A subsidiary of 
International, Inc.
12501 Telecom Drive, Tampa Florida 33637
INSTALLATION, OPERATING,
AND MAINTENANCE INSTRUCTIONS 20/1.5.2 Rev.3
PARTS LIST
LESLIE PILOT CONTROLLERS
TABLE OF CONTENTS
ADJUSTABLE PROPORTIONAL BAND PILOT CONTROLLERS (PDAP and PRAP Types)
SECTION I — INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SECTION II —OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 SECTION III — MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 SECTION IV — SETTING OF ADJUSTING PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
STEM LENGTH AND SENSITIVITY ADJUSTMENT (PRA-1 and PRQ-1 Types)
CONSTANT PRESSURE PILOT CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
CONSTANT, DIFFERENTIAL PRESSURE AND RATIO PILOT CONTROLLERS Force Balance, Fixed Band Types
SECTION I — INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 SECTION II — OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 SECTION III — MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-25
ILLUSTRATION INDEX
DRAWING, DIMENSIONS, TYPICAL INSTALLATIONS AND MISCELLANEOUS DATA
Figure 1 - Pilot Controller Piping Details - Pressure Reduction Station . . . . . . . . . . . . . . . . . .2 Figure 2 - Pilot Controller with 1:1 Volume Booster Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Figure 3 - Pilot Controller wit 1:1 Volume Booster and Reset Relay . . . . . . . . . . . . . . . . . . . . .3 Figure 4 - Pilot Controller with Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Figure 5 - Pilot Controller with Inverse Derivative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Figure 6 - Type PRAP Pilot Controller (5-80 psig range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Figure 7 - Type PDAP Pilot Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Figure 8 - Position of sliders for nut/blade spring adjustment . . . . . . . . . . . . . . . . . . . . . . . . .5 Figure 9 - Min./Max. Proportional Band Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Figure 10 - Adjustable Proportional Band Pilot Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Figure 11 - PRA-1, PRW-1, PRQ, Pilot Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Figure 12 - Pilot Controller piping details — Typical Installation . . . . . . . . . . . . . . . . . . . . . . . .8 Figure 13 - Drawing showing Direct Acting Type Pilot Controller (PDA-1, etc.) . . . . . . . . . . . .9 Figure 14 - Partial Drawing showing lever and lever pin, etc. . . . . . . . . . . . . . . . . . . . . . . . . . .9 Figure 15 - Diaphragm assembly for Pressure Ranges 13 PSIA - 20 PSIG to 50-125 . . . . . .11 Figure 16 - Back Pressure or Pressure Relief Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Drawing - Pilot Controllers Types PDA-1, PDQ-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Drawing - Pilot Controller Types PRA-1, PRA-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Drawing - Pilot Controller Type PDAP-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Drawing - Pilot Controller Types PRAP-1, Range 5-70 & 50-800 . . . . . . . . . . . . . . . . . . . . .20 Drawing - Differential Pilot Control Type UDDV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Drawing - Pilot Controller Type DDD, 15-75 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6" Vertical Section (Min.) |
Impulse LIne-Use 1/2" schedule 40 pipe or tubing |
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with equivalent I.D. |
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Avoid loops or pockets in impulse line to insure |
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Union |
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true pressure signal to pilot diaphragm. |
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Slope as shown for condensible gas service 1" per |
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Air Lines-Use 1.4" I.D. pipe or tubing. |
1" |
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foot minimum. |
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Use noncorrosive pipe and fittings. |
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Slope toward pilot for steam and liquids. |
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12" |
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Connect air supply to Pilot Controller |
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under gauge marked Operating Supply. |
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Gage |
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Connect outlet from Pilot Controller |
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under gauge marked Control Valves to |
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Diaphragm Control Valve. |
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Stop Valve |
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LESLIE Class AF-2 Pressure Reducing |
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Valve. Set reducing valve to supply 20- |
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22 psig air to pilot. |
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Figure 1. Pilot Controller Piping Details — Pressure Reduction Station |
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SECTION I - INSTALLATION |
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HYDROSTATIC HEAD PRESSURE |
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Install pilot controller vertically, in an accessible location. Allow removal space for ease of maintenance.
Pilot controller may be located above or below line controlled.
IMPULSE LINE CONNECTION AND LENGTH
Connect impulse line from top of diaphragm cover to controlled pressure line. Make connection at least 3 feet from the valve body opening or the end of any expander. Best results are obtained when the impulse line does not exceed 30 feet. Avoid connections near turbulent areas such as those created by orifices, elbows, sharp bends, or other flow direction changing components.
