Rosemount HAGAN 4 x 5 Torque Type Power Positioner-Rev J Manuals & Guides

HAGAN
POWER POSITIONER

TORQUE TYPE 4x5

Instruction Bulletin I&102-204
Supercede.~ IB-102-204 dated October. 1993

Rev. )

ROSEMOUNT’ANALYTICAL

ASHER.RDSEMDU~ManagingThe PIOIXSS BelW

ROSEMOUNT WARRANTY

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

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

The remedy(&) 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 deterioration due to environment. Factors such as

corrosive. gases and solid paticulates can be detrimental and can create the need for repair 01 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.

PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the Hagan 4 X 5 Power

Positioner, components, functions, installation, and maintenance.

This manual is designed to provide information about the Hagan 4 X 5 Power Positioner. We

recommend that you thoroughly familiarize yourself with the Description and Installation sections before.

installing your power positioner.

The overview presents the basic principles of the power positioner along with it’s performance
characteristics and components. The remaining sections contain detail procedures and information necessary
for installation and servicing of the power positioner.

Before contacting Rosemount concerning any questions, fast 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.

WARNING

Highlights an operation or maintenamx procedure, practice, condition, statement, etc., if not stictly

observed, could result in injury, death, or long-term health hazards of personnel.

CAUTION

Highlights an operation or maintenance procedure, practice, condition, statement, etc., if not slx’ictly
observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure, condition, or statement.

NOTE TO USERS

The Pw number in the lower right corner of the illustrations in this publication are manual
illustration numbers. They are not part numbers, and are not related to the illustration in any technical
manner.

TABLE OF CONTENTS

Section

RosemountWarranty . . . . . . . . . . .

I.

II.

In.

N.

DESCRIPTION

l-l. Component Checklist of Typical System (Package Contents) .

l-7.. Model Number Matrix ............................

1-3.
1-4.
l-5.

INSTALLATION

2-l. Overview ........................................

2-2. Special Installation Considerations
2-3.
2-4.
2-5. Current to Pneumatic Signal Converter (I/P) Electrical Connections
2-6.

REVERSE OPERATION
3-1. Operational Description
3-2. Procedures for Reversing Operation

CALIBRATION
4-1.
4-2.
4-3. Current to Pneumatic Signal Converter (UP) Calibration

4.4. Linkage Calibration .........................

System Overview ...............................

Model PP405TR Specifications ......................

storage Inshllctions .............................

.......................

Power Positioner Mounting Instructions ...................

Air Supply Installation ...............................

Linkage Instauation .................................

..................

..........

Check Power Positioner Calibration ..............

Stroke Calibration .............................

.........

.........

.........

.........

.........

.........

.........

......... 2-l

......... 2-3

......... 2-5

.........

.........

.........

.........

.........

.........

.........

Page
i

l-l
l-l
l-l
1-5
1-5

2-l

2-l

2-5

3-1
3-l

4-1
4-3
4-5
4-5

V.

VI.

VII.

TROUBLESHOOTING
5-l.
5-2. Troubleshooting Chart

PERIODIC MAINTENANCE
6-l. overview
6-2. Maintenance Schedule.
6-3. General Cleaning and Lubrication
6-4. Pilot Valve Cleaning and Inspection
6-5.
6-6.
6-l. Cylinder and Piston, Cleaning and Lubrication

CORRECTIVE MAINTENANCE
7-1. Overview

7-2.

overview ..........................

.................

..........................

.................

.........

.......

Air Filter Cleaning and Draining ..........

Diaphragm Cleaning and Inspection ........

..........................

Parts Replacement ....................

.........

.........

......... 6-l

......... 6-l

......... 6-l

......... 6-l

......... 6-4

......... 6-4

......... 6-5

.........

..........

5-l
5-1

7-1
l-l

TABLE OF CONTENTS (Continued)
section
VIII.

Ix. RECOMMENDED SPARE PARTS
X.

OPTIONS
8-l Overview

. . . . . . . . . . . . . . . . . . .._.___....................

8-2 Air Lock . . . . . . . . . . ..t................................

8-3 Electric Position Transmitter @‘T)
8-4 Heater/Thermostat . . .

RETURNING EQUIPMENT TO THE FACTORY
INDEX

LIST OF ILLUSTRATIONS

Figure

l-l.

l-2.

l-3.

2-l.

2-2.
2-3.
2-4.
2-5.
2-6.
2-l.
2-8.
2-9.
2-10.
2-11.
2-12.
3-l.
4-l.
4-2.
4-3.

4-4.

4-5.

5-l.

5-2.
6-l.
6-2.
6-3.
6-4.
7-1.
7-2.
l-3.
7-4.
l-5.

Typical System Package .......................................

Power Positioner Operation .....................................

Typical Power Positioner Installation ..............................

ClearanceRequirements .......................................

Mounting and Installation (Footprint) Drawing

4 x 5 Power Positioner Torque Chart ..............................

Air Piping Schematic .........................................

Linear Linkage Design ........................................

Vertical Arm Travel ..................................

Driven Shaft Angular Rotation

...................................

Connecting Linkage Length .....................................

Linear Linkage Design ........................................

DiiectActingCam ...........................................

Inverse Acting Cam ..........................................

Characterized Cam Example ....................................

Reverse Operation

...........................................

Calibration Flowchart
Piston Stroke Calibration

.......................................

I&' Calibration ..............................................

Linear Linkage Calibration .....................................

Characterized Linkage. Calibration . .

4 X 5 Power Positioner Air Piping Schematic

4 X 5

Power Positioner Air Piping Schematic (with Bypass Valve and Air Lock)

Lubrication Chart ............................................

Pilot Valve Exploded View

Diaphragm Exploded View .....................................

Cylinder Exploded View

Air Filter ..................................................

Pilot Valve ................................................

Receiver Exploded View

Cylinder Exploded View

.......................................

.......................................

CamReplacement ............................................

. .

........................

........................

........

Page

8-1

8-1

8-4

8-4

Page

l-l
l-3
l-5

2-2
2-2
2-3
2-4
2-5
2-6
2-l
2-9
2-10
2-14
2-15
2-16
3-2
4-o
4-4
4-5
4-6
4-6
5-l
5-2
6-2
6-3
6-5
6-6
7-l
l-3
7-5
7-6
7-5

LIST OF ILLUSTRATIONS (Continued)

Figure

8-l
8-2
8-3
84

Table

1-l
l-2

1-3
2-l
2-2
4-l
4-2
4-3
5-l
6-1
9-l
9-2
9-3

AirLock . . . . . . . . .

Air Lock Brake Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Lock Diaphragm Exploded View

Heatben’Thermostat . . . . . . . . . . . . ..__._______._.......................

. . . . . . . . . . . .

LIST OF TABLES

Model Number Matrix .............................

Specifications for Model PP405TR Power Positioner
Specifications for Recommended Rust Preventive Compound

System Flow Chart ...............................

CamRotationPoints

Device Travel (%) ................................

Piston Travel (Stroke) Calibration Schedule

Direct and Inverse Calibration Signal Pressures ............

Troubleshooting Chart .............................

Maintenance Schedule .............................

Recommended Spare Pm for PP405TR 4 X 5 Power Positioner
Spare Parts for Options (PP405TR 4 X 5 Power Positioner Only)

Bill of Material for PP405TR 4 x 5 Power Positioner .......

..............................

..............

........

.

.
.

.

. .

. . .

Page
8-l

8-2
8-3
8-5

Page

1-o
l-4
l-5

2.11
2-13

4-l
4-2
4-3

5-3
6-1
9-1
9-2
9-2

Table 1-l. Model

Number Matrix.

DESCRIPTION

PP405TR

PNEUMATIC POWER POSITIONER

4 x 5 TORQUE TYPE

FRAME DESCRIPTION

Standard/Brass Connections ____________________..........................

Manual LockBr*ss connections

At, Lccwsrass connections

Sta,,dard,Stainless Steel ConnectIons

Manual Lock/Stainless Steel Connections .._.......________....... 6

Air LocldStainless Steel Connections

SIGNAL RANGE

3.16PSiG .,,,,,.,.___________....................................................... 1 1

O-30 PSlG

4.20 ,,,A

CAM SELECTION

Linear Standard Rotation
Linear Reverse Rotation

Square Rwt Standard Rotation (Direct System) ............... 3

Square Root Reverse Rotation (Direct System) ................

Square Root Standard Rotation (Inverse System) _________.___
Square Root Reverse Rota6on (Inverse System)

LIMIT SWITCH

None . . . . . .._...................................................................

Electric Positioner Transmitter _..........................................

Standard Limit Switch SPDT (See Note 1) ________...._.___.._.....

Heavy Duty Limit
Standard
Heavy Duty Limit Switch and

........................................................................... 2

.............................................................................. 3

.................................................... 1

..................................................... 2

.............. 6

Switch DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Limit Switch and EPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EPT 5

TYPE INPUT CAM SWITCHIEPT

1
2
3
4

6

4

6

0

1

2

I

k

UMlr MINIMUM

HEATER LIMIT STOP

T

HEATER

None ._....__..._________............................................................... ”

117 VW, 160 Watt Heater ________________..................................

MINIMUM LIMIT STOP

I

*I

SECTION I. DESCRIPTION

l-l. COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS). A typical
Rosemount 4 X 5 Power Positioner package should
contain the items shown in Figure. l-l.

1-2. MODEL NUMBER MATRIX. Use model number

matrix, Table 1-1, to verify your style number. The
first pat of matrix defines the model. The last part
defines various options and features of the power
positioner. Copy your model number from data plate
located on side of power positioner, into top of matrix
Table 1-1. Check your model number against power
positioner features and options, making sure options
specified by this number are on unit. Use this
complete model number for any correspondence with
Rosemount.

1-3. SYSTEM OVERVIEW.

a. m. This Instruction Bulletin supplies details

needed to install, operate, and service the
Rosemount 4 X 5 Torque Type Power Positioner
(Figure l-l). The standard power positioner
comes with manual lever, manual lock, bypass
valve, current to pneumatic signal converter (I/P),
pressure regulator/filter, supply air filter, clevis,
and dust cover. Power positioner options include
electric position transmitter, limit switches,
heater/thermostat, air lock, and minimum limit

stop. Service instructions for these options are

covered in appendices to this manual.

b. Power Positioner Features. The standard model

power positioner includes the following features:

1. The manual lever provides leverage so
operator can manually change position of the
device being controlled by hand.

2. The manual lock allows operator to lock
piston and output shaft assembly in any
position. This is done by turning lock handle
fully clockwise, manually shutting off air
supply, and opening bypass valve.

3. A bypass valve provides a passage between
top and bottom of piston. This equalizes air
pressure on both sides of piston, allowing
manual positioning of device being
controlled.

4. The current to pneumatic signal converter
(VP) controls signal air to power positioner
through an electrical signal. This electrical
signal can be either a direct 4 to 20 mA
signal, or an inverse 20 to 4 mA signal. The
power positioner can be ordered without the
I/p converter. Without the UP converter, an

ITEM DESCRIPTION

1 Model PP405TR Power

Positioner

2

Air Filter

3

Instruction Bulletin

9

Figure l-l. Typical System Package

air signal controls the power positioner. This
air signal can be direct or inverse, and
have a range of 3 to 15, 0 to 30, 3 to 27, or
0 to 60 psig.

5.

The pressure regulator/filter “l”i”t”i”s a

stable and filtered air supply to the I/P

converter.

6.

The supply air filter will remove finely
dispersed water or oil droplets from supply

air. Supply air must be free of oil and water

to prevent pilot valve Xicking.

I.

The clevis provides a connection from
power positioner to linkage, transferring
piston movement to device being controlled.

8.

A dust cover provides a NEMA type 3
enclosure. It is removable and splash proof.

As signal air decreases the calibration spring
pressure moves the diaphragm up. The
upward movement of the diaphragm moves
the pilot valve stem up, directing air
pressure above the piston. This forces the

piston, piston rod, and operating lever

downward. The downward movement of the

piston rod, working through the cam bar and

roller, lowers the crdibrrdion spring socket
and reduces pressure on the calibration
spring. This decreased pressure on the
calibration spring returns the receiver’s
diaphragm to a neutral position, closing the

pilot valve air ports.

Cam. The cam can be shaped (cut) to

produce a linear (x), square (x2), or a

square-root (Jx) relationship between input
signal and operating lever stroke. Refer to

paragraph 2.6b(2) for cam cutting.

c. Operational Description. Model PP405TR

Torque Type Power Positioner has a pneumatic
driven, double acting, piston type power cylinder,
in which each input signal positions operating

lever to a specific setting. The paver positioner
can position devices such as dampers, inlet vanes,

and control valves.

1. Automatic Operation. Figure 1-2 depicts a
direct acting power positioner. I” this type
of positioner, an increase in signal air
pressure to the receiver causes the
diaphragm to overcome the tension of the
calibration spring, moving diaphragm
downwards. The downward motion is
transmitted to the pilot valve through a
connecting link. This positions the pilot
valve stem to send supply air, above the
piston, forcing the piston, piston rod, and
operating arm downwards. Air from below
the piston is exhausted through the pilot
valves exhaust silencer plug.

The shaft assembly rotates as piston rod
moves downward. The cam is directly

attached to shaft assembly and rotates with

it. This causes the compensator lever roller,
riding on the cam, to lift the spring socket,
increasing pressure on the calibration spring.
The increased pressure. on the calibration

spring returns the diaphragm to its neutral
position, closing the pilot valve air ports.
Without additional air, piston movement is

stopped.

(a) Linear Shaped Cam. A linear, non-

characterized cam will produce a linear
shape (1:l) relationship between the
input signal and output response.

(b) Squared Shaped Cam. The square (x2)

shape will produce a small output
change for a large input change during
the lower portion of the signal range.
When operating in the upper portion of
the signal range, a smrdl input change
will produce a large output change.

