Rosemount HAGAN 8 x 14 Torque Type Power Positioner-Rev 1.0 Manuals & Guides

HAGAN POWER

ROSEMOUNT”ANALYTICAL

POSITIONER

TORQUE TYPE

8x14

Instmction Bulletin IB-102-208

Rev. 1

FISHER.ROSEMOUNT”Managing The Process Better:

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of

defects in workmanship or material. Should any failure to conform to this warranty become apparent during

a period of one year after date of shipment, Rosemount shall, upon prompt written notice from the
purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or pats.
Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with
respect to the quality of the equipment.

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

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

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

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

PURPOSE

The purpose. of this manual is to provide a comprehensive understanding of the Hagan 8 x 14 Power

Positioner, components, functions, installation, and maintenance.

This manual is designed to provide information about the Hagan 8 x 14 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, first consult this manual. It describes most

situations encountered in your equipment’s operation and details necessary action.

DEFINITIONS

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

NOTE

Highlights an essential operating procedure,
condition, or statement.

NOTE TO USERS

The P­illustration numbers. They are not part numbers and are not related to the illustration in any technical
manner.

number in the lower right corner of the illustrations in this publication are manual

TABLE OF CONTENTS

Page

Rosemount Warranty

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

Purpose ...................................................

I.

DESCRIPTION ....................................

1-1. Component Checklist of Typical System ...............

1-2. Model Number Matrix ...........................

1-3. System Overview ...............................

1-4. Model PP814T Specifications

1.5. Storage Instructions .............................

II.

INSTALLATION ......................................

2-1. overview ................ ........................

2-2. Special Installation Considerations ......................

2-3. Power Positioner Mounting Instructions

2-4. Air Supply Installation ..............................

2-5. Current to Pneumatic Signal Converter (I/p) Electrical Connections

2-6. Linkage Installation ................................

III.

REVERSE OPERATION .............................

3-1. Operational Description ...........................

3-2. Procedures for Reversing Operation ..................

Iv.

CALIBRATION ....................................

4-l. Check Power Positioner Calibration ..................

4-2. Stroke Calibration ...............................

4.3. Current to Pneumatic (I/P) Signal Converter Calibration

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

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2-1

3-l
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4-l
4-l
4-4

4-5
4-5

V.

VI.

VII.

TROUBLESHOOTING ...............................

5-l. Overview .....................................

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. Air Filter Cleaning and Draining
6-6. Diaphragm Cleaning and Inspection

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

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

6-7. Air Lock Adjustment ............................

6.8. Exhaust Blocking Valve Cleaning and Inspection .........

6-9. Cylinder and Piston, Cleaning and Inspection ............

6.10. Mechanical Linkage System Cleaning and Inspection ......

CORRECTIVE MAINTENANCE

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

7-1. Overview .....................................

7-2. Parts Replacement ..............................

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5-l
5-l

5-l
6-l

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7-1

7-1
7-1

IB-102-208

iii

TABLE OF CONTENTS (Continued)

SlXtiOIl

VIII. OPTIONS .., .., __ ___ ._ .., __

8-l. Overview
8-2. Electric Position Transmitter

Current to Pneumatic (I&‘) Converter and Regulator

8-3.

Lit Switch

8-4.

8-5. HeatWTbennostat
IX. RECOMMENDED SPARE PARTS 9-l
X. RETURNING EQUIPMENT TO THE FACTORY

APPENDIX A. LINKAGE INSTALLATION FOR EITHER A CHARACTERIZED

FLOW CONTROL DEVICE, OR A LINEAR FLOW CONTROL DEVICE

APPENIDX B. ELECTRIC POSITION TRANSMITTER FOR 8 INCH X 14 INCH

POWER POSITIONER

INDEX ._.._.__.____..____..._.___.........................___.._...__.

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Page

8-l
8-l
8-l

8-l
8-2
8-4

10-l

A-l

B-l

I-l

LIST OF ILLUSTRATIONS

Figure

l-l.
l-2.

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

6-4.

6-5.

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

Typical System Package
Power Positioner Operation
Typical Power Positioner Installation
Clearance Requirements
Mounting Dimensions
Power Positioner Torque Chat
Air Piping Schematic
Angular Relationship of Drive and Driven Arms
Reverse Operation
Calibration Flowchart
Stroke Adjustment
Current to Pneumatic converter
Linear Linkage Calibration
Characterized Linkage. Calibration
Lubrication Chat
Pilot Valve Exploded View
Diaphragm Exploded View
Air Lock Diaphragm
Exhaust Blocking Valve
Cylinder Exploded View
Mechanical Linkage
Pilot Valve Exploded View
Air Filter
Receiver Exploded View
Air Lock Diaphragm
Cylinder Exploded View

Title

Page

l-l
l-3

l-4
2-2
2-2
2-3
2-4
2-5

3-l
4-l
4-4
4-5
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4-6

6-2

6-3

6-5

6-6

6-7

6-9

6-11

l-2

7-3

l-4

7-6

7-8

LIST OF ILLUSTRATIONS (Continued)

Figure

1.6.
8-l.
8-2.

8-3.

A-l.
A-2
A-3.
A-4.
A-S.
A-6.
A-l.

Table

l-l.

1-2.
4-l.

4-2.
4-3.
S-l.
6-l.
9-1.
9-2.
9-3.
A-l.
A-2.

Title

Shaft Exploded View
Current to Pneumatic Converter and Regulator Replacement
Limit Switch Exploded View
Heater/Thermostat Replacement
Linear Linkage Design
Vertical Am Travel
Driven Shaft Angular Rotation
Connecting Linkage Length
Characterized Linear Linkage Design
Cam Shaping
Characterized Cam Example

LIST OF TABLES

Model Number Matrix
Specifications for Model PP814T Power Positioner
Device Travel (%)
Piston Travel (Stroke) Calibration Schedule
Calibration Signal Pressures
Troubleshooting Chat
Maintenance Schedule

Recommended Spare Parts for PP814T 8 x 14 Power Positioner

Spare Parts for Options (PP814T 8 x 14 Power Positioner Only)
Bill of Material for PP814T 8 x 14 Power Positioner

SystemFlowChart ..______.._...__.___......____

Cam Rotation Points

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8-O
8-3

8-S
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A-2
A-3
A-S
A-6

A-10
A-11

Page

1-2

1-s

4-2
4-3
4-s

s-1
6-1
9-l
9-2

9-3
A-l
A-9

SECTION I. DESCRIPTION

l-l. COMPONENT CHECKLIST OF TYPICAL

SYSTEM. A typical Rosemount 8 x 14 Power
Positioner package should contain the items shown in
Figure l-l

1-3. SYSTEM OVERVIEW.

a. w.

designed to supply details needed to install,
operate, and service the Rosemount 8 x 14
Torque Type Power Positioner (Figure l-l). The

power positioner can be configured with optional

manual operator wheel, transfer valve, air lock,

bypass valve, supply air filter, clevis and dust
cover. Options for the power positioner include
electric position transmitter, limit switches,
heater/thermostat and current to pneumatic (I/P)
converter.

b. Power Positioner Features. The fully featured

model 8 x 14 power positioner includes the
following features:

1. The manual operator wheel can be used by

This Instruction Bulletin has been

the operator to manually change the position
of the device being controlled. In the event
of a power loss, continued operation of
power positioner is possible through manual
operator wheel.

ITEM DESCRIPTION

1 Model PP814T Power

Positioner

2 Air Filter

3 Instruction Bulletin

Figure 1-1. Typical System Package

l-2. MODEL NUMBER MATRIX. The PP814T has

a piston 8 inches in diameter and a maximum stroke
of 14 inches. Use model number matrix, Table l-l, to
verify your style number. The fust part of the matrix
defines the model. The last part defines the various
options and features of the power positioner. Copy
your model number from data plate located on back
of power positioner, compare this to Table l-l. Check
your code model number against the features and
options of the power positioner, making sure the
options specified by this number are on this unit. Use
this complete number for any correspondence with
Rosemount.

2. The transfer valve is a two position valve
that allows the operator to simultaneously
engage the air lock and manual operator, and

open the bypass valve. In the manual
position, air lock is engaged, manual
operator is engaged and bypass valve is
open. In automatic position, air lock is
disengaged, manual operator is disengaged
and bypass valve is closed.

(a) The air lock allows the operator to lock

the piston and output shaft assembly in
any position. This is done by moving
the transfer valve on top of the
positioner to the manual position.
When in the manual position, the
transfer valve C”ts off air pressure to
the air lock diaphragms, allowing the
fail-safe air lock to engage. When the
transfer valve is in the automatic
position, air pressure causes the air
lock diaphragms to disengage the air
lock.

Table l-l. Model Number Matrix.

Includes air filter style 372538-Z and Cl&s, style 274472

Code
452167

457696

Mallual

Operator

Dust

COVW

X
X

Lock

I x I I x I

443700 X X X
457031

Code Description

I7362C69GO2

7362C69GO3
7362C69GO4

UP 4 _ 20 In4 Input

I code

9885A31HOl Current/Pneumatic Converter
27543 l-007 Pressure gage

l~lectric Position Transmitter

Limit Switches (2) DPDT - Nema 4, 13, Factory wired to terminal box
Electric Positioner Transmitter and Limit Switches (2) DPDT - Nema 4, 13,

Factory wired to terminal box

I Description

X X X X

Air

Heater and

Thermostat

X

Shp Wgt

Ibs/kgs
850/385,9
860/390,4

1 880/399,5 1

900/408,6
910/413,1

1 20/9,1 1

5l2,3

25/l 1,4

I I

4505C21GOl Filter regulator

Fail-Safe Option (4)

Code

SKI - 63580

Master Slave Positioners

Code

t 6630D09GOl 1 Master Man. Guer., Dust Cover Air Lock, Heater 1 920/417,7 I

6630D08GOl Slave Man. Oper., Dust Cover Air Lock, Heater

To Order, Specify: 1. Desired input signal 13 15, 0 30 psig (21-103, O-207 Irpa), or 4-X mA See Accessodes].

