HAGAN 2½ x 5 Thrust Type, Swivel Mounted Pneumatic Power Positioner-Rev 1.1
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Loading...Rosemount HAGAN 2½ x 5 Thrust Type, Swivel Mounted Pneumatic Power Positioner-Rev 1.1 Manuals & Guides
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5
Thrust Type, Swivel Mounted
Pneumatic Power Positioner
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In-
struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program,
and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts
specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.
Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical shock
and personal injury.
The information contained in this document is subject to change without notice.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
HIGHLIGHTS OF CHANGES
Effective May, 1995 Rev. 1
Page Summary
Page 2-2 Figure 2-1. Added a callout regarding placement of positioner arm in
relation to pilot valve.
Page 2-1 Added paragraph 2-2. Mounting regarding the correct positional rela-
tionship of the arm, calibration spring, and pilot valve.
Page 7-1 Tables 7-1 and 7-2, Added “Maintenance Tool Kit” to both lists of rec-
ommended spare parts.
Effective April, 2001 Rev. 1.1
Page Summary
Page 4-2 Added NOTE 4 to Figure 4-1.
Hagan 2-1/2 x 5 Power Positioner
TABLE OF CONTENTS
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................P-1
Safety Instructions .......................................................................................................... P-2
1-0 DESCRIPTION ................................................................................................................ 1-1
1-1 Scope............................................................................................................................... 1-1
1-2 Package Contents .......................................................................................................... 1-1
1-3 Equipment Description ................................................................................................... 1-1
2-0 INSTALLATION AND ADJUSTMENTS ....................................................................... 2-1
2-1 Location ........................................................................................................................... 2-1
2-2 Mounting .......................................................................................................................... 2-1
2-3 Air Connections .............................................................................................................. 2-1
2-4 Wiring............................................................................................................................... 2-4
2-5 Adjustment of Standard Units....................................................................................... 2-4
2-6 Adjustment of On/Off Units........................................................................................... 2-6
2-7 Adjustment of Optional Limit Switches ........................................................................ 2-6
Instruction Manual
IB-102-202N
April 2001
3-0 THEORY OF OPERATION ........................................................................................... 3-1
3-1 Standard Unit.................................................................................................................. 3-1
3-2 On/Off Standard Option ................................................................................................. 3-3
4-0 MAINTENANCE AND SERVICE .................................................................................. 4-1
4-1 Scheduled Maintenance of Standard Units ................................................................. 4-1
4-2 Scheduled Maintenance of On/Off Units ..................................................................... 4-3
4-3 Repairs to Control System............................................................................................ 4-5
4-4 Repairs to Cylinder Assembly (Standard and On/Off) .............................................. 4-5
4-5 Installation of Limit Switches ........................................................................................ 4-7
5-0 TROUBLESHOOTING .................................................................................................... 5-1
5-1 Troubleshooting Standard Units .................................................................................... 5-1
5-2 Troubleshooting On/Off Units ........................................................................................ 5-3
6-0 RETURN OF MATERIAL .............................................................................................. 6-1
6-1 Return Procedure ........................................................................................................... 6-1
6-2 Repair Terms .................................................................................................................. 6-1
7-0 REPLACEMENT PARTS ............................................................................................... 7-1
8-0 INDEX.............................................................................................................................. 8-1
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Figure 1-1. Standard 2-1/2 Inch x 5 Inch Power Positioner
Figure 1-2. On/Off 2-1/2 Inch x 5 Inch Power Positioner
Figure 2-1. Installation Dimensions.......................................................................................... 2-2
Figure 2-2. Mounting Pivot Base Assembly (Part No. 371763) ............................................... 2-3
Figure 2-3. Standard Unit Adjustment...................................................................................... 2-4
Figure 2-4. Limit Switch Option ................................................................................................2-6
Figure 3-1. Standard Power Positioner - Main Components ................................................... 3-2
Figure 3-2. On/Off Power Positioner ........................................................................................ 3-4
Figure 4-1. Pilot Valve Assembly — Exploded View................................................................ 4-2
Figure 4-2. Solenoid Valve Assembly — Exploded View......................................................... 4-4
Figure 4-3. Limit Switch Installation ......................................................................................... 4-8
Figure 5-1. Standard Unit, Exploded View ............................................................................... 5-4
Hagan 2-1/2 x 5 Power Positioner
LIST OF ILLUSTRATIONS
(Variable Position Pilot Valve Type) ...................................................................... 1-1
(On/Off Standard Option, Solenoid Valve Type) ................................................... 1-2
LIST OF TABLES
Table 5-1. Standard Unit Troubleshooting .............................................................................. 5-2
Table 5-2. On/Off Unit Troubleshooting .................................................................................. 5-3
Table 7-1. Recommended Spare Parts for the Standard Power Positioner ........................... 7-1
Table 7-2. Recommended Spare Parts for the On/Off Power Positioner ............................... 7-1
Table 7-3. Recommended Spare Parts for the Standard Pilot Valve Assembly..................... 7-1
Table 7-4. Bill of Materials for the 2-1/2 x 5 Power Positioner................................................ 7-2
ii Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
PREFACE
The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Hagan 2-1/2 x 5 Power Positioner.