OPERATING

DIRECT ACTING - INCREASING

SIGNAL SCHEMATTIC

Figure 1-2. Power Positioner Operation

,

SILENCER PLUG pm

\

I CALBRATION

SPRING

I

CONNECTING

PILOT VALVE

(c) Square-Root Shaped Cam. The square-

root (Jx) shape will prcduce a
relatively large output change. for small
input chaoges during approximately the
first 10% of signal range. When
operating in the “pper portion of the
signal range, a large input change will
be required to produce a small output
change.

3. Inverse Operation. On inverse acting power
positioners, the cam bar is reversed top to
bottom and the reversal manifold is turned
90”. This causes the supply air to be diiected
to the bottom of the piston when signal air
pressure is increased and to the top of the
piston when signal air pressure is decreased.

I” this type of installation, piston movement

is inversely related to the signal -as signal
pressure decreases, the piston lowers, as
signal pressure raises, the piston raises.

4. Manual Operation. Power positioner can be
contmlled manually through manual lever.
Moving this lever directly controls position
of device being controlled. To operate
manual lever, shut off supply air and open
bypass valve.

System Gmsiderations. Prior to installation of
your Rosemount 4 X 5 Power Positioner, check
that you have all components necessary to install
system completely.

Once you have verified that you have all
components, select mounting location. A typical
installation is illustrated in Figure 1-3. Determine

where power positioner will be placed in tams of

serviceability, available power supply, ambient
temperatures, environment”1 considerations, and
convenience. Power Positioner operating specifi­cations are listed in Table 1-2. Become familiar
with Section II, Installation, before instrilling “nit.

Table l-2. Specikations for Model PP405TR Power Positioner.

Signal Requirements

Inputs:

Direct - 4-20 mA/3-15 psig/O-30 psig/3-27 psig
Inverse - 20-4 mA/15-3 p&/30-0 psig/27-3 psig

OUtpUt.%

5 inch Stroke (80” Shaft Rotation)

Performance

Repeatability . .
Full Stroke Time (““loaded) .

Cylinder Air Pressure
Supply Air Co”sumptio”
Control Torque
Stall Torque .

Physical Characteristics

Weight ___ _____ _______ .___ .._. _. ________
Dust Cover

Supply Air Inlet

Environmental Requirements

Ambient Temperature Limits

Without heater .
With Heater

Relative Humidity

Air Supply Requirements

Operating Air Supply Pressure Range

Recommended Air Supply Pressure

0.15% of full stroke
3 set Maximum Allowable

120 psig

0.5 scfnl free air
240 ft-lbs
400 ft-lbs

SO lbs, typical

Designed to meet NEMA type 3 Requirements

l/4 inch NPT female connection

40°F to 14OV (4.5’C to 60°C)

-lOOF to 14ooF (-23.3”C to 60°C)
Operable up to 100% RH

45 to 120 psig

100 psig

b. Power Positioner Preparation for Storage.

WARNING
Keep Tectyl 506 away from beat, sparks,
and open flames. Use with adequate
ventilation to cure and to prevent an
explosive atmosphere from for&g.

CAUTION
Use only approved thinning methods when
applying rust-preventive compounds. Do not
apply heat to compound. Fire or explosion
may result. Refer to manufacture of rust­preventive compound for specific
application, thinning, clean-up and removal
instructions.

Coat all non-painted surfaces and exposed metal
with a rust-preventive compound (Tectyl 506 or
a comparable substitute). If not using Tectyl506,
compare substitute with specifications for Tectyl
506 (Table 1-3. Specifications for Recommended
Rust Preventive Compound).

Table 1-3. Specilkations for Recommended Rust

F’reventive Compound.

I

SIGNAL

AIR

SUPPLY
AIR

Figure 1-3. Typical Power Positioner Installation

1-4. MODEL PP405TR SPECXFICATIONS. Model

PP405TR Power Positioner specifications, Table 1-2,

contains information about power positioner operating
characteristics. Use Table l-2 to make sure that
available conditions are suitable for power positioner

before choosing mounting location.

l-5. STORAGE INSTRUCTIONS. Use the following

guidelines for power positioner storage.
a. Storage Environment. Store power positioner in

a warehouse environment that maintains the
following conditions:

REQUIREMENTS PROPERTIES

Approximate air dry time

1 hour

Low Temperature Flexibility (90” bend with

no flaking or cracking) -10°F (-22S”C)

Volatile Organic

Content (V.O.C.)

3.24 lbs/U.S. Gallon
400 grams/Iiter

Accelerated Corrosion Tests: (5% Salt Spray (Hours))

ASTM (see Note 1) B-117 at 1.3 mils (2 x 4 x

l/8 inch Polished Steel Panels)

2OlXl

DIN (see Note 2) 50021 at 32.5 microns

(125 x 200 mm DIN 1623 Panels)

168

NOTES: (1) ASTM (American Society for Testing and

Materials)

(2) DIN (Deutsche Industrie Normen)

c. Storage Preventive Maintenance. If storing

power positioner for more than six months, use
the following preventive maintenance guidelines.

1. Cycle cylinder and piston, either manually or
by air, every 6 months.

1. Ambient temperatures above 45°F (7°C).

2. Humidity below 80% RH.

2. Perform General Cleaning and Lubrication
(paragraph 6.3). and Cylinder and Piston,
Cleaning and Lubrication (paragraph 6-7).
before installing power positioner.

SECTION II. INSTALLATION

2-1. OVERVIEW. The power positioner is designed to

be installed upright. The floor stand is bolted to a
prepared horizontal foundation. A minimum of
45 psig to a maximum of 120 psig supply air pressure
is needed at mounting location. The power positioner

must be controlled by either an elect&J signal, when
using ao I/P signal converter, or by an air signal. All
wiring must conform to local and national codes.

2-2. SPECIAL INSTALLATION CONSIDERATIONS.

a. Foundation. The power positioner’s torque is

transmitted to operating arm of device being
positioned. This torque is also transferred to
power positioner’s mass aad it’s foundation. The

foundation must be designed to handle the torque
produced to keep power positioner stationary.

Refer to paragraph 2-3 for detailed foundation
requirements.

b. Supply Air. A supply air pressure of 45 psig to

120 psig, minimum of 1 scfm, is required Supply

air must be free of oil and water to prevent pilot

valve sticking.

c. Linkage Design. Final control components play

a large part ia a control system. Special
characteristics of device being controlled affect

system response and must be regarded in design
and setup of a power positioning system.

Control valves and damper drives regularly allow
large flow rate. changes, compared to valve
movement, near the closed position. Smaller flow
rate changes, compared to valve movement, occur

near the fully open position. In normal damper
application, there may be no flow rate changes
after damper has reached 70% open. This
characteristic is represented by the following
equation:

Flow = k (Position)*

k = Constant

position is reduced. As valve or damper closes,

the rate at which flow changes per valve position

is increased. The coostant is a number that allows

the equation to work for different flow control

devices.
Conduct flow tests before attempting to liiit

damper opening. Testing is necessary to confm
actual damper characteristics and to make sore
control response is proportionate to input signal
throughout the flow range. When installing a new
paver positioning system, take care to properly
design the system for linkage size and action. In
a properly designed system, a percentage change
in control signal produces the same percentage
change in flow rate. Refer to paragraph 2-6 for
detailed information on design aad installation of
a liiearized control action power positioning
system.

23.

POWER POSITIONER MOUNTING
INSTRUCTIONS.

a. Working Clearance Requirements. Make sure

area is clear of obstructions that will interfere
with powerpositioner operation and maintenance.

For standard unit, allow ao open area of 22

inches (vertically from foundation) by 16 inches
(side to side) by 28 inches (front to back). This
will allow for removal of dust cover, maioten­axe, and full travel of operating lever. For
extended cover unit, allow aa additional 4 inches
vertically (26 inches from foundation) for
increased space requirements of thii power

positioner (Figare 2-l).

b. Location Selection.

1. Select location for power positioner as near
to the device b&g controlled as possible,
making sure necessary clearance for

operation and maintenance, as specified in
paragraph 2-3a, is available.

This equation means that flow is proportional to
the square of valve position. As damper or valve
opens, the. rate at which flow changes per valve

2. Use Specifications for Model PP405TR
Power Positioner, Table l-2, to make sure

environmental conditions are suitable for the

power positioner.

1:o

I-

7.5 -

13.5

tl”

/

1.2!

5

I

Fire 2-1. Clearance Requirements

-

Ii

I-

9.25

3.0

7

~

DIMENSIONS ARE IN INCHES.

Figure 2-2. Mounting and Installation (Footprint) Drawing

MOUNTING HOLES (4)

IB-lGZ-204

2.2

3. Become familiar with all of Section II,
Installation, before actual installation is

started.

e. Mounting Procedure.

1. Design and Manufacture Foundation.
Foundation m”st be able to withstand at
least 500 ft-lbs torque plus X0 lbs weight.
Refer to Figure 2-2 for footprint dimensions
of power positioner. Use this footprint as a
guide to design foundation to match base of
power positioner. Mounting holes in base are
drilled for l/2 inch foundation bolts. Decide
which foundation material is best suited for
your application, steel or concrete, and
design and manufacture foundation.

2. Installation.
Install paver positioner on foundation

(a)

with l/2 inch bolts and standard flat
washers.

(b) Make sure power positioner is level.

Check by measuring side to side and
front to back with a level.

(c) If power positioner is not level, remove

l/Z inch bolts that secure power
positioner to foundation and install
shims between the power positioner
and foundation. Continue this process
until power positioner is level when

l/2 inch mounting bolts are tightened.
This will prevent distortion of power

positioner stand.

(d) If installed on a concrete foundation,

grout foundation with additional

concrete to prevent distortion of power
positioner stand.

2-4. AIR SUPPLY INSTALLATION. Using Figure 2-3,

match the torque load needed to position your device
to the “maximum torque required” axis along the
bottom of the graph. From this point, move vertically
up to the control torque curve. From the point that
intersects control torque curve, move horizontally to
the left scale labeled “supply air pressure”. This is the
mini”““” supply air required to develop the required
control torque. The stall torque curve represents the
maximum amount of toque the power positioner will

produce for given supply air pressure before stalling

0”t.

120

100

80

60

40

20

0

100 200 300 400

MAXlMUM TOROUE REQUIRED (FT-LBS)

Figure 2-3. 4 x 5 Power Positioner Torque Chart

600

Pcwm

1/4$zLIPT
CONNECTION

PRESSURE

REGULATOIUFILXR

,

SHUT-OFF VALVE

POWER POSITIONER

CURRENT TO PNEUMATII

POWER POSITIONER WITH

PNEUMATKZ CONTROL SIGNAL

VIEWA

,.A..\,sY”TCD ,.m

CyI”“S”lS” ,.i)

VIEWS

WITH

C SIGNAL

SHUT-OFF VALVE

AIR

FILTER

/

AIR

FILTER

1

I

15 FEET

MAXIMUM

-j ZPHRAGM
?-?O PILOT

--j VALVE

15 FEET
MAXIMUM

Figure 2-4. Air Piping Schematic

a.

Air Line Reauirements. Installation of air falter
is necessary for proper power positioner

operation. A manual shutoff valve should be
installed in the air supply line before the air

filter, Figure 2-4.

The air filter will remove finely
dispersed water or oil droplets, preventing pilot
valve stem from sticking.

If your unit is not equipped with an I/P signal
convertq install a separate signal line as shown

in Figure 2-4 View B. The power positioner can
accept different ranges of signal air pressures.

18-102-204

2.4

Refer to your model number and model number

matrix (Table l-l) to determine signal air

pressure reqdred.

Supply Air

b.

and Signal Air Connections. Basic
schematics are shown in Figure 24. The
installation of the air fdter is as follows:

1. Mount bracket for air filter directly on the
back of the stand assembly. If this is
unsuitable, mount air filter within 15 feet of
power positioner.

NOTE

Prior to connecting supply air line or signal

air line, purge air system until all moisture
and debris are blown out.

2. Purge air supply system and connect air
supply line to the air filter inlet. Run a
second line from the air filter outlet to the

power positioner supply air inlet connection.
All fittings arc l/4 inch NPT.

3. Purge signal air line and connect to signal
air connection on paver positioner.

2-5. CURRENT TO PNEUMATIC SIGNAL

CONVERTER (I/P) ELECTRICAL

CONNECTIONS. Connect electrical signal input to
I/P converter and calibrate if necessary. Refer to
paragraph 4-3 for calibration procedures. The
connections must be made by screw terminals. If the
I/I’ has pigtail leads instead of screw terminals, the
connection must be made at a terminal block. Gage of
wire required is 18 gage signal wire. The signal that
will control the JfP should have a range of 4 to
20 mA at a voltage of 24 Vdc.

a. Direct Acting. Connect positive signal to black

lead and negative signal to white lead.

b. Reverse Acting. Connect positive signal to

white lead and negative signal to black lead.

2-6. LINKAGE INSTALLATION. Install linkage for

either a characterized flow control device, or linkage
for a linear flow control device. Linkage described is
pipe (3/4 inches diameter), maximum length of
21 feet 9 inches. Maximum horizontal offset is

22 inches, at widest part of linkage system.

DRIVE

LEVER ---

AIR
DUCT

POWER

POSITIONER

L

Figure 2-5. Linear Linkage Design

4. Measure angle (9,) of device’s driven lever
from vertical center line.

5. Install power positioner’s drive lever so its

angle (tl,) is the same as the device’s driven
lever @J.

a. Linkage Installation for a Characterized Flow

Control Device.

1. Measure length of driven lever (R,) on
device to be controlled (Figure 2-5).

2. Attach the linkage clevis to the power
positioner’s drive lever so that distance R2 is

equal to R,.

