clamp, 0.750 - 1.00-in. dia

29 0.125 dia x 0.750 Groove pin, type 1

0.190-32 x 0.875 Screw, pan head machine (2 req)

18 0.312-18 x 0.500 Screw, hex head cap (2 req)

ADDITIONAL SPARE PARTS 9 - 6

SUPPORT SERVICES

Figure 9-1. Mounting Kits

Table 9-23. Rotary Actuator Retrofit Mounting Kits

Kit Number Drive Nomenclature Retrofit Mounting Kit

5400309 258493 258494 258527 258528 258529 258530 258527 258528 258529 258530

_1 UP1, UP2 Type AP positioner to _1 UP3, UP4 _1 UP5, UP6 _1 AC0404 _1 AC0608 _1 AC0816 _2 AC1016 _1 AC0404 ABB part number pilot _1 AC0608 _1 AC0816 _1 AC1016

Type AV positioner

valve positioner to Type AV positioner

ADDITIONAL SPARE PARTS

9 - 7

SUPPORT SERVICES

Table 9-24. Bypass Valve Assembly (Optional)

Parts List (Part No. 5326945 _1 — Fig. 9-2)

Item Part Number Description

1 5327226 2 5326946 3 195159 4 195727 5 195171 6 1962833 7 NBZAC16006 Screw, pan head 8 NTJAC09030 Lock washer 9 NLMAC16000 Nut, hex

10 1951041

_1 3-way valve

_1 Air line connection assy _3 Elbow connector _2 Brass nipple _3 Wheatherhead tee

_1 Designation plate

_1 Sch pipe plug

Figure 9-2. Bypass Valve Assembly

ADDITIONAL SPARE PARTS 9 - 8

SUPPORT SERVICES

Table 9-25. Type AV1 Positioner Parts List for Figure 9-3

Item Part No. Description Item Part No. Description

1 5400253 _3 Housing 46 197865 _ 2 Stroke adjustment screw 2 Refer to Table 9-26 Cover assembly 47 197865 _ 1 Stroke adjustment screw 3 5400259 _ 1 Valve stem 48 NKJHA16004 Zero adjustment set screw 4 Refer to Table 9-26 Valve body 49 NBAHA16020 Span adjustment screw 5 5400261 _ 1 Valve clip 50 Form MP481-494 Label, CSA/FM 6 5400263 _ 1 Beam assembly 51 NIDHA13005 Indicator screw 7 5400264 _ 1 Hinge 52 NIDHA15012 Pilot valve screw (2 req) 8 258544_ 1 Cam follower arm assembly 53 NBMHA13006 Diaphragm support screw

9 5400271 _ 1 Spring arm 54 NTCHA07000 Diaphragm support scr washer 10 5400272 _ 1 Pivot 55 NTGHA10000 Cam washer 11 5400273 _ 1 eyebolt 56 NTJHA09030 Span adjustment washer 12 5400275 _ 1 Retaining nut 57 Fm MP432-889 Label, indicator 13 Refer to Table 9-27 Cam 58 197893 _ 1 Thread forming screws 14 Refer to Table 9-29 Cam shaft 59 6639559 _ 1 Termination assembly 15 5400279 _ 1 Zero adjustment nut 61 MP409-393 Label, terminal block 16 5400280 _ 1 Range spring 62 1963318 _ _ Nameplate, universal 17 Refer to Table 9-27 Manifold assembly 63 Refer to Table 9-29 Drive arm 18 193214 _ 1 Bearing 64 Refer to Table 9-27 Manifold O-ring 19 5400286 _ 1 Indicator 65 NTJHA09030 Manifold washer 20 Refer to Table 9-26 Small diaphragm 66 NBAHA16020 Manifold screw 21 Refer to Table 9-28 Potentiometer assembly 67 NBAHA16024 Manifold screw 22 5400292 _ 1 Diaphragm spacer 68 R9025-0046 Tubing (6.4 cm (2.5 in.)) 23 Refer to Table 9-26 Diaphragm support 69 1951651 _ 1 Plug 24 5400294 _ 1 Diaphragm ring 71 193197 _ 1 Span adjustment bearing 25 Refer to Table 9-26 Diaphragm cover 72 114B094U01 Plug button 26 5400296 _ 1 Exhaust mesh 73 Refer to Table 9-26 Large diaphragm 27 193243 _ 1 Large position transmitter

28 1951652 _ 1 Barb fitting (2 req) 75 NTMHA13000 Lock washer 29 Refer to Table 9-26 Plug button 77 6639479 _ 1 30 197120 _ 28 Cam nut 81 Refer to Table 9-26 Bumper grommet (3 req) 31 19734 _ 45 Washers 32 197777 _ 50 Retaining ring, cam (2 req) 83 5400268 _ 2 Bracket, pot mounting 33 197164 _ 18 Retaining ring, span 84 193242 _ 1 Small position xmttr gear 34 197227 _ 1 Special hex head sems screw186 1943187 _ 1 Cable clip 35 Refer to Table 9-26 O-ring (3 req) 87 MP409-393 Label, connection 36 197843 _ 1 Fastener, push-on, removable 88 MP409-393 Label, position transmitter 37 1945750 _ 1 Pull plug (4 req) 89 5400317 _ 1 Gear adapter 38 5400072 _ 2 Knife base 90 NKJHA13004 Socket head cup pt set screw 39 5400073 _ 1 Knife edge 91 NKJHA16004 Socket head cup pt set screw1 40 NBZHA21014 Cover screw 92 1951041 _ 4 Socket head pipe plug 41 NBZHA21040 Cover screw 93 Refer to Table 9-26 O-ring 42 NBAHA15006 Hinge screw (4 req) 94 NKJHA23006 Socket head cup pt set screw 43 NPSHA05000 Hairpin clip (2 req) 95 258567 _ 1 NEMA 4X kit 44 NTBTF13150 Teflon washer (3 req) 96 5400264 _ 2 Hinge 45 NBAHA13006 Diaphragm cover screw (4 req)