2. If 4 20 m.4 input is required, also order UP from accessories.

Description

(2) Check Valves, (2) Diapbr. Valves
(1) 2.2 Ft. Tank, (1) Press. Switch
(1) Solenoid Valve. Mtd. & Pioed

Description

when the bypass valve is open it provides
a passage between the top and bottom of
the piston; this equalizes air pressure on
both sides of tbe piston, allowing manual
psitioning of device being controlled.
‘Ibis valve is operated by moving the
hansfer valve to the manual position.
When the transfer valve is in the
automatic p&ion, air pressure causes
bypass valve to close off passage between
top and bottom of cylinder.

50/22,7

800/363,2

3. The supply air filter removes water and oil
droplets from the supply air. Supply air must
be free of oil and water to prevent pilot

valve sticking.

4. The clevis provides a connection i&n power
positioner to liokage so movement can be
transferred to the device t&g controllEd.

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

c. Operational Description. The Model PP814T

Torque Type Power Positioner is a pneumatic
driven, double acting piston type power cylinder
in which the linkage lever is positioned to a
specific setting for each input signal. The power
positioner is mounted on a steel floor stand. The
unit is covered and protected by a splash proof
metal dust cover. The power positioner is used to

position devices such as inlet vanes, control

valves, and dampers.

1. Automatic Operation. Figure l-2 depicts a
direct acting power positioner. In this type
of positioner, an increase in signal air

pressure to the receiver causes the
diaphragm to overcome the tension of the
calibration spring and move downward. The

downward motion is transmitted to the pilot
valve through a connecting link. This
positions the pilot valve stem to send supply
air below the piston, forcing the piston,

piston rod, and cylinder lever upward. Air

from above the piston is exhausted through
the pilot valve exhaust tubing and then
through the open exhaust blocking valve.

NOTE

Figure 1-2 depicts the model 8 x 14 power
positioner with the optional handwheel and
airlock. The 8 x 14 power positioner can be
configured without these items. Refer to
Table l-l.

TO EXHAWT

BLOCKING VALVE

Figure 1-2. Power Positioner Operation

“5tm-208

1-3

M

The upward movement of the piston rod
moves the cam downward. This causes the
follower arm, riding on the cam, to lift the
spring nut, increasing pressure on the
calibration spring. This increased pressure on
the calibration spring returns the diaphragm
to its neutral position, closing the pilot valve
air ports. Without additional air pressure,
piston movement is stopped.

As signal air decreases the calibration spring

pressure moves the diaphragm up. The

upward movement of the diaphragm nioves
the pilot valve. stem up, directing air above
the piston. This forces the piston, piston rod,
and linkage lever downward. The downward
movement of the piston rod, working

through the cam and follower arm, lowers
the calibration 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.

The sector gear movement is transferred to
the linkage lever to control the position of
the device being controlled. To place the
power positioner in manual operation move
the transfer valve to the manual position.

d.

Svstem Considerations. Prior to installation of
your Rosemount 8 x 14 Power Positioner, check
that you have all the components necessary to
make the complete system installation.

Once you have verified that you have all the
components, select mounting location. A typical
installation is illustrated in Figure l-3. Determine
where power positioner will he placed in terms of
serviceability, available power supply, ambient
temperatures, environmental considerations, and
convenience. Power positioner operating
specifications are listed in Table l-2. Become
familiar with Section II, Installation, before
installing unit.

Cam. The standard cam from Rosemount
produces a linear relationship between input
signal and the distance the operating lever is
moved. Additional cams can be purchased
from Rosemount to produce either a squared
(2) relationship or a square root (Jx)
relationship. Custom cam shaping in the
field can produce other relationships needed.
Refer to Section II, Installation for
procedures to custom shape a cam.

Inverse Operation. On inverse acting power
positioners, the cylinder air hoses and the
cam position are reversed. This causes the
supply air to be directed to the top of the
piston when signal air pressure is increased,
and to the bottom of the piston when signal
air pressure is decreased. In this type of
installation, piston movement is inversely
related to the signal - as signal pressure
decreases, the piston raises, as signal
pressure raises, the piston lowers.

Manual Operation. The power positioner
can be controlled manually through the
manual operator handwheel. The handwheel
is connected to a sprocket and chain which
turns a worm shaft when the wheel is
rotated. This worm shaft moves a sector

gear attached to the power positioner shaft.

I

AIR FLOW

f fff

OPERATING

SUPPLY

AIR

LEVER

PWWB

Figure l-3. Typical Power Positioner Installation

Table 1-2. Specitlcations for Model PPS14T Power Positioner.

Signal Requirements

Inputs: 4.20 mA/3-15 psigB30 psig

PWfOl?%BKX

Repeatability ................................

Full Stroke Time (unloaded) ......................

Maximum Cylinder Air Pressure

Supply Air Consumption ........................

ControlTorque ...............................

Maximum Friction Load ........................

Stall Torque .................................

outputs ....................................

Physical Characteristics

Weight ....................................

Dust Cover. .....................

Requirements

Supply Air Input Fitting ........................

Signal Air Input Fitting .........................

Environmental Requirements

Ambient Temperature Limits: .....................

Air Supply Requirements

Operating Air Supply Pressure ....................

Recommended Air Supply Pressure

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

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

1% of full stroke or better

2.5 seconds
120 psig

2 scfm steady state

2700 fi-lbs

1100 ft.lbs

4600 ft.lbs

80” shaft rotation

900 lbs
Designed to meet NEMA type 3

318 inch NPT

114 inch NPT
40°F to 140°F (4.4”C to 60°C)
45-120 psig

100 psi

1-4.

MODEL PP814T SPECIFICATIONS. Model
PP814T Power Positioner specifications contain
information about the operating characteristics of the
power positioner. Use Table l-2 to make sure that
available conditions are suitable for the power
positioner before choosing mounting location.

1-5.

STORAGE INSTRUCTIONS. Use the following
guidelines for storage of tbe power positioner.

a.

Storage Environment. Store power positioner in
a warehouse environment that maintains the
following conditions:

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

2. Humidity below 80% RH.

Power Positioner Preparation for Storage.

b.

Coat all non-painted surfaces and exposed metal
with a rust-preventive compound (Tectyl 506 or
a substitute with similar properties).

c. Storaee Preventive Maintenance. If storing

power positioner longer than six months, observe
the following preventive maintenance guidelines.

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

2. Perform General Cleaning and Lubrication
(paragraph 6.3), and Cylinder and Piston,

Cleaning and Lubrication (paragraph 6.9),
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 a” electrical signal, when
“sing a” I/P signal converter, or by a” 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 am of device being
positioned. This torque is also transferred to
power positioner’s mass and it’s foundation. The
foundation must be designed t” 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 2 s&n, is required. Supply
air must be free of oil and water to prevent pilot
valve sticking.

e. Linkage Design. Final control components play

a large part in a control system. Special charac­t&tics of device being controlled affect system
response and must be regarded in design and
setup of a power positioning system.

which flow changes per valve position is increawl.
The constant is a “unba that allows the eq”ati0” to
work for different flow control devices.

Conduct flow tests before attempting to limit
damper opening. Testing is necessary to confirm

actual damper characteristics and to make wre
control response is proportionate to input signal
throughout the flow range. When installing a new
power 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 and installation of
a linearized control action power positioning
SYSte”L

2-3. POWER POSITIONER MOUNTING

INSTRUCTIONS.
a. Working Clearance Requirements. Make sure

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

For standard ““it, allow an open area of 24
inches (side to side) by 23 inches (front to back)
by 49 inches (vertically from foundation) plus

enough room to operate handwheel. This will
allow for removal of dust cover, maintenance,
and operation of handwheel (Figure 2-l).

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, OCCUI
“ear 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)z

k = Constant

This equation means that flow is propotional to the
square of valve position. As damper or valve “pens,
the rate at which flow changes per valve position is
reduced. As valve or dampa closes, the rate at

b. Location Selection.

1. Select location for power positioner as near
to the device being controlled as possible,
making sure necessary clearance for
operation and maintenance, as specified in
paragraph 2.3a, is available.

2. Use Specifications for Model PP814T Power
Positioner, Table l-2, to make sure environ­mental conditions are suitable for the power
positioner.

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

started.

NOTE: DIMENSIONS ARE IN INCHES.

1

PI

,

5

0.5c

I

Figure 2-l. Clearance Requirements

c. Mounting Procedure.

1. Design and Manufacture Foundation. Foun­dation must be able to withstand at least

1670 ft-lbs torque plus 900 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 3/4 inch foundation bolts. Decide
which foundation material is best suited for
your application, steel or concrete, and
design and manufacture foundation.

7

-

0

@=il

until power positioner is level when
3/4 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.

NOTE: DIMENSIONS ARE IN ,NCHES

2. I”stallatio”.
(a) Install power positioner on foundation

with 3/4 inch bolts and standard flat
washers.

(b) Make we 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

314 inch bolts that seame power
positioner to foundation and install

shims between the power positioner
and foundation. Continue this process

IS-102-208

2.2

I\\

’ c3

0

0

-

0

71 I

J

~

I

Figure 2-2. Mounting Dimensions

I 7.00

POOWS

0 1000 2000 3000 4000 5000 6000

MAXIMUM TORQUE REQUIRED (FT-LBS)

Figure 2-3. Power Positioner Torque Chart

PC0006

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 minimum supply air required to
develop the required control torque. The stall torque
curve. represents the maximum amount of torque the
power positioner will produce for given supply air
pressure before stalling out.

a. Air Line Requirements. Installation of air filter

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
convater, install a separate signal line as shown in
Figure 2-4 View B. The. power positioner can accept
diffmat ranges of signal air pressures. Refer to your
model number and model number matrix (Table.

l-l) to determine signal air pressure required.

b. Supplv Air and Signal Air Connections. Basic

schematics are. shown in Figure 2-4. The
installation of the. air filter is as follows:

1. Mount bracket for air filter directly on the
back of the stand assembly. If this is unsuit-

able, 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.