3. Close damper of device being controlled to

minimum flow position.

6. Measure distance (!?) between drive and
driven levers connection holes. Allowing for
clevis length, cut pipe to fit this
measurement. Install &vises.

7. Install linkage pipe between drive and driven
levers. Check for freedom of movement by
operating power positioner’s manual lever.
Make minor adjustments to linkage length
by turning linkage clevis fitting in or out as
“C.C!C.S~.

b. Linkage Iastallation for a Linear Flow Control

m. Linear flow control devices require a

characterized control system. This can be
accomplished by either characterizing linkage or

characterizing power positioner.

If greater torque is rqdred at start of power
positioner movement, characterize lb&age system.
This is covered in step 1. below.

(h) Figure out how far vertically the

operating lever travels using Figore 2-6
and the following equation:

Y-2& tsin ( w,+p,) /2

NOTE

* 0) 1 a- rsin~,/2.01z

If this additional starting torque is not required,

a linear lib&age can be installed. The power

positioner cam must be shaped to characterize

power positioner. This is cover.4 in step 2.

NOTE

Linkage installation described in this section
of the manual is for direct acting power
positioners.

1. Characterized Linkage System.
(a) Make sm. a linear cam is installed to

get linear outputs from power
positioner.

The following known values are wed to
calculate tbe vertical distance travelled by
the drive lever; “Y”.

R, = Length of drive lever (from shaft

center to clevis pin center) measured
in inches.

0, = Total angular rotation of drive lever.

If power positioner is at full stroke,

this measurement is 809

p, = Angular measurement of drive lever

from vertical centerline with piston
fully extended.

To perform the following procedure, a
calculator with basic functions, plus the
following scientific functions, is

necessary:

-Sine Function (SIN)

-Square Function (x2)
Use the following procedure to

determine Y, the vertical distance
travelled by drive lever:

POWER POSITIONER

Fire 2-6.

Vertical Arm Travel

DRIVE
LEVER

1 Add vahxe of e1 to value of fl,.
2 Divide answer from step 1 by

2.0.

1 Enter answer from step 2 and

press sine key (SJN).
4 FESS square key (x3.
2 Multiply answer from step 2 by

length of drive lever (R,).

6 Multiply answer from step 2

by 2.

1 Write down answer from step 6

and label it 6 for use later on.

2 Enter value of BP
s Press sine key (SIN).
,lJ Divide answer from step JQ by

2.0.

12 Press square key (usually key

marked x3.

13 Write down answer from step 12

and label it B.

E Enter vahx. marked 5 and

subtract value marked u.

& The value in step s is equal to

ve.rticd distance travelkd by
drive lever “Y”.

(c) Figure out angular rotation of driven

lever. This is done in terms of drive
lever rotation. The angular rotation
follows Figure 2-7 and the relationship:

POWER

PoSITloNER

I I Pcc.x?

Figure 2-7. Driven Shaft Angular Rotation

NOTE

The following known values are used to

calculate the total angular rotation of the
driven lever; C&.

Or = Total angular rotation of the drive

lever. If power positioner is at full
stroke, this measurement is 80’.

R, = Length of the drive lever (from shaft

center to clevis pia center) measured
in inches.

Q = Length of the driven lever (from

shaft center to clevis pin center)
measured in inches.

PI = Angular measurement of drive lever

from vertical centerline with piston
fully extended.

!.3* = Angular measurement ofdriven lever

from vertical centerline with damper
fully closed.

To perform the following prcccdurc, a
calculator with basic functions, plus the
following

scientific functions, is

necessary:

-Sine Function (SIN)

-Inverse Sine Function (SIN“) or (INV
SW

-Square Function (x”)

-Power Function (y”)

Use the following procedure to
de&mine @, the angular rotation of
the driven lever.

1. Add value of !3, to value of 8,.
2 Enter answer from step 1. and

press sine key (SIN).

3 Divide answer from step 2 by

2.0.

4 Multiply answer from step 3 by

length of driven lever (FQ.

IB-IM-204

2.7

Write down answer from step 2
and label it 2. Clear calculator.

Enter value for length of drive
lever (RI).

Divide value from step 6 by
value ma&cd 3.

Write down answer from step 25
and label it 3.

Enter value for 8.

Divide value from step 28 by 2.
F’ress square key (x3.
Write down answer from step 3

and Iabel it 3 for use later.
Clear calculator.

Enter value for B1 and press sine
key (SW).

Divide answer fxom step 11 by 2.

F’ress square key (x3.

Write down answer from step 13
and label it 13 for later use.

Enter value for a and press sine
key (SW.

Divide answer fmm JJ by 2.
Press sqnm key (x2).
Write down answer from .lJ and

label it u for later use.
Clear calcldator.

Write down answer from step 29

and label it z. Clear calculator.

Enter value from step 3.

Subtract value from step 2.

Multiply answer from step 22

by 2.

The value in step 33 is equal to

total angular rotah% of driven

lever “v.

(d) Figure oat length of connecting linkage

based on length of drive lever, driven

lever, and the initial offset of both. Use
Figure 28 and the following
relationship:

NOTE

The following known values are used to

calculate the length of the linkage in inches;

“P’.
Enter value marked 3.
Subtract value marked 13 from

value marked &.

Subtract value marked 11 from
step 21,

Press power function key (y”).

Enter 0.5.
Press inverse sine @NV SIN or

SIN“).

L = Length between drive and driven

shaft center lines, measured in

inches.

R, = Length of the drive Iever (from shaft

center to clevis pin center) measured
in inches.

R* = Length of the driven lever (from

shaft center to clevis pin center)
measured in inches.

b, = Angular measurement of drive lever

from vertical canter line with piston
falIy extended.

p1 = Angular measurement of driven lever

from vertical center tine with
damper fully closed.

5 Clear calcnlator.
6 Enter value for & and press

cosine key (COS).

z Multiply answer from step 6 by

length of drive lever (R,).

& Write answer from step 1 down

and label 2. Clear cakxlator.

2 Add answer from step 8 to value

marked 2.

Press square key (x3.

@

11. Write down answer from step .lJ
and label lo.

12 Clear calcnlator.

Enter distance between drive and

13

driven shaft (L).

Fire 2-8. Connecting Linkage Length

To perform the following procedure, a
calculator with basic functions, plus the
following scientific functions, is
necessary:

-Sine Function (SIN)

-Cosine Function (COS)

-Square Function (x3

-Power Function (y”)
Use the following procedure to

determine I, the length of connecting
linkage in inches:

I Clear calculator.
2 Enter value for b1 and press

cosine key (COS).

14 Subtract value marked u from

step ,lJ.

15 Write down answer from step 14

and label fi.

16 Clear calculator.
11 Enter value for B1 and press sine

key (SIN).

19 Multiply answer from step .lJ by

length of drive lever (RI).
Write down answer from step 18

19

and label Is.

20 Clear calculator.

Enter value for a and press sine

21

key WN.

22 Multiply answer from step 21 by

length of driven lever &).

3 Multiply answer from step 2 by

length of drive lever (R,).

4 Write down answer from step 3

and label 1.

Write down answer from step 22

23

and label 22. Clear calculator.

24 Subtract value marked 22 from

value marked j&

Add answer from step 2 to

25

value marked 2.

Press power function key (y’).

2.5

Enter 0.5 into calculator.

27

The value in step 27 is equal to

28

length of connecting liige

“P “.

Design linkage system by “sing values

for lengths of drive and driven levers,
angtdar position of both levers frm”
vmtical (offsets), and distance between
drive and driven levers centers to
calculate length of liige.

Close dmnper to minimum flow

(e)

position. Make sure driven lever is at

angle (PJ and drive lever is at angle
0%).

Cut liige pipe to length (p) allowing

0

for both clevises. Attach clevises and
install linkage between operating
1eJWs.

Check for freedom of movement by

(9)

operating power positioner’s manual
lever. Make minor adjustments to
linkage length by turning pipe to clevis
fitting in or out as necessary.

2. Characterized Power Positioner.
Measure full @avel of device being

(a)

controlled from full open to full closed.
Record maximum and minimum

positions.

Install Linear Linkage.

(b)

1 Measure length of driven lever

(R,) on device to be controlled
(Figure 2-9).

2. Attach cl&s to drive lever so
that distance R, is equal to R,.

3 Close damper of device being

controlled to minimum flow

position.

Figure 2-9. Linear Linkage Design

Measure angle (0,) of device’s

driven lever from vertical center
Sine.

Install power positioner’s drive

lever so its angle from vertical
center line (03 is equal to
device’s driven lever angle (0,).

Measure distance Q between

drive and driven levers
connection holes. Allowing for
clevis length, cut pipe to fit this
measurement. Attach clevises.

Install liige pipe between drive
and driven levers. Check for
freedom of movement by
operating power positioner’s
manual lever. Make minor
adjustments to linkage length by
turning linkage clevis fitting in or
0”t as necessary.

Check power positioner calibration and

Cc)

make sure linear cam is installed. Refer
to paragraphs 4-2 and 4-3. Make any
adjustments to power positioner prior

to cutting cam.

Table 2-1. System Flow Chart.

INPUT

SIGNAL FLOW FLOW

6)

ACTUAL PERCENT

I

(scfm)

(961

Copy “System Flow Chart” (Table

(4

2-l). Measure and record actual flow
of system starting at 0% input signal to

power positioner and increasing up to

100% in increments of 20%. Divide
actual flow by flow at 100% input
signal to determine percent flow. Enter

percent flow in percent flow column in

Table 2-l.

Near bottom edge on a sheet of graph

(e)

paper, draw a baseline (Graph 1)
twenty blocks long. Label “% Flow”.

Starting at left edge of baseline, draw

Q

a vertical line 20 blocks long. Label
this line “% Input Signal”.

0%

20%

40%

60%
80%

100%

Starting at right edge of baseline, draw

(g)

a vertical line 20 blocks long. Label
this line “% Cam Rotation”.

Scale “% Input Signal” line by marking

00

baseline 0%. Mark 10% point two
blocks upward. Continue labeling in

10% blcrements up to 100%.

% OF

INPUT

SIGNAL

% FLOW

Graph 1

90

80

70

60

YiPuq:

SIGNAL 5o

40

30

20

10

0

BASE LINE

% CAM

ROTATION

0 20 40 60 80 100

% FLOW

Graph 2

90

80

70

60

‘kP%

SIGNAL 5o

40

30

20

10

0

BASE LINE

i--

i..

i..

i

0 20 40

% FLOW

Graph 3

60 80

100

RECORD POINTS
IN TABLE 2-2

(i) Scale baseline by marking left end 0%.

Mark 20% point four blocks to right
horizontally. Continue labeling in 20%
increments up to 100%.

(j) Plot points on graph (Graph 2) with

data fmm system flow chart (Table
2- 1). For example: Using Table 2- 1 in
Graph 2, at a 20% input signal, percent
of flow is 35%; follow 20% input
signal line until it intersects 35% flow
line; place a mark at this point. Repeat
thii procedure for 40%. 60%, SO%, and

100% input signals, placing marks at
each intersection with corresponding
flow line. Connect these. points with a

smooth c~rye. starting at a point with

zero % flow and zero % input signal.
Label curve X.

(k) Draw a straight line from zero point on

cnrve x to 100% point on curye x.
Label this line curve Y.

(1) From 10% increment on “% Input

Signal” scale, draw a horizontal line to
curve Y (Graph 3).

(m) From point in step (l), draw a vertical

line downward to meet clwe X.

(n) From point in step (m), draw a

horizontal line to “% Cam Rotation”
scale.

(0) Repeat process from step (1) through

steo (n) for 20% to 90% inuut sienal.

_

- I

@) Value of “% Cam Rotation” is read

where line in step (n) intersects “%
Cam Rotation” scale. Estimate value by
using percentage scale on left edge of
graph. Copy Table 2-2 and record
values in 46 Cam Rotation in blank
column and again in Table 4-l
Characterized column for future
reference.

(q) If power positioner is direct acting,

make a copy of Figure 2-10, Direct
Acting Cam. If power positioner is to
be reverse acting, make a copy of

Figure 2-11, Inverse Acting Cam.

Table 2-2. Cam Rotation Points.

Example:

% INPUT SIGNAL

0 0 0

% CAM ROTATION % INPUT SIGNAL

10 3 10

20 9 20

30

16 30
40 23 40
50 33 50
60 45 60
70

55
80 67 80
90 84 90

100 100 100

Record Values from step (0):

96 CAM ROTATION

70

PERCENT CAM

ROTATION KW3

80.

Fiire Z-10. Direct Acting Cam

LB-102.204

2-14

PERCENT CAM

ROTATION [CCi’Vl

Figure Z-11. Inverse Acting Cam

(I) Plot points i?om Table 2-2 on copy of

cam. Refer to example in Figure 2-12.

(s) Set compass for 0.4375 inch radius and

draw 0.875 inch circles using points

plotted in step (r) as center.

(t) Draw a smooth cmve connecting edges

of circles that are on same side as
cam’s mounting holes. This is shape of
new cam contour. Make several copies
for future reference..

DIRECT ACTING CAM

Figure 2-12. Characterized Cam Example

INVERSE ACTING CAM

(II) Cut out paper cam leaving new cam

contour, mounting hole, and slotted
hole.

(v) Lie up mounting and slotted holes of

paper cam to mounting and slotted

holes of metal cam. Cement paper cam
to metal cam. Remove material from
cam as needed to give metal cam shape
of paper cam. Using a file or similar
tool, smooth carve until no ridges or
imperfections are felt on edge of c.arve.

(w) Install cam on power positioner and

check for a linear relationship between

actual flow of system and input signal

to power positioner. A 10% input
signal will produce a 10% flow, a 50%
input signal will produce a 50% flow.

Make minor adjustments by draw filing

cam.