NOTE:

1. Refer to Tables 9-26, 9-27, 9-28 and 9-29 for quantities.

2. Items 53 & 54 replaced by SEM screw NBMHA13006A as of November 23, 2009/Serial Number 3K620000029936

gear

74 NDPAC15004 Screw

4 to 20-mA pos xmttr assembly

82 Refer to Table 9-26 Bumper grommet (2 req)

1 1 1

ADDITIONAL SPARE PARTS

9 - 9

ADDITIONAL SPARE PARTS

9 - 10

Table 9-26. Input Signal Parts Reference for Type AV1 Positioners (Fig. 9-3)

SUPPORT SERVICES

Item

(Quantity)

Type

Item (Part Number)

2 4 20 23 25 29 35 73 81 82 93 31 94 95

AV11 _ _ _ _ 0 5400258 _ 1 5400260 _ 1 5400288 _ 2 5400293 _ 1 5400295 _ 1 114B095U01 1951398 _ 12 5400288 _ 1 1951755 _ 1 1951755 _ 2 1951631 _ 206 2 Omit Omit AV11 _ _ _ _ N 5400258 _ 1 5400260 _ 1 5400288 _ 2 5400293 _ 1 5400295 _ 1 1943573 _ 1 1951398 _ 12 5400288 _ 1 1951755 _ 1 1951755 _ 2 1951631 _ 206 2 2 1 AV11 _ _ _ _ P 5400258 _ 1 5400260 _ 2 5400288 _ 2 5400293 _ 1 5400295 _ 1 114B095U01 1951398 _ 12 5400288 _ 1 1951755 _ 1 1951755 _ 2 1951631 _ 206 2 Omit Omit AV12 _ _ _ _ 0 5400258 _ 1 5400260 _ 1 5400288 _ 2 5400293 _ 2 5400295 _ 2 114B095U011951398 _ 12 5400288 _ 3 1951755 _ 1 1951755 _ 2 1951631 _ 206 2 Omit Omit AV12 _ _ _ _ N 5400258 _ 1 5400260 _ 1 5400288 _ 2 5400293 _ 2 5400295 _ 2 1943573 _ 1 1951398 _ 12 5400288 _ 3 1951755 _ 1 1951755 _ 2 1951631 _ 206 2 2 1 AV12 _ _ _ _ P 5400258 _ 1 5400260 _ 2 5400288 _ 2 5400293 _ 2 5400295 _ 2 114B095U011951398 _ 12 5400288 _ 3 1951755 _ 1 1951755 _ 2 1951631 _ 206 2 Omit Omit AV15 _ _ _ _ 0 5400258 _ 3 5400260 _ 1 5400288 _ 5 5400293 _ 1 5400295 _ 1 1945803 _ 1 1951779 _ 10 5400288 _ 4 1951755 _ 3 Omit 1951799 _ 206 Omit 2 Omit AV15 _ _ _ _ N 5400258 _ 3 5400260 _ 1 5400288 _ 5 5400293 _ 1 5400295 _ 1 1943573 _ 1 1951779 _ 10 5400288 _ 4 1951755 _ 3 Omit 1951799 _ 206 Omit 2 1 AV15 _ _ _ _ P 5400258 _ 3 5400260 _ 2 5400288 _ 5 5400293 _ 1 5400295 _ 1 1945803 _ 1 1951779 _ 10 5400288 _ 4 1951755 _ 3 Omit 1951799 _ 206 Omit 2 Omit AV16 _ _ _ _ 0 5400258 _ 3 5400260 _ 1 5400288 _ 5 5400293 _ 2 5400295 _ 2 1945803 _ 1 1951779 _ 10 5400288 _ 6 1951755 _ 3 Omit 1951799 _ 206 Omit 2 Omit AV16 _ _ _ _ N 5400258 _ 3 5400260 _ 1 5400288 _ 5 5400293 _ 2 5400295 _ 2 1943573 _ 1 1951779 _ 10 5400288 _ 6 1951755 _ 3 Omit 1951799 _ 206 Omit 2 1 AV16 _ _ _ _ P 5400258 _ 3 5400260 _ 2 5400288 _ 5 5400293 _ 2 5400295 _ 2 1945803 _ 1 1951779 _ 10 5400288 _ 6 1951755 _ 3 Omit 1951799 _ 206 Omit 2 Omit

Table 9-27. Cam Selection and Manifold/Gage Block Parts Reference for Type AV1 Positioners (Fig. 9-3)

Type

AV1 _ 1 _ _ __ 5400289 _ 1,2 — — — — — — —

_ 2 _ ___ 5400281 _ 1,2 — — — — — — —

AV1

_ 0 __ _ — Omit Omit Omit Omit Omit Omit Omit

AV11/2

_ 1 ___ — 5400282_ 1 5311428_ 207 (4 req) 4 2 2 Omit Omit

AV11/2

_ 2___ — 5400282_ 2 5311428_ 207 (4 req) 4 2 2 Omit Omit

AV11/2

_ 3___ — 5400318_ 1 5311428_ 207 (4 req) 3 3 Omit 3 3

AV11/2

_ 00__ — Omit Omit Omit Omit Omit Omit Omit

AV15/6

_ 30 __ — 5400318_ 1 5311428_ 207 (4 req) 3 3 Omit 3 3

AV15/6

13 17 64 65 66 67 91 92

Item (Part Number) Item (Quantity)