Supply air fitting is 3/8 inch NPT.

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

air fitting is l/4 inch NPT.

l&102-208

2-3

REGULATORJFILTER

PRESSURE

l/4 INCH NPT

FEMALE

CONNECTION

t

T -/ ’

TO
DIAPHRAGM

AIR

CONNECTION
MANIFOLD

SUPPLY AIR

>I00 PSIG

POWER POSITIONER WITH

CURRENT TO PNEUMATIC SIGNAL

SUPPLY AIR

>I00 PSIG

POWER POSITIONER WITH

PNEUMATIC CONTROL SIGNAL

VIEW A

CONVERTER (l/P)

VIEW B

SHUTOFF VALVE

15 PSIG OR I

3-.- -.- -..

O-30 PSIG

SIGNAL AIR

PRESSURE

AIR

FILTER

t-----L

i/4 INCH NPT

FEMALE

CONNECTION

II

AIR $8)

FILTER CONNECTION

3/S INCH NPT

FEMAL:

/i

2~~ TO PILOT

--- VALVE

15 FEET
MAXIMUM

\

-MANIFOLD

AIR

CONNECTION

Figure 2-4. Air Piping Schematic

2-5. CURRENT TO PNEUMATIC SIGNAL

CONVERTER WP) 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/P has pigtail leads instead of screw terminals, the
connection must be made at a tam&d block. Gage of

wire required is 18 gage signal wire. The signal that
will control the I/p should have a range of 4 to 20
mA at a voltage of 24 vdc.

IE-102-208

2-4

2-6. LINKAGE INSTALLATION. I” a “mnal

installation, most customers install the linkage with
both the drive Amy and damper driven arm positioned
so that both anns establish a” approximate right angle
(90”) to the drive line at mid range of travel as
illustrated in Figure 2-5.

DRIVEN

For more detailed information on linkage arrangement
and options refer to Appendix A LINKAGE
INSTALLATION FOR EITHER A
CHARACTERIZED FLOW CONTROL DEVICE,

OR A LINEAR FLOW CONTROL DEVICE.

I

- LINKAGE

DRIVE

Figure 2-5. Angular Relationship of Drive and Drive” Arms

SECTION III. REVERSE OPERATION

3-1. OPERATIONAL DESCRIPTION. In reverse related to the signal. A falling signal air pressure

acting positioners, the piston and piston rod operate. raises the piston and an increasing signal air pressure
the same as when set up for direct acting (Figure lowers the piston.

l-2). The cam is reversed front to back and the
cylinder air hoses are exchanged. These alterations
cause supply air to be directed to the top of piston 3-2. PROCEDURES FOR REVERSING
when signal air pressure is increased and to the
bottom of piston when signal air pressure is cylinder, refer to Figure 3-1 and use the following
decreased. In this case, piston movement is inversely procedures.

OPERATION. To reverse the operation of the

I

Figure 3-1. Reverse Operation

ITEM DESCRIPTION

1
2
3

4
5
6
I

8
9

10
11
12
13
14
15

Linkage Lever
Cl&s
Stroke Adjustment

Lock Screw
Pivot Screw
CL%”
Cam Mounting Bracket
Spring Nut
Set screw
Upper Cylinder Hose
Upper Cylinder Head
Lower Cylinder Hose
Lower Cylinder Head
Gland Cap
Clevis Head
Piston Rod

a. Reverse Com~ematine

Assembly.

1. Remove power positioner from service.

2. Close the supply air valve

3. Set signal air to 0.

c. Calibrate Stroke.

1. Disconnect linkage lever (1, Figure 3-l) at
clevis (2) from device being controlled.

2. Open supply air valve. This will cause
piston rod (15) to move to top of its stroke.

Set signal air to minimum.

3. Using an allen wrench loosen set screw (8)

holding spring nut (7).

4. Remove pivot screw (4) and stroke adjust­ment lock screw (3) securing cam (5) to cam
mounting bracket (6) and remove cam.

5. Invert cam as shown in Figure 3-1, View A.
Install pivot screw (4) and stroke adjustment
lock screw (3) through cam into cam mount­ing bracket.

b. Exckanae Cvlinder Hoses.

1. Tag and remove upper cylinder hose (9) and
lower cylinder hose (11) from cylinder
heads.

2. Install upper cylinder hose into lower cylin­der head (12). Install lower cylinder hose.
into upper cylinder head (10).

4. Turn spring nut counterclockwise until
piston rod (1.5) starts to move downward.

5. Turn spring nut (7) slowly clockwise. until
piston rod reaches maximum position.

6. Tighten set screw (8) to hold spring nut
fdy in place.

7. Set signal air to maximum amount and
check movement of piston rod (15) for full

stroke. The piston rod should just reach
bottom of stroke with maximum signal to
pilot valve. If necessary, loosen stroke ad­justment lock screw (3) and move cam (5)

away from shaft until full stroke is reached.

8. Reconnect linkage lever (1) at cl&s (2) to
device being controlled.

SECTION IV. CALIBRATION

4 -1. CHECK POWER POSITIONER CALIBRATION.

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

IS PERCENTAGE

OF TRAVEL OF

DEVICE EQUAL TO

CORRESPONDING

PERCENTAGE OF

CHECK STROKE

POSITION FOR

EACH PERCENT

OF SIGNAL LISTED

IN TABLE 4-2

1

I

IS PISTON IN
PROPER POSITION
FOR EACH SIGNAL

AIR PRESSURE?

CALIBRATE STROKE

AND I/P. REFER TO

PARAGRAPHS 4-2

Figure 4-1. Calibration Flowchart

I

CALIBRATE LINKAGE

PARAGRAPH 4-4.

POW16

NOTE

If cam was shaped (characterized), values of
percent output desired must be recorded

upon instalIation in Table 4-1, Schedule D.

This is necessary to check calibration. If

values were not recorded, refer to Appendix
A, paragraph A-2.b and calculate correct
positions using formulas.

a. Device Travel.

1. Measure distance that the controlled device’s
driven lever arm travels from 0% signal air
to 100% signal air. Record this as total
distance.

2. Set signal air to 0%.

3. Measure controlled device’s driven lever
arm travel from 0% to 10% signal air.

Divide measurement by total distance
measured in step a. Record this as the
percentage of output travel for 10% signal

air. Measure and record percentage of output

travel in the same. fashion in 10%
increments up to 100% signal air.

4. Compare recorded readings with percent

driven lever travel in Table 4-l. Use

ICSPtXth

columns for characterized

systenls, linear, square root, or square. cams.

If recorded percentages of travel are equal to
those in Table 4-1, the system does not need
calibration. If recorded readings do not
equal those in Table 4-l continue checking
procedure.

PERCENT SIGNAL

AIR PRESSURE

0 0 0.0 0.0

10
20 20 44.8 4.0
30 30 54.8

40
50 50 70.7 25.0
60 60 77.5
70 70 83.7 49.0
80 80 89.4 64.0
90 90 94.9 81.0

100

Table 4-1. Device Travel (%).

l-

LINEAR

10

40 63.25 16.0

100 100.0 100.0

PERCENT DRIVEN LEVER TRAVEL

SQUARE ROOT

CJX)

31.6

SQUARE

cx’,

1.0

9.0

36.0

CHARACTERIZED

b. Piston Travel.

1. Set signal air to 0%

2. Measure distance from top surface of gland
cap (13, Figure 3-1) to bottom surface of
clevis head (14). Label this distance “A”.

3. Increase signal to 100%.

4. Measure distance from surface of gland cap

(13) to bottom surface of cl&s head (14).

Label this distance “B”.

5. Subtract distance “A” from distance “B”.
This is total stroke travel of the power
positioner. Record this distance as total

stroke travel.

6. Set signal air to O%,

7. Measure the piston travel (stroke) when a

10% signal is sent to the power positioner.

Record this as stroke travel for 10% signal

air. Measure and record percentage of output
travel in the same fashion in 10%
increments up to 100% signal air.

NOTE

Values for characterized stroke measured
in inches and percent corresponding to
input pressures are recorded in Table
4-2, Schedule D. If values were not
recorded, refer to Appendix A, paragraph
A-2.b., and calculate correct positions
using formulas.

8. Compae actual stroke movement with
desired stroke movement. Desired stroke
movements appear in Table 4.2, Calibration
Schedule. Schedule “A” is for a linear cam,

“B” for a square root cam, “C” for a square
cam, and “D” for a characterized cam. If
actual stroke of power positioner is equal to
desired value in Table 4-2, refer to para­graph 4-4 and calibrate linkage. If it is not
equal, calibrate stroke @amgraph 4-2) and
then calibrate I/P (paragraph 4-3).

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

CALIBRATION SCHEDULE “A” - LINEAR CAM

INPUT SIGNAL

3-15 psig (UP)

3.0 0

4.2 3 10

5.4 6 20 2.80 20

6.6 9 30

7.8

9.0 15

10.2

11.4 21 70 9.80

12.4

13.8

15.0 30 100

3.0

4.2

5.4

6.6

7.8

9.0

10.2

11.4

12.4

13.8

15.0

!

