Rosemount HAGAN 2½ x 5 Thrust Type, Swivel Mounted Pneumatic Power Positioner-Rev 1.0 Manuals & Guides

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Page 1

HAGAN 2-1/2 x 5 THRUST TYPE, SWIVEL MOUNTED PNEUMATIC POWER POSITIONER

Instruction Bulletin IB-102-202N Rev. 1

Page 2

Page 3

PAGE SUMMARY

HIGHLIGHTS OF CHANGES

Effective May, 1995 Rev. 1

3-0

3-1

6-1

Figure 3-1. Aded a callout regarding placement of positioner arm in relation to pilot valve.

Added paragraph 3-2. Mounting, regarding the correct positional relationship of the arm, calibration spring, and pilot valve.

Tables 6-1 and 6-2. Added "Maintenance Tool Kit" to both lists of recommended spare parts.

IB-102-202N

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ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount shall, upon prompt written notice from the purchaser, correct such non-conformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure of Rosemount to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it, will be subject to the same warranty as is extended to Rosemount by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system. Experience shows that systems installed and not supplied with services can be damaged either by the process or by the external environment and Rosemount will not accept any responsibility for this consequence.

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PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the Hagan 2-1/2 Inch x 5 Inch

Power Positioner, components, functions, installation, and maintenance.

This manual is designed to provide information about the 2-1/2 x 5 standard and on/off type power positioners. We recommend that you thoroughly familiarize yourself with the Overview and Installation sections before installing your power positioner.

The overview presents the basic principles of the power positioner along with its performance, characteristics, and components. The remaining sections contain detailed procedures and information necessary for installation and servicing of the power positioner.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment's operation and details necessary action.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc., that if not strictly observed, could result in injury, death, or long-term health hazards of personnel.

NOTE

Highlights an essential operation procedure, condition, or statement.

Highlights an operation or maintenance procedure, practice, conditions, statement, etc., that if not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

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TABLE OF CONTENTS

Section Page

Rosemount Warranty ......................................................... i

Purpose .................................................................. ii

I. OVERVIEW OF HAGAN 2-1/2 INCH X 5 INCH POWER POSITIONER

1-1. Scope ............................................................... 1-1

1-2. Package Contents ...................................................... 1-1

1-3. Equipment Description .................................................. 1-1

II. THEORY OF OPERATION

2-1. Standard Unit ......................................................... 2-1

2-2. On/Off Standard Option ................................................. 2-2

III. INSTALLATION AND ADJUSTMENTS

3-1. Location .............................................................. 3-1

3-2. Mounting ............................................................ 3-1

3-3. Air Connections ....................................................... 3-1

3-4. Wiring .............................................................. 3-1

3-5. Adjustment Of Standard Units ............................................ 3-2

3-6. Adjustment of On/Off Units ............................................. 3-4

3-7. Adjustment of Optional Limit Switches ..................................... 3-4

IV. TROUBLESHOOTING

4-1. Troubleshooting Standard Units ........................................... 4-1

4-2. Troubleshooting On/Off Units ............................................ 4-3

V. SERVICE AND NORMAL MAINTENANCE

5-1. Scheduled Maintenance of Standard Units .................................. 5-1

5-2. Scheduled Maintenance of On/Off Units .................................... 5-2

5-3. Repairs to Control Systems ............................................... 5-4

5-4. Repairs to Cylinder Assembly ............................................ 5-4

5-5. Installation of Limit Switches ............................................ 5-6

VI. RECOMMENDED SPARE PARTS ............................................ 6-1

VII. RETURNING EQUIPMENT TO THE FACTORY ............................... 7-1

INDEX .............................................................................. I-1

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LIST OF ILLUSTRATIONS

Figure Page

1-1 Standard 2-1/2 Inch x 5 Inch Power Positioner (Variable Position Pilot Valve Type) ....... 1-1

1-2 On/Off 2-1/2 Inch x 5 Inch Power Positioner (On/Off Standard Option,

Solenoid Valve Type) ....................................................... 1-2

2-1 Standard Power Positioner - Main Components .................................... 2-1

2-2 On/Off Power Positioner ...................................................... 2-3

3-1 Installation Dimensions ....................................................... 3-0

3-2 Mounting Pivot Base Assembly (Part No. 371763) ................................. 3-2

3-3 Standard Unit Adjustment ..................................................... 3-3

3-4 Limit Switch Option .......................................................... 3-4

4-1 Standard Unit, Exploded View ................................................. 4-4

5-1 Pilot Valve Assembly - Exploded View .......................................... 5-0

5-2 Solenoid Valve Assembly - Exploded View ....................................... 5-3

5-3 Limit Switch Installation ...................................................... 5-7

LIST OF TABLES

Table Page

4-1 Standard Unit Troubleshooting ................................................. 4-1

4-2 On/Off Unit Troubleshooting .................................................. 4-3

6-1 Recommended Spare Parts for the Standard Power Positioner ......................... 6-1

6-2 Recommended Spare Parts for the On/Off Power Positioner .......................... 6-1

6-3 Recommended Spare Parts for the Standard Pilot Valve Assembly ..................... 6-1

6-4 Bill of Materials for the 2-1/2 x 5 Power Positioner ................................. 6-2

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SECTION I. OVERVIEW OF HAGAN

2-1/2 INCH X 5 INCH POWER POSITIONER

1-1. SCOPE.

install, operate, maintain and service all models of the Hagan 2-1/2 Inch x 5 Inch Thrust Type, Swivel Mounted Power Positioner.

1-2. PACKAGE CONTENTS

comes completely assembled and carefully packaged to prevent damage in shipping. Inspect the packaging before removing the unit, and report any damage to the shipping agent.

Carefully pull the unit lengthwise out of the box. Find the packing list that is included in each shipment. Check the items received against the packing list to verify that the shipment is complete and correct. Make sure that the signal range stamped on the pilot valve is the one the packing list calls for. If a pivot base has been ordered, make sure it is attached to the unit. Check all items for damage.

1-3. EQUIPMENT DESCRIPTION

a. Purpose

This manual gives information needed to

The power positioner

The Hagan Power Positioner is typically used to position the damper of a large volume boiler. To do this, the power positioner connects to a lever on the damper jackshaft. The jackshaft connects to the damper. When the power positioner moves, the lever moves the jackshaft, which moves the damper.

The difference between the two positioner types is in the control power air system.

1. The Standard Power Positioner, Figure 1-1, uses a variable, low pressure control air circuit and a pilot valve assembly to control the single pressure power air. The higher the control air pressure, the farther the piston extends. With this type of equipment, boiler controls can move the power positioner to any point along its five inch stroke.

b. Operation

positioners available: the standard variable position pilot valve type, and the on/off standard option with a solenoid valve. Both use the same power components. In both types, power air pressure moves a piston in a cylinder. When air flow goes to the bottom of the cylinder the piston moves upward. When air flow goes to the top of the cylinder, the piston moves downward. As the piston travels, a clevis (attached to the piston rod) moves the damper lever.