SUPPORT SERVICES

Figure 9-3. Type AV1 Positioner

ADDITIONAL SPARE PARTS

9 - 11

SUPPORT SERVICES

Table 9-28. Shaft Position Transmitter Parts Reference for Type AV1 Positioners (Fig. 9-3)

Item (Part Number) Item (Quantity)

Type

AV1

_ _ _ 0 _ _ Omit Omit — Omit Omit Omit _ _ _ 1 _ _ 6639542 _ 2 1 3+1 6 Omit 2

AV1

_ _ _ 2 _ _ 6639542 _ 1 1 3 +1 8 1 2

AV1

27, 50, 59, 61, 75,

83, 84, 86, 87, 89

31 58 77, 78 90

Table 9-29. Drive Shaft Parts Reference

for Type AV1 Positioners (Fig. 9-3)

Type

_ 1 _ _ 0 _ 5400287 _ 1 5327445 _ 21

AV1

_ 2 _ _ 0 _ 5400287 _ 1 5327445 _ 11

AV1

_ _ _ _ 1 _ 5400278 _ 1 Omit Omit

AV1

_ _ _ _ 2 _ 5400287 _ 2 Omit Omit

AV1

_ _ _ _ 3 _ 5400287 _ 3 Omit Omit

AV1

_ _ _ _ 4 _ 5400287 _ 4 Omit Omit

AV1

_ _ _ _ 5 _ 5400287 _ 5 Omit Omit

AV1

Item (Part Number) Item (Quantity)

14 63 34

Table 9-30. Type AV2 Positioner Parts List for Figure 9-4

Item Part No. Description Item Part No. Description

1 5400253 _ 3 Housing 54 NTCHA07000 2 5400258 _ 1 Cover assembly 55 NTGHA10000 Cam washer 3 5400259 _ 1 Valve stem 56 NTJHA09030 Span adjustment washer 4 Refer to Table 9-31 Valve body 57 Form MP432-889 Label, indicator 5 5400261 _ 1 Valve clip 58 197893 _ 1 Thread forming screw (8 req) 6 5400263 _ 1 Beam assembly 59 6639559 _ 1 Termination assembly 7 5400264 _ 1 Hinge 61 197893 _ 1 Label, CSA/FM 8 258544_ 1 Cam follower arm assembly 62 1963318 _ _ Nameplate, universal

9 5400271 _ 1 Spring arm 63 Refer to Table 9-31 Drive arm 10 5400272 _ 1 Pivot 64 5311428 _ 207 Manifold O-ring 11 5400273 _ 1 Eyebolt 65 NTJHA09030 Manifold washer 12 5400275 _ 1 Retainer nut 66 NBAHA16020 Manifold screw 13 Refer to Table 9-31 Cam 67 NBAHA16024 Manifold screw 14 Refer to Table 9-31 Cam shaft 68 R9025-0046 Tubing (50.8 cm (20.0 in.)) 15 5400279 _ 1 Zero adjustment nut 70 NIDHA09005 Pan head sems screw 16 5400280 _ 1 Range spring 71 193197 _ 1 Span adjustment bearing 17 Refer to Table 9-32 Manifold assembly 72 1943187 _ 1 Cable clip 18 193214 _ 1 Bearing 73 5400288 _ 1 Large diaphragm 19 5400286 _ 1 Indicator 74 114B094U01 Plug 20 5400288 _ 1 Small diaphragm 75 1951655 _ 1 Brass fitting (1 req) 21 Refer to Table 9-33 Potentiometer assembly 76 5400989 _ 2 I/P bracket 22 5400292 _ 1 Diaphragm spacer 77 5400304 _ 1 I/P support 23 5400293 _ 1 Diaphragm support 78 24 5400294 _ 1 Diaphragm ring 79

Diaphragm support scr washer

1 1 1

ADDITIONAL SPARE PARTS 9 - 12

SUPPORT SERVICES

Table 9-30. Type AV2 Positioner Parts List for Figure 9-4 (continued)

Item Part No. Description Item Part No. Description

25 5400295 _ 1 Diaphragm cover 80 07958063 I/P converter 26 5400296 _ 1 Exhaust mesh 81 1943187 _ 2 Cable clip (2 req) 27 193243 _ 1 Large position transmitter gear 82 NDPAC15004 Pan head screw 28 1951652 _ 1 Barb fitting (2 req) 83 1951747 _ 1 T-fitting 29 Refer to Table 9-31 Plug button 84 30 197120 _ 28 Cam nut 85 197860 _ 1 Cable strap 31 19734 _ 45 Washers 32 197777 _ 50 Retaining ring, cam (2 req) 88 6638288 _ 1 Barb fitting filter 33 197164 _ 18 Retaining ring, span 90 MP409-393 Connection label 34 197227 _ 1 Special hex head sems screw 91 6639479 _ 1 4 to 20-mA position xmttr assy 35 1951398 _ 12 O-ring (3 req) 92 197893 _ 1 Thread forming screw 36 197843 _ 1 Fastener, push-on, removable 93 R9023-0205 Heat shrink tubing 37 1945750 _ 1 Pull plug (3 req) 94 1946162 _ 4 Pin receptacle 38 5400072 _ 2 Knife base 95 5400268 _ 2 Bracket, pot mounting 39 5400073 _ 1 Knife edge 96 193242 _ 1 Small position transmitter gear 40 NBZHA21014 Cover screw 98 1951755 _ 1 Bumper grommet (3 req) 41 NBZHA21040 Cover screw 99 1951755 _ 2 Bumper grommet (2 req) 42 NBAHA15006 Hinge screw (4 req) 100 NTMHA13000 Lock washer 43 NPSHA05000 Hairpin clip (2 req) 101 MP409-393 Label, position transmitter 44 NTBTF13150 Teflon washer (3 req) 102 197893 _ 1 Thread forming screw 45 NBAHA13006 Diaphragm cover screw (4 req) 103 5400317 _ 1 Gear adapter 46 197865 _ 2 Stroke adjustment screw 104 NKJHA13004 Socket head cup pt set screw 47 197865 _ 1 Stroke adjustment screw 105 NKJHA16004 Socket head cup pt set screw 48 NKJHA16004 Zero adjustment set screw 106 1951041 _ 4 Socket head pipe plug 49 NBAHA16020 Span adjustment screw 107 NKJHA23006 Socket head cup pt set screw 50 1951041 _ 1 Socket head pipe plug 108 1951631 _ 206 O-ring 51 NIDHA13005 Indicator screw 109 258567 _ 1 NEMA 4X kit 52 NIDHA15012 Pilot valve screw (2 req) 110 5400264 _ 2 Hinge 53 NBMHA13006 Diaphragm support screw