(x) Record power positioner characterized

action ia Table 4-2, schedule 7’. Use

the following procedure:

1 Set signal air to 0%.
2 Measure distance. from top of

packing washer to bottom of

cl&s head.
1 Increase signal air to 10%.
4 Measure distance from top of

packing nut to bottom of clevis

head. Subtract value in step 2.

Record thii value as piston

movement in inches for 10%

signal air in Table 4-2.

5 Repeat steps 3 and 2 for 20% to

90% in 10% increments.

6 Divide actual distance traveled at

each signal by total distance

traveled to determine percent of

full sh-eke. Enter percent traveled

at each signal in percent of full

stroke column.

SECTION III. REVERSE OPERATION

3-1. OPERATIONAL DESCRIPTION.

action positioners, piston and piston rod movement
react opposite as direct acting positioners (Figure

l-2). An inverse cam is installed and supply air hoses
to the cylinder are reversed. ‘Ihe switched hoses cause
supply air to pressurize below piston for increasing
signal air pressures and above piston for decreasing
signal air pressures. In this case, piston movement is
inversely related to the signal. A falling input signal

pressure causes piston to raise and an increasing input

signal pressure lowers piston.

3-2. PROCEDURES FOR REVERSING OPERATION.

To reverse power positioner operation, refer to Figure
3-1 and use the following procedures.

a. Reversing Action Procedure.

WARNING

Before performing any maintenance,

adjustment, or repair action cm power
positioner, shut off supply air, signal air,
and any electrical supply or electronic
signals to power positioner. Isolate power
positioner from all systems connected to the
power positioner. Severe injury or death
may result from large torque power
positioner is capable of producing, or from
electrical shock.

1. Remove power positioner from service.

2. Disconnect increasing signal supply air hose
from 90” elbow (3, Figure 3-1) at top of
cylinder (4).

3. Disconnect decreasing signal supply air hose
from 90’ elbow (3) at bottom of cylinder (4)
and connect to 90” elbow at top of cylinder.

4. Connect increasing signal supply air hose (1)
to lower cylinder 90” elbow (3).

5. Remove lock screw (5). adjustment screw
(6) and washers (7) securing cam (8) to cam

huh (9). Remove cam from hub.

In reverse

7. Using manual lever, position piston (11) at
bottom of cylinder (4). Piston will lx at
bottom of cylinder when clevis head is at
lowest pint.

8. Install inverse cam (8) on cam hub (9).
Align cam so adjustment screw hole is in
center of adjustment slot. Secure inverse
cam to cam hub with lock screw (5),
adjustment screw (6) and washers (7).

9. Lwsen socket head cap screws (12) securing
cam hub (9) to shaft assembly (13).

10. Adjust cam hub (9) so compensator lever
roller (14) is in pocket of inverse cam. Tbii
point is cam’s zero position.

11. Tighten socket head cap screws (12)
securing position of cam huh (9) on shaft

assembly (13).

12. Loosen lock screw (5) and adjustment screw
(6) searing cam (8) to cam hub (9).

13. Make minor adjustments to position of cam
(8) and zero compensator roller. Make sore

roller is perfectly aligned to zero point on
cam.

b. Calibrate Stroke. This procedure is to be used

only for power positioners with an inverse acting
cam.

WARNING

Before performing any maintenance,
adjustment, or repair action on power
positioner, shut off supply air, signal air,
and any electrical supply or electronic
signals to power positioner. Isolate power
positioner from all systems connected to the
power positioner. Severe injury or death
may result from large torque power
positioner is capable of producing, or from
electrical shock.

6. Open bypass valve (10).

1. Remove power positioner from sewice.

ROLLER SHOWN

ITEM

1

2

3
4
S
6
I
8

9
10
11
12
13
14
IS
16
17
18
19

20
21

DESCRIPTION
Increasing Signal

Supply Air Hose

Decreasing Signal

Supply Air Hose
90” Elbow
Cylinder
Lock Screw
Adjustment Screw
Washer

Cam Hub
Bypass Valve.
Piston
Socket Head Cap Screw
Shaft Assembly
Compensator Lever
Set Screw
Spring Socket
Piston Rod
Packina Plate
Air Supply Manifold
Tubing (Signal Input)
Tubing (Air Supply)

-

Figure 3-1. Reverse Operation

2. Disconnect increasing signal supply air hose
(1, Figure 3-l) from 90 elbow (3) at bottom
of cylinder (4).

14.

If distance measured in step 14 is less than
5 inches, “se the following procedure to
calibrate piston travel.

3. Disconnect decreasing signal supply air hose

(2) from 90” elbow (3) at top of cylinder (4)

and connect to 90” elbow at bottom of

CYli"dB.

4. Connect increasing signal supply air hose (1)
to upper cylinder 90” elbow (3).

5. Slowly open supply air shut off valve.

6. Slowly move piston to bottom of travel by
increasing input signal and sending 100%
signal pressure to power positioner.

7. Loosen set screw (15) securing spring socket
(16) in place.

8. Turn spring socket (16) slowly clockwise

until piston moves away from bottom of its

travel.

9. Turn spring socket (16) slowly

counterclockwise until piston just ret”r”s to
bottom of travel.

10. Lock spring socket (16) in place by
tightening set screw (15).

11. Using a grease pencil, make a reference
mark on piston rod (17) at top of packing
plate (18).

Loosen lock screw (5) and adjustment

screw (6).

Move cam (8) in slightly (about l/64

inch).
Tighten adjustment screw (6) and lock

screw (5). Repeat steps 13 and 14 as
necessary to make. total piston h;lvel
equal to 5 inches.

15.

Observe piston travel while increasing input
signal to 100%. Slowly decrease input signal
to 0%. If piston reaches bottom of have1

before input signal reaches 0%, “se the

following procedure to calibrate piston
travel.

Loosen lock screw (5) and adjustment
screw (6).

pull cam (8) slightly outward (about

1164 inch).

Tighten adjusbnent screw (6) and lock

screw (5). Repeat step 15 as necessary
to make piston reach bottom as signal

input reaches 0%.

16.

Remove increasing signal supply air hose (1)

from 90” elbow (3) at top of cylinder (4).

12. Slowly move piston to top of travel by
decreasing input signal and sending 0%
signal pressure to power positioner.

13. Measure distance from top of packing plate

(18) to reference mark on piston rod (17)

made in step 11.

17.

Remove decreasing signal supply air hose

(2) from 90” elbow (3) at bottom of cylinder
(4) and to 90” elbow at top of cylinder.

18.

Connect increasing signal supply air hose (1)
to 90” elbow at bottom of cylinder (4).

19.

Close bypass valve (10).

YES

CHECK PISTON MOVEMENT FOR EACH
PERCEM OF SIGNAL LISTED IN
TABLE 4-2. (USE CORRECT
SCHEDULE FOR CAM INSTALLED)

IS PISTON IN PROPER POSITION FOR
EACH SIGNAL AIR PRESSURE?

SYSTEM DOES NOT

REQUIRE CALIBRATION

CALIBRATE LINKAGE
PARAGRAPH 4-4

CALIBRATE PISTON STROKE AND I/p.
REFER TO PARAGRAPHS 4-2 AND 43.

Figure 4-1. Calibration Flowchart

SECTION IV. CALIBRATION

4-l. CHECK POWER POSITIONER CALIBRATION.

Use the. following procedure to check calibration of
pcmw positioner. Figure 4-1, Calibration Flowchart,
is provided as a quick reference guide.

NOTE

TO perform the following calibration
procedures, reference values for percent
travel are needed. Values for linear, square
root, and square outputs are provided in
Table 4-l. Also a blank column for a
characterized cam is provided. If cam was

characterized,

upon installation to complete calibration
sequence. If percent travel was not recorded
when cam was sbaped, calibrate stroke of
power positioner (paragraph 4-2), then
to paragraph 2-6b.2 and perform procedure
to shape cam. Record fmdings in Table 4-1.

a. Measure distance that controlled device’s

operating arm travels out from 0%

100% signal air. Record this value as total

percent travel was recorded

refer

signal air to

b. Set signal air to 0%.
c. Measure distance that controlled device’s

operating arm moves out from 0% signal air to

10% signal air. Divide measurement by total
distance from step a. Record this as percentage
output travel for 10% signal air.

d. Measure and record percentage of output have1

for 20% to 100% in 10% increments and record
as percentage output. Thii recorded data will be
compared to reference data in Table 4-1.

e. Compare recorded readings with percent output

desired in Table 4-1. Use respective columns for
characterized systems, linear, squares root, or
square cams. If recorded readings are equal to
desired values, system does not need calibration.
If recorded vahxs do not equal desired values,
continue checking procedure.

f.

Set signal air to 0%.

g. Measure distance from top surface of packing

cover to bottom edge of clevis head. Label this
distance “A”.

PERCENT SIGNAL

AIR PRESSURE

0

10

20
30
40

50
60
70
80
90

100

Table 4-1. Device Travel (%).

r

LINEAR (x) SQUARE ROOT (s,,

0

10
20 44.8
30

40 63.25

50 70.7
60 77.5
70 83.7
80 89.4
90 94.9

100 100.0

PERCENTDRIVEN LEVER TRAVEL

0.0

31.6

54.8

SQUARE (9) CHARACTERIZED

0.0

1.0

4.0

9.0

16.0

25.0

36.0

49.0

64.0

81.0

i

100.0

Table 4-2. Piston Travel (Stroke) Calibration Schedule.

CALIBRATION SCHEDULE “A” - LINRAR CAM

INPUT SIGNAL

O-64 psig (I/P) 3-15 psig 3-27 psig

0

6
12
18

24
30
36
42
48
54
60

0

6 4.2

12 5.4
18
24 7.8
30 9.0

36 10.2
42 11.4
48 12.4

54 13.8

60 15.0

3.0 3.0

4.2 5.4

5.4 7.8

6.6 10.2

7.8 12.6

9.0 15.0

10.2 17.4

11.4 19.8

12.4 22.2

13.8

15.0 27.0

3.0

6.6

24.6

CALIBRATION SCHEDULE “B” - SQUARE ROOT CAM

3.0 0

5.4

7.8 6

10.2 9

12.6 12

15.0 15

17.4 18

19.8 21

22.2 24

24.6 27

27.0 30

O-30 psig Percent of Signal

0

3
6

9
12
15
18

21
24

27

30

:

3

0% 0.00

10% 0.50
20%
30% 1.50
40% 2.00
5090 2.50
60% 3.00
70% 3.50
80% 4.00
90% 4.50

lco% 5.00

0% 0.00 0.0%
10% 1.58 31.6%
20% 2.24
30% 2.74 54.8%

40% 3.17
50% 3.54 70.7%
60% 3.88 77.5%
70% 4.19 83.7%

80% 4.47

90% 4.75 94.9%

100% 5.00 100.0%

I DESIRED STROKE

Inches

1.00

44.8%

62.3%

86.4%

CALIBRATION SCHEDULE “C” - SOUARE CAM

0 0.0 3.0 0

6 4.2 5.4 3
12 5.4 7.8 6
18 6.6 10.2 9

24 7.8 12.6 12
30 9.0 15.0 15

36 10.2 17.4 18

42
48 12.4 22.2 24
54 13.8 24.6 27
60

0 3.0

6 4.2
12 5.4
18 6.6

24 7.8

30 9.0
36 10.2

42
48 12.4
54 13.8
60 15.0

11.4 19.8

15.0 27.0 30
CALIBRATION SC :HEDULE “D” - CHARACTERIZED CAM

3.0 0 0%

5.4 3 10%

7.8 6 20%

10.2 9 30%

12.6 12 40%

15.0 15 50%

17.4 18 60%

11.4

19.8 21 70%

22.2 24 80%

24.6 27 90%

27.0 30 100%

21

0% 0.00 0%

10% 0.05 1%
20% 0.20 4%
30% 0.45
40% 0.80 16%
50% 1.25 25%
60% 1.80 36%
70% 2.45 49%

80% 3.20
90% 4.05 81%

100% 5.00 100%

9%

64%

h.

Increase signal to 100%.

I.

Meawe distance from top surface of packing
cover to bottom edge of cl&s head. Label this
distance “B”.

Subtract distance “A” from distance “B”. Record

j.

this as total piston travel.

k.

Set signal air to 0%.

1.

Send a 10% signal to power positioner.

In.

Measure distance from top of packing cover to
bottom of clevis head.

n.

Subtract distance “A” tiom 10% signal and
record this as piston travel for 10% signal air.

0.

Measnre and record piston travel for 20% to

100% signal air in 10% increments.

Compare actual piston movement with piston

P.

movement provided in Table 4-2. Use correct
schedule for cam installed on power positioner.
Schedule “A” is for power pxitioners with linear
cams, schedule “B” is for square root cams,
schedule “c” is for square cams, and schedule

“D” is for a characterized cam. If actual piston
movement is equal to piston movement provided,
refer to paragraph 4-4 and calibrate linkage. If it
is not equal, calibrate piston movement
(paragraph 4-2). Calibrate J/F’ signal converter
@amgraph 4-3).

4-2. STROKE CALIBRATION. Use the following

procedure to adjust power positioner’s piston
movement (stroke).

a. Dhwt Acting Power Positioner.

WARNING

Before performing any maintenance,
adjustment, or repair action on power
positioner, shut off supply air, signal air,
and any electrical signals to power
positioner. Isolate power positioner from all
systems connected to the power positioner.
Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

1. Remove power positioner from service.

2. Purge supply air and signal air lines to
remove water and debris.

3. Making sure bypass valve is closed, set
signal air to 0%. Refer to Table 4-3 for
percent to signal air pressure conversion.

4. Loosen set screw (1, Figure 4-2) securing
spring socket (2) in place.

STROKE

POSITION

0%

100%

Table 43. Direct and Inverse Calibration Signal Pressures.