Some sections may describe equipment not used in your configuration. The user should
become thoroughly familiar with the operation of this module before operating it. Read
this instruction manual completely.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.
Instruction Manual
IB-102-202N
April 2001
Highlights an operation or maintenance
procedure, practice, condition, statement, etc. If not strictly observed, could
result in injury, death, or long-term
health hazards of personnel.
Highlights an essential operating procedure,
condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
Highlights an operation or maintenance
procedure, practice, condition, statement, etc. If not strictly observed, could
result in damage to or destruction of
equipment, or loss of effectiveness.
NOTE
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.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should
be strictly adhered to in order to assure compliance with the Low Voltage Directive. NonEU states should also comply with the following unless superseded by local or National
Standards.
1. Adequate earth connections should be made to all earthing points, internal and external,
where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.
The integrity of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
Hagan 2-1/2 x 5 Power Positioner
IMPORTANT
SAFETY INSTRUCTIONS
OF THIS APPARATUS
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.
5. All cable glands used should be of such internal dimensions as to provide adequate cable
anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be
made through a circuit breaker which will disconnect all circuits carrying conductors during a
fault situation. The circuit breaker may also include a mechanically operated isolating switch.
If not, then another means of disconnecting the equipment from the supply must be provided
and clearly marked as such. Circuit breakers or switches must comply with a recognized
standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazard-
ous voltages are likely to be present beneath. These covers should only be
removed when power is removed from the equipment — and then only by
trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a
danger from hot surfaces beneath. These covers should only be removed by
trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to
the Operator Manual for instructions.
10. All graphical symbols used in this product are from one or more of the follow-
ing standards: EN61010-1, IEC417, and ISO3864.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
1
SECTION 1
DESCRIPTION
Instruction Manual
IB-102-202N
April 2001
1-1 SCOPE
This manual gives information needed to 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
The power positioner 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.
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.
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.
1-3 EQUIPMENT DESCRIPTION
a. Purpose
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.
b. Operation
There are two types of power 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.
685001
Figure 1-1. Standard 2-1/2 Inch x 5 Inch Power
Positioner (Variable Position Pilot Valve Type)
Rosemount Analytical Inc. A Division of Emerson Process Management Description 1-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
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 3, 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.
Hagan 2-1/2 x 5 Power Positioner
685002
Figure 1-2. On/Off 2-1/2 Inch x 5 Inch Power
Positioner (On/Off Standard Option,
Solenoid Valve Type)
1-2 Description Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
2
SECTION 2
INSTALLATION AND ADJUSTMENTS
Instruction Manual
IB-102-202N
April 2001
2-1 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.
2-2 MOUNTING
Before installation, carefully note the clearance
dimensions and other mounting information
shown in Figure 2-1. 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 2-2.
The power take-off clevis (Figure 2-1) 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.
1/8 in. NPT taps. Refer to Figure 2-1. 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.
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).
Minimum air supply pressure is 45 psi
(310 kPa).
b. On/Off Units
Connect power air to the 0.25 in. NPT air
tap on the valve body as shown in Figure
3-2. 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.
2-3 AIR CONNECTIONS
a. Standard Units
Connect air to the pilot valve assembly.
Control signal and power air connections,
located in the pilot valve assembly, are
Rosemount Analytical Inc. A Division of Emerson Process Management Installation and Adjustments 2-1
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).
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
5.50
(140)
Hagan 2-1/2 x 5 Power Positioner
MAX R 9/16 (14)
3.7
(94)
MAX WIDTH
1-3/4
(45)
FOR CLEVIS MOUNT
MAX DIA
FOR PIN MOUNT
1.50
(38)
PLACE ARM
DIRECTLY ABOVE
PILOT VALVE.
0.500 (12.7)
0.498 (12.65)
1-1/2 (38)
THROAT
ARM
CLEVIS
ADJUSTMENT
9/16
(14)
2
(51)
1/4
1/4
(6)
(6)
PISTON ROD
MOVES OUTWARD
WITH INCREASE
INPUT SIGNAL
PRESSURE
5 STROKE
(127)
15-13/16
(402)
C
L
LINKAGE
SHAFT
LEVER
C
L
C
L
'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)
CLEVIS PIN
o
BY MEANS OF LOCKNUT
C
L
PIVOT PIN
MOUNTING
DETAILS
1/8 N.P.T.