O-30 psig Percent of Signal

0 0.00 0

12 40 5.60

50 7.00 50

18 60 8.40 60

24 80 11.20 80

27 90 12.60 90

CALIBRATION SCHEDULE “B” - SQUARE ROOT CAM

0 0 0.00 0.0

3 IO 4.43 31.6
6
9 30 7.68 54.8

12 40 8.72 62.25
15 50 9.90 70.70

18 60 10.85 77.50
21 70 11.72 83.70
24 80 12.52 89.40
27 90 13.29
30

CALIBRATION SCHEDULE “C” - SQUARE CAM

20 6.28

100 14.Oil 1oJJ.00

I

DESIRED STROKE

Inches

1.40 10

4.20 30

14.00 100

I

I

I

Percent of Full Stroke

40

70

44.8

94.90

3.0

4.2

5.4

6.6

7.8

9.0

10.2

11.4

12.4

13.8

15.0

0 0
3
6 20 0.56
9 30

12 40

15 50
18

21 70
24 80 8.96 64
27 90 11.34
30

10 0.14 1

60 5.04 36

loo 14.00 100

I

CALIBRATION SCHEDULE “D” - CHARACTERIZED CAM

3.0 0 0 0

4.2 3

5.4

6.6 9 30 30

7.8 12 40 40

9.0 15

10.2 18

11.4 21 70 70

12.4 24 80 80

13.8 27 90 90

15.0 30

6 20 20

10 10

50 50
60 60

100 100

0.00 0
4

1.26 9

2.24 16

3.50 25

6.86 49

81

I%10%208

4.3

4-2. STROKE CALIBRATION. Use the following nut slowly clockwise until piston rod moves to

procedures to adjust power positioner stroke.

a.

Purge air lines to remove any water or debris.

b,

Move transfer valve to automatic position and set
signal air to minimum stroke position (0%).

c.

Loosen set screw (3, Figure 4-2) holding spring
nllt (2)

counterclockwise until piston rod (4) begins
moving up from bottom of stroke. Turn spring

ITEM DESCRIPTION

1 Stroke Adjustment I
2 Spring Nut
3 Set screw

Piston Rod

4
5

CEUII

in place. TUXl spring nut

lowest position. Tighten set screw.

d.

Increase signal air to maximum (100%). Refer to
Table 4-3 for percent to signal air conversion.

e.

Loosen stroke adjustment lock screw (1). Move
loose end of cam toward shaft until piston rod

(4) moves downward. Slowly move cam away
from shaft until piston rod moves to maximum
position or to desired length of travel. Tighten
lock screw.

Figure 4-2. Stroke Adjustment

Table 4-3. Calibration Signal Pressures.

NOTE

SIGNAL AIR

STROKE

POSITION

3-15 psig (I/P) O-30 psig

0% 3 0

100% 15 30

4-3. CURRENT TO PNEUMATIC (I/P) SIGNAL

CONVERTER CALIBRATION. Calibrate current
to pneumatic signal converter after mounting,
changing mounted position, or when loss of control is
noticed (refer to Section V, Troubleshooting). Use the
following procedures to calibrate the signal converter:

a. Remove protective plastic caps from “Zero” and

“Span” adjustment screws (Figure 4-3).

ADJUSTMENT

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

b.

Set signal value to 4 mA and adjust “Zero” screw
until output pressure is at 3 psig. Turn screw
counterclockwise to increase pressure, clockwise
to decrease pressure. If output pressure does not
change when screw is turned, turn screw counter­clockwise until pressure starts to rise.

c.

Set signal value to 20 mA. Adjust “Span” screw
until output pressure is at 15 psig.

d.

Repeat steps b. and c. until no further adjustment
is needed.

e.

Replace protective caps,

4 TO 20 mA

Figure 4-3. Current to Pneumatic Converter

ADJUSTMENT

4-4. LINKAGE CALIBRATION.

a. m. Check angular travel of power positioner

drive lever at cl&s. Compare this to device
driven lever angular travel. If angular distances
are not the same, use the following procedure to
adjust offset of power positioner drive lever to
the same angle as the device driven lever. When
adjushnent is complete, both operating levers
must be parallel with each other.

1. Measure angle PI J%xn vertical line extending
from shaft hub, to power positioner drive lever
(Figure 4-4). This is the power positioner
drive lever offset.

POWER

POSITIONER

L-

Figure 4-4. Linear Linkage Calibration

2. Measure angle 8, from vertical line extend­ing from device lever hub, to driven lever of
device being controlled. Tbis is the driven

lever offset.

3. Compare angle !3, and angle &. Adjust
length of linkage for minor adjustments by
threading pipe in or out of clevis. Change
drive lever angle PI for major adjustments
by repositioning on shaft.

b. Characterized. Verify linkage design angles and

length against actual installation. Use the follow­ing procedure and Figure 4-5, and adjust angles

and lengths as necessary.

1. Measure angle p, from vertical line
extending from shaft hub to power
positioner drive lever. This is the power
positioner drive lever offset.

2. Measure angle b2 from vertical line
extending from device lever hub to
drivenlever of device being controlled. This
is the driven lever offset.

Figure 4-5. Characterized Lbkage Calibration

3. Measure length between connecting levers.
This distance is represented by the letter 8.

4. Measure length of power positioner drive
lever (R,) from shaft to center of clevis pin.

5. Measure lengtb of device driven lever (RJ
from shaft center to center of clevis pin.

6. Compare angle PI, p2, distance 0, and
length R, and Rz with setup dimensions and
angles recorded in Appendix A, Figure A-4.
If setup dimensions and angles were not
recorded, use formulas in Section II to
calculate correct design for the positioning
system and record in Appendix A, Figure
A-4. Adjust length of linkage for minor
adjustments by threading pipe in or out of
cl&s. Change drive lever angle fi, for
major adjustments.

l&to*-208

‘l-6

SECTION V. TROUBLESHOOTING

5-l. OVERVIEW. Troubleshooting of common problems

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

Table 5-1. Troubleshootim Chart.

PROBLEM

1. Erratic operation

2. No response from
power positioner to a
signal air pressure.
change

3. Power positioner
does not remain at

setpoint; continues to

CVCk

4. System over shoots
or under shoots
setpoint

CAUSE
Pilot valve sticking.

Linkage binding or loose.

Manual lock engaged.
Air supply shutoff valve closed.
Ruptured receiver diaphragm.

Cylinder head gasket leak.
Bypass valve air connection loose
Bypass valve. leaking internally.
I/P o”t of calibration.
I/p failure.
Piston stroke travel not properly set.

Cam not shaped properly,
Pin hole in diaphragm.

the related probable cause, and finally by what action
is necessary to correct the defect.

5-2. TROUBLJZSHOOTTNG CHART. Refer to Table 5-l.

CORRECTION
Clean or replace pilot valve. Refer t” paragraph 6-4

for cleaning procedures and paragraph 7-2~
for replacement procedures.

Linkage pivot joints corroded, dirty, or worn. Clean
and lubricate or reulace “arts.

Disengage manual lock.
open air supply valve.
Replace diaphragm. Refer to paragraph 7.2.~.
Replace leaking gasket. Refer to paragraph 7-2.x.
Tighten or replace air connection.
Replace bypass valve.
Calibrate UP. Refer to paragraph 4-3.
Replace J/P per paragraph 8.3.b.
Calibrate stroke travel of piston.

paragraph 4-2.
Replace cam. Refer to paragraph 7.2.g.
Replace diaphragm. Refer to paragraph 7.2.~.

Refer to

H

5. Sluggish operation

6. Power positioner
operates nor”lally
but flow that is being
controlled remains
“nchaneed

I. Power positioner

locks up and won’t

operate with transfer
valve in automatic
mode

Air filter/separator full of water, oil, or

sediment.
Air filter dii.
Ambient temperature is lower than the

power positioner is designed for.
Device being controlled has a broken

valve stem or co”nectio” to the
linkage.

Hole in air lock diaphragm(s).

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

Replace filter element. Refer to paragraph 7.2.b.
Install power positioner heater.

Repair or replace controlled device.

Replace air lock diaphragm(s),

SECTION VI. PERIODIC MAINTENANCE

6-1.

OVERVIEW. This section describes preventive
maintenance for the Rosemount Model PP814T Power
Positioner. Preventive maintenance is necessary at
specific intervals to reduce wear and tear on the

power positioner.

6-2.

MAINTENANCE SCHEDULE. Use the
maintenance schedule, Table 6-1, as a guideline for

preventive mai”tenance. The frequency of this

maintenance varies directly with plant conditions and

operational load on the power positioner. Extremely
dusty conditions or high temperatures will require
more frequent maintenance on the power positioner.

6-3.

GENERAL CLEANING AND LUBRICATION.
Clean power positioner exterior of all grease buildup
with commercial dry cleaning solvent. To lubricate
power positioner, refer to Figure 6-1, Lubrication
Chart.

TIME INTERVAL

(APPROXIMATE)

6 months
6 months
6 months
2 years
2 years
2 years
2 years
2 years

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 filter. Refer to paragraph 6-5.
Clean and inspect diaphragm. Refer to paragraph 6-6.
Clean and inspect air lock diaphragm. Refer to paragraph 6-7.
Clean and inspect exhaust blocking valve. Refer to paragraph 6-8.
Lubricate, clean and inspect cylinder and piston assemblies. Refer to paragraph 6-9.
Lubricate, clean and inspect mechanical linkage. Refer to paragraph 6-10.

LUBRICATION CHART

GREASE GUN FILLED
WITH McLUBE M&,-793

SEE NOTE 1.

McLUBE M&,-793
SEE NOTE 2.