POWER POSITIONER ACTION

DIRECT INVERSE

PNEUMATIC I/P

O-30 3-15

Psig PSig Psig Psig Psig PSig psig Psig

0 3

30 15

3-21 O-60 O-30 3-15 O-27 O-60

21 0 30 15 3 60

3 60 0 3 21 0

PNEUMATIC

I/P

ITEM DESCRIPTION

1

Set Screw
2 Spring Socket
3 F%ton
4 Piston Rod
5 Packing Plate
6

Lock Screw
7 Adjustment Screw
8 CElm
9 Upper Bypass Tubing

10 Lower Bypass Tubing

Figure 4-2. Piston Stroke Calibration

5. Turn spring socket (2) slowly
counter&&vii until piston (3) moves
away from top of its travel.

6. Turn spring socket (2) slowly ckxkwise
until piston (3) just returns to top of its
havel.

7.

Lock spring socket (2) in place by tightening
set screw (1).

8.

Slowly move piston (3) to bottom of travel
by increasing input signal to 100%.

9.

Using a grease pencil, make a reference

mark on piston rod (4) at top of pecking

plate (5).

IB-W-204

4-4

Slowly move piston to bottom of travel by

10.
increasing input signal to 0%.

11.

Measure distance from top of pecking plate
(5) to reference mark on piston rod (4) made
in step 9.

12.

If distance measured in step 11 is not 5
inches, use the following procedure to
calibrate piston travel.

(a) Loosen lock screw (6) and adjustment

screw (7). Move cam (8) in slightly

(abut l/64 inch).

(b) Retighten adjustment screw (7) and

lock screw (6).

(c) Repeat steps 11 and 12 as necessary to

make distance equal to 5 inches.

13.

Observe piston travel while increasing input
signal to 100% and then slowly decreasing
input signal to 0%

14.

If piston reaches top of travel before input
signal reaches 0%. use the following

procedure to calibrate piston travel.

Loosen lock screw (6) and adjustment

(4

screw (7). Pull cam (8) slightly

outward (about 1/64th inch).
Retighten adjustment screw (7) and

@)

lock screv/ (6).
Repeat steps 13 and 14 as necessary to

Cc)

make piston reach top of travel at same
time as input signal reaches 0%.

b. Reverse Acting Power Positioner. For

procedures to calibrate a reverse acting power
positioner, refer to paragraph 3-2b.

4-3. CURRENT TO PNEUMATIC SIGNAL

CONVERTER 0/P) CALIBRATION. Calibrate
cm-rent to signal converter after mounting, changing
mounted position, or when loss of control is noticed
(refer to Troubleshooting, Section V). Use the
following procedures to calibrate the signal converter
W).

a. Remove plastic caps tiom “Zero” and “Span”

adjustment holes (Figure 4-3).

NOTE

Make sure input rating of power positioner
is same as pressure rating of current to
pneumatic signal converter.

b. Set input signal value to 4 mA (20 mA if I/F’ is

in an inverse setup) and adjust “Zero” screw until
output pressure is at 0 psig. Turn screw counter­clockwise to increase pressure, clockwise to
decrease pressure. If output pressure does not
change when screw is tamed, tarn screw counter­clockwise until pressure starts to rise.

c. Set signal value to 20 mA (4 mA if I/l’

inverse setup).

is

in an

PFE~~E

Figure 4-3. I/P Calibration

d. Adjust “Span” screw until output pressure is at

60 psig.

e. Repeat steps b and c until no forther adjustment

is needed.

f. Replace protective caps.

4-4. LINKAGE CALIBRATION.

a. m. Check angle of power positioner’s drive

lever from centerline. Compare this to angle of
device’s driven lever from centerline. If angular
measurements are not equal, use the following

procedure to adjust offset of power positioner’s

drive lever to equal offset of device’s driven
lever. When adjustment is complete, both
operating lever and driven levers must be parallel
with each other.

1. Measure angle PI from vertical centerline, to
power positioner’s drive lever centerline

(Figure 4-4). This is power positioner’s
offset.

2. Measure angle a from vertical centerline of
device being contxolled to driven lever

centerline. This is driven lever’s offset.

3. Compare angles PI and !&. Adjust length of
linkage for minor adjustments by threading

pipe in or out of clevis. Change operating

lever offset (p,) for major adjustments.

POWER

POSITIONER

Figure 4-4. Linear Linkage Calibration

b. Characterized. Use installation plans to verify

angles and lengths of actual iastallation. If
installation plans for the linkage are unavailable,
refer to paragraph 26.1 for procedure to

calculate correct angles and lengths. Use the
following procedure to measure aad adjust
characterized linkage @gore 4-5).

1. Measure angle p, fmm vertical centerline, to
power positioner’s operating lever (Figure

4-5). This is power positioner offset.

2. Meame. angle b2 from vertical centerline of
device being controlled to driven lever. Thii
is driven lever’s offset.

POSITIONER

I-

Figure 4-5. Characterized Linkage Calibration

3. Measure length (I) between connecting
levers at clevis.

4. Measure lengths of drive lever (R,) and
driven lever (Rb.

5. Compare angles &, 8, distance (Q, and
lengths R, and Rz with design for your

system. Adjust angles and linkage length as
necessary. Adjust length of linkage (P) by
threading pipe in or oat of clevis for minor

adjustments, or changing operating arm
angle b, for major adjustments.

SECTION V. TROUBLESHOOTING

5-1.

OVERVIEW. Troubleshooting of common problems
is provided for in troubleshooting chart (Table 5-l).
The chart describes cxamnon problems, followed by

the related probable cause, and finally, by what action
is oezessary to correct the defect. Figures 5-l and 5-2

provide pneumatic schematics as aa aid for
troubleshooting pneumatic problems.

5-2. TROUBLESHOOTING CHART. Refer to Table

5-1.

RECEIVER
ASSEMBLY

~ 3

SUPPLY

AIR

~

Figure 5-1. 4 X 5 Power Positioner Air Piping Schematic

0 0 %“’

,-.,rs

MANIFOLD

PILOT
VALVE

L!l

RECEIVER

ASSEMBLY

uu

II II

AIR AlRkCK

MANIFOLC

Figure 5-2. 4 X 5 Power Positioner Air Piping Schematic

(with Bypass Valve and Air Lock)

VALVE

(OPTION)

BY PASS

VALVE

FC.XT24

Table 5-1. Troublesbooting Chart.

PROBLEM CAUSE

1. Ermtic Operation

pilot valve sticking

Clean or repiace pilot valve. Refer to paragraph

CORRECTION

6-4 for cleaning procedures and paragraph 7-2c
for replacement procedures.

Lhlkage bhuli”g or loose. Linkage pivot joints corroded, dirty, or worn.

Clean and lubricate or replace parts.

2. No response born power Manual lock engaged
positioner to a signal air
pressure change

Air supply shut-off valve closed open air supply valve.
Ruptured receiver diaphragm

Disengage manual lock.

Replace diaphragm. Refer to paragraph 7-2d.

3. Power Positioner does Cylinder bead gasket leak Replace leaking gasket. Refer to paragraph 7-2e.

not remain at setpoint,
co”thnles to cycle

By-pass valve air connection loose

Tighten or replace air connection.

By-pass valve leaking internally. Replace by-pass valve.

4. System over shoots or

under shoots setpoint

l/P oat of calibmtion

l/P faihm?

Piston stroke have1 not property set

Calibrate I/P. Refer to paragraph 4-3.
Replace I/P per paragraph 7-2b.

Calibrate piston stroke. Refer to paragraph 4-2.

cam bent Replace cam. Refer to paragraph 7-2f.

Pin hole in diaphragm Replace diaphragm. Refer to paragmph 7-2d.

I

5. Sluggish operation

Air fdter/separator fall of water,
oil, or sediment.

Air fdter dirty
Ambient temperature is lower than

Drain air tiMcr/separator. Refer to paragraph 6-5.

I

Replace filter element. Refer to paragraph 7-2~

Install power positioner heater.
the power positioner is designed
for.

6. Power positioner oper- Device being controlled has a Repair or replace controlkd device.
atcs normally but flow broken valve stem or connection to
that is wig controlled the linkage.
remains unchanged

I

I

,a-Kr-20-l

5-3/s-4

SECTION Vi. PERIODIC MAINTENANCE

6-1.

OVERVIRW. Thii section describes preventive
maintenance for the Rosemoont Model PP405TR
Power Positioner. Preventive maintcnancc is
necessary at specific intervals to reduce wear and tear
on the power positioner.

WARNING

Before performing any maintenance or

repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power

positioner. Isolate power positioner from all
systems connected to the power positioner.

Severe injury or death may result from
large torque power positioner is capable of

producing, or from electrical shock.

6-2.

MAINTENANCE SCHEDULE, Use the

maintenance schedule, Table 6-1, as a guideline for
preventive maintenance. The frequency of this

maintenance varies directly with plant conditions and

operational load. Extremely dusty conditions or high

temperatures will require more frequent maintenance

to the power positioner.

WARNING

Clean power positioner in a well ventilated

area. Avoid inhalation of solvent fumes and

prolonged exposure of skin to cleaning

solvent. Follow ail instructions on the
Material Safety Data Sheet (MSDS) of the

solvent being used. Severe injury or death

may result from improper use.

6-3.

GENERAL CLEANING AND LUBRICATION.
Clean power positioner’s exterior of all grease build
up with commercial dry cleaning solvent. To lubricate
power positioner,
equivalent and refer to Figure 6-1, Lubrication Chart.
McLobe MO&-793 can be purchased from Rosemount
Analytical Inc. (part #183512) or directly from the
manufacturer:

McGee Industries, Inc.
9 Crozerdle Rd.

Aston, PA 19014

6-4.

PILOT VALVE CLEANING AND INSPECTION.
In normal service, pilot valve assembly requires

cleaning and inspection at intervals of approximately

six months, or upon any indication of sticking.

Before performing any maintenance or

repair action on power positioner, shut off

supply air, signal air, and any electrical

supply or electronic signals to power

positioner. Isolate power positioner from all

systems connected to the power positioner.

Severe injury or death may result from

large torque power positioner is capable of

producing, or from electrical shock.

a. Remove power positioner from service.

use McLobe. MO&793 or

WARNING

TIME INTERVAL

(Approximate)

6 months
6 months
6 months

2Yc=s
2Ym

Table 6-1. Maintenance Schedule.

MAINTENANCE ACTION
Perform general cleaning and lubrication. Refer to paragraph 6-3.

Clean and inspect pilot valve. Refer to paragraph 6-4.
Clean and drain air filters. Refer to paragraph 6-5.
Clean and inspect diaphragm. Refer to paragraph 6-6.
Lubricate and clean cylinder and piston assemblies. Refer to paragraph 6-7.

LUBRICATION CHART

GREASE GUN FILLED
WITH MCLUBE MoS*-733

SEE NOTE 1

SEE NOTE 2

NOTE 1: USING A GREASE GUN,

LUBRICATE ZERK FllTlNGS

AT COMPENSATING LEVER,

PISTON ROD, CLEVIS PIN, AND

AT TRUNNION SCREWS.

Figure 6-1. Lubrication Chart

IB-1D2-204

.5-z

NOTE 2: WIPE PISTON ROD WITH

CLEAN SHOP TOWEL. APPLY
LIGHT COATING OF
MCLUBE M&-793. WIPE
EXCESS GREASE OFF WITH
CLEAN SHOP TOWEL.

ITEM

2

3

4

5
6
I
8

9
10
11

12

Figure 6-2. Pilot Valve Exploded View

DESCRIPTION

1

Stem Assembly
connecting Lii
Ball Socket Nut
Air Supply Tubing
Elbow
Socket Head Cap Screw
Manifold
Stand Assembly
valve cap

Exhaust Silencer Plug
Pilot Valve Body
Pilot Valve Gasket

b. Carefully hold upper end of pilot valve’s stem

assembly (1, Figure 6-2). Free connecting link (2)

from pilot valve stem by tuning connecting
link’s ball socket nut (3) counter&&vise.

c. Disconnect air supply tubing (4) from elbow (5).
d. Remove socket head cap screws (6) that secure

pilot valve body (11) and manifold (7) to stand
assembly (8). Remove pilot valve and manifold.

CAUTION

Do not use an abrasive for cleaning valve

stem assembly or valve body. Abrasive, even

as fme as crocus cloth, witt cause scratches

in stem assembly and air leakage by pilot

valve stem assembly.
e. Remove valve cap (9). stem assembly (1). and

exhaust silencer plug (10) from pilot valve body

(11).

WARNING

Clean pilot valve in a well ventitated area.
Avoid inhalation of solvent fames and
prolonged exposure of skin to cleaning
solvent. Follow all iostractions on the
Material Safety Data Sheet (MSDS) of the
solvent being used. Severe injury or death
may result from improper usage.

f. Thoroughly clean pilot valve body (11). valve cap

(9), and stem assembly (1) in commercial Q
cleaning solvent or equivalent. Allow pilot valve
to completely air dry. Do not “se abrasive of any

kind on stem.

g. Thoroughly clean exhaust silencer plug (10) with

commercial dry cleaning solvent or cqaivalent,
making sure its exhaust ports are open.

NOTE

Pilot valve stem and body are a matched
set. If either is damaged or wora to a non­serviceable condition, entire pilot valve mast
be replaced.

h. Inspect stem assembly (1) and pilot valve body

(11). If any signs of wear or damage are found,

replace pilot valve.

i. Install stem assembly (1) into valve body (11).

j. Install exhaust silencer plug (10) and valve cap

(9) on pilot valve body (11).

maintenance will depend on supply system air quality.
After installation, drain both fdters by slowly opening
filter and filter/reg&tors petcock valves. Initially
drain monthly, gradually increasing time between
drahdig. Schedule periodic draining when falters are
approximately l/4 fall. Continue draining water and
debris at this interval unless plant supply air
conditions change. If element in air filter is dirty,
refer to Section VII for replacement procedure.