There are two types of power

Figure 1-1. Standard 2-1/2 Inch x 5 Inch Power

Positioner (Variable Position Pilot Valve Type)

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2. The On/Off Standard Option, Figure 1-2, uses electrical signals and a solenoid valve to control power air. The piston stops travel only at fully extended or fully retracted positions. The power positioner stays in position until the solenoid valve is electrically shifted. This makes the on/off type the best choice in applications where the damper must stay in position during an electrical power failure.

See Section II, Theory of Operation, for detailed explanations of the operation of both power positioner models.

c. Limit Switch Option

Both the standard and on/off power positioners are available with limit switches. These limit switches signal the boiler control system when the power positioner is at the fully extended or fully retracted position. This option is available direct from the factory, or as a kit for field installation.

Figure 1-2. On/Off 2-1/2 Inch x 5 Inch Power

Positioner (On/Off Standard Option,

Solenoid Valve Type)

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685003

SECTION II. THEORY OF OPERATION

2-1. STANDARD UNIT.

a. General

Refer to Figure 2-1, Standard Power Positioner - Main Components. The piston assembly and power take-off clevis of the standard power positioner move away from the mounting pivot with an increase in control signal pressure. Movement of the piston, which is equipped with graphite impregnated teflon piston cups, begins when the increasing control signal at

NOTE: AN ASTERISK (*) INDICATES ITEMS ARE

INCLUDED IN THE PILOT VALVE ASSEMBLY.

POSITIONER ARM

the pilot valve assembly causes the stainless steel stem to move downward from the neutral setting. The pilot valve assembly then directs power air through the bottom tubing assembly to the bottom of the aluminum cylinder and exhausts air at the other end of the cylinder to atmosphere. The resulting pressure difference across the piston moves it upward.

POWER TAKE-OFF CLEVIS

TOP HEAD ASSEMBLY

DIAPHRAGM

ASSEMBLY*

INPUT SIGNAL

(CONTROL AIR)

(CUSTOMER

SUPPLIED)

POWER AIR (CUSTOMER

Figure 2-1. Standard Power Positioner - Main Components

CYLINDER

CALIBRATION

SPRING

SUPPLIED)

PILOT VALVE

ASSEMBLY

TEM AND SLEEVE ASSEMBLY*

TEFLON

PISTON CUPS

TOP TUBING ASSEMBLY

PISTON ASSEMBLY (INCLUDES TEFLON CUPS)

BOTTOM TUBING ASSEMBLY

MOUNTING PIVOT

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As the piston moves upward, it raises the upper end of the calibration spring. Tension in the spring is the feedback force in the pilot valve assembly. Piston movement continues until the spring force equals the force from the control signal, restoring the pilot valve stem to the neutral position. This blocks the flow of power air to cylinder and prevents further piston movement until signal pressure changes again.

For each control signal pressure, the piston is at a particular distance from the bottom of the cylinder. At the minimum signal it is at the lowest point in the cylinder. At the maximum signal it is at the upper limit, a distance of 5 in. (127 mm) from the lowest point. At any other signal, the distance from the bottom of the cylinder is proportional to the signal pressure. Full stroke time is two seconds or less. Toggling of the piston rod at or near full stroke is prevented by the large area guide bearings which are set relatively far apart in the top head assembly. The guide bearings are made of sintered teflon.

b. Pilot Valve

The pilot valve is a force/balance device. The pilot valve makes use of an external calibration spring (connected to the positioner arm), an internal dual-diaphragm assembly, and a sleeve and stem assembly.

increase of the control signal pressure causes a downward movement of the pilot valve diaphragm assembly. This forces the stem downward, uncovering ports in a stainless sleeve which permit power air to flow into the lower end of the cylinder and the air in the upper end to exhaust to atmosphere. The piston moves upward, pulling on the calibration spring. Tension in this spring increases until it balances the force due to the control signal acting in the diaphragm assembly. The stem then returns to the neutral position and blocks the ports in the sleeve, preventing further movement of the piston.

With a decrease in control signal pressure, the opposite actions occur. In this case, the force due to the control signal becomes less than the force of the calibration spring. The spring then pulls the spring post and stem seat upward. The stem is pushed upward by the spring in the pilot valve assembly and uncovers ports which transmit power air from the pilot valve to the top of the cylinder and exhaust the bottom of the cylinder. The piston then moves downward, reducing the tension in the calibration spring until it balances the force due to the lower control signal. The pilot valve assembly stem will then be in the neutral position again and prevent further movement of the piston.

Pilot valve operation is determined by the interaction of two primary forces:

1. A downward force developed by the control signal as it acts upon the diaphragm assembly.

2. An upward force created by the tension of the calibration spring.

In operation, the pilot valve diaphragm assembly moves up or down and repositions the stem when the force of the calibration spring and the force due to the signal pressure are not in balance. Starting with the stem in the neutral position, an

2-2. ON/OFF STANDARD OPTION

a. General

On/off type power positioners, Figure 22, use the same cylinder and piston assembly as the standard type positioner. The on/off type, however, uses an electric solenoid assembly in place of a pneumatic pilot valve.

The solenoid assembly allows pressurized air to enter one end of the cylinder, while exhausting air from the opposite end to atmosphere. During operation, air pressure builds on one side of the piston, forcing the piston to move toward the low pressure side. Air from the low pressure side simultaneously exhausts through a fitting on the solenoid valve body.

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SOLENOID B LAST ENERGIZED

SOL B SOL B

SOLENOID A LAST ENERGIZED

PRESSURE PRESSURE

EXHAUST EXHAUST

SOL A SOL A

NOTE: IF SOLENOID B WAS LAST ENERGIZED, THE PISTON

WILL BE FULLY EXTENDED. IF SOLENOID A WAS LAST ENERGIZED, THE PISTION WILL BE FULLY RETRACTED.

SOLENOID B

PORT A

2-1/2 X 5 CYLINDER

EXHAUST

FITTING

Figure 2-2. On/Off Power Positioner

b. On/Off Solenoid Valve

A solenoid operated, on/off valve controls air flow in the on/off standard option to the Rosemount power positioner. This system uses electrical impulses instead of pilot air pressure to control main air flow. There are only two positions for this type of equipment: piston fully out, and piston fully

POWER AIR

PORT B

SOLENOID A

685004

in. Once in a position, the piston stays in that position until the opposite solenoid is actuated. This means that if power fails, the piston stays in the same position. This feature makes the on/off type of valve the best choice in a system in which the damper must stay in place if power fails.

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PLACE ARM

DIRECTLY ABOVE

PILOT VALVE.

