Cashco 9540R P-P User Manual
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
MODEL 9540R
P/P - PNEUMATIC POSITIONER FOR ROTARY VALVES
I. DESCRIPTION AND SCOPE
Model 9540R is a single acting, compact, force-balance, pneumatic positioner used together with a
rotary motion adapter baseplate for 90° rotary control
valves. This positioner is utilized to characterize the
relationship between valve stem position and the
system’s control signal. This design is only suitable for
nominal 3-15 psig (.21-1.0 Barg) input signals, or split
range variations thereof.
IOM-9540R
06-03
SECTION I
Each unit comes complete with a set of built-in gauges
within the internals, and a visual stem position indicator; the cover includes a clear see-thru panel to
monitor gauges. Gauges monitor input “SIG” and
output “LOAD”.
The Model 9540R P/P positioner may be utilized as an
alternate to the standard Model 9000R rotary P/P
positioner, with the following current Cashco product
models:
Ranger QCT
Premier EZO
Premier (unlined)
PCV
5-13 psig
SIG
15-3 psig
PC
REV.
PROCESS
P2 = 100 psig
IAS
P1 = 500 psig
3-15 psig
DIR.
ATO-FC
P/P
LOAD
IAS
Figure 1: Typical Pressure Reducing Pneumatic
Control Loop – PCV with P/P Positioner
20 psig
Model 9540R Mounted on a
Cashco Ranger QCT Control Valve
IAS – Instrument Air Supply
PC – Pressure Controller
PCV – Pressure Control Valve
ATO-FC – Air-to-Open, Fail Close
ATC-FO – Air-to-Close, Fail Open
P/P – Pneumatic Input/Pneumatic Output
DIR – Direct Acting
REV– Reverse Acting
SIG – Controller Output Signal
V – Vent
CW – Clockwise Rotation
CCW – Counter-Clockwise Rotation
II. METHOD OF OPERATION (See Figure 2)
The positioner operates with the force balance
principle: the input signal “SIG” (3-15 psig) acts on the
input diaphragm (50). The stroke of the input
diaphragm is transferred to the flapper lever (38). The
resulting movement of the flapper varies the dynamic
pressure at the nozzle (51). This pressure acts on the
amplifier (53) and the change in output pressure
causes a movement of the valve’s rotary stem.
The rotary movement is back fed from the valve stem
(55), thru a characterization cam (24), to the feedback
lever (13) of the positioner, and transferred to the
stroke factor lever (19). The stroke factor lever (19) is
connected to the flapper lever (38) by means of a
range spring (41).
SECTION II
The normal factor set position of the bypass switch (3)
is “EIN” (ON) (pointer at 6 o’clock), and the positioner
will be operational. If the positioner bypass switch (3)
is set to the “AUS” (OFF) position (pointer at 9 o’clock),
the input signal “SIG” is supplied direct to the actuator;
i.e. the positioner is only practical for control valves
where the positioner action is “Direct” and the actuator
bench range is approximately equal to the 3-15 psig
“SIG”. Use of bench ranges with upper limits greater
than 15 psig will cause the control valve to not be able
to fully stroke when bypassed.
3
SIG
"LOAD"
Y
50
44
53
A force balance is created on the flapper lever (38)
when the force generated by the input diaphragm (50)
balances with the counter-force produced on the range
spring (41). This ensures that the valve stem position
is always characterized to the input signal.
Dynamic matching to the actuator (sensitivity, stability) is factory set by means of the throttle screw (42)
and the damping throttles (44). The stroke range and
zero are set by means of the stroke factor thumbscrew
(40) and the zero thumbscrew (39). The changeover
plate (15) is used to set either an increasing or
decreasing output pressure for an increasing input
signal, i.e. direct or reverse acting.
III. MOUNTING TO SPRING DIAPHRAGM
ACTUATORS
A. The following text applies to the field mounting of
a positioner to a valve originally not supplied with
a shaft-end positioner. See Appendix A to remove
9000R.
B. Mounting Kit:
1. A factory-supplied field mounting kit must
be obtained. Request “Model 9540R P/P
Field Installation Kit” (FIK) and indicate the
following:
Figure 2: Single-Acting Positioner Functional Diagram
SECTION III
Travel
38
24
13
Valve
Stem
41
51
52
N
15
19
U
e. Desired characteristic; i.e. =%, linear
f. ATO-FC or ATC-FO action.
2. An airset with gauge is required. Request
separately from positioner KIT.
3. If a positioner indicating switch (by Bettis or
Proximity Controls) is shaft-end-mounted, the
use of the position switch(es) must be abandoned or replaced with probe-type proximity
switch(es) (“Go” Series 70) mounted on the
yoke. NOTE:
These units are available on
1” – 4” Rangers and 3” – 4” Premiers only.
C. Mounting Side:
"IAS"
42
39
40
a. Unit’s serial number
b. Product model; i.e. Ranger, Premier, or
Premier EZO
c. Valve body size
d. Actuator bench range
When viewed from the valve stem end, with the
actuator casing defined as upwards (above stem),
the position indication portion should be to the
“left”, and the positioner section should be to the
“right’.