TAP FOR
INPUT SIGNAL
2-1/2
(64)
ALLOW FOR CLEARANCE
REQUIRED TO WITHDRAW
VALVE SLEEVE
C
L
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.
11/16
(18)
R
1/8 N.P.T. TAP FOR
AIR SUPPLY
MAX 125 PSIG
(862 kPa GAUGE)
2-5/32
(56)
5/8
(16)
685005
Figure 2-1. Installation Dimensions
2-2 Installation and Adjustments Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
2
Instruction Manual
IB-102-202N
April 2001
1-5/16
(34)
1-13/16
(46)
1/2 R
(13)
C
L
4 HOLES 13/32 O/(11)
1-5/16 (34)
1-5/16 (34)
1-13/16 (46)
1-5/16
(34)
C
3-5/8
(98)
L
1-1/2 (38)
3-5/8 (98)
PILOT VALVE
C OF CYLINDER MUST NOT FALL
L
OUTSIDE OF THIS ZONE
o
60
o
60
REQ.
NOTE: DIMENSIONS IN INCHES WITH
LINE
2
1
1
MILLIMETERS IN PARENTHESES.
1
2
3
NAME
"E" RING
CLEVIS PIN
PIVOT BASE
PAR T NO.
120079-10
171762
371738
60
o
1/2
(13)
BRACKET AND BOLTING
NOT BY HAGAN
685006
Figure 2-2. Mounting Pivot Base Assembly (Part No. 371763)
Rosemount Analytical Inc. A Division of Emerson Process Management Installation and Adjustments 2-3
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
2-4 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.
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.
2-5 ADJUSTMENT OF STANDARD UNITS
The 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. Refer to Figure 2-3 and use
the following procedure to make the adjustment:
a. Disconnect the mechanical linkage from the
clevis.
b. With the control (input) signal and power air
supply lines disconnected from the pilot
valve, clean the lines with high pressure air.
MECHANICAL
LINKAGE
CLEVIS
SET SCREW
POSITIONER
ARM
PISTON ROD
b. On/Off Units
Remove metal retaining clip (1, Figure 4-2)
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.
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.
CALIBRATION
SPRING
CONTROL
SIGNAL
LINE
PILOT
VALV E
POWER AIR
SUPPLY LINE
Figure 2-3. Standard Unit Adjustment
BOTTOM
CYLINDER
HEAD
685007
2-4 Installation and Adjustments Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
2
Instruction Manual
IB-102-202N
April 2001
c. Open the air supply filter drain and blow out
accumulated moisture and foreign particles.
d. 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.
3. Move the positioner arm up until the
piston moves to the bottom of the
cylinder.
4. Move the positioner arm down until the
piston begins to move upward.
5. Move the positioner arm down until the
piston just returns to lowest position.
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.
g. 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:
6. Lock this setting by tightening the set
screw until the positioner arm binds to
the piston rod.
f. 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.
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.
Pa
x Ca =
Pm
Where:
Pa = Signal pressure at which piston
Pm = Maximum control signal pres-
Ca = Actual number of active coils
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.
h. 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
Number of active
coils required
reaches upper limit
sure to be used
Rosemount Analytical Inc. A Division of Emerson Process Management Installation and Adjustments 2-5
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
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:
Sr
Sa
x Ca =
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.
i. Repeat step e to check minimum setting
again.
switch when the piston reaches its fully retracted limit. Adjust the switches as follows:
a. 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.
b. 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.
UPPER
LIMIT
SWITCH
MOUNTING
SCREW
j. Check mechanical linkage between the po-
sitioner and the damper or valve that the
positioner positions. All links must be properly aligned.
k. Reconnect mechanical linkage to clevis.
2-6 ADJUSTMENT OF ON/OFF UNITS
There is no adjustments for on/off units.
2-7 ADJUSTMENT OF OPTIONAL LIMIT
SWITCHES
Refer to Figure 2-4. 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
STRIKER
LOW LIMIT
SWITCH
SWITCH
BRACKET
Figure 2-4. Limit Switch Option
685008
2-6 Installation and Adjustments Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
3
SECTION 3
THEORY OF OPERATION
Instruction Manual
IB-102-202N
April 2001
3-1 STANDARD UNIT
a. General
Refer to Figure 3-1, 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 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.
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.
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 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.
Rosemount Analytical Inc. A Division of Emerson Process Management Theory of Operation 3-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
NOTE: AN ASTERISK (*) INDICATES ITEMS ARE
INCLUDED IN THE PILOT VALVE ASSEMBLY.