6-6. DIAPHRAGM CLEANING AND INSPECTION.

Disassemble, clean, and inspect diaphragm assembly
approximately every two years or if power positioner
is not reaching set points. Refer to Figure 6-3 and use
the following procedure.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from all
systems connected to the power positioner.
Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

a. Remove power positioner from service.
b. Remove hex head cap screw (1, Figure 6-3) and

washers (2) securing diaphragm cover (3) to
receiver body (4).

k. Install manifold (7) and assembled pilot valve

with pilot valve gasket (12) onto stand assembly
(8). securing with socket head cap screws (6).

I. Carefully hold upper end of pilot valve’s stem

assembly (1). Attach connecting Iii (2) to pilot
valve’s stem assembly (1) by turning connecting
link’s ball socket nut (3) clockwise.

m. Calibrate sh-oke of power positioner (paragraph

4-2).

n. Return power positioner to service.

6-5. AIR FILTER CLEANING AND DRAINING. I”

normal service, supply air falter and signal air
filter/regulator require draining of water and
debris at least every 6 months. The frequency of this

c. Remove zero balance spring (5) from top of

diaphragm.

d. Using a clean shop towel, thoroughly wipe off

any di or debris on upper side of diaphragm (6).

e. Visually inspect diaphragm. Replace if nicks,

cuts, or hardened robber areas (from excess heat)
are visible. Refer to Section VII for replacement
procedures.

f. Clean diaphragm cover (3) and zero balance

spring (5) with commercial dry cleaning solvent

and allow to air dry.

g. Align edges of diaphragm (6) with stop ring (7)

to make a” air tight seal.

h. Replace zero balance spring (5).

ITEM

Fire 6-3. Diaphragm Exploded View

i.

Making sum the diaphragm is not folded or

pinched, replace diaphragm cover (3) and align

sealing edge of diaphragm cover on top of
diaphragm.

Secure diaphragm cover (3) with socket head cap

i.

screws (1) aad washers (2). Tighten alI scnws
hand tight. Then snag screws down and tinaRy,
complete installation by tightening in a
diagonal sequence. Torque screws to 11 foot-lbs

(1.52 kg-m).

k.

Test for air kxkage around diaphragm cover and
receiver body. Use a leak detector, such as

“SlUWp”, and apply an air signal to power

positioner. If leak is detected, repair as necessary.

I.

Return power positioner to service.

6-l.

CYLINDER AND PISTON. CLEANING AND
LUBRICATION. Disassemble, clean and lubricate

piston and cylinder assembly approximately every two

years. Refer to Figure 6-4 and use the following

procedure.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from all
systems connected to the power positioner.
Severe injury or deatk may result from
large torque power positioner is capable of
producing, or fmm electrical shock.

a. Remove power positioner from service.

6. Shut supply air valve and set signal air pressure
to 0 psig. Open bypass valve.

WARNING

Residual air must be bled off of cylinder
before removal of cylinder head. If air is not
bled On, eye injury may result.

e. Bleed residual air through pilot valve supply air

connection.

m-m-204

6-5

ITEM

1

2

3

4 Decreasing Signal Supply Air HOST

5
6
I

8

9
10
11
12 Tie Bolt

13
14 Washer
15 Head Gasket

16
17
18 Washer
19 Packing cover

20

DESCRIPTLON
Increasing Signal Supply Air Hose
90” Elbow
Upper Cylinder Head

Lower Cylinder Head
Retaining Ring

Clevis Pin
Clevis Head
cylinder

Tnmnion Screw
Piston

Hex Nut

piston Rod

Hex Head Cap Screw

Female Adaptor

Figure 6-4. Cylinder Exploded View

Note

Tbis procedure and Figure 6-4 are set up
for direct acting power positioners. In a
reverse acting power positioner, increasing
signal supply air hose (1, Figure 6-4) would

be at bottom of cylinder and decreasing
signal supply air hose (4) would be at top of
cylinder.

d. Remove increasing signal supply air hose (1,

Figure 64) from 90” elbow (2) at upper cylinder

head (3). Mark supply hose (1) “upper”.

e. Remove decreasing signal supply air hose (4)

from 90” elbow (2) at lower cylinder head (5).

Mark supply hose (1) “lower”.

f. Remove retaining rings (6) and drive out clevis

pin (7) from clevis head (8).

g. While supporting cylinder (9), remove lronnion

screws (10).

equivalent Lightly coat piston rod (16) with
Mclnbe. MO&-793 grease. Wipe excess grease off
with clean shop towel.

m.

With a clean shop towel and commercial grade

dry cleaning solvent, wipe interior surface of
cylinder (9). Allow to air dry before assembly.

n.

Remove hex bead cap screws (17) and washers

(18). securing packing cover (19) to upper

cylinder head (3). Remove packing cover (19)

from upper cylinder head.

0.

Clean and inspect female adaptor (20) under
packing cover (19). Replace female adaptor,
packing, and male adaptor if female adaptor
appears damaged OT was leaking. Refer to Section

VII for replacement pmced”res.
Pack area around female adaptor (20) with

P.

McLuhe M&-793 grease or equivalent. Secure
packing cover (19) to upper cylinder head (3)

with hex bead cap screws (17).

b. Remove assembled cylinder from tmnnion and

move it to a workbench to continue disassembly.

CAUTION

Do not scratch piston rod. Use caution when
removing and handling upper cylinder bead,

piston, and piston rod. If piston rod is
scratched, power positioner will produce
lower torque and decreased packing life will
result.

i. Remove hex nuts (13), washers (14) and tie bolts

(12).

CAUTION

Do not pull piston and shaft assembly out of
cylinder bead. Damage to packing gland
bushings and Vee-packing may occar.

j. Remove upper cylinder head (3) from cylinder by

sliding piston (11) out of cylinder (9).

k. Remove and discard upper and lower cylinder

bead gaskets (15).

I. Clean old grease off piston (11) and piston rod

(16). Wipe with commercial grade dry cleaning
solvent and let air dry. Pack concave area of
piston with McLuhe MO&-793 type grease or

Install tie bolts (12) through lower cylinder head

9.
(5).

r.

Install cylinder (9) with a new cylinder head
gasket (15) onto lower cylinder head (5).

s.

Place new upper cylinder head gasket (15) o” top

of cylinder. Making sure hotb gaskets are in

place, slide piston (11) and upper cylinder head H ’

assembly onto cylinder (9). Align tie bolts
through upper cylinder head (3) holes and secure
with hex nuts (13). Tighten hex nuts evenly “sing

a diagonal tightening sequence.

t.

Install cylinder assembly onto power positioner
h-me by aligning upper cylinder head (3)
mounting boles with hunnion holes in stand
assembly. Secure cylinder in stand with bunnion
screws (10).

u.

Secure clevis (8) to shaft lever with clexis pin
(7). Secure clevis pi” with retaining rings (6).

Y.

Install supply hose marked “upper” (1) to 90
elbow (2) at upper cylinder head (3). I”staU
supply hose marked “lower” (4) to 90” elbow at
lower cylinder head (5).

W.

Refer to paragraph 4-2 and calibrate power
positioner shake. Return power positioner to
service.

IS-IM-204

6.716.8

SECTION VII. CORRECTIVE MAINTENANCE

7-1. OVERVIEW. This section describes corrective

maintenance for the Rosemount PP405TR Power
Positioner. If specific cause of problem is not known,
refer to Section V, Troubleshooting. Spare parts
referred to are available from Rosemount. Refer to

Section VIII of this manual for part numbers and
ordering information.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic sighals to power
positioner. Isolate power positioner from aU
systems connected to the power positioner.

Severe injury or death may result from

large torque power positioner is capable of

producing, or from electrical shock.

7-2. PARTS REPLACEMENT.

a. Air Filter. Regularly inspect disposable filter

element as needed, according to plant air supply

quality. If filter element needs to be replaced,

new elements are available from the factory. Use

the following prwedure to replace filter element

6.

Install air filter sump (2) into filter housing
(6). Secure sump with cap nut (3) and cap
nut gasket (4).

7.

Open supply air shut off valve and check for
leaks.

8.

Return system to service.

1. Remove power positioner from service and
close supply air shut off valve.

2. Open air filter’s drain valve (1, Figure 7-1)
and bleed off any air pressure and moisture
remaining in system.

3. Remove air filter’s sump (2) by removing

cap nut (3) and cap nut gasket (4) on top of

air filter. Save cap nut gasket for

installation.

4. Remove used filter element (5) by grasping
and pulling it downward.

5. Install new filter element (5).

ITEM DESCRIPTION

1 Drain Valve
2 Sump
3 Cap Not

4

5 Filter Element
6 Filter Housing

Cap Nut Gasket

Figure 7-1. Air Filter

J/P Converter. Use the following procedure for

b.

replacement of the current to pneumatic signal
converter (I/P).

WARNING

c. Pilot Valve. Use the following procedure to

replace the pilot valve.

Before performing any maintenance or

repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from all
systems connected to the power positioner.

Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

1. Remove power positioner from service.

2. Tam electrical signal transmitter off, making
sure no electxical voltage or current is being

applied to the I/P.

3. Bleed off any residual air pressure through
connection of signal tubing to I/P.

4. Remove inlet and outlet piping to I/P.

5. Remove input signal leads from I/p’s screw
terminals. If screw terminals are not installed
on I/P, remove I/P pigtails from screw
terminals.

6. Remove screws securing old I/P converter to
mounting bracket and discard I/P.

7. Attach inlet and outlet piping to respective
ports 0” I/P.

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from alJ
systems connected to tbe power positioner.
Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

1. Remove power positioner from service.

2. Carefully hold upper end of pilot valve’s
stem assembly (1, Figure 7-2). Turn
connecting lii ball socket nut (3)
coanterclockwii and free connecting link

(2) from pilot valve stem assembly.

3. Disconnect supply air tabiig (4) from elbow

(5).

4. Remove socket head cap screws (6) that
secure pilot valve (7) and manifold (8) to
stand assembly (9). Remove pilot valve and
manifold.

5. Install new pilot valve (7). pilot valve gasket
(lo), and manifold (8) onto stand assembly

(9.

8. Connect leads to electrical signal wires. For
direct acting power positioners, connect
positive signal to I/P’s black lead and
negative signal to white lead. For reverse
acting power positioners, connect positive
lead to I/p’s white signal and negative lead
to black signal.

9. Install new I/p to same mounting location,
sewing with old hardware.

10. Open supply air valves and test for leaks
using a “snoop” type leak detector.

11. Calibmte I/F and return unit to service.

Refer to paragraph 4-3 for calibration
procedures.

6. Attach supply air tubing (4) to elbow (5).
Open supply air shut off valve and test for
leaks using a “snoop” type leak detector.
Close supply air valve.

7. Carefully hold upper end of new pilot
valve’s stem assembly (1). Attach stem
assembly to connecting lii (2) by turning
connecting link’s ball socket nut (3)
clockwise.

8. Refer to paragraph 4-2 and calibrate stroke
of power positioner.

9. Return power positioner to service.

ITEM DESCRIPTION

1 Stem Assembly
2 Co”“ec!i”g Link
3 Nut
4

Supply Air Tubing

5 Elbow

6 Socket Head Cap

screws

I Pilot valve

8 Manifold

9 Stand Assembly

10 F’ilot Valve Gasket

Figure 7-2. Pilot Valve

PART NUMBER

6639-003
7791-021

6292A08H12
771B867H05 (Brass)
771B868H05 (Stainless Steel)
70041AHo55

3531B17GOl

152168

6631D53GOl
5057-002

d. Diaphramn and Calibration Spring. Use the

following procedure for replacement of the
receivers diaphragm and replacement of the
calibration spring.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from all
systems connected to the power positioner.
Severe injury or death may result from
large torque power positioner is capable of
producing or from electrical shock.

IB-NY-204

1. Remove power positioner from service.

2. Disconnect signal air tubing (2, Figure 7-3)
and remove 90” elbow (1).

3. Remove hex head cap screws (3) and
washers (4) securing diaphragm cover (5) to

receiver body (25).

4. Remove zero balance spring (6) from top of
diaphragm.

5. Carefully hold upper end of pilot valves
stem assembly (26). Tom connecting links
lower ball socket nut (14) counterclockwise
and free connecting link (13) from pilot
valve stem assembly.

7-3

6. Rdhg up on diaphragm (8). remove
diaphragm and connecting link assembly
from receiver My.

7. Remove calibration spring (21).

connecting link (13) to pilot valve stem
assembly.

19. Reinstall 90” elbow (1) and signal air tubing

(21.

8. Install new calibration spring (21). Make
sure spring washer (22) is in bottom of

spring socket (20).

9. Remove connecting link (13) from
diaphragm by toming upper ball socket not
(12) countercbx%vise.

10. Remove spring nut (11) from diaphragm
stud (7). Separate diaphragm (8). stop ring

(9), and shield (10).

11. Assemble new diaphragm (8) with stop ring
(9) and shield (10). Secure in place with
diaphragm stud (7) and spring nut (11).

12. Install connecting link (13) on new
diaphragm assembly securing with upper
ball socket not (12).

13. Place diaphragm assembly and connecting
lii in receiver so connecting Iii is aligned
with pilot valve stem assembly (26).

14. Align edges of diaphragm (8) with stop ring
(9) to make an air tight seal.

15. Place zero balance spring (6) on top of
diaphragm (8).

16. Making sore diaphragm is not folded or
pinched, replace diaphragm cover (5) and
align sealing edge of diaphragm cover on
top edge of diaphragm.