IOM-9540R2
D. Existing Control Valve Modifications:
1. Refer to IOM-48 or IOM-148 for instructions
for the rotary actuators used on Ranger QCT,
Premier EZO and Premier (unlined).
d. Position the new positioner spacer (17)
over the valve stem (7 - Ranger, 3.2 Premier) end, oriented as shown below in
Figure 2.5.
2. All indicated Item Numbers that are with
respect to IOM-48 or IOM-148 will be in parenthesis and underscored; i.e. (
32). All part Item
Numbers that are with respect to this
IOM-9520R are not underscored; i.e. (32).
NOTE:
If no handwheel (58) or adjusting screw
assembly is provided with the actuator, it is
recommended that the rod end (9) be uncoupled from the arms (5) by removal of bolt
(40). See IOM-48 or IOM-148. Use of air
loading into the actuator casing (1) is possible, but introduces safety considerations;
i.e. use “tools” and not “fingers” inside the arm
housing (4) area.
3. Remove cover plate (20).
4. Steps to change the mounting and stem interconnection between the valve end-of-shaft
and the positioner unit. These changes bring
the positioner into compliance with NAMUR
Standard VDI/VDE #3845.
#48 Actuator: (See Figure 3)
a. Turn actuator handwheel CW to remove
stem windup torque. The linkage from the
actuator stem (9) will become slack. May
require 1-3 revolutions. This will ease
removal of cap screws (31).
b. Remove three cap screws (31), dial lens
(14), travel indicator dial (15), cover plate
(13), cap screw (32), travel indicator (16),
lock washer (55) and pin (51). Remove
bearing (18), both bearing flanges (19)
and indicator spacer (17).
c. Discard removed dial lens (14), travel
indicator dial (15), cap screw (32), travel
indicator (16), washer (55), pin (51) and
indicator spacer (17). Save only cover
plate (13), bearing (18) and both bearing
flanges (19) for re-use.
(Viewed looking
17
Actuator Casings
1, 2) on Topside
(
77
at Shaft end.)
Ranger
7
Premier
3.2
Figure 2.5: Spacer Orientation
e. Put Locktite #242 thread locking sealant,
or equal, onto the set screw (77). Engage
the set screw (77) into the tapped end of
the spacer (17), until the set screw (77) is
projecting out of the spacer (17)
3/16" – 1/4" (5 – 6 mm).
f. Position positioner baseplate (26) to
positioner mounting bracket (76) properly
oriented such that positioner baseplate
(26) bottom edge is parallel to the bottom
edge actuator arm housing (4). Opposite
side boltholes of bracket (76) must also
align with boltholes of actuator arm housing (4) and cover plate (13). Use four cap
screws (79) to secure the baseplate (26)
to the bracket (76). Place connected
parts (26, 76, 79) aside.
g. Position bearing flanges (19) with re-
tainer ball bearing (18) over the spacer
(17). Align the bearing flange (19) bolt
holes with the arm housing (4) bolt holes.
h. Position cover plate (13) over the bearing
flanges (19) aligning the cover plate (13)
bolt holes with those of the bearing
flanges (19). Hold cover plate (13) on
outer edge with fingers. NOTE:
Ensure
that the three tapped holes in the cover
plate (13) used to mount the bracket (76)
are near the 1 o'clock, 5 o'clock and 9
o'clock positions.
Engage three cap
screws (31) to secure spacer (17), bearing flanges (19) and cover plate (13)
securely to arm housing (4). NOTE
: It
may be necessary to rotate the actuator
manual handwheel operator (58) downwards, or alternately supply a small level
of air pressure (5-7 psig, .34 - .50 Barg) to
assist in aligning bolt holes for cap screws
(31). Do not tighten one cap screw (31)
until all three cap screws are partially
thread-engaged.
i. Position connected parts (26, 76, 79) of
Step 4f., above, with the bracket (76) up
and pressing against the cover plate (13),
engaging the tongue-and-groove joint
between the positioner baseplate rotary
shaft (32) and the spacer (17) with its
protruding set screw (77). Engage new
cap screws (78) to secure the bracket
(76) to the cover plate (13).
IOM-9540R
3
#148 Actuator: (See Figure 3)
a. Turn actuator handwheel (
58) CW to remove stem windup torque. The linkage
from the actuator stem (9) will become
slack. May require 1-3 revolutions. This
will ease removal of cover plate (13).
b. Remove four cap screws (34), two cap
screws (31), dial lens (14), travel indicator
dial (15), cap screw (32), travel indicator
(16), lock washer (55) and pin (51).
c. Remove cover plate (13) carefully, prying
out with a screwdriver or similar instrument. Shaft-end bearing (18) may slide
out when cover plate (13) is removed;
otherwise, remove bearing (18).
d. Remove indicator spacer (17).
e. Discard removed dial lens (14), travel
indicator dial (15), coverplate (13), two
cap screws (31), travel indicator (16), cap
screw (32), indicator spacer (17), pin (51)
and washer (55). Save only four cap
screws (34) for re-use.
f. Position the spacer (17) over the valve
stem (7 Ranger, 3.2 Premier) end, oriented as shown in Figure 2.5.