5.50

(140)

MAX R 9/16 (14)

3.7

(94)

MAX WIDTH

LINKAGE SHAFT

1-3/4

(45)

FOR CLEVIS MOUNT

CLEVIS PIN

MAX DIA

FOR PIN MOUNT

PIVOT PIN

1.50 (38)

1-1/2 (38)

THROAT

ARM

0.500 (12.7)

0.498 (12.65)

CLEVIS

ADJUSTMENT 9/16 (14)

(51)

1/4

(6)

PISTON ROD MOVES OUTWARD WITH INCREASE INPUT SIGNAL PRESSURE

5 STROKE

(127)

15-13/16

(402)

LEVER

'S MUST BE PARALLEL

WITHIN 2

CLEVIS HEIGHT CAN BE ADJUSTED

IN 1/2 TURNS ONLY FROM POSITION

SHOWN AND MUST BE REALIGNED

WITH ARM AND LOCKED-IN PLACE

0.69 R (18)

BY MEANS OF LOCKNUT

MOUNTING DETAILS

2-1/2

(64)

ALLOW FOR CLEARANCE

REQUIRED TO WITHDRAW

VALVE SLEEVE

0.501 (12.72)

0.502 (12.78)

PIVOT

0.750 (19)

0.755 (19.2)

2-1/4 (57)

NOTE: DIMENSIONS ARE IN

INCHES WITH MILLIMETERS IN PARENTHESES.

Figure 3-1. Installation Dimensions

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3-0

11/16

(18)

1/8 N.P.T. TAP FOR INPUT SIGNAL

1/8 N.P.T. TAP FOR AIR SUPPLY MAX 125 PSIG (862 kPa GAUGE)

2-5/32

(56)

5/8

(16)

685005

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SECTION III. INSTALLATION AND ADJUSTMENTS

3-1. LOCATION.

The positioner should be located in a clean, dry area free of excessive shock and vibration, with a continuous ambient temperature between 0° and 170°F (-18° and 77°C). It should be easily accessible for servicing.

3-2. MOUNTING

Before installation, carefully note the clearance dimensions and other mounting information shown in Figure 3-1. As shown in this figure, the positioner may be either clevis or pin mounted.

The positioner may be installed in any direction: vertical, horizontal, or inverted, whichever is most convenient. The mounting pivot base assembly (P/N

371763) is shown in Figure 3-2.

The power take-off clevis (Figure 3-1) should be properly aligned in relation to the axis of the mounting pivot. The center lines of the mounting pivot pin, linkage clevis pin, and linkage shaft must be parallel within two degrees.

Ensure that the arm anchoring the top of the large calibration spring is placed directly above the pilot valve, and that the spring is not twisted in such a way that will allow the pilot valve stem to rub on the sides of the casting.

b. On/Off Units

Connect power air to the 0.25 in. NPT air tap on the valve body as shown in Figure 2-2. Copper tubing with a 1/4 in. OD and 0.035 in. wall thickness is best. Note that the entire power positioner assembly moves when the piston extends. To keep this movement from stressing the copper air line, coil three turns of the line near the unit.

A shutoff valve and air filter should be provided in the air supply line. The shutoff valve is necessary to isolate the positioner when servicing it. Recommended air supply pressure is 100 psi (689 kPa). Maximum air supply pressure is 125 psi (862 kPa).

3-4. WIRING

All wiring must comply with local and

national electrical codes. Connections are designed for

0.50 in. conduit. Since the entire power positioner moves when the piston extends, use flexible conduit for all wiring. If the unit is likely to get wet, use liquid tight flexible conduit.

a. Standard Units

Wiring is not necessary on a

standard unit with no limit switches.

3-3. AIR CONNECTIONS

a. Standard Units

assembly. Control signal and power air connections, located in the pilot valve assembly, are 1/8 in. NPT taps. Refer to Figure 3-1. On the pilot valve the upper tap is for the input signal and the lower one is for the air supply. Copper tubing with 1/4 in. (6.35 mm) OD and 0.035 in. (0.89 mm) wall thickness is best. Note that the entire power positioner assembly moves when the piston extends. To keep this movement from stressing the copper air lines, coil each air line three turns near the unit.

Connect air to the pilot valve

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3-1

Be careful when removing the retaining clip to wire the solenoid valve. The retaining clip will spring upward when it disengages. This could cause injury.

Make sure that the solenoids and the electrical source are the same type. AC and DC solenoids are different internally and will be damaged by the wrong electrical current.

b. On/Off Units

Remove metal retaining clip (1, Figure 5-2) and rotate solenoid backplate (8) to the necessary position. Make the wiring connections necessary for the control system. Then replace the housing and nameplate and reinstall the retaining clip.

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685006

1/2 R

(13)

4 HOLES 13/32 O/(11)

C OF CYLINDER MUST NOT FALL

OUTSIDE OF THIS ZONE

1-5/16

(34)

1-13/16

(46)

1-5/16 (34)

1-13/16 (46)

1-5/16 (34)

3-5/8

(98)

1-1/2 (38)

3-5/8 (98)

PILOT VALVE

REQ.

NOTE: DIMENSIONS IN INCHES WITH

LINE

1 1

MILLIMETERS IN PARENTHESES.

1 2

NAME "E" RING CLEVIS PIN

PIVOT BASE

PAR T NO .

120079-10 171762

371738

1/2

(13)

BRACKET AND BOLTING

NOT BY HAGAN

Figure 3-2. Mounting Pivot Base Assembly

c. Limit Switches

To wire limit switches on either type of unit, remove the cover plate that is held by two screws, and wire the limit switches to the system controls as necessary.

3-5. ADJUSTMENT OF STANDARD UNITS

standard power positioner must be adjusted so the piston is at the lower limit when the control signal is at minimum pressure, and moves to the upper limit when the signal is increased to maximum pressure.

(Part No. 371763)

Refer to Figure 3-3 and use the following procedure to make the adjustment:

The

Disconnect the mechanical linkage from the clevis.

With the control (input) signal and power air supply lines disconnected from the pilot valve, clean the lines with high pressure air.

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POSITIONER

Number of active coils required

ARM

MECHANICAL LINKAGE

CLEVIS

SET SCREW

PISTON ROD

6. Lock this setting by tightening the set screw until the positioner arm binds to the piston rod.

With the piston at the bottom of the cylinder, place a mark on either the clevis or the 1/2-in. diameter chrome plated piston rod. The mark is for use in measuring the piston stroke. If the stroke is not correct, increase or decrease the number of active coils in the calibration spring. Active coils are those which are free of the positioner arm and which flex when under load.

CALIBRATION

SPRING

CONTROL

SIGNAL

LINE

POWER AIR

SUPPLY LINE

PILOT

VALV E

BOTTOM CYLINDER HEAD

Figure 3-3. Standard Unit Adjustment

Open the air supply filter drain and blow out accumulated moisture and foreign particles.

Reconnect the control signal and power air supply lines. Adjust power air supply pressure to desired value.

e.Apply minimum control signal to the pilot valve.

The piston should move to the lowest position, against bottom cylinder head. Check this in the following manner:

1. Maintain minimum control signal on the pilot valve.

2. Loosen the set screw on the positioner arm.

685007

Determine stroke by increasing control signal pressure slowly and observing travel of the mark (discussed in preceding paragraph).

1. If the piston moves to upper limit before the control signal reaches maximum pressure, the number of active coils must be decreased as described in step g.

2. If piston travel is less than desired when maximum signal is applied, the number of active coils must be increased as described in step h. Maximum travel is approximately 5 in. (127 mm).