PITCH OR SLOPE OF IMPULSE LINE
Steam and liquid impulse lines should slope toward the sensing head. This ensures that the lines stay full of liquid or condensate. Pre-fill the sensing line before startup.
For noncondensing gases such as air, slope the lines away from the pilot, so that any liquid contaminants drain back to the process. Minimum slope is 1" per foot.
Accessary Equipment
Volume booster relays, positioners, reset relays, derivative units, etc. may be used with Leslie adjustable proportional band pilot controllers where system characteristics require their use.
When the pilot controller is installed under the line controlled, the total pressure resulting from hydrostatic head and controlled pressure must not exceed the maximum range of the pilot controller
SECTION II - OPERATION
The pilot is factory set and requires no adjustments other than those necessary to obtain the controlled pressure desired and the width of proportional band required by the system.
1.Close inlet and outlet stop valves around the control valve.
2.Open air supply line and impulse line stop valves. Set proportional band adjustment at “Maximum Band.”
For Pressure Reducing Service Only (Refer to Figures 6 & 7)
3.Turn adjusting nut (22) of pilot controller counter-clock- wise until control valve is wide open.
4.Open outlet stop valve partially. Fully open inlet stop valve slowly.
5.Make final adjustment for desired controlled pressure value. To increase controlled pressure screw adjusting nut (22) counter-clockwise. To decrease pressure screw adjusting nut clockwise.
6.Open outlet stop valve fully.
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Pressure Reduction
PDAP
N.O. Valve
Figure 2. Pilot Controller with 1:1 Volume Booster Relay
Pressure Reduction
PDAP
N.O. Valve
Figure 3. Pilot Controller with 1:1 Volume Booster and Reset Relay
For Back Pressure Service Only
3.Turn adjusting nut (22) of pilot controller counter-clock- wise until control valve is fully closed.
4.Open inlet stop valve fully. Partially open outlet stop valve. Turn adjusting nut (22) of pilot controller clockwise until control valve just begins to open. Open outlet stop valve fully.
5.Make final adjustments for desired controlled pressure value. To increase controlled pressure screw adjusting nut (22) counter-clockwise. To decrease controlled pressure screw adjusting nut clockwise.
Pressure Reduction
PRAP
N.C. Valve
Figure 4. Pilot Controller with Positioner. Split Ranging may also be done.
Back Pressure
PRAP
N.O. Valve
Figure 5. Pilot Controller with Inverse Derivative
ADJUSTMENT FOR REQUIRED
PROPORTIONAL BAND
Pilot controller is now ready for operation. Adjust for required width of proportional band as follows:
Turn adjusting know (76) counter-clockwise, moving pointer toward minimum band setting until the output air pressure begins to cycle. Widen the proportional band until the cycling stops.
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SECTION III - MAINTENANCE
DISMANTLING (Refer to Figures 6 and 7)
1. Bypass the control valve if system operation is necessary during maintenance work. Shut off air supply to pilot controller.
2. Take out body screws (36). Slide pilot body assembly off base in a downward direction away from adjusting pin (64).
3. Remove bottom plug (47). Remove diaphragm plate (30) from pilot body by removing capscrews.
NOTE: Do not disturb position of proportional band parts on diaphragm plate, unless work is required on them.
Take out diaphragm nozzle disc (29) remove flange ring (37) and gasket (40). In PRAP types remove nozzle valve (79) and spring (80).
Cleaning and Reassembling Pilot Body Assembly
1. Wipe all parts clean. Check ports in pilot body, nozzle and orifice to be sure they are clear. DO NOT use sharp abrasives. Open air supply and blow out supply line.
Figure 6. Type PRAP Pilot Controller (5-80 psig range)
Figure 7. Type PDAP Pilot Body Assembly
*NOTE: Spring (81) and spring seat (82) are not used in the 50800 psig range PRAP Pilot Controller.
2. Replace bottom plug (47) in pilot body. Place gasket (40) in pilot body. In PRAP types reinsert nozzle valve (79) and spring (80). Position flange ring (37) with nozzle upward on gasket (40). Insert flange ring screws and tighten.
3. Insert diaphragm nozzle disc (29) in pilot body with flat disc end toward nozzle. Replace diaphragm plate (30) on pilot body, with knob (76) on the right hand side. If blade spring (66) was removed from the assembly, be sure to reassemble it with the preformed end bends pointing upward.