g. Put Locktite #242 thread locking sealant,
or equal, onto the setscrew ( 77). Engage
the setscrew (77) into the tapped end of
the spacer (17), until the setscrew (77) is
projecting out of the spacer (17) 3/16"–
1/4" (5–6 mm).
h. Position bearing (18) over the spacer (17)
and push fully inwards.
i. Position cover plate (13) over bearing
(18) ensuring that cover plate (13) gets
properly centered and shouldered within
the arm housing (4). Align the four bolt
holes within the arm housing (4). Engage
the cap screws (34) to secure the cover
plate (13) to the arm housing (4), tightening cap screws (34) evenly. NOTE
: It may
be necessary to rotate the actuator
manual handwheel operator (58) downwards, or alternately supply a small level
of air pressure (5-7 psig), (0.35-0.50
Barg) to assist in properly shouldering the
cover plate (13) within the arm housing (4).
5. Rotate handwheel operator (58) until slack, or
release all air pressure from the actuator.
6. Position mounting bracket (76) onto the
positioner base plate (26) and secure with
78
79
26
POSITIONER
SUB-ASSY.
GAUGE
BLOCK
79
POSITIONER
SUB-ASSY.
32
77
26
Figure 2.8: VDI/VDE #3845
Positioner Mounting Bracket
32
28
24
27
Detail of Parts
23, 24, 27, 28, 32
76
17
13
19
77
MODEL 48 ACTUATORS
17
78
13
76
MODEL 148, 148X
ACTUATORS
Figure 3
23
18
18
RANGER
7
PREMIER
3.2
4
7
RANGER
3.2
PREMIER
4
IOM-9540R4
13
31
Main
Positioner
Unit
21
17
Figure 4 - Rear View
four cap screws (79). The bracket should end
up with four holes to mount the positioner unit
and its baseplate (26) as shown in Figure 2.8.
7. Attach the baseplate and mounting bracket
(76) assembly to housing cover (13) using
four cap screws (78). Align baseplate (26) to
be parallel with bottom of valve's arm housing
(4). See III.C. NOTE:
Engage the tongueand-groove joint between the positioner
baseplate rotary shaft (32) and the spacer
(17) with its protruding set screw (77).
12. As shown in Figure 4, attach the feedback lever
(13) onto the positioner unit’s main shaft (17) by
hand-tightening socket cap screw (21). DO
NOT WRENCH TIGHTEN SCREW (21).
13. Remove the two plastic screws in the right side
of the main positioner unit where cap screws
(11) would be inserted. (See Figure 5.)
14. Begin to set the main positioner unit near its
final position on baseplate (26). Using needle
nose pliers grasp compensating spring (18)
and “hook” the end of the spring (18) under the
lower side of the feedback lever as indicated
in Figure 5.
Main Positioner
Unit
G2
11
12
WC
G2 = Air Supply "IAS"
G3 = Output "LOAD"
11
12
22
DC
A3
A3
"Notch"
G1
AB
33
26
8. Determine characterization cam's (24) proper
orientation as indicated in Figures 8 thru 15;
cut a spacer from wood or heavy cardboard to
the dimension “X” indicated.
NOTE:
Whether air-to-open (ATO) or air-toclose (ATC), Cashco's Ranger QCT, Premier
(unlined) or Premier EZO all rotate clockwise
(CW) to “close” valve, or counter clockwise
(CCW) to “open” valve, when viewed from
stem (7) end.
9. Place a thin film of adhesive, glue or pipe
thread sealant on the “back” side of cam (24)
to secure toothed lock washer (28) to cam
(24). Use post end screw (23) to correctly
align centers of these three parts (24, 27 &
28); do not allow the post-end screw (23) to
adhere to these parts.
10. Using the spacer of Step 8., position cam (24)
with adhered parts (27 & 28) up to the end of
positioner rotary shaft (32). Carefully screw-in
post-end screw (23) while holding cam (24) in
its approximate position. Hand-tighten postend screw (23) until certain that the washers
(27 & 28) have remained in alignment. (If
washers (27 & 28) are misaligned, the cam
(24) will not be able to be secured.)
11. Using the spacer of Step 6. above, wrenchtighten post-end screw (23) into a preliminary
position.
A1
Illustrated Position:
Ait to Close
Fail Open
24
31
17
18
AB
Figure 5
15. Position the positioner unit onto baseplate
(26), ensuring that the feedback lever’s (13)
roller is placed into contact with characterization cam (24) into the approximately proper
location. (See Figures 8 thru 15.)
16. Fasten the positioner unit to the baseplate
(26) inserting two cap screws (11) with lock
washers (12) thru the side of baseplate (26).
17. Remove the positioner cover (WC). Remove
plastic plug (33) from the upper edge of baseplate (26), allowing access to the socket cap
screw (21).
18. Press the stroke factor lever (19) (See Figure
6) of the positioner’s internals against the
travel stop pin (20) and hold firmly in place.
Using the #5 Allen wrench provided, tighten
socket cap screw (21) to the main shaft (17)
while holding the stroke factor lever (19).
Replace plastic plug (33).
11
12
13
11
12
IOM-9540R
5
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