3. If piston stroke is satisfactory, perform steps i, j and k.

To decrease the number of active coils, use the following procedure:

1. Reduce control signal to zero.

2. Count the active coils of calibration spring. Active coils are those which are free of the positioner arm and which flex when under load.

3. Determine the exact control signal pressure at which the piston reaches upper limit.

4. Determine the number of active coils required by using the following equation:

3. Move the positioner arm up until the piston moves to the bottom of the cylinder.

Where:

4. Move the positioner arm down until the piston begins to move upward.

Pa = Signal pressure at which piston

reaches upper limit

5. Move the positioner arm down until the piston just returns to lowest position.

Pm = Maximum control signal pressure

to be used

Ca = Actual number of active coils

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5. Reduce active coils to the number required by turning the calibration spring further onto the positioner arm.

6. Repeat step f to check the stroke again.

To increase the number of active coils, use the following procedure:

1. Reduce control signal to zero.

2. Count active coils of calibration spring. Active coils are those which are free of the positioner arm and which flex when under load.

3. Determine exact piston stroke by measuring amount of travel of the mark (on piston rod or clevis) when control signal is increased from zero to maximum pressure.

4. Determine the number of active coils required by using the following equation:

3-7. ADJUSTMENT OF OPTIONAL LIMIT

SWITCHES.

Refer to Figure 3-4. Adjust the upper limit switch so the switch striker activates the switch when the piston reaches its fully extended limit. Adjust the lower limit switch so the striker activates the switch when the piston reaches its fully retracted limit. Adjust the switches as follows:

Observe the limit switches while running the power positioner. Each switch should activate just as the piston reaches its mechanical limit, and switch off as the piston begins to move in the other direction.

To adjust a limit switch, loosen the switch mounting screws to allow the switch assembly to slide on its bracket. Slide switch assembly as necessary, then retighten the screws. Watch the switch again while running the positioner. Readjust as necessary.

Sr Sa

Number of active coils

required

Where:

Sa = Actual stroke Sr = Required stroke Ca = Actual number of active coils

5. Increase the number of active coils by turning spring off of the positioner arm.

6. Repeat step f to see if desired stroke is obtained.

Repeat step c to check minimum setting again.

Check mechanical linkage between the positioner and the damper or valve that the positioner positions. All links must be properly aligned.

Reconnect mechanical linkage to clevis.

3-6. ADJUSTMENT OF ON/OFF UNITS

adjustment of on/off units.

There is no

UPPER

LIMIT

SWITCH

MOUNTING

SCREW

SWITCH

STRIKER

LOW LIMIT

SWITCH

BRACKET

Figure 3-4. Limit Switch Option

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SECTION IV. TROUBLESHOOTING

4-1. TROUBLESHOOTING STANDARD UNITS.

The four most common causes of poor operation of the standard power positioner are listed below. Check if any of these conditions exist and make corrections, if necessary, before starting any repairs. If none of these conditions apply, Refer to Table 4-1, Standard Unit Troubleshooting.

Air supply pressure is below normal. Check for the following conditions:

1. Complete loss of air supply or less than normal air supply pressure.

2. Air supply to the positioner shut off at a valve or cut off due to a change or break in the piping.

Table 4-1. Standard Unit Troubleshooting.

Unless otherwise indicated, item numbers are in reference to Figure 4-1.

NOTE

3. Pressure reducing valves in the system incorrectly adjusted.

4. Air filters restricting flow due to dirty elements. Blow down all filters.

Plugged signal or air supply line. Check that all lines are clean. Clear out any foreign material which may be blocking them.

Leaks in signal lines, air supply lines and tubing assemblies. Go over each joint and connection in these lines with soap suds to check for air leaks. Stop any leaks found.

Excessive friction at mounting pivot, clevis and associated mechanical linkage. Check that these points are well oiled, not binding, or otherwise inhibited.

SYMPTOM CAUSE SOLUTION

1. Erratic operation along with one of the following:

a. Piston moves in a jerky manner. a. Sticky material on inside of

a. Clean cylinder walls.

cylinder wall.

b. Piston fails to move to desired

position quickly when signal

b. Stem (15, Figure 5-1) sticking

due to gummy deposits.

b. Clean stem and sleeve.

changes.

c. Power air [100 psi (689 kPa)]

continuously blowing through

c. Stem (15, Figure 5-1)

excessively worn.

c. Replace stem and sleeve.

exhaust ports of pilot valve assembly.

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Table 4-1. Standard Unit Troubleshooting (Continued).

NOTE

Unless otherwise indicated, item numbers are in reference to Figure 4-1.

SYMPTOM CAUSE SOLUTION

2. Piston does not move full stroke when maximum signal is applied and one of the following symptoms is present:

a. No other symptoms. a. Too few active coils in

calibration spring (8).

a. Increase number of active coils

in spring (8). Refer to paragraph

3.5.h.

b. Signal air [15, 30, or 60 psi (103,

207, or 414 kPa)] continuously

b. Broken diaphragm in pilot

valve assembly.

b. Replace broken diaphragm.

leaking from exhaust ports of pilot valve assembly (27).

c. Power air [100 psi (689 kPa)]

c. Piston cups (22) worn. c. Replace both piston cups. blowing continuously through exhaust ports of pilot valve assembly (27).

3. Piston does not return to bottom of cylinder when signal is zero and one of the following symptoms is present:

a. No other symptoms. a. Positioner requires adjustment. a. Perform Adjustments of

Standard Units, paragraph 3-5.

b. Power air leaking past piston rod

b. Piston rod seal (12) worn. b. Replace piston rod seal.

(5) at seal retainer (11).

c. Power air continuously blowing

c. Piston cups (22) worn. c. Replace both piston cups. out of exhaust ports of pilot valve assembly (27).

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4-2. TROUBLESHOOTING ON/OFF UNITS.

Table 4-2, On/Off Unit Troubleshooting, for a listing of possible symptoms, causes and solutions for

Refer to

problems with an on/off type power positioner. Cylinder and piston assembly parts are identical to those of the standard unit (Figure 4-1).

Table 4-2. On/Off Unit Troubleshooting.

NOTE

Unless otherwise indicated, item numbers are in reference to Figure 5-2.

SYMPTOM CAUSE SOLUTION

1. Erratic operation along with one of the following:

a. Piston moves in a jerky manner. a. Sticky material on inside of

cylinder wall.

b. Piston fails to move to desired

position quickly when solenoid

b. Core subassembly (12) sticking

due to gummy deposits.

changes.

c. Power air [100 psi (689 kPa)]

continuously blowing through

c. Valve (18) or piston cups (22,

Figure 4-1) excessively worn. exhaust ports of solenoid valve assembly.

2. Piston does not move full stroke when solenoid is energized and one of the following symptoms is present:

a. No other symptoms. a. Open or burned out coil (6) in

solenoid.

Faulty control circuit.

b. Excessive leakage at solenoid

valve.

b. Worn or damaged parts in

solenoid valve assembly.

a. Clean cylinder walls.

b. Clean core subassembly.

c. Replace worn components.

a. Check continuity of coil. Replace

if necessary.