POSITIONER ARM
CYLINDER
CALIBRATION
SPRING
POWER TAKE-OFF CLEVIS
TOP HEAD ASSEMBLY
TOP TUBING ASSEMBLY
PISTON ASSEMBLY
(INCLUDES TEFLON CUPS)
DIAPHRAGM
ASSEMBLY*
INPUT SIGNAL
(CONTROL AIR)
(CUSTOMER
SUPPLIED)
POWER AIR
(CUSTOMER
Figure 3-1. Standard Power Positioner - Main Components
SUPPLIED)
PILOT VALVE
ASSEMBLY
STEM AND SLEEVE ASSEMBLY*
TEFLON
PISTON CUPS
BOTTOM TUBING
ASSEMBLY
MOUNTING PIVOT
685003
3-2 Theory of Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
3
Instruction Manual
IB-102-202N
April 2001
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.
3-2 ON/OFF STANDARD OPTION
a. General
On/off type power positioners, Figure 3-2,
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.
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 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.
Rosemount Analytical Inc. A Division of Emerson Process Management Theory of Operation 3-3
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
SOLENOID B
LAST ENERGIZED
SOL B SOL B
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.
AA
BB
SOLENOID A
LAST ENERGIZED
SOLENOID B
PORT A
EXHAUST
FITTING
POWER AIR
PORT B
Figure 3-2. On/Off Power Positioner
SOLENOID A
2-1/2 X 5
CYLINDER
685004
3-4 Theory of Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
4
SECTION 4
MAINTENANCE AND SERVICE
Instruction Manual
IB-102-202N
April 2001
4-1 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 5-1), 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 4-1.
NOTE
Many parts are small and may be easily lost or misplaced.
3. Unscrew sleeve retainer (18, Figure
4-1). Remove bottom loading spring
(17) and bottom stem seat (16). Be
careful not to lose stem, bottom stem
seat and bottom loading spring.
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
To clean and inspect the pilot valve, use the
following procedure:
1. Shut off power air supply to pilot valve
assembly.
2. Reduce control signal to zero.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-1
Stem and sleeve must be replaced as
a complete assembly if stem is bent or
if either is worn.
9. Check that O-rings (13) on sleeve (14)
are in good condition. Install new ones
if necessary.
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
(NOTE 1)
4
Hagan 2-1/2 x 5 Power Positioner
2
1
EXHAUST PORT
(1 OF 2)
3
12
PORT TO
CYLINDER TOP (*)
SPRING POST
7
INPUT SIGNAL
PORT (*)
9
PORT TO
CYLINDER BOTTOM (*)
POWER
5
6
AIR
SUPPLY
PORT (*)
13
14
1. Socket Head Cap Screw
2. Rubber Boot
15
3. Top Spring Retainer, Standard
4. Top Loading Spring
5. Top Diaphragm Seat
16
6. Top Diaphragm
7. Center Block
8. Center Diaphragm Post
8
17
9. Bottom Diaphragm
10. Bottom Diaphragm Seat
11. Top Stem Seat
12. Valve Body
18
13. O-Rings (4)
14. Sleeve
15. Stem
16. Bottom Stem Seat
10
11
685010
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
NOTE 2: AN ASTERISK (*) INDICATES A 1/8 NPT TAPPED PORT.
NOTE 3: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR INDIVIDUAL SALE. SEE SECTION 7, REPLACEMENT PARTS,
NOTE 4: ITEM 4 (TOP LOADING SPRING) IS USED FOR 0-30 PSI SIGNAL ONLY.
DIAPHRAGM COVER IN PLACE OF ITEM (3). IN THE STANDARD PILOT VALVE ASSEMBLY A TOP DIAPHRAGM
COVER IS NOT USED.
FOR A LIST OF AVAILABLE PARTS.
Figure 4-1. Pilot Valve Assembly — Exploded View
4-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
4
Instruction Manual
IB-102-202N
April 2001
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.
4-2 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 5-1), 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 4-2)
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.
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 enclo-
sure (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).
4. Slide core subassembly (12) toward
cylinder port B side of valve body. Remove detent (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 4-2, slide
core subassembly into cylinder port A
side of valve body.
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.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-3
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
1
2
3
B
8
9
10
11
13
14
4
5
6
7
(NOTE 1)
12
(NOTE 2)
22
CYLINDER
PORT A
CYLINDER
PORT B
21
17
18
21
17
19
20
11
10
23
ITEMS 3-8
A
ASSEMBLED
2
15
16
NOTE 1: TORQUE TO 20 TO 25 IN-LBS (2 TO 3 N M).
NOTE 2: GROOVED END OF ITEM (12) MUST FACE SOLENOID "A" WITH
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 (18).