Cleaning or Replacing Parts in Superstructure
NOTE: If maintenance work is necessary on superstructure alone, remove pilot body assembly from base as described in Step 2., Section III then proceed as shown below:
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Dismantling Superstructure
1.Loosen setscrew (63) and disassemble adjusting pin (64) from stem (13).
2.Remove diaphragm cover (3), diaphragm spring (81) and diaphragm spring seat (82), diaphragm (6), diaphragm disc (7), diaphragm spacer (15) and diaphragm guide (16). Lift out top spring seat (17) with stem (13), stem nut (19) and yielding spring (18). Remove adjusting spring (12), bottom spring seat (20), thrust bearing (21), adjusting nut (22) and locknut (23).
3.Clean all parts. Replace any worn or damaged part. To disassemble stem (13) from top spring seat (17) hold top spring seat rigidly on hex, press down on stem and remove stem nut from top spring seat.
REASSEMBLING SUPERSTRUCTURE
1.Reassemble locknut (23) (countersunk side downward), adjusting nut (22), thrust bearing (21), bottom spring seat (20) and adjusting spring (12) to adjusting sleeve
(14).Replace top spring seat (17) with assembled stem in yoke (10). Place diaphragm guide (16) in recess of yoke (10).
2.Place diaphragm spacer (15) on yoke (10) with raised face downward. Position diaphragm disc (7) on top spring seat (17). Place diaphragm (6), diaphragm spring seat (82), diaphragm spring (81) and diaphragm cover
(3)on diaphragm. Replace bolts (8) and nuts (2). Tighten firmly. Reassemble adjusting pin (64) to stem
REASSEMBLING PILOT BODY ASSEMBLY TO BASE
1.Slide pilot body assembly upward on base so that adjusting pin (64) passes smoothly through proportional band blade spring. Replace pilot body screws (36) and tighten firmly. Reconnect impulse line to diaphragm cover. Open air supply line. Adjust pilot as described in Section IV.
SECTION IV - SETTING OF ADJUSTING PIN
Supply 20-22 psig operating pressure to controller. Turn adjusting nut to compress adjusting spring to set upper diaphragm against its top limit stop. If possible, remove fluid pressure from top of diaphragm, if not, compress spring sufficiently to overcome fluid pressure and move diaphragm to stop.
For PDAP Adjustable Proportional Band Type
Adjust sliders ZC\zn” apart as shown in sketch below. Move proportional band nut upward on adjusting pin thread sufficiently to keep nut from touching blade spring during stem length adjustment. Loosen adjusting pin set screw and turn adjusting pin either up or down until pilot air output is 0 psig then turn adjusting pin downward toward pilot body until pilot air output increases from 0 to 21 psig. Lock set screw. Turn
proportional band nut down against blade spring until air output pressure decreases from 21 to 18 psig. With pin in stem hole to keep stem from turning, loosen set screw and turn adjusting pin upward away from pilot body approximately 1Z\v turns. Lock set screw.
For PRAP Adjustable Proportional Band Type
Adjust slider ZC\zn” apart as shown in sketch below. Move proportional band nut upward on adjusting pin thread sufficiently to keep nut from touching blade spring during stem length adjustment. Loosen adjusting pin set screw and turn adjusting pin either up or down until pilot air output is 21 psig. Then turn adjusting pin downward toward pilot body until pilot air output decreases from 21 to 0 psig. Lock set screw. Turn proportional band nut down against blade spring until air output pressure increases from 0 to 3 psig. With pin in stem hole to keep stem from turning, loosen set screw and turn adjusting pin upward away from pilot body approximately 1Z\v turns. Lock set screw.
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Stem (13) |
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Nut (65) |
Blade Spring (66) |
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Slider (70) |
Slider 975) |
Knob |
(76) |
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13/16" |
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Figure 8. Position of sliders for nut/blade spring adjustment
NOTE: When the above adjustments have been properly made, the proportional bands noted in Table - Figure 9 will be obtained when the sliders are set the approximate distances apart as shown.