17. Secure diaphragm cover (5) to receiver body
(25) with hex head cap screws (3) and
washers (4). Fit tighten screws until hand
tight. Then snug screws down and tinally
complete tightening in a diagonal pattern.
Toque to 11 foot-lbs (1.52 kg-m).

18. Carefully hold upper end of pilot valve stem
assembly (26). Tarn connecting link’s lower
ball socket not (14) clockwise and secure

20. Test for leakage around diaphragm cover
and receiver body. Use a leak detector such
as “snoop”, and send an air pressure signal

to power positioner. If leak is detected,

repair as necessary.

21. Refer to paragraph 4-2 and calibrate stroke
of power positioner.

22. Return power positioner to service.

e. Cylinder. Use the following procedure to

disassemble and reassemble the power cylinder

on model PP405TR power positioner. Replace

items that are damaged or worn beyond a

serviceable condition determined by
troubleshooting or by inspection. Replace cylinder
head gaskets each time cylinder is disassembled.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power

positioner. Isolate power positioner from all

systems connected to the power positioner.

Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

1. Remove power positioner from sewice.

2. Shot supply air valve and set signal air
pressure to 0 psig. Open bypass valve.

WARNING

Residual air must he bled off of cylinder
before removal of cylinder head. If air is not

bled off, eye injury may result.

Bleed residual air through pilot valve supply

3.
air connection.

ITEM

1
2
3
4
5
6
I
8
9

10
11
12
13
14
15
16

I7
18

19
20
21
22

23
24
2s
26

DESCRIPTION
90” Elbow
Signal Air Tubing
Hex Head Cap Screw

Washer
Diaphragm Cover
Zero Balance Spring

Diaphragm Stud
Diaphragm

stop Ring

Shield
Spring Nut
Upper Ball Socket Nut
Connecting Link

Lower Ball Socket Nut
Compensator Lever
Roller
Tnmnion Screw

Trunnion

set screw
Spring Socket

Calibration Spring

Spring Washer

Hex Head Screw
Washer
Receiver Body
Pilot Valve Stem

Assembly

PART NUMBER
771B869HO4
6292AO4HO3
701OODXO4K
7052OBPlOP
252228

175464348
142374

93.51-007
5014-019

5015.027

5015.14

352222

142033
5015-015
5015-007

7002OBA63J
5015-014

Refer to Section 9

5973.007
70100DXOCK

7052OBPlOS
241762

6693.001

w

@-

Figure 7-3. Receiver Exploded View

14
I5

16
17

18

19

20

21
22
23
24
25

Tie Bolt

Lower Cylinder Head

705208PlOP

152174

6295A55HOl

252230
7718867HOS (Brass)

771B868H05 (Stainless Steel)

6292AOBHC4

139656-001
702008LB1A
705208PlW

141846

252232

141843

252231

14*633-001
nG?l39-cm7
142031

152295
142108
141885-001
142107

Figure 7-4. Cylinder Exploded View

18.102-204

7-6

This procedure and Figure 7-4 are set up
for direct acting power positioners. In a
reverse acting power positioner, increasing
signal supply air hose (10, Figure 7-4) would
be at bottom of cylinder and decreasing
signal supply air hose (11) would be at top
of cylinder.

4. Remove increasing signal supply air hose
(10, Figure 7-4) from 90” elbow (9) at upper
cylinder head (8). Mark supply air hose
“upper”.

5. Remove decreasing signal supply air hose
(11) from 90” elbow (9) at lower cylinder

bead (16). Mark supply air hose “lower”.

6. Remove retaining rings (1) and drive out

clevis pin (2) from clevis bead (3).

7. While supporting cylinder (18), remove
trunnion screws (7).

8. Remove assembled cylinder from trunnion.
Move it to a workbench to continue
disassembly.

CAUTION

Do not scratch piston rod. Use caution when
removing and handling upper cylinder bead,
piston, and piston rod. If piston rod is

scratched,

power positioner will produce
lower torque and decreased packing life will
result.

12. If piston is to be replaced, remove stop nut
(19). o-ring (ZO), and piston (21). Replace
with new piston and o-ring, securing with

same stop nut.

13. If piston was not replaced, clean old grease
off piston (21) and piston rod (22). Wipe
with commercial grade dry cleaning solvent
and let air dry.

14. Remove hex head cap screws (4) and
washers (5) securing packing cover (6) to
upper cylinder head (8). Remove packing
cover from upper cylinder bead.

15. Remove and inspect female adaptor (23).
Replace female adaptor, V-packing (24), and
male adaptor (25) as a set if any one appears
damaged or if air was leaking through

packing.

16. Install male adaptor (25), V-packing (24)
and female adaptor (23). Pack area around

female adaptor with McLube grease or
equivalent. Secure packing cover (6) to

upper cylinder head (8) with hex bead cap

screws (4) and washers (5).

17. With a clean shop towel and commercial
grade dry cleaning solvent, wipe interior
surface of cylinder (18). Allow to air dry
before assembly.

18. Pack concave area of piston with McLube
MoS,793 type grease or equivalent. Lightly
coat piston rod (22) with McLube
M&-793 grease. Wipe excess grease off
with clean shop towel.

9. Remove hex nuts (13), washers (14), and tie
bolts (15).

CAUTION

Do not pull piston and shaft assembly out of
cylinder bead. Damage to packing gland
bushings and V-packing may occur.

10. Remove upper cylinder bead (8) by sliding
piston (21) out of cylinder (18).

11. Remove and discard upper and lower
cylinder head gaskets (17).

19. Install tie bolts (15) through lower cylinder
head (16).

20. Install cylinder (18) with a new cylinder
bead gasket (17) onto lower cylinder head

(16).

21. Place new upper cylinder bead gasket (17)
on top of cylinder. Making sure both gaskets
are in place, slide piston (21) into upper
cylinder head (8) and onto cylinder (18).

22. Align tie bolts (15) through upper cylinder
head (8) boles and secure with hex nuts (13)
and washers (14). Tighten hex nuts evenly,

using a diagonal tightening sequence.

23.

Install cylinder assembly by aligning upper
cylinder head’s (8) mwnting holes with
tnmnion holes in stand assembly. Secure
cylinder in stand with tmnnion screws (7).

24.

Attach cl&s head (3) to shaft lever with
clevis pin (2). Secure clevis pin with

retaining rings (1).

2.5.

Install supply hose marked “upper” (10) to
90” elbow (9) at upper cylinder head (8).

Install supply hose marked “lower” (11) to

90” elbow at lower cylinder head (16).

26.

Open supply air valves and check for leaks
by using a “snoop” type leak detector.

21.

Refer to paragraph 4-2 and calibrate power
positioner stroke. Return power positioner to

service.

f. Cam. Use the following procedure to replace

cam. This pro&ore is to be used for
replacement of cam with same part number
replacement cam.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from all
systems connected to the power positioner.

Severe injury or death may result from
large torque power positioner is capable of
producing or from electrical shock.

1. Remove power positioner from service.

2. Remove lock screw (1, Figure 7-5), washer
(Z), adjustment screw (3). and washer (4)

securing cam (5) to cam hub (6). Remove

cam fmm hub.

3. Install new cam (5) on cam hub (6). Align

cam so adjustment screw hole is in center of
adjustment slot. Secure cam to cam hub with
washers (2 and 4), lock screw (I), and
adjustment screw (3). Do not tighten screws.

4. Rotate cam to make sure roller is perfectly
aligned with zero point on cam.

ITEM DESCRIPTION

1 Lock Screw

2 Washer
3 Adjustment Screw
4 Washer
5 Cam
6 Cam Hub

Figure 7-5. Cam Replacement

5. Tighten lock screw (1) and adjustment screw
(3).

6. Refer to Section IV and calibrate power

poSitiO”CX.

I. Retam power positioner to service.

SECTION VIII.

8-1. OVERVIEW. The options for the PP405TR power

positioner covered in this section include an air lock,

electric position bansmitter, and heater/thermostat.

8-2. AIR LOCK.

a. Descrtpticm. The air lock, Figure 8-1,

automatically locks the power positioner piston
and shaft assembly when there is a loss of supply
air. when supply air pressure falls below a set
value, the air lock diaphragm collapses causing a
spring to move the lock lever. This clamps the
friction plate and locks the piston and shaft
assembly. Upon loss of supply air pressure, the
automatic lock can be overridden by mming the
air lock release handle fully clockwise. The
operator must then open the bypass valve,
manually position the output shaft, and lock the
output shaft by turning the air lock release handle
fully counterclockwise.

b. Adjustment.

WARNING

Before performing any maintenance or

repair action on power positioner, shut off
supply air and signal air, and disconnect
any ekcttical supply or electronic signals to
power positioner. Isolate power positioner
from all systems connected to power
positioner. Severe tnjury or death may

dt from large torque power positioner is
capable of producing, or from electrical

ShOCk.

1. Remove power positioner from service, close
supply air shut off valve. Disconnect
electrical power to power positioner.

2. Turn the air lock release handle, Figure 8-1,
clockwise until the lock lever (1, Figure 8-2)
brake shoe is clear of the sector.

Figure 8-1. Air Lock

ITEM DESCRIPTION

1 Lock Lever
2 Brake Shoe
3 Spacer Block

4 Anvil Screw

5 Hex Head Screw

(3%16 x l-112)

6 Lock Washer

(3/8 Int Tooth)

I Lock Fulcrum

Pivot Pin

8

PART NUMBER

142007
141889
152179
152296

7OlOODXO7L

705208PlOQ

152177
120175-l

Figure 8-2. Air Lock Brake Exploded View

3. Turn the brake anvil screw (4) in until the
anvil brake shoe (2) just clears face of
sector.

4. Turn air lock release handle fully
counterclockwise.

5. Restore air and electrical power to

positioner.

c. Air Lock Brake Shoe Replacement.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air and signal air, and disconnect
any electrical supply or electronic signals to
power positioner. Isolate power positioner
from all systems connected to power
positioner. Severe injury or death may
result from large torque power positioner is
capable of producing, or from electrical
shock.

2.

Remove hex head screws (5, Figure 8-2) and

lock washers (6).

3. Set spacer blocks (3) aside and move
assembled lock lever (1) back, clear of
sector.

4.

Using a punch, tap brake shoes (2) free from

lock lever (1).

5. Remove anvil screw (4) and brake shoe (2).
Pull brake shoe out of anvil screw.

6. Install new brake shoe in anvil screw and
replace anvil screw in air lock frame.

7. Install new brake shoe (2) in lock lever (1).

8.

Position lock lever against frame with spacer
blocks (3) and secure in place with lock

washers (6) and hex head SCI~WS (5).

9. Adjust air lock brake in accordance with
paragraph 8-2.a. above.

1. Remove power positioner from service, close 10. Restore air and electrical power to
supply air shut off valve, and isolate positioner.
electrical power from power positioner.

ITEM

1

2

Figure 8-3. Air Lack Diaphragm Exploded View

PART NUMBER
6292AOSHO3
77188693304
7718870HLM

142042
142021
152166
152598-l
152220
152178
152221
141869

9351-7

142374
152236

7cQ41AHo95

c. Diaphragm Replacement.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air and signal air, and disconnect
any electrical supply or electronic signals to
power positioner. Isolate power positioner
from all systems connected to power
positioner. Severe injury or death may
result from large torque power positioner is
capable of producing, or from electrical
shock.

1. Remove power positioner from service, close
supply air shut off valve, and isolate

electrical power from power positioner.

2. Turn air lock release handle, Figure 8-1,
fully counterclockwise to release any
pressure on the diaphragm.

3. Remove socket head cap screws (1.5, Figure.

8-3) and air lock housing (14) from power

positioner.

4. Hold rod sleeve (9), being careful not to
strip threads, and remove diaphragm stud

(13) and diaphragm (12) from power

positioner.

5. Make sure that diaphragm washer (10) and
diaphragm seat (11) are in place and install

new diaphragm (12), securing with

diaphragm stud (13).

6.

Install air lock housing (14), securing with

socket head cap screws (15).

I.

Restore. air and electrical power to
positioner.

8-3.

ELECTRIC POSITION TRANSMITTER (EPT].
For information on tbe EF’f for PP405TR Power
Positioner, refer to IB-10%204A, Field Retrofit Kit
Electric Position Transmitter.

8-4.

HEATRR/THRRMOSTAT. The heater/themmstat
helps prevent freezing of moisture. or condensate in

power positioner supply and signal air lines. This

allows the pilot valve to operate better in
temperatures below freezing. With the
heater/thermostat installed the power positioner can
effectively operate. in temperatures down to -10°F
(-23.3”(Y). Operation below this ambient temperature

is not recommended.

a. Heater Replacement

WARNING

Before performing any maintenance or

repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from aU
systems connected to power positioner.

Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

1. Remove power positioner from service, close
supply air shut off valve, and isolate
electrical power from power positioner.

2. Remove heater supply (1 and 2, Figure 8-4)
from terminals 2 and 5 on terminal block

(3).

3. Remove screws (4), washers (5), nuts (6).
and heater (7) from bracket (8).

4. Install new heater, securing with screws (4),
washers (5), and nuts (6).

5. Connect black heater lead (1) to terminal 2

and white heater lead (2) to terminal 5 on
terminal block (3).

h. Thermostat Replacement.

WARNING

Before performing any maintenance or
repair action on power positioner, shut off
supply air, signal air, and any electrical
supply or electronic signals to power
positioner. Isolate power positioner from all
systems connected to power positioner.
Severe injury or death may result from
large torque power positioner is capable of
producing, or from electrical shock.

1. Remove paver positioner from service, close
supply air shut off valve, and isolate
electrical power from power positioner.

2. Remove thermostat leads (9 and 10, Figure
8-4) from terminals 3 and 4 on terminal

block (3).

3. Remove screws (1 1), washers (12),

grounding lead (13), and thermostat (14)
from bracket (8).