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)
8. Baseplate
9. Upper Bonnet Plate
10. Washer
11. Solenoid Base Subassembly
12. Core Subassembly
13. Disc
14. Sleeve
15. Quad Ring Gasket
16. Disc
1
685011
17. Body Gasket
18. Valve Body
19. Detent
20. Detent Washer
21. Mounting Bracket
22. Bonnet Screw
23. Lower Bonnet Plate
Figure 4-2. Solenoid Valve Assembly — Exploded View
4-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
4
Instruction Manual
IB-102-202N
April 2001
4-3 REPAIRS TO CONTROL SYSTEM
a. Replacement of Pilot Valve Diaphragms
Refer to Figure 4-1. 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.
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
4-1).
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.
11. Turn screws (1) 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 4-2c).
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.
6. Replace diaphragms if broken, hard
and brittle, or soft and spongy. Reassemble diaphragm assembly with Loc-
TM
tite
sealant on threads of top stem
seat (11). Torque assembly to 1 to
1-1/2 ft-lbs (1 to 2 N·m).
4-4 REPAIRS TO CYLINDER ASSEMBLY
(Standard and On/Off)
a. Replacement of Piston Rod Seal
Refer to Figure 5-1. Excessive air leakage
from the top head assembly (15, Figure 5-1)
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.
2. Disconnect linkage at clevis (3, Figure
5-1).
3. On standard units only, mark the location of positioner arm (6) on piston rod
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-5
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
(5). Disconnect lower end of calibration
spring (8) from pilot valve spring post.
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
TM
MOS2-200
grease.
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
TM
MOS2-200 grease.
10. Install a new seal after lubricating it
with McLubeTM MOS
-200 grease.
2
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.
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 5-1). For the positioner
to operate properly, the cylinder walls must
be clean.
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 4-1c or 4-2c. If this does not
solve the problem, proceed as follows:
NOTE
Unless otherwise indicated, item numbers refer to Figure 5-1.
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 5-1) or solenoid valve assembly
(Figure 4-2). Disconnect mechanical
linkage at clevis (3, Figure 5-1).
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.
12. After reassembling unit, perform steps
in paragraph 2-5, Adjustment of Standard Units. The positioner will then be
ready for operation.
4-6 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
5. Disconnect tubing connections from
bottom cylinder head (26).
6. Remove hex nuts (13), lockwashers
(14), and four steel tie-rods (28).
Hagan 2-1/2 x 5 Power Positioner
4
Instruction Manual
IB-102-202N
April 2001
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.
10. Remove cylinder (19) from piston assembly by slowly turning the cylinder
clockwise while pulling it upward, away
from top head assembly (15).
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 (24)
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:
Install outer piston cup (22), outer
piston cup follower (21) and garter
spring (20); reassemble entire
piston. Tighten locknut (25).
(e) Hold top head assembly and pull
cylinder back over piston assembly
until piston is approximately half
way into cylinder.
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.
4-5 INSTALLATION OF LIMIT SWITCHES
The following instructions cover the installation
of a limit switch kit onto either a standard or
on/off type power positioner.
a. Check parts kit items against those of
Figure 4-3.
(a) Assemble parts of piston on end of
piston rod, except outer garter
spring (20) and outer piston cup.
(b) Turn locknut (25) until only finger
tight.
(c) Check that gasket (17) is in place
at top 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).
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-7
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.
b. Orient power positioner as shown in Figure
4-3. Clevis must be up, and pilot valve or
solenoid valve to the right.
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
c. Assemble limit switches (1, Figure 4-3) 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.
d. Remove two tie-rods (A) from left side of
cylinder.
Hagan 2-1/2 x 5 Power Positioner
C
7
B
1
e. Install bottom bracket (3) on tie-rods (A) and
insert tie-rods through cylinder heads. Install top bracket, lockwashers (D) and nuts
(E) on top of tie-rods (A) and torque to 8 to
12 ft-lbs (11 to 16 N·m).
f. 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.
g. 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
TM
flexible conduit. If the unit is
likely to get wet, use liquid-tight flexible
conduit.
h. Adjust limit switches so that they switch as
the piston reaches the fully extended and
fully retracted positions.
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 4-3) until switch assembly will
slide. Slide switch assembly as necessary, then retighten screws. Watch
switch again while running piston. Readjust as necessary.
4, 5, 6
2
3
NOTE: LETTER DESIGNATIONS REFER TO NON-KIT
ITEMS MENTIONED IN INSTALLATION TEXT,
PARAGRAPH 5-5.
LIMIT SWITCH KIT ITEMS
ITEM DESCRIPTION QTY
1 LIMIT SWITCH
2 SWITCH STRIKER
3 SWITCH BRACKET
4 PAN HEAD SCREW
5 FLAT WASHER
6 LOCKWASHER
7 NUT PLAT
A
2
1
2
4
4
4
2
D, E
685012
Figure 4-3. Limit Switch Installation
4-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
5
SECTION 5
TROUBLESHOOTING
Instruction Manual
IB-102-202N
April 2001
5-1 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 5-1, Standard Unit Troubleshooting.
a. 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.
