Honeywell RP920A, RP920C, RP920B, RP920D Installation Instructions Manual

Modular Pneumatic Controllers

3 (75) MINIMUM CLEARANCE

4

(102)

3-3/8 (86)

9/32

(7)

RP920A: 1-1/2 (36)

RP920B-D: 3-1/4 (83)

5-7/8
(148)

1/8 (3)
MINIMUM
SPACING
BETWEEN
MODULES

RP920A: 1-7/8 (48)

RP920B-D: 3-13/16 (96)

M17581

INSTALLATION

Adjustments Before Mounting

1.

If a connection to port 4, 6, 7, or 8 (Fig. 2) is required,
remove the self-tapping screw from port 8 and use the
screw to tap the appropriate port.

2.

Install 14003755-001 Barb Fit ting and O-ring fing er-tight
in the appropriate port.

3.

Reinstall the screw in port 8 if not used.

4.

If a remote restriction is used for the primary sensor,
block the internal air supply (adjustable after gage
installation, but easier to adjust before installation):
a. Loosen the screw one turn (Fig. 3) and rotate the

switchplate (light grey) 90 degrees co unterclockwise
to the sensor supply blocked position.

b. Retighten the screw and check for leaks. If a leak is

found, reposition the switchplate.

RP920A,B,C,D

INSTALLATION INSTRUCTIONS

Device Mounting

1.

2.

Connections

1.

2.

NOTES:
— The switchplate screw mu st be tightene d securely

to prevent a false inoperative senso r condi tio n.

— The compensation sensor on port 5 requires an

external restricted main air supply.

Mark and drill two No. 8 fastener mounting holes using
the controller or Fig. 1 dimensions as a template.
Mount the controller with two No. 8 fasteners (not
supplied).

Push the tubing on the port barb fittings according to
the job drawings. See Fig. 2 for port locations.
Install the gage or plug:
a. If no gage is used, tighten gage plugs finger-tight.

If a gage is used, remove the plug and, by hand,
screw the gage into the gage port three turns.

b. If the gage is not oriented for correct viewing, rotate

the gage counterclockwise unti l corre ct.

NOTE: A soft-rubber, factory-installed seal allows

plug or gage rotation (for alignment) without
leakage.

Fig. 1. RP920 Dimensions in in. (mm).

After Mounting Adjustments and Changes

Controller Action Change

1.

Loosen the four Proportional Module screws (Fig. 4).

2.

Remove the module.

3.

Rotate the module and its gasket 180 degrees, and
reinstall. Ensure that the notch on the module lines up
with the proper indication on the controller label (base).

4.

Retighten the four screws.

5.

Recalibrate if required.

Negative (Winter) to Positive (Summer)
Compensation Change (RP920 B and D only)

1.

Loosen the four compensation module screws (Fig. 5).

2.

Remove the module.

3.

Rotate the module and its gasket 180 degrees, and
reinstall. Ensure that the notch on the module lines up
with the proper indication on the controller label (base).

4.

Retighten the four screws.

5.

Recalibrate, if required.

® U.S. Registered Trademark
Copyright © 2000 Honeywell • All Rights Reserved

95- 7392EF

RP920A,B,C,D MODULAR PNEUMATIC CONTROLLERS

GAGE PLUG

PRIMARY SENSOR
GAGE PORT

Connector
Block Module

BLP TEST TAP

Setpoint
Module

Proportional
Module

RP920A

4 8 9

2 3 1

60

40

20

W

1

0

%

5

10

20

40

30

DIR.

REV.

RP920A

1 – MAIN
2 – BRANCH
3 – PRIMARY

SENSOR

132

4 – VENT
8 – CLOSED/REMOTE

SETPOINT

9 – CPA

80

100

Xp (%)

45

PRIMARY SENSOR
GAGE PORT

Connector

Block Module

BLP TEST TAP

Setpoint

Module

PROPORTIONAL
BAND ADJUSTMENT
KNOB

Proportional

Module

RP920B,C,D

4 8 9

32

2 3 1

60

40

20

W

1

0

%

5

10

20

40

30

DIR. REV.