NOTE:

1. Refer to Tables

2. Items 53 & 54 replaced by SEM screw NBMHA13006A as of November 23, 2009/Serial Number 3K620000029936

9-31, 9-32 and 9-33 for quantities.

86 MP409-393 Label, terminal block

1 1

Table 9-31. Cam and Drive Shaft Parts Reference for

Type AV2 Positioners (Fig. 9-4)

Type

AV231 _ _ 00 5400260 _ 1 5400289 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV231 _ _ 0N 5400260 _ 1 5400289 _ 1,2 5400287 _ 1 1943573 _ 1 532744 5 _22121 AV231 _ _ 0P 5400260 _ 2 5400289 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV231 _ _ 10 5400260 _ 1 5400289 _ 1,2 5400278 _ 1 1 14B095U01 532744 5 _1 2 Omit Omit Omit

_ _ 1N 5400260 _ 1 5400289 _ 1,2 5400278 _ 1 1943573 _ 1 532744 5 _1 2 Omit 2 1

AV231 AV231

_ _ 1P 5400260 _ 2 5400289 _ 1,2 5400278 _ 1 1 14B095U01 532744 5 _1 2 Omit Omit Omit

AV231 _ _ 20 5400260 _ 1 5400289 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV231 _ _ 2N 5400260 _ 1 5400289 _ 1,2 5400287 _ 2 1943573 _ 1 Omit 2 Omit 2 1 AV231 _ _ 2P 5400260 _ 2 5400289 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit

41314296331

Item (Part Number) Item (Quantity)

34 107 109

ADDITIONAL SPARE PARTS

9 - 13

SUPPORT SERVICES

Table 9-31. Cam and Drive Shaft Parts Reference for

Type AV2 Positioners (Fig. 9-4)

(continued)

Type

AV231 _ _ 30 5400260 _ 1 5400289 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV231 _ _ 3N 5400260 _ 1 5400289 _ 1,2 5400287 _ 3 1943573 _ 1 Omit 2 Omit 2 1 AV231 _ _ 3P 5400260 _ 2 5400289 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV231 _ _ 40 5400260 _ 1 5400289 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV231 _ _ 4N 5400260 _ 1 5400289 _ 1,2 5400287 _ 4 1943573 _ 1 Omit 2 Omit 2 1 AV231 _ _ 4P 5400260 _ 2 5400289 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV231 _ _ 50 5400260 _ 1 5400289 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV231 _ _ 5N 5400260 _ 1 5400289 _ 1,2 5400287 _ 5 1943573 _ 1 Omit 2 Omit 2 1 AV231 _ _ 5P 5400260 _ 2 5400289 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 0 0 5400260 _ 1 5400281 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV232 _ _ 0 N 5400260 _ 1 5400281 _ 1,2 5400287 _ 1 1943573 _ 1 532744 5 _22121 AV232 _ _ 0 P 5400260 _ 2 5400281 _ 1,2 5400287 _ 1 114B095U01 532744 5 _2 2 1 Omit Omit AV232 _ _ 10 5400260 _ 1 5400281 _ 1,2 5400278 _ 1 114B095U01 532744 5 _1 2 Omit Omit Omit AV232 _ _ 1N 5400260 _ 1 5400281 _ 1,2 5400278 _ 1 1943573 _ 1 532744 5 _1 2 Omit 2 1 AV232 _ _ 1P 5400260 _ 2 5400281 _ 1,2 5400278 _ 1 114B095U01 532744 5 _1 2 Omit Omit Omit AV232 _ _ 20 5400260 _ 1 5400281 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 2N 5400260 _ 1 5400281 _ 1,2 5400287 _ 2 1943573 _ 1 Omit 2 Omit 2 1 AV232 _ _ 2P 5400260 _ 2 5400281 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 30 5400260 _ 1 5400281 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 3N 5400260 _ 1 5400281 _ 1,2 5400287 _ 3 1943573 _ 1 Omit 2 Omit 2 1 AV232 _ _3P 5400260 _ 2 5400281 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 40 5400260 _ 1 5400281 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 4N 5400260 _ 1 5400281 _ 1,2 5400287 _ 4 1943573 _ 1 Omit 2 Omit 2 1 AV232 _ _ 4P 5400260 _ 2 5400281 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 50 5400260 _ 1 5400281 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV232 _ _ 5N 5400260 _ 1 5400281 _ 1,2 5400287 _ 5 1943573 _ 1 Omit 2 Omit 2 1 AV232 _ _ 5P 5400260 _ 2 5400281 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 00 5400260 _ 1 5400289 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV271 _ 0 0N 5400260 _ 1 5400289 _ 1,2 5400287 _ 1 1943573 _ 1 532744 5 _22121 AV271 _ 0 0P 5400260 _ 2 5400289 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV271 _ 0 10 5400260 _ 1 5400289 _ 1,2 5400278 _ 1 1 14B095U01 532744 5 _1 2 Omit Omit Omit AV271 _ 0 1N 5400260 _ 1 5400289 _ 1,2 5400278 _ 1 1943573 _ 1 532744 5 _1 2 Omit 2 1 AV271 _ 0 1P 5400260 _ 2 5400289 _ 1,2 5400278 _ 1 1 14B095U01 532744 5 _1 2 Omit Omit Omit AV271 _ 0 20 5400260 _ 1 5400289 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 2N 5400260 _ 1 5400289 _ 1,2 5400287 _ 2 1943573 _ 1 Omit 2 Omit 2 1 AV271 _ 0 2P 5400260 _ 2 5400289 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 30 5400260 _ 1 5400289 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 3N 5400260 _ 1 5400289 _ 1,2 5400287 _ 3 1943573 _ 1 Omit 2 Omit 2 1 AV271 _ 0 3P 5400260 _ 2 5400289 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 40 5400260 _ 1 5400289 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 4N 5400260 _ 1 5400289 _ 1,2 5400287 _ 4 1943573 _ 1 Omit 2 Omit 2 1 AV271 _ 0 4P 5400260 _ 2 5400289 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit

41314296331

Item (Part Number) Item (Quantity)

34 107 109

ADDITIONAL SPARE PARTS 9 - 14

SUPPORT SERVICES

Table 9-31. Cam and Drive Shaft Parts Reference for

Type AV2 Positioners (Fig. 9-4)

(continued)

Type

AV271 _ 0 50 5400260 _ 1 5400289 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV271 _ 0 5N 5400260 _ 1 5400289 _ 1,2 5400287 _ 5 1943573 _ 1 Omit 2 Omit 2 1 AV271 _ 0 5P 5400260 _ 2 5400289 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 00 5400260 _ 1 5400281 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV272 _ 0 0N 5400260 _ 1 5400281 _ 1,2 5400287 _ 1 1943573 _ 1 532744 5 _22121 AV272 _ 0 0P 5400260 _ 2 5400281 _ 1,2 5400287 _ 1 1 14B095U01 532744 5 _2 2 1 Omit Omit AV272 _ 0 10 5400260 _ 1 5400281 _ 1,2 5400278 _ 1 1 14B095U01 532744 5 _1 2 Omit Omit Omit AV272 _ 0 1N 5400260 _ 1 5400281 _ 1,2 5400278 _ 1 1943573 _ 1 532744 5 _1 2 Omit 2 1 AV272 _ 0 1P 5400260 _ 2 5400281 _ 1,2 5400278 _ 1 1 14B095U01 532744 5 _1 2 Omit Omit Omit AV272 _ 0 20 5400260 _ 1 5400281 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 2N 5400260 _ 1 5400281 _ 1,2 5400287 _ 2 1943573 _ 1 Omit 2 Omit 2 1 AV272 _ 0 2P 5400260 _ 2 5400281 _ 1,2 5400287 _ 2 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 30 5400260 _ 1 5400281 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 3N 5400260 _ 1 5400281 _ 1,2 5400287 _ 3 1943573 _ 1 Omit 2 Omit 2 1 AV272 _ 0 3P 5400260 _ 2 5400281 _ 1,2 5400287 _ 3 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 40 5400260 _ 1 5400281 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 4N 5400260 _ 1 5400281 _ 1,2 5400287 _ 4 1943573 _ 1 Omit 2 Omit 2 1 AV272 _ 0 4P 5400260 _ 2 5400281 _ 1,2 5400287 _ 4 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 50 5400260 _ 1 5400281 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit AV272 _ 0 5N 5400260 _ 1 5400281 _ 1,2 5400287 _ 5 1943573 _ 1 Omit 2 Omit 2 1 AV272 _ 0 5P 5400260 _ 2 5400281 _ 1,2 5400287 _ 5 114B095U01 Omit 2 Omit Omit Omit

NOTE:

1. Item quantity differs for Type AV2 positioners with the shaft position transmitter option. Refer to Table 9-33 for the quantity.

41314296331

Item (Part Number) Item (Quantity)

34 107 109

Table 9-32. Manifold/Gage Block Parts Reference for Type AV2 Positioners (Fig. 9-4)

Type

AV23 _ 0 _ _ _ Omit Omit Omit Omit Omit Omit AV23 _ 1 _ _ _ 5400282 _ 1 4 4 2 2 Omit AV23 _ 2 _ _ _ 5400282 _ 2 4 4 2 2 Omit AV23 _ 3 _ _ _ 5400318 _ 1 4 3 3 Omit 3 AV27 _ 00 _ _ Omit Omit Omit Omit Omit Omit AV27 _ 10 _ _ 5400282 _ 1 4 4 2 2 Omit AV23 _ 20 _ _ 5400282 _ 2 4 4 2 2 Omit AV23 _ 30 _ _ 5400318 _ 1 4 3 3 Omit 3

Item (Part Number) Item (Quantity)

17 64 65 66 67 105, 106

Table 9-33. Shaft Position Transmitter Parts Reference for Type AV2 Positioners (Fig. 9-4)

Type

AV23 _ _ 0 _ _ Omit Omit 2 Refer to Table 9-31 Omit Omit Omit AV23 _ _ 1 _ _ 6639540 _ 2 1 3+1 Omit Omit 2 Omit AV23 _ _ 2 _ _ 6639540 _ 1 1 3+1 Omit 1 2 2

Item (Part No.) Item (Quantity)

21 27, 95,96, 103 31 63 91, 101 92, 104 102

ADDITIONAL SPARE PARTS

9 - 15

SUPPORT SERVICES

Figure 9-4. Type AV2 Positioner (Page 1 of 2)

ADDITIONAL SPARE PARTS 9 - 16

Figure 9-5. Type AV2 Positioner (Page 2 of 2)

Table 9-34. Conversion Kits

SUPPORT SERVICES

Part No. Qty Application Description

258651_1 1 AV23 I/P Conversion Kit

NOTE:

1. Replaces older I/Ps that required an internal 22 psi pressure pre-regulator.

ADDITIONAL SPARE PARTS

9 - 17

APPENDIX A - POSITION TRANSMITTERS

INTRODUCTION

This appendix provides operation and calibration information for ABB position transmitter options. Refer to Table 1-4 (potentiometric position transmitter) or Table 1-5 (four to 20-milliamp position transmitter) for position transmitter performance specifications. A position transmitter provides additional control features to T ype AV positioners and can be ordered through nomenclature.