3. Pressure reducing valves in the system
incorrectly adjusted.
4. Air filters restricting flow due to dirty
elements. Blow down all filters.
b. Plugged signal or air supply line. Check that
all lines are clean. Clear out any foreign
material which may be blocking them.
c. 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.
d. Excessive friction at mounting pivot, clevis
and associated mechanical linkage. Check
that these points are well oiled, not binding,
or otherwise inhibited.
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Table 5-1. Standard Unit Troubleshooting
Unless otherwise indicated, item numbers are in reference to Figure 5-1.
Symptom Cause Solution
1. Erratic operation along with one of
the following:
Hagan 2-1/2 x 5 Power Positioner
NOTE
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 signal
changes.
c. Power air [100 psi (689 kPa)]
continuously blowing through
exhaust ports of pilot valve
assembly.
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 cali-
b. Signal air [15, 30, or 60 psi
(103, 207, or 414 kPa)] continuously leaking from exhaust ports
of pilot valve assembly (27).
c. Power air [100 psi (689 kPa)]
blowing continuously through
exhaust ports of pilot valve assembly (27).
b. Stem (15, Figure 4-1) sticking
due to gummy deposits.
c. Stem (15, Figure 4-1) exces-
sively worn.
bration spring (8).
b. Broken diaphragm in pilot
valve assembly.
c. Piston cups (22) worn. c. Replace both piston cups.
a. Clean cylinder walls.
b. Clean stem and sleeve.
c. Replace stem and sleeve.
a. Increase number of active
coils in spring (8). Refer to
paragraph 2-5h.
b. Replace broken diaphragm.
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.
b. Power air leaking past piston
rod (5) at seal retainer (11).
c. Power air continuously blowing
out of exhaust ports of pilot
valve assembly (27).
5-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management
b. Piston rod seal (12) worn. b. Replace piston rod seal.
c. Piston cups (22) worn. c. Replace both piston cups.
a. Perform Adjustments of
Standard Units, paragraph
2-5.
Hagan 2-1/2 x 5 Power Positioner
5
Instruction Manual
IB-102-202N
April 2001
5-2 TROUBLESHOOTING ON/OFF UNITS
Refer to Table 5-2, On/Off Unit Troubleshooting,
for a listing of possible symptoms, causes and
Table 5-2. On/Off Unit Troubleshooting
NOTE
Unless otherwise indicated, item numbers are in reference to Figure 4-2.
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 signal
changes.
c. Power air [100 psi (689 kPa)]
continuously blowing through
exhaust ports of pilot valve
assembly.
b. Core subassembly (12)
sticking due to gummy
deposits.
c. Valve (18) or piston cups (22,
Figure 5-1) excessively worn.
solutions for problems with an on/off type power
positioner. Cylinder and piston assembly parts
are identical to those of the standard unit
(Figure 5-1).
a. Clean cylinder walls.
b. Clean core subassembly.
c. Replace worn components.
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. Open or burned out coil (6) in
solenoid.
Faulty control circuit.
b. Excessive leakage at solenoid
valve.
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:
b. Worn or damaged parts in
solenoid valve assembly.
a. Open or burned out coil (6) in
solenoid.
Faulty control circuit.
NOTE
ASCO Valves
Automatic Switch Co.
Florham Park, NJ 07932
a. Check continuity of coil. Re-
place if necessary.
Energize solenoid; listen for
metallic click. No click means
no voltage.
b. Replace solenoid valve
assembly.
a. Check continuity of coil. Re-
place if necessary.
Energize solenoid; listen for
metallic click. No click means
no voltage.
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-3
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
1
Hagan 2-1/2 x 5 Power Positioner
9
3
10
11
22
2
4
5
6
15
12
17
19
13
14
18
16
17
24
25
21
20
23
16
26
27
7
8
20
21
16
22
16
28
685009
Figure 5-1. Standard Unit, Exploded View
5-4 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
5
LEGEND FOR FIGURE 5-1
Instruction Manual
IB-102-202N
April 2001
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
15. Top Head Assembly
16. Elbow Fitting
17. Cylinder Head Gasket
18. Top Tubing
19. Cylinder
20. Gaster 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
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-5
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
5-6 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
6
SECTION 6
RETURN OF MATERIAL
Instruction Manual
IB-102-202N
April 2001
6-1 RETURN PROCEDURE
If factory repair of defective equipment is required, proceed as follows.
a. 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.
b. Carefully pack defective unit in a sturdy box
with sufficient shock absorbing material to
insure that no additional damage will occur
during shipment.
c. 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.
d. Enclose a cover letter and purchase order,
and ship the defective equipment according
to instructions provided in Rosemount Return Authorization, prepaid to:
Rosemount Analytical Inc.