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SLIDER |
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PILOT |
TEST |
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DISTANCE |
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RANGE |
PRESSURE |
MIN. |
MAX. |
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BAND (PSIG) |
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(PSIG) |
(PSIG) |
BAND |
BAND |
MIN. |
MAX. |
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5-70 |
50 |
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23⁄4" |
11⁄4" |
2.0 - 4.5 |
7.0 - 11.0 |
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50-800 |
80 |
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23⁄4" |
11⁄4" |
5.5 - 8.5 |
15.0 - 21. |
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Figure 9. Min./Max. Proportional Band Table
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Figure 10. Adjustable Proportional Band Pilot
Controllers
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STEM LENGTH AND SENSITIVITY ADJUSTMENT
TYPES PRA-1 AND PRQ-1
CONSTANT PRESSURE PILOT CONTROLLERS
FORCE BALANCE, FIXED BAND TYPES
ADJUSTMENT PROCEDURE
Supply 20-22 psig operating pressure to the pilot controller. Turn adjusting nut to compress adjusting spring to set upper diaphragm against its top limit stop. If possible remove fluid pressure from top of diaphragm, if not compress springs sufficiently to overcome fluid pressure and move diaphragm to stop.
ADJUSTING RESPONSE SENSITIVITY
Remove nozzle disc pin, pilot cover and diaphragm nozzle disc.
For Normal Response Sensitivity adjust pilot controller for very minor or no leak off. To do this relieve pressure of blade spring on nozzle stop by pressing lightly downward on it with finger. Then screw nozzle stop downward until it is felt to barely seat on nozzle nut.
For Supersensitive Response adjust pilot controller for continuous leak off. To do this slowly screw nozzle stop further downward until operating pressure flow is just detectable through nozzle bleed port. To check amount of leak off place finger lightly over nozzle bleed port to seal air (do not press down on nozzle). Air pressure in output line to diaphragm control valve should not build up any faster than 3-5 psig in 20-30 seconds. Lock nozzle stop with blade spring.
To Test Pilot Controller Body and Diaphragm Control Valve for response press downward on center of nozzle until 20-22 psig air pressure registers on output gauge. Control valve should move through full travel. Release nozzle. Air output pressure should drop to 0 psig and control valve should return to its original position.
After completing sensitivity adjustment replace diaphragm nozzle disc, nozzle disc pin and pilot cover.
LEVER SCREW ADJUSTMENT
Desired pilot controller performance will be obtained only if the upper (sensing) diaphragm is operating at or near its mean position, i.e. half way between its top and bottom limit stops in base and cover. Its position is determined by adjusting length of lever adjusting screw.
NOTE: THIS ADJUSTMENT IS FACTORY SET and should not be disturbed unless it is obvious that the original setting has been changed or major parts replacements were made which may cause need for readjustment.
These adjustments can be made when the pilot controller is set for either continuous or non-continuous leak off.
PRA-1 AND PRQ PILOT CONTROLLERS
1.Loosen locknut on lever setscrew. With 20 psig air pressure on out put gauge turn setscrew upward into lever until output air pressure just begins to fall away from 20 psig.
2.Then turn lever screw downward (out of lever) 3/4 turn for all low pressure pilots (up to and including the 50-125 psig range) 1-1/4 turns for high pressure ranges (100200) psig and over). Tighten locknut.
NOTE: With pilot air output at 20/22 psig, lever should be approximately in the parallel position. If not parallel loosen nozzle disc pin locknut and screw lower section of pin into or out of upper section of pin until lever is parallel. Tighten locknut.
Figure 11. PRA-1, PRW-1, PRQ, Pilot Controllers
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CONSTANT, DIFFERENTIAL PRESSURE AND RATIO
PILOT CONTROLLERS
Force Balance, Fixed Band Types
Types Covered:
PDA-1 |
PDW-1 PDQ-1 |
UDDV* |
DDD** |
PRA-1 |
PRW-1 PRQ-1 |
UDRV* |
UDDD*** |
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STOP — LOOK — READ |
OBSOLETE |
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ADHERENCE TO THESE INSTRUCTIONS
GUARANTEE OPTIMUM RESULTS
INSIST UPON THEIR BEING FOLLOWED.
SECTION I — INSTALLATION
Install Pilot Controller vertically in an accessible location. Allow removal¬ space for ease of maintenance. Pilot Controller may be located above or below line controlled.
NOTE: Whenever hydrostatic head exists on diaphragm effect must be considered with relation to obtainable pressures.
Piping Details
Figure 1 shows control pilot piping details. Control valve piping shown in figures is schematic only. Consult Control Valve Instructions for piping details.