1

NOTE 1: USING A GREASE GUN, LUBRICATE ZERK NOTE 2: WlPE PISTON ROD WITH A CLEAN SHOP

FITINGS AT PISTON ROD CLEVIS, FOLLOWER TOWEL. APPLY A LIGHT COATING OF
ARM, SHAFT ASSEMBLY, BUSHING BLOCKS, McLUBE M&-793. WIPE EXCESS GREASE
HANDWHEEL SHAFT BLOCK, WORM SHAFT
BLOCK AND BEARING BLOCKS.

OFF WITH CLEAN SHOP TOWEL.

Figure 6-1. Lubrication Chart

6-4. PlLOT VALVE CLEANING AND

INSPECTION. In normal service, the pilot valve

assembly (Figure 6-2) requires cleaning and

inspection at intervals of appmimately six months, or
upon any indication of sticking.

120017-019
120103-1632175

252590

Figure 6-2. Pilot Valve Exploded View

IB-102-20s

63

26

POW22

Remove power positioner from service.
Carefully hold upper end of pilot valve stem

(4, Figure 6-2) with a 506 inch open end
wrench. Free connecting link (1) from pilot valve

stem by turning connecting link lower ball socket
nut counterclockwise.

Disconnect air supply tubing (8) from elbow (7).
Disconnect exhaust connector (11) from tube

connector (10).

h. Thoroughly clean pilot valve body (5), valve cap

(3) and pilot valve stem (4) in commercial dry
cleaning solvent. Allow pilot valve to completely
air dry. Do not use abrasive of any kind on pilot
valve stem. Thoroughly clean reducing bushing
(9) in commercial dry cleaning solvent.

NOTE

pilot valve stem and valve body sleeve are a

matched set. If either is damaged or worn to
a non-serviceable condition, entire pilot
valve must be replaced.

Remove nuts (12) and lock washers (13) that

secure pilot valve to threaded studs (15) on pilot
valve manifold (17). Remove pilot valve and cork

gasket (14) from pilot valve manifold.

e. Remove screws (2) and valve cap (3) from pilot

V&S.
f. Remove pilot valve stem (4) from pilot valve.
g. Remove reducing bushing (9) from pilot valve.

i.

Inspect pilot valve stem (4) and pilot valve sleeve
(6) for scoring. If any signs of wear or damage
are found, replace pilot valve.

Install pilot valve stem (4) into valve body.

i
k.

Install reducing bushing (9) in pilot valve body.

1.

Install valve. cap (3) on valve body with screws (2).

m

Install assembled pilot valve with new cork

gasket (14), securing with nuts (12) and lock
washers (13).

n.

Connect air supply connector (8) to elbow (7).
Conneaexhaustconnector(ll)~blbeconnector(10).

0.

Carefully hold upper end of pilot valve stem (4).
Attach connecting link (1) to pilot valve stem by

turning connecting link lower ball socket nut
clockwise.

Return power positioner to service.

P.

6-5. AIR FILTER CLEANING AND DRAINING.

I” nornml service, supply air filter and signal air
filter/regulator require draining of water and debris at
least way 6 months. The frequency of this mainte­“ante will depend upon supply air quality. After
installation, drain both filters by slowly opening filter
and filter/regulator petcock valve. Initially drain

monthly, gradually increasing time between draining.

Schedule periodic draining when filters are
approximately l/4 full. Continue draining water and

ITEM DESCRIPTION PART NUMBER

1

SCEW

120088.033

2 Diaphragm Cover 242687

3 Diaphragm Housing 34273 1
4 Zero Balance Spring 175464.348
5 Diaphragm 9351-002

debris at this interval unless plant supply air
conditions change. If element in air filter is dii,

refer to Section VII for replacement procedure.

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

Figure 6-3. Diaphragm Exploded View

a. Remove power positioner from service.

6-7. AIR LOCK ADJUSTMENT. Use the following

procedure for adjustment of the air lock.

b. Remove screws (1, Figure 6-3) securing

diaphragm cover (‘2) to diaphragm housing (3).
Remove diaphragm cover.

c. Remove zero balance spring (4) from top of

diaphragm.

d. Using a clean, damp shop towel, thoroughly wipe

off any dirt or debris on upper side of diaphragm
(5). Allow diaphragm to air dry completely
before reassembling.

e. Visually inspect diaphragm (5). Replace if nicks,

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

procedures.

f. Clean diaphragm cover (2) and zero balance

spring (4) with commercial dry cleaning solvent
and allow to air dry.

g. Align the edges of diaphragm (5) with diaphragm

housing (3) to make an air tight seal. Replace

zero balance spring (4).

a. Remove power positioner from service. Reduce

signal air to 0%. Move transfer valve to
automatic position so clapper lever (3, Figure
6-4) opens. Prop clapper lever open.

3

6

h. Making sure the diaphragm (5) is not folded or

pinched, replace diaphragm cover (2) on top of

diaphragm.

i. Secure diaphragm cover (2) with screws (1).

Snug up all saws evenly then tighten in a criss
cross pattern. Make. sure. all screws are tightened
equally to prevent distortion of diaphragm.

j. Test for air leakage sound diaphragm cover (2)

and diaphragm housing (3). Using a leak detector,
such as “Snoop”, apply an air signal to power

positioner. If leak is detected, repair as necessary.

I

ITEM DESCRIPTION PART NUMBER

1 Worm Gear Sector 341183
2 Worm Shaft 341156-001
3 Clapper Lever
4 Shaft Bearing 141168-008
5 Lock Nut 120036-002
6 Stop Bolt

Figure 6-4. Air Lock Diaphragm

357720

120090-052

b. Measure clearance between worm shaft (2) and

worm gear sector (1). Clearance should be
between l/8 to 3116 inch. If clearance is not in
this range, loosen lock nut (5) and adjust stop
bolt (6) until worm shaft to gear sector clearance
is between l/X and 3/16 inch. Tighten lock nut.

c. Remove prop from clapper lever (3). Move

transfer valve to manual position and check to
ensure worm shaft (2) engages gear sector (1).

d. Return power positioner to service.

6-8. EXHAUST BLOCKING VALVE CLEANING

AND INSPECTION. Disassemble, clean and
inspect exhaust blocking valve every two years, or
upon indication of leakage.

a. Remove power positioner from service.
b. Release residual exhaust air pressure by pulling

on exhaust valve link nut (18, Figure 6-5).
Disconnect exhaust connector (1) from exhaust
blocking valve assembly.

ITEM DESCRIPTION PART NUMBER

1 Exhaust Tubing 252592
2 Adapter 120020.007
3 Nut 120033-006
4

End Cover 2831A30HOl
5 Gasket 142674
6

spring
I Thrust Plate

140914
142675

8 Exhaust Valve Body 2831A29HOl

9 Link 141181.005

F&we 6-5. Exhaust Blocking Valve

ITEM DESCRIPTION PART NUMBER

10 Studscrew 142617
11
12
13
14

SC”%’
SCEW

120093-090
120088-004

Pin 141181-002
Valve Lever

141181-003

15 Nut 120033-002
16

SCEW

120093.092
17 Fulcrum Block 142676
18 Link Nut

120033-002

c. Remove link nut (18) from exhaust valve link (9)

and remove exhaust valve link.

d. Remove screws (12) securing exhaust blocking

valve assembly from frame and remove exhaust
blocking valve assembly.

e. Remove four screws (11 and 16) and nuts (3)

from exhaust blocking valve assembly. Remove
end cover (4) from exhaust valve body (8).

2. Draw exhaust valve link nut (18) onto ex­haust valve link (9) until it comes into
contact with clapper lever.

3. Carefully move valve lever (14) toward
frame to open exhaust valve. Holding valve
lever in open position, gently tighten link
nut (18) against clapper lever.

4. Remove prop from clapper lever.

f. Remove gasket (5) and discard. Remove thrust

plate (7) and spring (6). Inspect contact surfaces
of exhaust valve body (8) and thrust plate for
pitting and wear. Replace as required.

g. Using a sharp putty knife, prepare gasket surfaces

on end cover and exhaust valve body by remov­ing any old gasket material or dirt.

h. Place new gasket (5) on end cover (4). Install

spring (6) and thrust plate (7).

i. Assemble end cover (4) with exhaust valve body

(8) and install screws (11 and 16) and nuts (3).

j. Mount exhaust blocking valve assembly in frame

and install screws (12).

k. Install exhaust valve link (9) through diaphragm

base and clapper lever. Replace link nut (18) on
exhaust valve link only enough to keep it in
place.

1. Reattach exhaust connector (1) to exhaust valve
assembly.

n. Restore signal air pressure and return power

positioner to service.

6-9. CYLINDER AND PISTON, CLEANING AND

INSPECTION. Disassemble, clean and lubricate
piston and cylinder assembly approximately every two
years. Refer to Figure 6-6 and use the following

p*OCdU*e.

Remove power positioner from service.

a.
b.

Shut supply air valve and set signal air pressure
to 0 psig. Set transfer valve on top of machine to

manual.

c.

Loosen cylinder upper hose and cylinder lower
hose to bleed residual air from cylinder.

d.

Remove cylinder upper hose from upper cylinder
head and cylinder lower hose from lower cylinder
head.

e.

Remove cylinder clevis pin set screw (1) and
cylinder clevis pin (3). Disconnect cylinder lever
(2) from cylinder clevis (4).

m. Adjust exhaust valve link nut (18).

1. Move transfer valve to automatic position so
clapper lever opens and prop clapper lever
Opl.

Support cylinder assembly with 2 x 4 inch board

f.

long enough to provide leverage. This will

prevent cylinder from falling to floor when

cylinder support nuts (10) are removed from
bearing block (12) and frame.

Remove nuts (10) and lock washers (11) from

g.

screws (13) securing bearing blocks (12) to frame
assembly. Remove cylinder from frame assembly.
Remove bearing blocks from cylinder head.

h.