Energize solenoid; listen for metallic click. No click means no voltage.

b. Replace solenoid valve

assembly.

3. Piston does not return to bottom of cylinder when opposite solenoid is energized.

Replacement parts for the solenoid valve assembly are available from ASCO Valves at the following address:

a. Open or burned out coil (6) in

solenoid.

Faulty control circuit.

NOTE

ASCO Valves Automatic Switch Co. Florham Park, NJ 07932

IB-102-202N

4-3

a. Check continuity of coil.

Replace if necessary.

Energize solenoid. Listen for metallic click. No click means no voltage.

Page 22

685009

Figure 4-1. Standard Unit, Exploded View

IB-102-202N

4-4

Page 23

LEGEND FOR FIGURE 4-1

ITEM DESCRIPTION

1 Retaining Ring 2 Clevis Pin 3 Clevis 4 Hex Nut 5 Piston Rod 6 Positioner Arm 7 Socket Head Cap Screw 8 Calibration Spring

9 Cap Screw 10 Lock Washer 11 Seal Retainer 12 Seal 13 Hex Nut 14 Lock Washer

ITEM DESCRIPTION

15 Top Head Assembly 16 Elbow Fitting 17 Cylinder Head Gasket 18 Top Tubing 19 Cylinder 20 Garter Spring 21 Piston Cup Follower 22 Piston Cup 23 Bottom Tubing 24 Washer 25 Elastic Stop Nut 26 Bottom Cylinder Head 27 Pilot Valve Assembly 28 Tie-Rod

IB-102-202N

4-5

Page 24

(NOTE 1)

EXHAUST PORT

(1 OF 2)

PORT TO CYLINDER TOP (*)

SPRING POST

INPUT SIGNAL

PORT (*)

PORT TO CYLINDER BOTTOM (*)

POWER

AIR

SUPPLY

PORT (*)

ITEM DESCRIPTION

1 Socket Head Cap Screw

2 Rubber Boot 3 Top Spring Retainer, Standard 4 Top Loading Spring

5 Top Diaphragm Seat 6 Top Diaphragm

7 Center Block 8 Center Diaphragm Post 9 Bottom Diaphragm

10 Bottom Diaphragm Seat 11 Top Stem Seat 12 Valve Body

685010

13 O-rings (4) 14 Sleeve 15 Stem 16 Bottom Stem Seat 17 Bottom Loading Spring 18 Sleeve Retainer

NOTE 1: 2-1/2 X 5 POWER POSITIONERS USING AN EPT REQUIRE A MODIFIED TOP SPRING RETAINER AND

A TOP DIAPHRAGM COVER IN PLACE OF ITEM (3). IN THE STANDARD PILOT VALVE ASSEMBLY A TOP DIAPHRAGM COVER IS NOT USED.

NOTE 2: AN ASTERISK (*) INDICATES A 1/8 NPT TAPPED PORT.

NOTE 3: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR INDIVIDUAL SALE. SEE SECTION VI,

REPLACEMENT PARTS, FOR A LIST OF AVAILABLE PARTS.

Figure 5-1. Pilot Valve Assembly - Exploded View

IB-102-202N

5-0

Page 25

SECTION V. SERVICE AND NORMAL MAINTENANCE

5-1. SCHEDULED MAINTENANCE OF

STANDARD UNITS.

Design and construction of the standard power positioner greatly reduces routine maintenance. Only the following components need routine maintenance:

a. Air Supply

Drain the air line moisture trap daily. Clean or replace the air filter as necessary, depending on humidity, dust, and filter manufacturer's specifications.

b. Linkage Components

Lubricate clevis pin (2, Figure 4-1), customer-supplied mount pin, and linkage between the positioner and the component it controls every six months. Use a few drops of light oil.

c. Sleeve and Stem

For normal operating conditions in which a clean and dry supply of compressed air is used, the pilot valve sleeve and stem require inspection and cleaning every six months.

The same procedure is necessary if the stem is sticking. A sticking stem is indicated when the piston fails to move quickly to the required position during control signal changes. A worn stem must also be replaced. It is indicated by power air continuously blowing through the exhaust ports in the pilot valve body. Refer to Figure 5-1.

To clean and inspect the pilot valve, use the following procedure:

4. Allow the stem to fall from pilot valve assembly on its own. Be careful that it does not fall on a hard surface. If stem will not fall out on its own, remove sleeve and stem as an assembly. The two can be separated on a bench without much danger of bending the stem.

5. Wash stem and sleeve with clean solvent. Do not use any abrasive or sharp edged tools. Dry sleeve with compressed air and wipe off stem with a clean lint free cloth.

6. Check stem for straightness by rolling it on a flat surface. If not perfectly straight, replace the stem and the sleeve.

7. Insert stem into bore of sleeve. (Since stem is symmetrical, it may be installed with either end up.)

8. Check stem in bore of sleeve. Stem must fall freely through sleeve by its own weight (when both stem and sleeve are dry, clean, and free of oil).

NOTE

Stem and sleeve must be replaced as a complete assembly if stem is bent or if either is worn.

1. Shut off power air supply to pilot valve assembly.

2. Reduce control signal to zero.

NOTE

Many parts are small and may be easily lost or misplaced.

3. Unscrew sleeve retainer (18, Figure 5-1). Remove bottom loading spring (17) and bottom stem seat (16). Be careful not to lose stem, bottom stem seat and bottom loading spring.

9. Check that O-rings (13) on sleeve (14) are in good condition. Install new ones if necessary.

10. Install sleeve in pilot valve assembly.

11. Insert stem in sleeve and replace pilot valve bottom stem seat (16), bottom loading spring (17), and sleeve retainer (18). Turn sleeve retainer in until it hits bottom of sleeve and holds it firmly in place.

12. Turn on air supply pressure and reapply control signal. Power positioner is then ready for operation.

IB-102-202N

5-1

Page 26

5-2. SCHEDULED MAINTENANCE OF ON/OFF

UNITS.

The on/off type power positioner requires very little maintenance. Only the following three components need scheduled maintenance:

a. Air Supply

Drain air line moisture trap daily. Clean or replace the air filter as necessary, depending on humidity, dust, and filter manufacturer's specifications.

b. Linkage Components

Lubricate clevis pin (2, Figure 4-1), mount pin and linkage between the positioner and the component it controls every six months. Use a few drops of light oil.

c. Solenoid Valve

If the air supply is clean and dry, inspect and clean solenoid valve (18, Figure 5-2) every six months, or if leaky, noisy or sluggish. To do this, follow this procedure:

1. Depressurize valve (18) and turn off electrical supply. Disconnect piping if that makes access to the valve easier.

4. Slide core subassembly (12) toward cylinder side of valve body. Remove detent

port B (19) and detent washer (20) from core subassembly. Remove core subassembly through cylinder port A

side of valve body.

5. Remove discs (13), sleeve (14), and quad ring

gasket (15) from core subassembly.

6. Inspect all parts. Replace solenoid valve

assembly if worn or damaged.