Position transmitters sense the position of the positioner cam shaft. Two variations exist:

• Potentiometric option (AV ____1__).

• 4 to 20-milliamp option (AV____ 2__ ).

DESCRIPTION AND OPERATION

Position transmitters are available as options (order through nomenclature).

The Type AV_ _ _ _ 1 _ _ potentiometric position transmitter option uses a high durability plastic film potentiometer. Gears connect the potentiometer to the positioner cam shaft. The position of the potentiometer shaft indicates the position of the actuator.

The relationship between the potentiometer and the cam shaft results in one degree of rotation of the cam shaft corresponding to approximately 9.9 ohms of resistive change at the potentiometer wiper. Three leads from the potentiometer are for customer use and are available at terminals TB1-1, TB1-2 and TB1-3.

The Type AV option also uses a high durability plastic film potentiometer and electronic circuitry. Gears connect the potentiometer shaft to the positioner cam shaft. The resistive change of the potentiometer outputs to a bridge circuit, producing a proportional voltage. EMI/ RFI protected circuitry converts the bridge voltage to a four to 20-milliamp current signal. Terminals TB1-1 (+) and TB1-2 (-) of the Type AV positioner provide customer access to the four to 20-milliamp control signal. Jumper position determines direct or reverse acting operation. Test jacks are available for in-line current monitoring.

_ _ _ _ 2 _ _ four to 20-milliamp position transmitter

INTRODUCTION

A - 1

POSITION TRANSMITTERS

CALIBRATION

There are two procedures for calibration; one for the potentiometric option (Type AV amp option (Type AV

Calibrating the Potentiometric Position Transmitter

This calibration example using the potentiometric position transmitter can be used as a guide for other applications. Final calibration of the potentiometric position transmitter option depends on the application. Field connections to the potentiometer are shown on a label located inside the positioner cover. The label is shown in Figure A-1.

_ _ _ _ 1 _ _) and another for the four to 20-milli-

_ _ _ _ 2 _ _).

AV23

AV33

AV44

AV ____1__

AV ____2__

Figure A-1. Terminal Block Connections

The nomenclature and terminal connections of Figure A-1 are:

The positive (+) and negative (-) connections at position TB1-4 and TB1-5 refer to the four to 20-milliamp signal to the I/P converter.

Not applicable. Not applicable. Depicts the connections for the potentiometric position trans-

mitter option. The positive (+) and negative (-) connections at position TB1-1

and TB1-2 refer to the output signal from the four to 20-milliamp position transmitter.

Direct acting cam rotation of zero to 100 percent produces increasing resistance between terminal block TB1-1 and TB1-2. Reverse acting cam rotation of zero to 100 percent produces decreasing resistance between TB1-1 and TB1-2.

CALIBRATION A - 2

POSITION TRANSMITTERS

The resistive change of the potentiometer is approximately 9.9 ohms (nominal) per degree of cam rotation, with a total resistance of 2000 ohms (nominal).

Application of the potentiometric option must consider the possibility of end resistance wrap-around.

POTENTIOMETRIC APPLICA TION EXAMPLE

A customer has a Type AV positioner with a 90-degree, direct acting cam, potentiometric position transmitter, along with a 24-VDC supply . The customer wishes to output a five-VDC signal when the Type AV positioner output is 80 percent.

1. Determine the angular rotation of 80% of 90.

0.80 x 90 = 72

72 of cam rotation is 80% of 90.

2. Determine the resistive change of the potentiometer through 72 of rotation. For every degree of rotation the resistive change is

9.9 (nominally):

72 x 9.9  = 712.8 

The change of resistance for this rotation is 712.8 , and appears between TB1-1 and TB1-2.

3. To guard against wrap-around, the minimum resistance at the potentiometer wiper at zero percent cam rotation is set to 200 . Therefore, the resistance between TB1-1 and TB1-2 should vary between 200 and 912.8 (712.8 + 200 = 912.8)  for a cam rotation of zero to 80%.

4. Determine the required current in the potentiometer that develops 5 VDC at the wiper at 80%:

5 VDC  912.8  = 5.48 mA

5. Determine the nominal voltage to produce 5.48 mA across the potentiometer:

5.48 mA x 2000  = 10.96 VDC

6. Determine the dropping resistor value that reduces the supply voltage to 10.96 VDC:

24.00 10.96– VDC

---------------------------------------------------- 2380=

5.48 mA

Connect a 2380-ohm variable resistor in series with the power supply . A variable resistor is required to account for the 20-percent

CALIBRATION

A - 3

POSITION TRANSMITTERS

tolerance of the potentiometer. Figure A-2 is a schematic diagram of this application example.

Figure A-2. Schematic Diagram

WARNING

CALIBRATING THE POTENTIOMETRIC EXAMPLE

The calibration information is based on the application put forth in

POTENTIOMETRIC APPLICA TION EXAMPLE.