100

Xp (%)

45

1

80

RP920D

7

GAGE
PLUGS

7 6 5

100

80

60

20

40

TR

0.5

1

300

Ac (%)

5

50

1 – MAIN
2 – BRANCH

5

6

Wc

%

0

B

+

C

+

B
C

Min

20

15

10

4

3

1.5

2

250

200

150

100

NEG.

POS.

3 – PRIMARY

SENSOR
4 – VENT
5 – COMPENSATION

SENSOR
6 – VENT
7 – VENT
8 – CLOSED/REMOTE

SETPOINT
9 – CPA

COMPENSATION SENSOR
OR BRANCH GAGE PORT

COMPENSATION STARTPOINT
ADJUSTMENT KNOB

Switch
Block
Module

Integral

7

Module

5

Compensation
Module

MODULE KNOB SCREWS
(DO NOT LOOSEN)

1

2

RP920C,D ONLY.

1

Fig. 2. Module and port Locations.

Connector
Block Module

SENSOR
SUPPLY OPEN

SWITCHPLATE

POSITION INDICATOR

2 3 1

SCREW

OPEN POSITION

BLOCKED POSITION

SENSOR SUPPLY BLOCKED
(EXTERNAL RESTRICTOR)

SWITCHPLATE

C5102

Fig. 3. Primary sensor air supply.

Gage Function and Integral Action Cut-off
Adjustment (RP920C and D)

The position of the gasket located under the switch block
module (Fig. 2) determines the function of the field-installed
Switch Block Module gage and enables/disables the integral
action cut-off function. See Table 1 for factory and field
settings.

RP920B,D ONLY.

2

CAPTIVE SCREW (4)

5

10

Xp (%)

20

45

40

30

DIR. REV. DIR. REV.

DO NOT
ADJUST
SCREW

NOTE LOCATION
OF NOTCH

CONTROLLER
LABEL

DIRECT ACTING

PROPORTIONAL MODULE

40

45

Xp (%)

5

REVERSE ACTING

Fig. 4. Changing controller action.

Table 1. Switch Block Gasket Position.

Model Field Setting

a

Options

RP920B B C
RP920C B B+
RP920D B C, C+, B+

a

Shipped from the factory in this position.
B = Branch line gage.
C = Compensation sensor gage.
+ = Integral action cut-off enabled.

M17584

30

20

10

C5103

95-7392EF 2

CAPTIVE SCREW (4)

CAUTION

250

300

Ac (%)

5

50

100

POS.

NEG.

NEGATIVE COMP. (FACTORY SET)

200

150

DO NOT
ADJUST SCREW

COMPENSATION MODULE

NOTE
LOCATION
OF NOTCH

100

150

200

250

POS.NEG.

POSITIVE COMP.

50

5

Ac (%)

300

C5104

Fig. 5. Changing from negative to positive compensation.

1.

Check the gasket tab position (Fig. 6, front view).

2.

Loosen the three switch block module screws and
remove the module.

3.

Remove the gasket and note the letters (B, B+, C, C+)
embossed on the module back.

4.

Rotate and/or flip the gasket until the gasket position
matches the functions desired (Fig. 6, back view).

RP920A,B,C,D MODULAR PNEUMATIC CONTROLLERS

Adjustments:

1.

If using a scaleplate o ve r lay, insert the overlay betw ee n
the setpoint knob and the transparent overlay retainer.
Note positions of the key and non-coded scaleplate
overlay notch (Fig. 7).

2.

Adjust the setpoint (W
using the setpoint knob.

3.

If the control point deviates excessively from the
setpoint (W
consideration.