Remove nuts (7) from studs (18) securing upper
cylinder head (9) to lower cylinder head (19).
Full piston assembly and cylinder head out of
cylinder assembly. Remove and discard upper
cylinder gasket (14).

ITEM

1
2
3
4
5
6
I
8
9

10

DESCRIPTION PART NUMBER

set

screw 120083-021
Cylinder Lever 324357
Clevis Pin 146009
Clevis

SCEW

Gland Cap
Nut

242370

120093-023
142367

120032-012
Rod Packing 283lA95GOl
Upper Cylinder Head 242407

Nut 120032.012

10

11

\

n

;:I

\

11 Lock Washer 120114-008
12 Bearing Block 142645

13
14

SCWV 120088.125

Gasket 141279
15 Piston Rod 242369
16 Piston 241282
17
18
19

Cylinder 242405

Cylinder Stud 243252

Lower Cylinder Head 342372

Figure 6-6.

i. Clean old grease off of piston assembly and

piston rod. Wipe piston and piston rod with dry
cleaning solvent. Replace piston if it appears
damaged or worn. Inspect piston rod area where
it passes through rod packing; replace if it
appears pitted. Refer to Section VII for
replacement procedures.

\

Cylinder

\

\

Exploded View

j. Remove screws (5) securing rod packing gland cap

(6) and remove rod packing cover plate. Replace
rod packing (8) if tom or causing air to leak. Refer
to Section VII for replacement procedures.

k. Carefully wipe away old grease from rod packing

(8). Pack ma around rod packing with McLube
MoS,-793.

II-102-208

6-9

1. Place gland cap (6) onto upper cylinder head (9)
and secure with screws (5).

m. Wipe piston rod (15) with a clean shop towel and

apply a light coating of McLube MoS,-793.

n. Pack concave area of piston with McLube

MoS,-793.

o. With a clean shop towel and commercial dry

cleaning solvent, wipe interior surface of cylinder
(17). Inspect cylinder for cracks or scoring.
Replace cylinder if it appears damaged. Refer to
Section VII for replacement procedures. Allow to
air dry completely before reassembling cylinder.

t. Open supply air valve and test for air leakage

around cylinder head. Use a leak detector, such
as “Snoop”, and send an air signal to power

positioner. If leak is detected, repair as necessaq.

u. Using grease gun filled with MoS,-793, lubricate

clevis and bearing blocks.

v. Calibrate power positioner stroke; refer to Section

IV. Return power positioner to service.

6-10. MECHANICAL LINKAGE SYSTEM

CLEANING AND INSPECTION. Clean power

positioner mechanical linkage of all grease buildup

and inspect for damage and wear every two years.

Refer to Figure 6-7 and use the following procedure.

Install upper cylinder head (9) and piston assem-

p.

bly into cylinder (17) with new cylinder gasket
(14). Secure upper cylinder head to lower cylin-

der head (19) with cylinder studs (18) and nuts
(7).

Place bearing blocks (12) on upper cylinder head

q.

(9). Place cylinder assembly in frame assembly
onto 2 x 4 inch board for support. Secure bearing
blocks to frame assembly with screws (13), lock
washers (11) and nuts (10). Remove 2 x 4 inch

board.
Insert end of cylinder lever (2) into slot of clevis

r.

(4).

Align holes in clevis (4) with hole in cylinder

s.

lever (2) and drive clevis pin (3) in securing
clevis to cylinder lever. Secure clevis pin with set

screw (1).

a. Remove power positioner from service.

b. Shut off supply air valve
c. Clean all grease off of handwheel sprocket (18)

and worm sprocket (2). Inspect sprockets for
damage or missing teeth.

d. Wipe old grease from chain (14) and inspect

chain for damaged links.

e. Ensure handwheel shaft block (22) and worm

shaft blocks (5) are tight and secure.

f. Rotate handwheel (16) and inspect worm shaft

(9) for damage.

g. Lubricate worm shaft block (4) and handwheel

shaft block (22) with grease gun filled with
MoS,-793. Wipe chain (14) with MoS,-793.

ITEM

1
2
3
4
5
6
7

8

9

10
11
12
13
14
15
16
17
18

19
20
21

22

23

DESCRIPTION
Nut
Worm Sprocket
Grease Fitting
Block
Worm Shaft Block

Thrust Washer
Collar

Cotter Pin
Worm Shaft
screw
Pin
Set screw
Key Bar
Chain
Nut
Handwheel

Key
Handwheel

Sprocket
Sprocket Shaft
Pin
Grease Fitting
Handwheel Shaft

Block

SCEW

PART NUMBER

138006-002

141156.006
139656-001
141156-002

141156.003

141156.008
152371
120010-013

141156.001

120088.064

141156.005

120083.021
141156-007
1411X6-001
129074-004

343495

141173.008
141156-004

152292

120175.022
139656-001
142644

120090-021

VW---

Figwe 6-7. Mechanical Linkage

SECTION VII. CORRECTIVE MAINTENANCE

7-1.

OVERVIEW. This section

maintenance of the Rosemount PP814T Power
Positioner. If specific cause of a 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 pat number and
ordering information.

7-2.

PARTS REPLACEMENT.

a. pilot

Valve.

Use the following procedure to

replace the pilot valve.

describes corrective

1.

Remove power positioner from service.

2.

Carefully hold upper end of pilot valve stem
(4, Figure 7-1) with a 5/16 inch open end
wrench. Free connecting link (1) from pilot
valve stem by turning lower connecting link
ball socket nut counterclockwise.

3.

Tag and disconnect air supply connector (9)
from elbow (8). Tag and disconnect exhaust
connector (12) from connector (11).

4.

Remove nuts (6) and lock washers (7) that

secure pilot valve (2) to pilot valve manifold
(5). Remove pilot valve body and cork

gasket (3) from pilot valve manifold.

5.

Using a sharp putty knife, prepare gasket

surface of pilot valve manifold (5) and pilot

valve (2)

for new cork gasket by removing

any old gasket material or dirt. Use a clean

shop towel and solvent to clean gasket

surfaces.

6.

Install pilot valve with new cork gasket

(3), securing with nuts (6) and lock

washers (7).

7.

Connect air supply connector (9) to elbow
(8). Connect exhaust connector (12) to
connector (11)

Carefully hold upper end of pilot valve

8.

stem (4). Attach connecting link (1) to
pilot valve stem by turning lower
connecting link ball socket nut clockwise.

9.

Return power positioner to service.

ITEM DESCRIPTION

1 Connecting Link
2 Pilot Valve
3 Cork Gasket
4 Pilot Valve Stem

Pilot Valve Manifold

5
6 Nut
I Lock Washer

8 Elbow
9 Air Supply Connector 250892

10 Reducing Bushing 120145-012
11 Connector 120020-008
12 Exhaust Connector 252592

Figure 7-1. Pilot Valve Replacement

b. Air Filter. Regularly inspect disposable filter 3. Remove air filter sump (2) by removing

elements as needed according to plant air cap nut (3) and cap nut gasket (4) on top

supply quality. If filter element needs to be of air filter. Save cap nut gasket for
replaced, new elements are available from the installation.
factory. Use the following procedure to
replace the filter element. 4. Remove used filter element (5) by

grasping and pulling it downward.

PART NUMRRR
1191-021
243384

8015.023
236195
342693

120032-005
120114-004

120017.021

1. Remove power positioner from service. 5. Install new filter element (5)

2. Open air filter drain valve (1, Figure 7-2) 6. Install air filter sump (2) onto body. Secure
and bleed any air pressure and moisture sump with cap nut (3) and cap nut gasket
remaining in the system.

(4).

ITEM DESCRIPTION

1 Drain Valve

2
3 Cap Nut
4 Cap Nut Gasket

5 Filter Element
6 Filter Housing

Sump

Figure 7-2. Air Filter

1.

Remove power positioner from service.

2.

Disconnect signal connector (3, Figure 7-3)

from elbow (2) and remove elbow.

3.

Remove bolts (1) securing diaphragm cover

(4) to diaphragm housing (11).

4.

Remove zero balance spring (5) from top of

thrust plate (6).

5.

Carefully hold upper end of pilot valve stem

(17) with a 506 inch open end wrench. Free
spring connecting link (10) from pilot valve
stem by turning lower connecting link ball

socket nut counterclockwise.

6.

Remove thrust plate (6), diaphragm (7) and
connecting link (10) from the diaphragm
housing (11).

I.

Open supply air shutoff valve and check for
leaks.

8.

Return system to service.

e. Diaphragm and Calibration Spring. Use the

following procedure for replacement of the
receiver diaphragm and replacement of the
calibration spring. If replacing the diaphragm
only, skip steps 7 and 12. If replacing calibration
spring only skip steps 8 through 11.

I.

Remove calibration spring (14) through tip
of diaphragm housing (11).

8.

Remove connecting link (10) from
diapbmgm (7) by turning upper ball socket
nut counterclockwise.

9.

Disassemble diaphragm assembly by
removing nut (9) from thrust plate (6).

Separate diaphragm (7), diaphragm seat (8)
and thrust plate.

-

I

9

N"f

10

Connecting Link

11

Diaphragm Housing
12
13
14
15
16
17
18
19

20
21
22
23
24
25
26
27
28

120036-003

120121-1924025

5015-007

142733
141161-006
142720

236795

139656.001

5015.015
342686

129074-005
142033
120090-016
142705
120083-013
320088-056
120114-007
120032-010

Figure 7-3. Receiver Exploded View

lx-102-208

7.4

10. Assemble new diaphragm (7) with
diaphragm seat (8) and thrust plate (6).
Secure in place with nut (9).

11. Screw connecting link (10) upper ball socket
nut into thrust plate (6) stud.

12. Ensure spring washer (15) is in bottom of
spring nut cup (16) and install new

calibration spring (14).