1. Move the actuator to the 0% output position.

2. Remove the field wiring from TB1-1, TB1-2 and TB1-3. Using an ohmmeter, measure the resistance between TB1-1 and TB1-2. If the reading is 200, 20 , remove the ohmmeter and proceed to Step 3. Otherwise continue with Step 2.

The pneumatic supply pressure must be turned off before removing the positioning cam. The final control element will go to one end of the stroke and can cause a process upset. Some process upsets may cause damage to equipment and endanger personnel.

a. Remove the cam by removing the screw, flag, nut and washer (Fig. A-3 and Table A-1).

b. Loosen the set screw on the hub of the small gear using a

16

-in. Allen wrench (Fig. A-3 and Table A-1).

c. Use a screwdriver to adjust the shaft on the potentiometer until the ohmmeter reads 200, 20 . While adjusting the resistance, hold the gears and cam shaft stationary so rotation does not occur. Only the potentiometer shaft should move while adjusting the resistance.

CALIBRATION A - 4

POSITION TRANSMITTERS

Figure A-3. Potentiometric Position Transmitter (Exploded View)

Table A-1. Potentiometric Position Transmitter Kit 258670_1

Item

No.

21 6639540_2 1 Potentiometer assembly 27 193243_1 1 Large position transmitter gear 31 19734_45 1 Washer 60 5400317_1 1 Gear adapter 92 NDPAC13012 2 Threaded forming screw 95 5400268_1 1 Potentiometer mounting bracket 96 193242_1 1 Small position transmitter gear

d. Tighten the set screw on the small gear hub.

NOTE: If the mesh between the large and small gears is not tight, adjust the position of the potentiometer mounting bracket (Fig. A-3 and Table A-1) so that backlash is eliminated.

e. Remove the ohmmeter from TB1-1 and TB1-2. Install the cam, screw, flag, nut and washer (Fig. A-3 and Table A-1).

Part No. Qty Description

CALIBRATION

A - 5

POSITION TRANSMITTERS

3. Connect the field wiring to the terminal block. Connect a DC voltmeter between TB1-1 (-) and TB1-2 (+).

4. Move the actuator to the 80% position. Adjust the resistor in series with the 24-VDC supply until the voltmeter reads five VDC.

5. Move the actuator to the 0% position to verify that the voltmeter reads less than five VDC.

6. Move the actuator to the 100% position to verify that the voltmeter reads greater than five VDC.

Calibrating the 4 to 20-mA Position Transmitter

Labels located inside the positioner cover show the location of jumpers, test points, calibration potentiometers and field connection terminals for the position transmitter (Figs. A-1 and A-4).

WARNING

Figure A-4. Calibration Features for

4 to 20-mA Position Transmitter

1. Remove the FOR/REV jumpers, and place the CAL/OPER jumpers in the calibrate (CAL) position (Fig. A-4).

2. Move the actuator to the 50% output position.

3. Insert ohmmeter leads into test jacks TP1 (-) and TP2 (+). If the resistance value is between 940 and 1060 , remove the ohmmeter leads and proceed to Step 4. Otherwise continue with Step

CALIBRATION A - 6

POSITION TRANSMITTERS

a. Remove the cam, by removing the screw, flag, nut and washer (Fig. A-5 and Table A-2).

Figure A-5. 4 to 20-mA Position Transmitter (Exploded View)

Table A-2. 4 to 20-mA Position Transmitter Kit 258670_1

Item

No.

21 6639540_1 1 Potentiometer assembly 27 193243 31 19734 58 NDPAC13005 2 Threaded forming screw 60 5400317 91 6639479

92 NDPAC13012 2 Threaded forming screw 95 5400268 96 193242

Part No. Qty Description

_1 1 Large position transmitter gear

_45 1 Washer

_1 1 Gear adapter _1 1 4 to 20 mA position transmitter assem-

bly

_1 1 Potentiometer mounting bracket

_1 1 Small position transmitter gear

CALIBRATION

A - 7

POSITION TRANSMITTERS

4. Place the CAL/OPER jumpers into the operate (OPER) position (Fig. A-4). If a direct acting cam is being used, place the FOR/ REV jumpers in the FOR position. For a reverse acting cam, place these jumpers in the REV position (Fig. A-4).

b. Loosen the set screw on the hub of the small gear using a

16

-in. Allen wrench (Fig. A-5 and Table A-2).

c. Use a screwdriver to adjust the shaft on the potentiometer until the ohmmeter reads 1000, 10 . While adjusting the resistance, hold the gears and cam shaft stationary so rotation does not occur. Only the potentiometer shaft should move while adjusting the resistance.

NOTE: If the mesh between the large and small gears is not tight, adjust the position of the potentiometer mounting bracket (Fig. A-5 and Table A-2) so that backlash is eliminated.

d. Tighten the set screw on the small gear hub. e. Remove the ohmmeter from TB1-1 and TB1-2. Install the

cam, screw, flag, nut and washer (Fig. A-5 and Table A-2).

5. Connect a 24-VDC external power supply across TB1-1 and TB1-2.

6. Move the actuator to the 0% position. Insert ammeter leads into TP2(+) and TP1(-). If the position of the cam limits access to TP1, connect the (-) lead to TB1-2 on the terminal block.

7. Adjust the zero potentiometer to 4.00 mA. Refer to Figure A-4 for the location of the zero potentiometer.

8. Move the actuator to the 100% position. Adjust the span potentiometer to 20.00 mA. Refer to Figure A-4 for the location of the span potentiometer.

9. Repeat Steps 7 and 8 until the indicated current readings are obtained.

CALIBRATION A - 8

APPENDIX B - QUICK START

INTRODUCTION

This section is intended for control engineers with in-depth knowledge of positioners and positioner applications. This quick start only highlights the primary tasks involved in installation and operation. Section 1 through Section 5, in the main body of this instruction address installation and operation in more detail.