R.M.R. Department
1201 N. Main Street
Orrville, Ohio 44667
6-2 REPAIR TERMS
a. If warranty service is requested, the defec-
tive 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.
b. 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.
Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 6-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
6-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
7
IB-102-202N
Hagan 2-1/2 x 5 Power Positioner
April 2001
SECTION 7
REPLACEMENT 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 7-1. Recommended Spare Parts for the Standard Power Positioner
Figure and Index No. Part Number Description Quantity
Figure 5-1, 12 152507-001 Seal 1
Figure 5-1, 17 4847B17H01 Cylinder Head Gasket 2
Figure 5-1, 22 170857 Piston Cup 2
Figure 4-1, 14 and 15 173283 Stem and Sleeve Assembly (Matched Set) 1
(Not shown) 3D39395G07 Maintenance Tool Kit 1
Table 7-2. Recommended Spare Parts for the On/Off Power Positioner
Figure and Index No. Part Number Description Quantity
Figure 5-1, 12 152507-001 Seal 1
Figure 5-1, 17 4847B17H01 Cylinder Head Gasket 2
Figure 5-1, 22 170857 Piston Cup 2
Figure 4-2 ASCO #8340A2 Solenoid Valve Assembly 1
(Not shown) 3D39395G07 Maintenance Tool Kit 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 7-3. Recommended Spare Parts for the Standard Pilot Valve Assembly
Figure and Index No. Part Number Description Quantity
Figure 4-1, 11 171323 Bottom Diaphragm 1
Figure 4-1, 8 170960 Top Diaphragm 1
Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Table 7-4, 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 Table 7-1, Table 7-2, and Table 7-3 for recommended spare parts.
Table 7-4. Bill of Materials for the 2-1/2 x 5 Power Positioner
Figure and Index No. Part Number Description Quantity
Figure 5-1, 1 120079-010 Retaining Ring 2
2 170924 Clevis Pin 1
3 170925-002 Clevis 1
4 120036-014 Hex Nut, 0.625-18 1
5 4847B25H01 Piston Rod 1
6 4513C25H02 Positioner Arm 1
7 120090-250125 Socket Head Cap Screw, 0.250-20 x 1.25 long 1
8 Calibration Spring (1 of 3 Tensions) 1
170952 0 - 30 lb Spring —
171267 3 - 15 lb Spring —
171266 3 - 27 lb Spring
9 163792-1932038 Cap Screw 2
10 120114-017 Lockwasher, #10 2
11 170949 Seal Retainer 1
12 152507-001 Seal 1
13 120026-019 Hex Nut, 0.312-24 4
14 120114-029 Lockwasher 4
15 4847B35G01 Top Head Assembly 1
16 771B867H01 Elbow Fitting 4
17 4847B17H01 Cylinder Head Gasket 2
18 3D39399H05 Top Tubing, 18” long, 1/8” 304 S.S. 1
19 4847B29H01 Cylinder 1
20 170941 Garter Spring 2
21 170942 Piston Cup Follower 2
22 170857 Piston Cup 2
23 3D39399H02 Bottom Tubing, 9” long, 1/8” 304 S.S. 1
24 120110-005 Washer, 0.500 Plain 1
25 120171-002 Elastic Stop Nut 1
26 Bottom Cylinder Head (1 of 2 Designs) 1
4846B57G02 Bottom Cylinder Head, G05 Group —
4847B34G01 Bottom Cylinder Head, G06/G08 Groups —
27 3D39398 Pilot Valve Assembly 1
Figure 4-1, 1 Socket Head Cap Screw 2
2 4847B19H01 Rubber Boot 1
3 4847B55H02 Top Spring Retainer, Standard 1
4844B16H01 Top Spring Retainer, EPT Option 1
173217-001 Top Diaphragm Cover, EPT Option 1
4 170964 Top Loading Spring 1
5 4847B82H01 Top Diaphragm Seat 1
6 170960 Top Diaphragm 1
7 4847B20H01 Center Block 1
8 4847B22H01 Center Diaphragm Post 1
9 171323 Bottom Diaphragm 1
Hagan 2-1/2 x 5 Power Positioner
NOTE
7-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
7
IB-102-202N
Hagan 2-1/2 x 5 Power Positioner
Table 7-4. Bill of Materials for the 2-1/2 x 5 Power Positioner
Figure and Index No. Part Number Description Quantity
Figure 4-1, 10 170959 Bottom Diaphragm Seat 1
11 4847B21 Top Stem Seat 1
12 3D39396H02 Valve Body 1
13 O-Rings 4
173283 Stem and Sleeve Assembly 1
14 Sleeve 1
15 Stem 1
16 170955 Bottom Stem Seat 1
17 170958 Bottom Loading Spring 1
18 170968 Sleeve Retainer 1
Figure 5-1, 28 174080-003 Tie Rod, 0.312-24 x 9.38 long 4
Figure 4-3, 1 8741-001 Limit Switch 2
2 3535B04G01 Switch Striker 1
3 3535B01H01 Switch Bracket 2
4 70001DAJ4B Pan Head Screw, 0.138-32 Thread 4
5 70500BD30C Washer, #6 Flat 4
6 70510CR10G Lockwasher, #6 Split 4
7 3535B09H01 Nut Plate, 0.138-32 Thread 2
3534B98 Instructions, Limit Switch Kit 1
Figure 4-2 ASCO #8340A2 Solenoid Valve Assembly
(On/Off Units only)
April 2001
1
Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 7-3
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
7-4 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management
Hagan 2-1/2 x 5 Power Positioner
I
SECTION 8
INDEX
This index is an alphabetized listing of parts, terms, and procedures having to do with the Hagan
2-1/2 x 5 Power Positioner. Every item listed in this index refers to a location in the manual by
one or more page numbers.