), calibrate, taking the throttling range into

1

), according to the job drawings,

1

REMOTE SETPOINT

Setpoint (W
primary sensor span from a remote 3 to 15 ps i (21 to 103 k Pa)

) is controlled from 0 to 100 percent of the

1

bleed-type signal.
Adjustments:

1.

Adjust the setpoint knob to 100 percent (Fig. 7) or to
the maximum remote setpoint limit to be applied.

2.

Install the 14003755-001 Barb Fitting and O-ring to
port 8 and connect to a bleed-type remote setpoint
device (e.g., SP970) and a remote setpoint gage.

NOTE: With the correct gasket position, only the

desired let ter shows.

5.

Install the gasket on the switch block module back.

6.

Reinstall the module, and tighten the three screws.

7.

If used, connect the integral action cut-off switching
components to ports 6 and 7.

GASKET SHOWN IN C POSTION. B, B+, AND C+ LEGENDS
CANNOT BE SEEN WITH GASKET IN THE C POSTION,
BUT ARE ILLUSTRATED HERE TO DISLPLAY LOCATION.

CAPTIVE SCREW (3)

Switch Block

+

B

+

C
B
C

B

B

+

GASKET TAB
IN C POSITION

C

C

+

BACK

C5105

60

FRONT

7 6 5

W

100

80

%

0

40

20

c

+

B

+

C
B
C

Fig. 6. Integral action cut-off and gage

function gasket position.

Setpoint (W1) Adjustment

The setpoint knob is embossed with a 0 to 100 percent scale
which correlates with the values in Table 3 (see Appendix).
Scaleplate overlays are included to directly match various
sensor ranges.

Three methods of controlling setpoint (W

LOCAL SETPOINT

Adjust setpoint (W

) directly on the controller.

1

) are available:

1

CONTROL POINT ADJUSTMENT (CPA)—AVAILABLE ON SPECIFIC
MODELS

Local (baseline) setpoint (W
and can be varied ±15 percent of the primary sensor span

) is adjusted on the controller

1

from a remote 3 to 15 psi (21 to 103 kPa) signal.
Adjustments:

1.

Pipe CPA to port 9.

2.

If used, select the proper scaleplate overlay.

3.

Note the position of key on the setpoint knob and the
non-coded scaleplate overlay notch (Fig. 7) for
controllers with U.S. A. labels. Controlle rs (RP920B,C,D)
with German labels must use “R” coded scaleplate
overlay notch when using a CPA device.

4.

Insert the scaleplate overlay between the setpoint knob
and the transparent overlay retainer.

5.

Adjust the setpoint (W
using the setpoint knob.

) according to the job drawings

1

Proportional Band (Xp) Adjustment

Adjust the proportional band (Xp), according to the job
drawings, using the proportional module proportional band
adjustment knob (see Fig. 2).

Control Loss Hazard.
Loosening knob screws can induce controller
leaks.

Use CCT819 and Authority S etting Ad justment Tool or
a narrow, stiff-blade putty knife to rotate adjustment
knobs (Xp and Ac).

Authority (Ac) Adjustment (RP920B and D only)

Adjust the authority (Ac), according to the job drawings, with the
compensation module authority adjustment knob (see Fig. 2).

3 95-7392EF

RP920A,B,C,D MODULAR PNEUMATIC CONTROLLERS

SCALEPLATE OVERLAY

"R" CODED SCALEPLATE
OVERLAY NOTCH

OVERLAY
RETAINER

SETPOINT KNOB

Setpoint
Module

LABEL

C5106

SETPOINT
KNOB KEY

R

NON-CODED
SCALEPLATE
OVERLAY NOTCH

60

40

20

20

80

W

1

100

0

%

5

10

Xp (%)

45

40

30

DIR. REV. POS. NEG.

HONEYWELL

RP920

SETPOINT

KNOB

TR

0.5

1

Ac (%)

5

Min

20

15

10

7
5

4

3

1.5

2

250

300

200

150

50

100

Fig. 7. Setpoint (W1) Adjustment.