PRODUCT IDENTIFICATION (NOMENCLATURE)

Table B-1. Nomenclature

Position 1 23456789

Type A V

_______

1 2

6 20.7 to 186.2 kPa (3.0 to 27.0 psig), high temperature applications

7 4 to 20 mA with explosionproof I/P converter (NEMA 7) (Type AV2)

Page

Characterizable Pneumatic Positioner

Characterizable 4 to 20-mA Input Positioner (actuator moves to 0% or 100% upon loss of signal)

Input Signal

(Type AV1)

Characterizable Positioners

Stroke/Rotary Motion (cam selection) 1 12.7 to 50.8 mm (0.5 to 20.0 in.) or 45° rotary motion 2 25.4 to 101.6 mm (1.0 to 4.0 in.) or 90° rotary motion

Manifold (includes filters)/Gage Block

0 No manifold 1 Manifold with equalizing valve, filters and gage ports (required for dou-

ble acting actuators with manual override)

2 Manifold with equalizing valve inoperable (includes filters and gage

3 Gage block (gage port only)

0 None (must be 0 for Types AV15, AV16 and AV27) 1 Potentiometric resistive output 2 4 to 20-mA output

ports)

Position Transmitter

INTRODUCTION

B - 1

QUICK START

Position 1 23456789

Type A V

_______

Table B-1. Nomenclature (continued)

Characterizable Positioners

NOTES:

1. High temperature Type AV1 positioners are only available without manifolds or position transmitters; however, gage blocks are permitted.

2. Explosionproof Type AV2 positioners are not available with position transmitters or manifolds.

3. No longer available as of October 2003.

Drive Shaft

actuators

Other Options

0 Standard (no other options) N NEMA 4X enclosure rating (when installed per drawing C258567) P Performance Series — high pneumatic gain for large actuators

MOUNTING THE POSITIONER

Install the positioner as required on the actuator. Figures B-1 and

B-2 show typical mounting arrangements. Use the following pro-

cedure for mounting guidelines.

NOTE: If the actuator is equipped with a Type AV positioner as ordered, verify that all the connections are secure and make any adjustments as required.

1. Set the actuator at the zero position. Connect the adjustable linkage to the drive arm. The drive arm holes correspond to stroke length of the actuator. Refer to Figure B-3 for the stroke length for each drive arm hole.

2. Install the cam (black, direct acting; or red, reverse acting) that will provide the required direction of rotation.

NOTE: Cams have three mounting holes: A, square root; B, linear; C, square. Each mounting hole is star shaped so the cam can be rotated in 45 increments to suit the application.

3. With the actuator in the closed position, adjust the connecting linkage so that the zero radial line on the cam intersects the center of the cam roller (Fig. B-4).

4. Lock all linkage components in place.

MOUNTING THE POSITIONER B - 2

QUICK START

Figure B-1. Mounting Using Linkage (Typical)

Figure B-2. Mounting Using Direct Coupling (Typical)

MOUNTING THE POSITIONER

B - 3

ABB AV1, AV2 Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

List of Figures

List of Tables

OVERVIEW

SECTION 1 - INTRODUCTION

INTENDED USER

DESCRIPTION

Performance Series Option

Explosionproof I/P Option

NEMA 4X Option

APPLICATION

FEATURES

INSTRUCTION CONTENT

REFERENCE DOCUMENTS

NOMENCLATURE

SPECIFICATIONS

INTRODUCTION

SECTION 2 - DESCRIPTION AND OPERATION

FUNCTIONAL OPERATION

INTRODUCTION

SECTION 3 - INSTALLATION

UNP ACKING AND INSPECTION

ENCLOSURE CLASSIFICATION

MOUNTING CONSIDERATIONS

MOUNTING TYPE AV POSITIONERS

TUBING CONNECTIONS

Air Supply Pressure

Air Supply Filtering

Air Supply Quality (Recommended)

Tubing Connections

WIRING TYPE AV2 POSITIONER

WIRING TYPE AV1 POSITIONER

RADIO FREQUENCY INTERFERENCE

WIRING REQUIREMENTS

INTRODUCTION

SECTION 4 - CALIBRATION

CALIBRATION

Zero Adjustment

Span Adjustment

CALIBRATION FOR PARTICULAR APPLICATION

Zero Adjustment

Span Adjustment

GAIN AND SPEED ADJUSTMENTS

Gain Adjustment

Speed Adjustment

TROUBLESHOOTING CALIBRATION ADJUSTMENTS

SECTION 5 - OPERATING PROCEDURES

INTRODUCTION

EQUALIZING AND AIR SUPPLY SHUTOFF VALVE

Transfer from Automatic to Manual Operation

Transfer from Manual to Automatic Operation

INTRODUCTION

SECTION 6 - TROUBLESHOOTING

INTRODUCTION

PREVENTIVE MAINTENANCE SCHEDULE

SECTION 7 - MAINTENANCE

PREVENTIVE MAINTENANCE PROCEDURES

MANIFOLD FILTERS

SECTION 8 - REPAIR AND REPLACEMENT

INTRODUCTION

REPLACEMENT PROCEDURES

Manifold

Gain Hinge Spring

Pilot Valve Assembly

I/P Converter

Diaphragm Assembly

PILOT VALVE STROKE ADJUSTMENT

INTRODUCTION

SECTION 9 - SUPPORT SERVICES

RECOMMENDED SPARE PARTS

ADDITIONAL SPARE PARTS

APPENDIX A - POSITION TRANSMITTERS

INTRODUCTION

DESCRIPTION AND OPERATION

CALIBRATION

Calibrating the Potentiometric Position Transmitter

Calibrating the 4 to 20-mA Position Transmitter