4. Install new thermostat. Reattach ground lead.

5. Connect thermostat leads (9 and 10) to

terminals 3 and 4 on terminal block (3).

7

VIEW

B - B

150W HEATER

JUMPER

HEATER POWER

MOUNTING SCREW

FOR THERMOSTAT

SUPPLY

1 ZOV, 60Hz, 15OW

T.S. SCREW SIZE #5

.3

WlRlNG DIAGRAM FOR HEATERfTHERMOSTAT

Figure 8-4. Heather/Thermostat

FIGURE and
INDEX No.

SECTION IX. RECOMMENDED SPARE PARTS

Table 9-1. Recommended Spare Parts for PP405TR 4 X 5 Power Positioner.

?ART NUMBER IJ%CRIPTION

QTY

Not Shown

7-3, 8 1351~007
7-3, 13 ‘791-021
6-2, 12 iO57-002
7-2, 7 i531Bi7GOl
7-4, 17 ~41843
7-4, 21 .42031
7-4, 24
7-4, 20 ~20039-007
l-4, 10 i292A08HO4
Not Shown
4-2, 9
4-2, 10
l-3, 21 42390

7.3, 21 ,42391
7-3, 21 44267

IA97805G02 ipare Parts Kit 4 x 5 Power Positioner

.A9780-5GO3

.A9780-X04

.A9780-X05

.A9780-SG06

.41X85-001

i292A78G03
i292AO4H03

i292AO4HO4

O-ring (120039-007)
O-ring (120039-010)
Cylinder Head Gasket (141843)

V-Packing Rings (141885-001)
Shoe Plug (141889)
Piston (142031)
Gasket (5057032)
Shoe Plug (141889)
Plastic Tube Air Line (6292A08HO4)
Ferrules for Cylinder Tubing (6292A78G03)
Diaphragm (9351-007)

ipare Parts Kit

4 inch Piston (142031)

lpare Pam Kit

V-Packing Rings (141885.cm)

ipare Parts Kit

Diaphragm (9531-007)

ipare Parts Kit

Cylinder Head Gasket (141843)
Xaphragm
hnecting Link
‘ilot Valve Gasket
‘ilot Valve Assembly (2 ports)
Cylinder Head Gasket
‘iston
I-Packing (3 to a set)
king
tiir Supply Tubing
+a~~les for Cylinder Tubing
Jpper Bypass Tubing
mver Bypass Tubing
Mibration Spring O-60 psig
Calibration Spring O-30 psig
Mibration Spring 3-15 psig

1

1
2
3
2

1

1
2

2
4
2

15

45

16

56

1
1
1
1

2

1
1
1

2
4

1
1
1
1
1

FIGURE and
INDEX No.

Table 9-2. Spare Parts for Options (PP405TR 4 X 5 Power Positioner Only).

PART NUMBER DESCRIPTION

Q=

8-4, I
8-4, 14

8-3, 5
8-3, 9
8-3, 13
8-3, 10
8-3, 12
8-2, 2
8-2, 4

145822

153407-001
6292AllGOl Thermostat Assembly
298291-001 Heavy-duty Limit Switch (Counterclockwise)
298292-001 Heavy-duty Limit Switch (Clockwise)
4511CO2GO2 Standard Limit Switch Kit

SSOSA52HO6
6296A25HOl Servo Potentiometer

8741.001 Aluminum Micro-switch

4844B27HOl
4516D67GOl Amplifier PC Assembly

142041 Air Lock Spring
152178

142374 Diaphragm Stud
152221 Diaphragm Washer

9351.7 Air Lock Diaphragm

141889 Brake Shoe
152296 Anvil Screw

Table 9-3, Bill of Material for PP405TR 4 x 5 Power Positioner,

includes part numbers and descriptions that are keyed to figure and
index number references. This listing provides information on all
basic PP405TR power positioner parts with the exception of

hardware.

Heater Receptacle
Heating Element (150 Watt)

O-ring Gasket

Potentiometer, 10 K

Rod Sleeve

NOTE

1
1
1

2

1

2

1

10

10

5

FIGURE and
INDEX NO.

3-1, 13

3-1, 9

1-2
1-2
l-2

7-4, 8
7-4,25
7-4, 24
7-4, 23
7-4, 6
7-4, 12
7‘%,21
7-4, 22
7-4, 20
7-4, 18
7-4, 17

Table 9-3. Bill of Material for PP405TR 4 x 5 Power Positioner.

PART NUMBER

6631D53GOl
352281

171087

6293A33GOl
241892
242008

174356-004
142009

252230

142107

141885.001
142108
152174

139656.001
142031
15229s
120039-007

25223 1

141843

DESCRIPTION
Frame Assembly

Shaft Assembly
Cam Hub Assembly
Collar
Operating Arm
Clevis
Clevis Pin
Pointer
Upper Cylinder Head
Male Adapter
V-Packing
Female Adapter
Packing Cover
Grease Fitting
Piston
Piston Rod
O-ring
Cylinder
Cylinder Head Gasket

Qm

1
1
1
1
1
1
1
1
1
1

3

1
1

5

1
1
1
1

2

Table 93. Bill of Material for PP405TR 4 x 5 Power Positioner - Continued

FIGURE

INDEX NO.

7-4, 16
l-4, 15
l-4,3
l-4, 2
l-4, I

7-3. 25
7-3; 10
l-3, 8
l-3, I
7-3, 13
l-3, 9
l-3, 6
l-3, 5
l-3, 22
7-3, 18
l-3, 17
7-3, 20
l-2, 8
7-2, 7
3-l. 14

3-1, 19

3-1, 21
3-1, 1 & 2
3-1, 20

l-3, 21
7-3, 21
l-3, 21

2-10

7-5, 5
3-1, 8

4-3
7-1
7-1, 5

and

PART NUMBER DESCRIPTION

252232 Lower Cylinder Head

141846 Tie Bolt
141772

170924 Clevis Pin
6295A55HOl Trunnion Screw
441761 Mounting Bracket
241162 Receiver Body
5015-027 Shield

93.51-007 Diaphragm

142374 Diaphragm Stud

7791.021 Connecting Link
5014-019 stop Ring

175464348 Zero Balance Spring
252228
5973-007 Spring Washer
5015-007 Tnmnion
5015-015 Trunnion Screw

5015.014 Spring Socket
152168 Manifold (Pilot Valve)
3531B17GOl Pilot Valve Assembly
352222 Compensator Lever
152164 Compensator Shaft
142033 Cam Follower
152170
352224 Top Cover
352231 Side Panel
241819-001
142057
126112
120079-010
126198
5292AO4H03
5292A08HO4 Tubing (Piston Supply)
5292A08H12 Tubing (Signal Input)
142390 Calibration Spring O-60 psig
142391 Calibration Spring O-30 psig
144267 Calibration Spring 3-15 psig
146823 Blank Cam
242044
243133 Linear Cam, Reverse Rotation
249001 Square Cam, Standard Rotation
249429 Square Cam, Reverse Rotation
249298
241-96-6080

372538.002 Air Filter

372538.023

Clevis Head

Diaphragm Cover

Air Supply Manifold

End Panel
Indicator

Nameplate

Retaining Ring (Clevis)
Serial Number Plate
Tubing (Air Supply)

Linear Cam, Standard Rotation

Square Root Cam, Standard Rotation

I/P Converter

Filter Element

QTY

1

4

1
1

2

1
1
1
1
1
1
1
1

1
1
1

2

1
1

1
1
1
1
1
1

2

1
1
1
1
1
1

2

1
1
1
1
1
1
1
1
1
1
1
1
1

1

SECTION X. RETURNING EQUIPMENT TO THE FACTORY

10-l. If factory repair of defective equipment is required,

proceed as follows:

a. Secure a return authorization from a Rosemount

Analytical Sales Oftice or Representative before
retnrning the equipment. Equipment must be
returned with complete identification

accordance with Rosemount instructions or it will

not be accepted.

In no event will Rosemount be responsible for

equipment without proper authorization and

identification.

b. Carefnlly pack defective unit in a sturdy box with

sufficient shock absorbing material to insure that

no additional damage will occur during shipping.

c. In a cover letter, describe completely:

1. The symptoms from which it was
determined 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 service or nonwarranty
service is requested.

5. Complete shipping instructions for return of
equipment.

in

d. Enclose a cover letter and purchase order and

ship the defective equipment according to
instructions provided in Rosemount Return

Authorization, prepaid, to:

Amel-ilMl

Rosemonnt Analytical Inc.
RMR Department

1201 N. h&in Street

Omille, Ohio 44667
European

Rosemount Ireland
Equipment Return Repair Dept.

Site 7 Shannon Industrial Estate
Co. Glare

Ireland

If warranty service is requested, the defective unit
will be carefully inspected and tested 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 b=e repaired at the factory and

retnmed as directed by the purchase order and

shipping instructions.

This index is a” alphabetized listing of parts, tams, and
procedures having to do with the Hagan Model PP405TR
Torque Type Power Positioner. Every item listed in this

index refers to a location in the manual by one or more page
numbers.

A

Air Lock, 8-1
Air Piping Schematic, 5-l
Air Piping Schematic, with Bypass Valve

and Air Lock, 5-2
Air Supply Requirements, l-4, 2-4
Automatic Operation, Description, l-2

B

Bill of Material, 9-3
Bypass Valve, Description, 1-l

D

Diaphragm Replacement, Air lock, 8-3
Diaphragm Replacement, Receiver, 7-3
Dust Cover, Description, l-2

E

Environmental Requirements, l-4
Electric Position Transmitter (EPT), 8-l
Electrical Connections, 2-5

F

Flow Verses Position Formula, 2-l
Formula, Angular Rotation of Driven Lever, 2-l
Formula, Linkage Length, 2-8
Fommla, Vertical Ann Travel, 2-6
Foundation, Special Installation Considerations, 2-l
Foundation, Strength Requirements, 2.3

C

Calibration Check, 4-l
Calibration, Current to Pneumatic Signal Converter, 4-5
Calibration, Linkage, 4-5
Calibration, Stroke, 4-3
Calibration, Quick Reference, Flowchart, 4-O
Calibration, Reverse Acting Power Positioner, 3-1
Calibration Spring Part Numbers, 9-l
Cam Shaping, Direct Acting Cam, 2-14

Cam Shaping, Inverse Acting Cam, 2-15
Characterized Cam Example, 2-16
Cl&s, Description, l-3
Corrective Maintenance, l-l

Corrective Maintenance, Air Filter Element, l-l

Corrective Maintenance, Calibration Spring, 7-3

Corrective Maintenance, Cam, 7-8

Corrective Maintenance, Current to Pneumatic

Signal (I/P) Converter, 7-2
Corrective Maintenance, Cylinder, l-4
Corrective Maintenance, Diaphragm, 7-3
Corrective Maintenance, Pilot Valve, l-2
Current to Pneumatic Signal Converter, Air Supply, 2-4
Current to Pneumatic Signal Converter, Calibration, 4-5
Current to Pneumatic Signal Converter, Description, l-2
Current to Pneumatic Signal Converter, Electrical

Connections, 2-5
Current to Pneumatic Signal Converter Electrical

Connections, Direct Acting, 2-5
Current to Pneumatic Signal Converter, Replacement, 7-3
Current to Pneumatic Signal Converter, Reverse

Acting, 2-5

Cylinder Head Gasket Replacement, 7-4
Cylinder Replacement, 7-4

G

General Operation, Description, l-2
Gasket, Cylinder Head, 7-4
Gasket, Pilot Valve, 6-2, 7-2, 7-3

H

Heater/Thermostat Replacement, 8-4

I
Installation, 2-1

Installation, Air Supply, 2-3

Installation, Linkage, 2-5
Installation, Power Positioner Mounting, 2-l
Installation, Special Considerations, 2-l

L

Linear Cam, Outputs, 1-2
Linkage Design, Special Installation Considerations, 2-l
Linkage, Material, 2-5
Linkage, Maximum Length, 2-5
Lubrication Chart, 6-2

M

Maintenance Schedule, 6-l
Manual Lever, Description, l-l
Manual Lock, Description, l-l
Manual Operation, Description, 1-4
Maximum Air Pressure, Cylinder, l-4
Model Number Matrix, 1-O
Mounting and Installation (Footprint) Drawing, 2-2
Mounting. Foundation Design, 2-3

M

Mounting Instructions, 2-1
Mounting, Location Selection, 2-1
Mounting, Working Clearance Requirements, 2-l

N

NEMA Rating, 1-4

0

options, 8-l

P
Package Contents, l-l
Performance Requirements, 1-4
Periodic Maintenance, 6-1
Periodic Maintenance, Air Filters, 6-5
Periodic Maintenance, Cylinder, 6-7
Periodic Maintenance, Diaphragm, 6-4
Periodic Maintenance, General, 6-l
Periodic Maintenance, Pilot Valve, 6-1

Periodic Maintenance, Piston, 6-5

Periodic Maintenance, Storage, l-5

Physical Characteristics, l-4

Power Positioner Torque, 2-3

Pressure Regulator, Description, 1-2

R

Recommended Spare Parts, 9-l
Reverse (Inverse) Operation, Description, l-5, 3-l

S

Signal Requirements, Input, 1-4
Signal Requirements, Output, l-4
Specifications, 1-4

Square-Root Cam, Outputs, l-4
squared cam, outputs, 1-2
Supply Air Filter, Description, l-3

Supply Air, Special Installation Considerations, 2-l
Supply Air Shut Off Valve, 2-4
Switch Ratings, SPST, 1-2

Stem, Cleaning, 6-1

Stem, Illustration, 6-3
Storage Instructions, 1-6

T

Thermostat Replacement, 8-4
Troubleshooting, 5-l
Troubleshooting Chart, 5-3

V

Valve, Pilot, 6-1, 7-2

W

working Clearances, 2-l
Wing Codes, 2-l