Compensation Startpoint (Wc) Adjustment
(RP920B and D only)

Adjust the compensation startpoint (Wc), according to the job
drawings (reset schedule), using the compensation startpoint
adjustment knob (see Fig. 2). For direct-acting sensors, the
knob setting is equal to the compensation value
corresponding to th e lowest value given for the pr imary senso r
(from the reset schedule). See Fig. 9 and 10. If the value
given is not a percentage, convert it to a percentage of the
compensation sensor range using Table 3 (see Appendix):

1.

Find the correct sensor range column.

2.

Find the desired temperature in the column.

3.

Read the equivalent pressure in the second column.

4.

Read the equivalent pe rcentage in the first co lumn.

Reset Time (Tr) Adjustment (RP920C and D only)

Adjust the reset time (Tr), according to the job drawing s, using
the reset time adjustment knob (see Fig. 2):

1.

Decrease setting until the system becomes unstable.

2.

Increase the setting slightly until the system becomes
stable.

Replacing Cover

1.

If a cover is used, snap the cover straight on the front.

2.

The cover can be secured further by tightening the self­tapping screw in the cover lower right corner.

CALIBRATION

Sensors

Sensors are calibrated to the sy st em a nd req uire n o separate
calibration.

Systems

All RP920 Controllers a re f actory calibrat ed. It i s int end ed tha t
the controller be adjusted to the field-calculated values listed
on the job drawing. This controller startup approach will be
adequate for most systems. If it is determined that closer
calibration is required, use the following procedures:

NOTES:

— The controller allows all adjustments to be made

independently. For example, changing the
proportional band (X
calibration of the: setpoint (W
startpoi nt (W

— If a CPA device is used, apply 9 psi (62 kPa) to

), or authority (Ac) adjustment.

c

port 9.

— If a remote setpoint is used, block port 8.

RP920A System

1.

Install either:
a. a temporary receiver gage (matching the primary

sensor) or a 0 to 30 psi (0 to 207 kPa) gage in the
primary sensor gage port if one is not permanently
installed, or

b. a “tee” gage into the sensor line (port 3).

2.

Apply mainline pressure (MLP) to the system.

3.

Install a 0 to 3 0 psi (0 to 207 kPa) gag e in the branchli ne
pressure (BLP) test tap (moisten the needle before
inserting).

4.

If the sensor reading is greater than ±10 percent of the
expected setpoint, remove the se nsor tubing from por t 3
and apply a pressure equivalent (expected setpoint)
using a CCT816B Calibration Unit.

NOTE: For the most accurate calibration, the actual

measured variable at the sensor must be
±10 percent of the expec ted se tpo int.

5.

With the sensor at or near the desired control point,
adjust the setpoint knob until the BLP equals the
controlled device throttling range midpoint, e.g., 8 psi
(55 kPa) for a 3 to 13 psi (21 to 90 kPa) range device.

6.

If the setpoint (W
match, remove the setpoint knob and replace it so the

) and primary sensor gage do not

1

setpoint matches the primary sensor gage reading.

7.

Ensure W

8.

Calibration is complete.

is at the desired setpoint.

1

RP920B Systems

1.

Install in port 5 either a receiver gage that matches the
compensation sensor, or a 0 to 30 psi (0 to 207 kPa)
gage (see Fig. 8).

) setting does not affect the

p

), compensation

1

95-7392EF 4

NOTE: If the controller is setup for a compensation

gage in the right gage p ort, plug port 5 and use
the existing gage.

RP920A,B,C,D MODULAR PNEUMATIC CONTROLLERS

PRIMARY SENSOR

FULL
COMP

SETPOINT

(W1 )

COMPENSATION
STARTPOINT (Wc )

COMPENSATION SENSOR

C5111

2.

Install a 0 to 30 psi (0 to 207 kPa) gage in BLP test tap
or in BLP gage port if one is not permanently installed.

3.

Apply MLP to the system.

4.