13. Place diaphragm assembly and connecting
link in diaphragm housing so connecting link

(10) is aligned with pilot valve stem (17).

14. Align the Edges of diaphragm (3 with the
diaphragm housing (11) to make an air tight seal.

15. Place zero balance spring (5) over thrust
plate (6).

2. Disconnect connector (18, Figure 7-4) from
tee (20).

3. Loosen nut (2) and remove screw (4) and
washer (3) from spring nut (1).

4. Hold exhaust blocking valve link (9, Figure

6-5) with a screwdriver and remove nut (38,
Figure 7-4). Remove. exhaust valve link.

5. Remove air lock stop bolt (43), washer (42)

and nut (25).

6. Remove screw (24) securing shaft bearing

(23) to bottom end of worm shaft (48).

7. Remove screws (41) securing clapper lever
(40) from couplings (32).

8. Swing clapper lever (40) out of the way

16. Making sure the diaphragm (7) is not folded
or pinched, replace diaphragm cover (4) and

align sealing edge of diaphragm cover on
top edge of diaphragm.

17. Secure diaphragm cover (4) with bolts (1).
Tighten all bolts hand tight. Tighten bolts
down making sure that all are tightened
WS”lY.

18. Connect connecting link (10) to pilot valve
stem (17) with lower link ball socket nut.

19. Reinstall elbow (2) and signal connector (3).

20. Test for air leakage around diaphragm cover
(4) and diaphragm housing (11). Use a leak
detector such as “Snoop”, and send an air
signal to power positioner. If leak is
detected, repair as necessary.

21. Refer to Section IV and calibrate power
positioner.

22. Return power positioner to service

d. Air Lock Diaphragm. Use the following

procedure for replacement of the air lock
diaphragm.

1. Remove power positioner from service

9. Remove screws (34) securing diaphragm
plate (33) to diaphragm chamber (22) and
remove diaphragm plate.

10. Pulling on coupling (32), remove diaphragm
assembly from diaphragm chamber (22).

11. Remove coupling (32) from diaphragm stud
(29). Separate diaphragm stud, diaphragm
(30) and shield (31).

12. Assemble new diaphragm (30) with stud
(29) and shield (31). Secure together with

coupling (32).

13. Place diaphragm assembly in diaphragm

chamber (22) and

(33).

14. Swing clapper lever (40) over diaphragm

and install screws (41) into couplings (32). !

15. Attach shaft bearing (23) to worm shaft (48)

with screw (24).

16. Install air lock stop bolt (43), washer (42)
and nut (25).

17. Install exhaust blocking valve link through

frame and clapper lever. Install nut (38) on
exhaust blocking valve link.

install diauhragm plate

_ - -

I

\

\

\

;>

/

/

/

/

47

,’

/

/

Figure 7-4. Air Lock Diaphragm

LEGEND FOR FIGURE l-4

ITEM DESCRIPTION

1 Spring Nut
2 Nut
3

4

5

Washer 120197.003

SCEW

Nut 120032-010

PART NUMBER

140903
120036-003

174306

6 Washer 120114-007
7

Spring Bracket 242647
8 Seal 141173-010
9 screw 120093.058

10
11

screw 120094-012

SW%

120088-003
12 Valve. Bracket 141176.003
13 Transfer Valve 141187
14 Washer 120110-006
15 Nut 120032-005
16 Adapter 120020-007
17
18 Co”“ector

Elbow 120117-003

125368.009

19 Supply Aii Co”“ector 252588

20 Tee 120019-015
21 Co”“ector

125368.007
22 Diaphragm Chamber 342376
23 Bearing 141168-008

24

SW34

120090.079
25 Nut 120036-002
26 Plug 120042-002

27 Wotm Guide 142646
28 Stud 141168-006
29 Stud 141168-005
30 Diaphragm 9351-003
31 Shield 141168-004

32 Coupling 141168-003
33 Diaphragm Plate 242406
34

SIXU

120088-031
35 set screw 120083.014
36 Spring Co”“ector 140904
37 Nut 120036-002
38 Nut 120033-002
39

SC”%

140905

40 Clapper Lever 357720

41

SC*eW

120088.084
42 Washer 1200197.010
43 Stop Bolt 120090-052
44 Pivot Pin 157704
45 SCEW 120088-034
46

SC*.%

120088-036
47 Spring 140895
48 Worm Shaft 341156.001
49

Sc*WJ

120088-056
50 Nut 120032-008
51 Nut 120032-008
52 Co”nector 252592

18.

Connect air lock spring nut (1) with screw
(4) and washer (3). Tighten nut (2) against
spring nut.

19.

Connect connector (18) to tee (20).

20.

Adjust air lock spring tension.

Apply supply air pressure of 30 psi to

(a)

positioner.
Move transfer valve to manual

(b)

position.

Loosen nut (2, Figure 7-4) by turning

(cl

counterclockwise and tighten screw (4)
until clapper lever is held closed by
spring (47). Tighten nut (2).

Move transfer valve to automatic

(4

position. If clapper lever does not

open, loosen nut (2) and decrease
spring tension with screw (4) until

clapper lever is fully open. Tighten ““t

(2) against spring nut (1).

21.

Return power positioner to service.

e. Cylinder Head Gaskets. Piston and Rod

paeking. Use the following procedures to

replace upper and lower cylinder head gaskets,
cylinder piston cup and rod packing. If not
replacing piston and rod packing, skip steps 10
through 16. If replacing piston, complete entire
procedure.

1. Remove power positioner from service.

2. Shut off supply air valve and set signal air
pressure to 0 psig.

3. Bleed residual air from cylinder by
loosening upper and lower cylinder head air
connections.

4. Disconnect cylinder upper hose from upper
cylinder head and cylinder lower hose from
lower cylinder head.

5. Remove set screw (1, Figure 7.5) securing
cylinder lever to clevis pin.

,' fY----z

1

/

Figure 7-5. Cylinder Exploded View

Eslo*-208

7-8

ITEM

1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18

19
20
21
22
23
24
25
26
27
28
29
30
31

LEGEND FOR FIGURE 7-5

DESCRIPTION PART NUMBER
set screw 120083-021
Cylinder Lever 342375
Clevis 242370
Clevis Pin
Grease Fitting
Gland Cap Screws 120093.023
set Screw
Gland Cap 142367

Rod Packing 2831A92HOl

Female Adapter
V-Ring Packing 2831A94HOl
Rod Packing Male Adapter 2831A93HOl
Nut
Upper Cylinder Head 242407
Piston Rod 242369
Nut 120032-012
Washer 120114-008
Bearing Block 142645

screws 120088-125
Gasket 141279
Elbow 120017-020
Cylinder Connector 250891
Upper Piston O-Ring
Piston Follower 342371
Lower Piston O-Ring 120039.032
Piston 241282
Stop Nut 129074.006
Cylinder 242405
Cylinder Stud 243252
Gasket 141279
Lower Cylinder Head 342372
Nut 120032-012

146009
139656-001

120083-022

120032-012

120039.016

8

Remove nuts (15) and washers (16) from
screws (18) securing cylinder bearing blocks
(17) to frame assembly. Remove cylinder
from frame assembly. Remove cylinder
bearing blocks from upper cylinder head
(13).

9,

Remove nuts (12) from cylinder studs (28)

securing upper cylinder head (13) to lower
cylinder head (30). Pulling on cylinder clevis
(3), pull piston assembly and upper cylinder
head o”t of cylinder (27). Remove and
discard upper cylinder bead gasket (19).
Remove lower cylinder head (30) and
discard lower cylinder head gasket (29).

10.

Remove gland cap screws (6) securing gland
cap (8) and move gland cap up piston rod.
Remove and discard old rod packings (9, 10
and 11).

11.

Remove stop nut (26) securing piston
assembly to piston rod (14). Remove piston
assembly from piston rod.

12.

Wipe piston rod (14) and inside of cylinder
(27) with clean shop cloth and spray with a
light coat of dry film lubricant (molybdenum
disulfide spray lubricant).

6. Remove cylinder clevis pin (4) and move
cylinder lever (2) out of the way.

7. Support cylinder assembly with 2 x 4 inch
board long enough to provide leverage. This
will prevent it from falling to floor when
cylinder bearing block nuts are removed.

13.

Place gland cap (8) over piston rod so top of

gland cap faces cl&s (3). Pack new rod

packing female adapter (9), V-ring packing

(10) and rod packing male adapter (11) with
MoS,-793 and carefully place over piston
rod in order shown in Figure 7-5.

14.

Insert piston rod (14) into upper cylinder
head (13) from top of cylinder head.

15.

Carefully press new rod packing components

(9, 10 and 11) into opening in upper

cylinder head (13). Secure gland cap (8) to

cylinder head with gland cap screws (6).

16. Insert new upper piston O-ring (22) into
piston follower (23). Screw piston follower
on piston rod (14). Insert new lower piston
o-ring (24) into bottom side of piston
follower. Place new piston (25) on piston
rod with machined side of piston toward
piston follower. Secure piston assembly to
piston rod with stop nut (26). Pack concave
area of piston seal with McLube M&,-793.

17. Using a putty knife, prepare gasket surfaces
of cylinder (27) and cylinder heads (13 and

30) for new gaskets by removing any old
gasket material or dirt. Wipe with a clean
shop towel.

detector, such as “Snoop”, and send an air
signal to power positioner. If leak is

detected, repair as necessary.

25. Calibrate power positioner stroke; refer to
Section N. Return power positioner to
service.

f. Cylinder Replacement. To replace the

assembled cylinder with a new cylinder follow
the procedures outlined in paragraph 7-2.e,
Cylinder Head Gaskets, Piston and Rod Packing.

Steps 1 through 9 cover cylinder removal, and
steps 17 through 2.5 provide installation
procedures.