7. Clean metallic parts with solvent and a stiff

non-metallic brush. Do not scratch parts or remove any material.

8. Reinstall discs (13), sleeve (14), and quad

ring gasket (15) in core subassembly (12).

9. Lubricate inside walls of valve body and

solenoid base subassemblies with high grade silicone grease. Carefully observing notes on Figure 5-2, slide core subassembly into cylinder port A

side of valve body.

Be careful when removing retaining clip. It is spring loaded and will spring upward when released. This could injure personnel.

2. Prevent retaining clip (1) from springing away. Remove the retaining clip from each side of the valve. Then remove each entire assembled solenoid enclosure (items 3 through 8) from the solenoid base subassembly.

3. Disassemble each solenoid by removing bonnet screws (22), bonnet plates (9 and 23), solenoid base subassembly (11), and body gasket (17).

10. Push core subassembly far enough toward cylinder port B

side to install detent (19) and detent washer (20). Then install each body gasket (17), solenoid base subassembly (11), upper bonnet plate (9), lower bonnet plate (23) and bonnet screws (22).

11. Reinstall both assembled solenoid enclosures (items 3 through 8). Put on nameplates (2) and secure each assembly with a retaining ring (1).

12. Operate the valve a few times to make sure it is working properly before returning power positioner to service.

IB-102-202N

5-2

Page 27

(18)

(NOTE 1)

12 (NOTE 2)

CYLINDER

PORT A

CYLINDER

PORT B

ITEMS 3-8

ASSEMBLED

NOTE 1: TORQUE TO 20 T O 25 IN-LBS (2 TO 3 N M).

NOTE 2: GROOVED END OF ITEM (12) MUST FACE SOLENOID "A" WITH

ITEM DESCRIPTION

1 Retaining Clip 2 Nameplate 3 Housing 4 Spring Washer 5 Insulating Washer

(Not on all units) 6 Coil 7 Insulating Washer

(Not on all units)

DETENT. ITEM (12) MUST BE INSERTED FROM PORT A-SIDE OF ITEM (18). THE PASSAGEWAY IN ITEM (12) MUST BE ORIENTED WITH THE PORTS OF ITEM

ITEM DESCRIPTION

8 Baseplate

9 Upper Bonnet Plate 10 Washer 11 Solenoid Base Subassembly 12 Core Subassembly 13 Disc 14 Sleeve

ITEM DESCRIPTION

17 Body Gasket 18 Valve Body 19 Detent 20 Detent Washer 21 Mounting Bracket 22 Bonnet Screw

23 Lower Bonnet Plate 15 Quad Ring Gasket 16 Disc

Figure 5-2. Solenoid Valve Assembly - Exploded View

IB-102-202N

5-3

Page 28

5-3. REPAIRS TO CONTROL SYSTEM.

a. Replacement of Pilot Valve Diaphragms

to Figure 5-1. Diaphragms (6 and 9) in the pilot valve assembly must be replaced if they are soft and spongy, hard and brittle, or broken. A broken diaphragm shows up as erratic operation of the power positioner with the piston not moving to the upper limit when the maximum signal is applied to the pilot valve. If the break is large, considerable signal air will be noticed continuously leaking from the pilot valve assembly.

Re fer

7. Reassemble items (1) through (11) to valve body (12). Only tighten screws (1) by hand at this time.

8. Apply and maintain 10 psi (69 kPa) air pressure between diaphragms through signal input port.

9. Turn screws (1) alternately and in stops to a torque of 2 ft-lbs (3 N

m).

•

10. Remove input signal air pressure.

Use the following procedure when inspecting and replacing diaphragms.

1. Shut off air supply.

2. Reduce control (input) signal to positioner to zero and disconnect input signal line at pilot valve assembly.

3. Disconnect calibration spring from top diaphragm seat spring post (5, Figure 5-1).

4. Remove socket head cap screws (1). Remove items (2) through (11) as an assembled unit.

NOTE

Top stem seat (11) unthreads from top diaphragm seat (5), allowing both diaphragms (6 and 9) to be removed.

5. Remove top stem seat (11).

Excessive clamping pressure produced by exceeding torque valve will damage diaphragms. Do not exceed specified torque valves.

11. Turn screws (11) alternately and in steps to a torque of 4 ft-lbs (5 N

m).

•

12. Connect the calibration spring to spring post.

13. Remove the 10 psi (69 kPa) line and reconnect the control signal line to pilot valve assembly. Turn on air supply pressure. Power positioner is then ready for operation.

b. Repairs To On/Off Control System

There are no repairs authorized on the on/off control system other than cleaning the solenoid valve (paragraph 5-2c).

5-4. REPAIRS TO CYLINDER ASSEMBLY

(Standard and On/Off).

a. Replacement of Piston Rod Seal

Refer to Figure 4-1. Excessive air leakage from the top head assembly (15, Figure 4-1) past the piston rod (5) indicates that the silicone seal (12) is worn and must be replaced. The instructions below apply to both standard and on/off type units. Where there is a difference between the units, be sure to follow instructions for the specific unit used. To replace piston rod seal proceed as follows:

1. Move piston to bottom of cylinder by either reducing control signal to zero (standard units) or actuating solenoid A

. Then shut off

air supply.

6. Replace diaphragms if broken, hard and brittle, or soft and spongy. Reassemble diaphragm assembly with Loctite

sealant

on threads of top stem seat (11). Torque

•

assembly to 1 to 1-1/2 ft-lbs (1 to 2 N

m).

IB-102-202N

2. Disconnect linkage at clevis (3, Figure 4-1).

3. On standard units only, mark the location of positioner arm (6) on piston rod (5). Disconnect lower end of calibration spring (8) from pilot valve spring post.

5-4

Page 29

4. On standard units, loosen clamping screw (7) in arm (6).

5. Hold clevis and loosen locknut (4) with a wrench. Unscrew clevis and locknut, and remove the arm from the piston rod.

6. Unscrew cap screws (9), and remove lockwasher (17), and seal retainer (11) to expose seal (12).

7. In order to ease removal of seal, place one layer of plastic electrical-type tape over piston rod threads. Start tape at outer end of piston rod and overlap it with raised edges facing the same direction the seal is to be removed. The tape should also be lubricated with a coating of McLube

MOS2-200

grease.

If graphite impregnated teflon piston cups (22) wear to the extent that air leaks past the piston, they should be replaced. This is indicated by power air blowing continuously through the exhaust openings of the pilot valve.

Before cleaning the cylinder walls or replacing the piston cups, make sure there is no problem in the control system. Both standard and on/off units can operate like there is a piston cup problem when their control system is dirty. Before replacing piston cups, follow cleaning procedures in paragraph 5-1.c. or 5-2.c. If this does not solve the problem, proceed as follows:

NOTE

Unless otherwise indicated, item numbers refer to Figure 4-1.

8. Slip seal off piston rod.

9. Before installing new seal, remove tape installed in step 7. Retape threads in opposite direction. Tape should be overlapped, with raised, sharp edges facing downward so that they will not scratch seal as it is pulled down piston rod. Tape should also be lubricated with a light coating of McLube

MOS2-200

grease.