Adjust the authority knob to minimum.

5.

Adjust the compensation startpoint knob until the
receiver gage (port 5) reads the pressure equivalent of
the compensation startpoint (W

6.

If the compensation startpoint (W
startpoint do not match, rem ov e the k no b and re pla ce it

) (Fig. 9 or 10).

c

) and desired

c

so they do match.

7.

The compensation startpoint (W

) is now calibrated.

c

NOTE: The response of the receiver gage may be

slow (up to one minute). The controller is not
defective under these conditions.

8.

Set up the CCT816B Calibration Unit (Fig. 11) to
connect to port 3 (primary sensor).

NOTE: Sensors are not connected.

THE GAGE RANGE MUST
MATCH THE RANGE OF THE
SENSOR FEEDING PORT 5

PRIMARY
SENSOR

4 8 9 7 5
2 3 1 6

M

C5109

17.

Remove the CCT816B Calibration Unit and pipe
sensors.

RP920C and D Systems

1.

Remove the integral module screw (Fig. 13) and install
the 14003755-001 Barb Fitting and O-ring in its place.

2.

Apply 8 psi (55 kPa) to the integral module.

3.

Calibrate the RP920:
a. RP920C: follow the procedure for the RP920A.
b. RP920D: follow the procedure for the RP920B

except that the calibration value of the BLP for

4.

Fig. 9. Negative compensation calibration reset sc hedule.

Steps 10 and 15 should both be 8 psi (55 kPa).
When calibration is complete, remove the barb fitting
from the integral module and replace the screw.

FULL
COMP

PRIMARY SENSOR

SETPOINT

(W 1)

COMPENSATION
STARTPOINT (Wc )

C5110

COMPENSATION SENSOR

Fig. 8. Piping for RP920B compensation

startpoint (W

9.

Apply a pressu re equ ivale nt of the p rimary sen sor valu e

c

corresponding to the compensation start (
the reset schedule (Fig. 9 or 10).

10.

Adjust the setpoint knob until the BLP equals the
expected pressur e of the cont rolled device at
conditions.

11.

If needed, remove the setpoint knob and replace it
so the setpoint matches the primary sensor value at

comp start

12.

The setpoint (W

13.

Set up the CCT816B Calibration Unit (Fig. 12) to

.

) is now calibrated.

1

connect to port 3 (primary sensor) and port 5
(compensation sensor).

14.

Apply sensor input pressures equivalent to the full
compensation on the building schedule.

15.

Adjust the authority (A
expected pressure of the controlled device at full

) knob until the BLP equals the

c

compensation conditions.

16.

Calibration is complete.

IMPORTANT

Changing compensation startpoi nt (W
(W1) affects only the one corresponding value of the
reset schedule, while changing authority (A
only the slope of the reset schedule.

NOTE: See the Compensation Startpoint (W

Adjustment section for more information.

) setting.

comp start

comp start

) or setpoint

c

) affects

c

)

c

) on

Fig. 10. Positive co m pen sa ti on c al ibr a ti on r e se t sc he du le .

RP920B Calibration Example

Assume the following conditions:
— A 10°F (5.6K) throttling range.
— Using a 2.5 to 6.5 psi (17 to 45 kPa) operator with a

normally open (N.O.) valve where conditions are: 6.5 psi

(45 kPa) with no load and 2.5 psi (17 kPa) with full load.
— See Fig. 14 for the schedule graph.
— See Table 2 for the reset schedule.

Table 2. Reset Schedule.

Compensation

Range

Start 120°F (49°C) (40%) 60°F (16°C) (50%)
Full 160°F (71°C) (60%) 0°F (-18°C) (20%)
Operating Span 40°F (22K) 60°F (33K)
Sensor Range 40 to 240°F

5 95-7392EF

Primary Sensor

(Discharge)

(4 to 11 6°C)

Compensation

Sensor (OA)

-40 to 160°F
(-40 to 71°C)