Control Pipe Connection and Length
Connect Control Pipe from top of diaphragm cover to controlled pressure line. Make connection in controlled pressure line at least 3 feet from the valve body opening or the end of the expander, if one is in use. Best results are obtained when length of control pipe does not exceed 30 feet. Avoid connections near turbulent areas such as those created by orifices, elbows, sharp bends, or other flow direction changing components.
Pitch or Slope of Control Pipe
Pilot Above Line Controlled — Slope control pipe downward, away from the Pilot Controller. Provide at least 6" of vertical pipe at connection to pilot cover.
Pilot Below Line Controlled — Slope control pipe downward toward Pilot Controller.
Hydrostatic Head Pressure
Where the Pilot Controller is to be installed under the line controlled (and liquids or condensible gases are to be controlled) total pressure resulting from hydrostatic head and controlled pressure must not exceed the maximum range of the control pilot.
AIR LINES — Use 5/16" (1/4" |
6" Vertical Section (Min.) |
AVOID LOOPS OR POCKETS IN |
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I.D.) pipe or tubing. Use non- |
CONTROL PIPES to insure true |
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corrosive pipe and fittings. |
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pressure signal to pilot diaphragm. |
Connect outlet of air reducing valve to inlet of Pilot Controller (immediately under gage marked “Operating Supply”). Connect outlet of Pilot Controller (immediately under gage marked “Control Valve”) to diaphragm connection of Control Valve.
Operating medium clean air** Set Reducing Valve to supply 20-22 psig to pilot.
Strainer
Control pipe — use 1/2" 40 sched-
Union ule pipe or tubing with equivalent internal diameter
(For ranges up to and including 50-125 psig: for ranges 100-200
psig and over use 3/8" pipe).
Stop Valve
Gage
*See NOTE
*NOTE: AIR CONNECTIONS — Pilot Controller is equipped with stainless steel air supply and output fittings. DO NOT remove. Connect air lines directly to these fittings.
**NOTE: Operating medium for Classes PRA-1, PDA-1, UDRV, UDDV etc. (aluminum construction) must be clean air. (Win Class designation) are suitable for oil or water as operating medium.
Figure 12. — Pilot Controller piping details — Typical installation
*Use with Instruction 20/2.5.3 for replacing upper diaphragms — UDDV, UDRV Types. **Use instruction 20/3.5.1 for replacing upper diaphragms — DDD, UDDD Types.
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SECTION II — OPERATION
PROCEDURE: Follow Steps 1 and 2 then proceed with Steps 3 through 5 whichever applies to the particular service.
1.Close inlet and outlet stop valves around the control valve.
2.Open air supply line stop valve. Adjust 1/4" reducing valve to supply 20-22 psig pressure to control pilot.
For Pressure Reduction Installation
3.Turn adjusting nut of Pilot Controller Until diaphragm control valve is wide open.
4.Open outlet stop valve partially and control pipe stop valve fully.
5.Open inlet stop valve slowly, until Pilot Controller takes hold and starts to close the diaphragm control valve. Screw adjusting nut upward to increase, downward to decrease the controlled pressure. After desired controlled pressure is obtained, open inlet stop and outlet valves fully.
For Overflow Relief Installation
3.Turn adjusting nut of Pilot Controller until diaphragm control valve is closed.
4.Open inlet, outlet, and control pipe stop valves fully.
5.Turn adjusting nut of Pilot Controller so that diaphragm control valve starts to open when desired inlet pressure is exceeded.
Differential Pressure Pilot Controllers
3.Turn adjusting nut of control pilot to adjust compression on adjusting spring until control valve is wide open.
4.Open outlet stop valve partially and control pipe stop valves fully.
5.Open inlet stop valve slowly, until controller takes hold and begins to close the control valve. Readjust the adjusting nut of the control pilot to obtain desired differential. To increase differential, when highest pressure is on top of diaphragm, screw adjusting nut upward; to decrease differential, screw adjusting nut downward. When highest pressure is on underside of diaphragm screw adjusting nut upward to decrease differential; downward to increase. After desired differential setting is obtained, open inlet and outlet stop valves fully.
NOTE: When systems are in full operation, use caution in cutting a controller in so that system differential will not be disturbed.
Figure 13. — Drawing showing Direct Acting Type Pilot Controller (PDA-1, etc.).
DO NOT DISTURB SETTING
OF THIS PIN
Figure 14. — Partial Drawing showing lever and lever pin, etc., in lever action Types (PRA-1, etc.,).
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