10. Install a new seal after lubricating it with McLube

MOS2-200 grease.

11. Reassemble power positioner, using preceding steps in reverse order. Clevis and arm must be properly aligned and located. Use the mark made in step 3 when reassembling arm (6) on standard units.

12. After reassembling unit, perform steps in paragraph 3-5, Adjustment of Standard Units. The positioner will then be ready for operation.

b. Replacement of Piston Cups

If the piston moves in a jerky manner, it is usually an indication of an accumulation of sticky material on the inside walls of the cylinder (19, Figure 4-1). For the positioner to operate properly, the cylinder walls must be clean.

1. Shut off all air supply. Disconnect electrical power to on/off units.

2. Disconnect power and control air supply lines to pilot valve assembly (27, Figure 4-1) or solenoid valve assembly (Figure 5-2). Disconnect mechanical linkage at clevis (3, Figure 4-1).

3. Remove pivot pin through bottom cylinder head (26) and place positioner on a work bench.

4. On standard units, disconnect calibration spring (8) from pilot valve.

5. Disconnect tubing connections from bottom cylinder head (26).

6. Remove hex nuts (13), lockwashers (14), and four steel tie-rods (28).

7. For on/off units, remove bottom cylinder head (26).

8. On standard units, remove pilot valve assembly (27) and bottom cylinder head (26).

9. Invert the remaining positioner assembly and support it vertically by clamping clevis (3) in a vise.

IB-102-202N

5-5

Page 30

10. Remove cylinder (19) from piston assembly by slowly turning the cylinder clockwise while pulling it upward, away from top head assembly (15).

(e) Hold top head assembly and pull

cylinder back over piston assembly until piston is approximately half way into cylinder.

11. Clean out bore of cylinder with a cloth soaked in a solvent. Do not scrape with sharp tools or use abrasive materials such as emery cloth.

12. Inspect piston cups (22). If worn, creased, or scratched, they must both be replaced.

13. If piston cups require replacement, remove locknut (25) and washer (14) from rod (5). Two piston cup followers (21) and piston cups may then be slipped off the end of the piston rod.

Be careful that piston cups are not creased or scratched during assembly. Damaged piston cups will impair positioner performance.

14. Reassemble piston assembly and insert it into cylinder in the following manner:

(a) Assemble parts of piston on end of

piston rod, except outer garter spring (20) and outer piston cup.

15. Remove positioner from vise. Pull top head assembly along piston rod until it hits the end of the cylinder. Reassemble positioner by installing control system assembly and bottom cylinder head at lower end of cylinder and installing studs, lockwashers and nuts.

16. Connect tubing assemblies to bottom cylinder head.

17. On standard units, connect calibration spring to pilot valve assembly.

18. Mount positioner and connect linkage to clevis. Connect power air supply and either control air signal lines or electrical lines to control system. Open control signal air or close electrical power switch.

19. Turn on power air supply pressure. The positioner is now ready for operation.

5-5. INSTALLATION OF LIMIT SWITCHES

following instructions cover the installation of a limit switch kit onto either a standard or on/off type power positioner.

Check parts kit items against those of Figure 5-3.

The

(b) Turn locknut (25) until only finger tight.

head assembly and then slip cylinder down over the piston assembly until washer (24) is about 1/4 in. (6 mm) from end of cylinder.

(d) Remove locknut (25), washer (24), and

outer piston cup follower (21). Install outer piston cup (22), outer piston cup follower (21) and garter spring (20); reassemble entire piston. Tighten locknut (25).

IB-102-202N

5-6

Shut off all air pressure and electricity to power positioner, and remove and block mechanical load before beginning this procedure. Failure to do this could allow the power positioner to move. This could injure personnel or damage equipment.

Orient power positioner as shown in Figure 5-3. Clevis must be up, and pilot valve or solenoid valve to the right.

Page 31

4, 5, 6

Assemble limit switches (1, Figure 5-3) and brackets (3), using nut plate (7), flat washers (5),

lockwashers (6) and screws (4). Orient limit switches as shown. Slide limit switches to outermost point in slots. This is to prevent damage

from switch striker (2) before adjustment.

Remove two tie-rods (A) from left side of cylinder.

Install bottom bracket (3) on tie-rods (A) and insert tie-rods through cylinder heads. Install top

D, E

bracket, lockwashers (D) and nuts (E) on top of tie-rods (A) and torque to 8 to 12 ft-lbs (11 to 16

•

m).

Loosen nut (B) under clevis (C); remove clevis. Install switch striker (2); reinstall clevis. Retighten nut under clevis, making sure switch striker lines up with switch actuator rollers.

Connect wiring to limit switches as the boiler controls require. Remove cover to get to terminal screws. Because the entire power positioner moves while in service, use Greenfield

flexible conduit. If the unit is likely to get wet, use liquid-tight flexible conduit.

Adjust limit switches so that they switch as the piston reaches the fully extended and fully retracted positions.

NOTE: LETTER DESIGNATIONS REFER TO NON-KIT

ITEMS MENTIONED IN INSTALLATION TEXT, PARAGRAPH 5-5.

685012

LIMIT SWITCH KIT ITEMS

ITEM DESCRIPTION QTY

1 LIMIT SWITCH

2 SWITCH STRIKER

3 SWITCH BRACKET

4 P AN HEAD SCREW

5 FLAT WASHER

6 LOCKW ASHER

7 NUT PLA T

Figure 5-3. Limit Switch Installation

1. Observe limit switches while running power positioner to both limits. Each switch should switch on just as the piston reaches its mechanical limit, and switch off as the piston begins to go in the other direction.

2. To adjust switch, loosen screws (4, Figure 5-3) until switch assembly will slide. Slide switch assembly as necessary, then retighten screws. Watch switch again while running piston. Readjust as necessary.

IB-102-202N

5-7/5-8

Page 32

Page 33

SECTION VI. RECOMMENDED SPARE PARTS

The following tables give listings of replacement parts for standard and on/off 2-1/2 inch x 5 inch power positioners, and for the standard pilot valve assembly.

Table 6-1. Recommended Spare Parts for the Standard Power Positioner.

FIGURE and INDEX NUMBER PART NUMBER DESCRIPTION QTY

4-1, 12 4-1, 17 4-1, 22 5-1, 14 and 15

152507-001 4847B17H01 170857 173283

Seal Cylinder Head Gasket Piston Cup Stem and Sleeve Assembly

1 2 2 1

(Matched Set)

(Not Shown)

3D39395G07

Maintenance Tool Kit

Table 6-2. Recommended Spare Parts for the On/Off Power Positioner

FIGURE and INDEX NUMBER PART NUMBER DESCRIPTION QTY

4-1, 12 4-1, 17 4-1, 22 5-2 (Not Shown)

152507-001 4847B17H01 170857 ASCO #8340A2 3D39395G07

Seal Cylinder Head Gasket Piston Cup Solenoid Valve Assembly Maintenance Tool Kit

1 2 2 1 1

NOTE

Order replacement parts for the solenoid valve assembly directly from ASCO at the following address:

ASCO Valves Automatic Switch Co. Florham Park, NJ 07932

Table 6-3. Recommended Spare Parts for the Standard Pilot Valve Assembly.