Instruction Manual
IB-102-202N
April 2001
A
Active Coils, 2-5
Adjustment of Standard Units, 2-4
Air Filter, 2-1, 4-1, 4-3
Ambient Temperature, 2-1
C
Calibration Spring, 3-3
Clevis, 1-1, 2-1
Clevis Pin, 2-1
Control Signal, 2-4, 3-1, 3-3
Control System, 4-5
Cylinder, 1-1, 4-3, 4-5, 4-7, 5-1
D
Damper, 1-1
Diaphragm, 3-1, 4-5, 5-2
Diaphragm Assembly, 3-1
E
Equation, 2-5, 2-6
G
Guide Bearings, 3-1
I
Installation, 2-1
L
Limit Switch, 1-2, 2-4, 2-6, 4-7, 4-8
Lower Limit, 2-4
M
Maintenance, 4-1, 4-3
Mounting Pivot, 2-1, 5-1
Mounting Pivot Pin, 2-1
O
On/Off Standard Option, 3-3
P
Pilot Valve, 1-1, 3-1, 5-1
Piston, 1-1, 3-1, 3-3
Piston Cups, 3-1, 4-6, 5-2
Piston Rod Seal, 4-5, 5-2
Power Air, 1-1, 3-1, 5-1, 5-2, 5-3
R
Replacement Parts, 7-1
S
Shutoff Valve, 2-1
Sleeve, 4-1, 5-1
Sleeve and Stem, 3-1, 4-1
Solenoid Operated Valve, 3-3
Solenoid Valve, 1-2, 4-3, 5-3
Stem, 3-1, 4-1, 5-1
U
Upper Limit, 2-4
W
Wiring, 2-4
Rosemount Analytical Inc. A Division of Emerson Process Management Index 8-1
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
8-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management
WARRANTY
Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from
defects in workmanship and material under normal use and service for a period of twelve (12)
months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid
junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and
material under normal use and service for a period of ninety (90) days from date of shipment by
Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or
material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the
goods, part(s) or consumables are returned to Seller's designated factory, transportation charges
prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in
the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in
effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day
warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and
consumables are capable of being renewed, repaired or replaced.
The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly
or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from
any other cause. All other warranties, expressed or implied are hereby excluded.
IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS,
SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD
WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC
GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER
AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT
ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT.
IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER
NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS
COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO
BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED
HEREUNDER.
Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond
Seller's direct control.
1849
3536/4-01
Instruction Manual
IB-102-202N Rev. 1.1
April 2001
Hagan 2-1/2 x 5 Power Positioner
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
E gas.csc@emersonprocess.com
ASIA - PACIFIC
Fisher-Rosemount
Singapore Private Ltd.
1 Pandan Crescent
Singapore 128461
Republic of Singapore
T 65-777-8211
F 65-777-0947
http://www.processanalytic.com
© Rosemount Analytical Inc. 2001
Fisher-Rosemount GmbH & Co.
Industriestrasse 1
63594 Hasselroth
Germany
T 49-6055-884 0
F 49-6055-884209
EUROPE, MIDDLE EAST, AFRICA
Fisher-Rosemount Ltd.
Heath Place
Bognor Regis
West Sussex PO22 9SH
England
T 44-1243-863121
F 44-1243-845354
LATIN AMERICA
Fisher - Rosemount
Av. das Americas
3333 sala 1004
Rio de Janeiro, RJ
Brazil 22631-003
T 55-21-2431-1882
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