FIGURE and INDEX NUMBER PART NUMBER DESCRIPTION QTY

5-1, 11 5-1, 8

171323 170960

Bottom Diaphragm Top Diaphragm

IB-102-202N

6-1

1 1

Page 34

NOTE

Table 6-4, Bill of Material for the 2-1/2 x 5 Power Positioner, includes part numbers and descriptions that are keyed to figure and index number references. The table covers all basic positioner parts. Refer to Tables 6-1, 6-2, and 6-3 for recommended spare parts.

Table 6-4. Bill of Materials for the 2-1/2 x 5 Power Positioner

FIGURE and INDEX NUMBER PART NUMBER DESCRIPTION QTY

4-1, 1

2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

5-1, 1

2 3

120079-010 170924 170925-002 120036-014 4847B25H01 4513C25H02 120090-250125

170952 171267 171266 163792-1932038 120114-017 170949 152507-001 120026-019 120114-029 4847B35G01 771B867H01 4847B17H01 3D39399H05 4847B29H01 170941 170942 170857 3D39399H02 120110-005 120171-002

4846B57G02 4847B34G01 3D39398

4847B19H01 4847B55H02 4844B16H01 173217-001 170964

Retaining Ring Clevis Pin Clevis Hex Nut, 0.625-18 Piston Rod Positioner Arm Socket Head Cap Screw, 0.250-20 x 1.25 long Calibration Spring (1 of 3 tensions) 0 - 30 lb Spring 3 - 15 lb Spring 3 - 27 lb Spring Cap Screw Lockwasher, #10 Seal Retainer Seal Hex Nut, 0.312-24 Lockwasher Top Head Assembly Elbow Fitting Cylinder Head Gasket Top Tubing, 18" long, 1/8" 304 S.S. Cylinder Garter Spring Piston Cup Follower Piston Cup Bottom Tubing, 9" long, 1/8" 304 S.S. Washer, 0.500 Plain Elastic Stop Nut Bottom Cylinder Head (1 of 2 Designs) Bottom Cylinder Head, G05 Group

Bottom Cylinder Head, G06/G08 Groups

Pilot Valve Assembly Socket Head Cap Screw Rubber Boot Top Spring Retainer, Standard

2 1 1 1 1 1 1 1

2 2 1 1 4 4 1 4 2 1 1 2 2 2 1 1 1 1

1 2 1 1 1 1 1

Top Spring Retainer, EPT Option

Top Diaphragm Cover, EPT Option

Top Loading Spring

IB-102-202N

6-2

Page 35

Table 6-4. Bill of Materials for the 2-1/2 x 5 Power Positioner (Continued).

FIGURE and INDEX NUMBER PART NUMBER DESCRIPTION QTY

5-1, 5

6 7 8 9 10 11 12 13

14 15 16 17

18 4-1, 28 5-3, 1

5-2

4847B82H01 170960 4847B20H01 4847B22H01 171323 170959 4847B21 3D39396H02

173283

170955 170958 170968 174080-003 8741-001 3535B04G01 3535B01H01 70001DAJ4B 70500BD30C 70510CR10G 3535B09H01 3534B98 ASCO #8340A2

Top Diaphragm Seat Top Diaphragm Center Block Center Diaphragm Post Bottom Diaphragm Bottom Diaphragm Seat

Top Stem Seat

Valve Body

O-rings

Stem and Sleeve Assembly

Sleeve

Stem

Bottom Stem Seat

Bottom Loading Spring

Sleeve Retainer

Tie-Rod, 0.312-24 x 9.38 long Limit Switch Switch Striker Switch Bracket Pan Head Screw, 0.138-32 x 1.25 Washer, #6 Flat Lockwasher, #6 Split Nut Plate, 0.138-32 Thread Instructions, Limit Switch Kit Solenoid Valve Assembly (On/Off Units only)

1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 4 2 1 2 4 4 4 2 1 1

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6-3/6-4

Page 36

Page 37

SECTION VII. RETURNING EQUIPMENT TO THE FACTORY

7-1. RETURN PROCEDURE.

If factory repair of

defective equipment is required, proceed as follows.

Secure a return authorization from a Rosemount Analytical Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

Carefully pack defective unit in a sturdy box with sufficient shock absorbing material to insure that no additional damage will occur during shipment.

In a cover letter, describe completely:

1. The symptoms which indicate that the equipment is faulty.

2. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.).

3. Site from which equipment was removed.

4. Whether warranty or nonwarranty service is requested.

5. Complete shipping instructions for return of equipment.

Enclose a cover letter and purchase order, and ship the defective equipment according to instructions provided in Rosemount Return Authorization, prepaid to:

American

Rosemount Analytical Inc. R.M.R. Department 1201 N. Main Street Orrville, Ohio 44667

European

Rosemount Ireland Equipment Return Repair Dept. Site 7 Shannon Industrial Estate Co. Clare Ireland

7-2. REPAIR TERMS

If warranty service is requested, the defective unit will be carefully tested and inspected at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount's option, and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter.

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

IB-102-202N

7-1/7-2

Page 38

Page 39

INDEX

This index is an alphabetized listing of parts, terms, and procedures having to do with the 2-1/2 Inch x 5 Inch Power Positioner. Every item listed in the index refers to a location in the manual by page number or numbers.

Active Coils, 3-3 Adjustement of Standard Units, 3-2 Air Filter, 3-1, 5-1, 5-2 Ambient Temperature, 3-1

Calibration Spring, 2-2 Clevis, 1-1, 3-1 Clevis Pin, 3-1 Control Signal, 2-1, 2-2, 3-2 Control System, 5-5 Cylinder, 1-1, 4-1, 5-4, 5-5

Damper, 1-1 Diaphragm, 2-2, 4-2, 5-4 Diaphragm Assembly, 2-2

Equation, 3-3, 3-4

Limit Switch, 1-2, 3-1, 3-4, 5-6, 5-7 Lower Limit, 3-2

Maintenance, 5-1, 5-2 Mounting Pivot, 3-1, 4-1 Mounting Pivot Pin, 3-1

On/Off Standard Option, 2-2

Piston, 1-1, 2-2 Piston Cups, 2-1, 4-2, 5-5 Piston Rod Seal, 4-2, 5-4 Pilot Valve, 1-1, 2-1, 4-1 Power Air, 1-1, 2-1, 4-1, 4-2

Shutoff Valve, 3-1 Sleeve, 4-1, 5-1 Sleeve and Stem, 2-2, 5-1 Solenoid Operated Valve, 2-3 Solenoid Valve, 1-2, 4-3, 5-2 Spare Parts, 6-1 Stem, 2-2, 4-1, 5-1

Guide Bearings, 2-2

Installation, 3-1

Upper Limit, 3-3

Wiring, 3-1

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2/95

5/95-1849