18. Place new upper cylinder head gasket (19)
on upper cylinder head (13). Place new
lower cylinder head gasket (29) on lower
cylinder head (30).

19. Install upper cylinder head (13) and piston
assembly onto cylinder (27). Install lower

cylinder head (30) on cylinder.

20. Secure upper cylinder head (13) to lower
cylinder head (30) with cylinder studs (28)

and nuts (12).

21. Place cylinder bearing blocks (17) onto
upper cylinder head (13). Place cylinder
assembly in frame assembly and secure
cylinder bearing blocks to frame assembly
with scwxs (18), washers (16) and nuts

(13.

22. Insert end of cylinder lever (2) into slot of
clevis (3).

23. Align holes in clevis (3) with hole in
cylinder lever (2). Drive clevis pin (4) in

securing clevis to cylinder lever. Tighten

cylinder lever set screw (1).

24. Open supply air valve. and test for air
leakage around cylinder head. Use aleak

g. m. Use the following procedure to replace cam.

1. Remove power positioner from service.

2. Remove screws (16, Figure 7.6), washers
(15) and cam (14) from cam mounting
bracket (12).

3. Place new cam (14) against cam mounting
bracket (12). Secure in place with screws
(16) and washers (15).

4. Refer to Section IV and calibrate power
positioner.

5. Return power positioner to service.

ITEM

1

2

3
4
5
6
I

8
9

10
11

12
13
14
15

DESCRIPTION PART NUMBER

Tube Sleeve 141193
Shaft 441157
Shaft Bushing 177488
spacer 2829A77H03
Grease Fitting 139656.001
Sector Gear 341183
SCEW 14090s

Key
Cylinder Lever 342375

=Y
SCC%V 120090-101

Bracket 242730
SCK?W 120090-016
CZ3lll 342136
Washer 120197-008

141201-006

141201.006

Figure 7-6. Shaft Exploded View

ITEM

16
17
18

19 SCEW 120090-1638075
20
21
22 Clevis 243914
23 Linkage Lever 342648
24
2s SCRW 120088-033
26 Spring Screw 174306
27 Washer 120197-008
28
29

DESCRIPTION PART NUMBER

SCreW 120090-011

Cam

Shoe

cam cap 6292ASSHOl

Retaining Ring 120079-012
Cl&s Pin 174358.004

SCWV

Spring Bracket 242647
Felt Gasket 141173.006

6292A89H02

120090-101

h. Shaft Bush&. Use the following procedure to

replace shaft bushings.

1. Remove power positioner from service. Set
signal air to zero.

2. Move transfer valve to automatic position
and prop air lock clapper lever open.

3. Remove screws (7, Figure 7-6) securing
sector gear (6) and remove sector and key
(8) from shaft (2).

4. Remove screws (11) securing cylinder lever
(9) and remove cylinder lever and key (10)

from shaft.

5. Remove screw (24) securing linkage lever

(23) and remove linkage lever from shaft.

6. Remove screws (13) securing cam mounting

bracket (12) and remove cam mounting
bracket from shaft.

7. Remove screws (19) securing limit switch

cam shoes (17) from cam caps (18) and
remove cams from shaft.

8. Pulling one end of shaft (2), remove shaft
from bushing blocks and remove spacer (4).

NOTE

Bushings are secured to stand assembly with
a coating of Loctite applied to the outside of
bushings. Insertion of new bushings and
complete b~~taUation of shaft assembly must
be completed before Lo&e sets. This is
needed to line up bushings properly. The
Loctite will set in approximately 3 minutes.
Complete instzdlation of shaft assembly
within 15 minutes from when adhesive was
applied.

11. Apply Loctite primer (llNA7901A30), to
outside surface of shaft bushing (3) and

allow primer to set for three to five minutes.

12. After primer has set 3 to 5 minutes, apply
Loctite adhesive #680 and slide shaft
bushing (3) in bushing block within three
minutes.

13. Insert shaft (2) through both bushing blocks
to align bushings.

9. Remove grease fitting (5) from bushing
block.

10. Break Loctite seal by pounding on shaft
bushing (3). Remove shaft bushing from
bushing block.

14. Allow Loctite to set for 15 minutes. Remove
shaft (2) and drill 506 inch hole into new
shaft bushing (3) through bushing block.

15. Insert shaft (2) through both bushing blocks
and spacer (4) as shown in Figure 7-6.

16.

Install limit switch cam shoes (17) and cam
caps (18) on shaft (2) with screws (19).

17.

Position can mounting bracket (12) on shaft
so mark at tip of cam aligns with center of
follower arm roller bearing. Tighten cam
mounting bracket SCIWS (13).

18.

Install linkage lever (23) with screw (24).

19.

Install cylinder lever (9) with key (10) and

screws (11).

Install sector gear (6) with key (8) and

20.
sixews (7).

Remove prop from clapper lever.

Remove transfer valve knob from transfer

valve.
Remove screws (9, Figure 74) and dust cover.
Remove supply air connector (19) from

elbow (17). Remove elbow from transfer

valve (13).

6.

Remove connector (18) from adapter (16).
Remove adapter from transfer valve (13).

7.

Remove screws (10) securing transfer valve
(13) from valve bracket (12) and remove
V&X.

Refer to Section VI and lubricate power

21.
positioner shaft bushings.

22.

Refer to Section N and calibrate power
positioner.

23.

Return power positioner to service

i. Transfer Valve. Use the following procedure to

replace the transfer valve.

1. Remove power positioner from service.

2. Close supply air shutoff valve.

8.

Install adapter (16) and elbow (17) in new
transfer valve. Install new valve on valve

bracket

9.

Connect air supply connector (19) to elbow

with screws (10).

(17). Connect connector (18) to adapter (16).

10.

Open air supply shutoff valve and test for
leakage around transfer valve with a leak
detector such as “Snoop”.

11.

Reinstall top cover and screws (9). Install
transfer valve knob.

12.

Return power positioner to service.

ITEM

1
2
3

4

5
6

7

8

9

10

DESCRIPTION
I/F Inlet Piping

Up Outlet Piping
SCXCWS
Signal Leads
screws
Regulator Inlet

Piping

Regulator Outlet

Piping
Mounting Bracket
J/F Convetter
Filter/Regulator

PART NUMBER

1

988SA31HOl

4SOSC21GOl

Figure 8-1. Current to Pneumatic Converter and Regulator Replacement

~8-lo2-208

8-O

SECTION VIII. OPTIONS

s-1.

OVERVIEW. This section of the manual provides
service information on the 8 x 14 power positioner
standard options. These options include Electric
Positioner Transmitter (EF’T), Current to Pneumatic
(I/P) Converter, Limit Switches, and
Heater/Thermostat.

8-2.

ELECTRIC POSITION TRANSMITTER. For
information on the EF’T for PP814T Power Positioner,

refer to IB-102.208A, Field Retrofit Kit Electric

Position Transmitter.

8-3.

CURRENT TO PNEUMATIC (I/P>
CONVERTER AND REGULATOR.

a. UP Adiustment. Refer to Section 4-3 and

calibrate converter.

b. I/P Replacement. Use the following procedure

for replacement of the current to pneumatic (VP)

signal converter.

5.

Remove screws securing signal leads (4)
from I/P screw co”“ectors. If screw
connectors are not installed on I/P, remove

I/p pigtails from screw connectors.

6.

Remove screws (3) securing old I/P
converter from frame and discard IK.

I.

Install new I/P to same mounting location
securing with screws.

8.

Connect signal leads.

9.

Attach I/P inlet piping (1) and I/P outlet
piping (2) to respective ports on I/P.

10.

Open supply air valves and test for leaks
“sing “Snoop” type leak detector.

11.

Refer to Section 4-3 and calibrate I&‘.

12.

Rehnn power positioner to service.

c. Regulator Replacement.

1, Remove power positioner from service.

2. Turn electrical signal transmitter off and
make sure no voltage or carrent is being
applied to the I/P.

3. Bleed off air pressure through connection of
I/P inlet piping (1, Figure 8-l) to I/P
converter (9).

4. Remove I&’ inlet piping (1) and I/P outlet
piping (2) from I/P.

1. Remove power positioner from service.

2. Shut off air supply to regulator.

3. Slowly bleed off pressure from both sides of
regulator and remove regulator inlet piping

(6, Figure 8-l) connector and regulator
outlet piping (7) connector.

4. Remove screws (5) securing regulator from
mounting bracket (8) and remove old
regulator.

5. Install new regulator on mounting bracket

with screws (5).

6. Attach regulator inlet piping (6) connector

and regulator outlet piping (7) connector to
appropriate ports on regulator.

7. Open supply air valves and test for leaks

“sing “Snoop” type leak detector.

8. Adjust regulator and calibrate positioner.

9. Return positioner to service.

I

d. Regulator Adiustment.

1. Remove positioner from service. Disconnect
electrical power from I/p converter.

2. Using adjusting knob on top of regulator,

adjust pressure until pressure gauge on

regulator reads 20 to 22 psi.

3. Connect electrical power to IIF converter.

engages upper limit switch (4), secure. cam
assembly (2) against shaft (3) with screws

(1).

5. Loosen screws (5) securing lower limit
switch cam assembly (6) to shaft (3).

6. Use manual operator wheel to position
linkage lever to lower lit stopping
position.

4. Return power positioner to service

8-4. LIMIT SWITCH.

a. Adiustment.

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

Move

transfer valve to manual position.

2. Loosen screws (1, Figure X-2) securing
upper limit switch cam assembly (2) to shaft

(3).

3. Use manual operator wheel to position

linkage lever to desired upper lit stopping
position.

4. Rotate upper limit switch can in

counterclockwise direction when viewed

from left of positioner. When cam shoe

7. Rotate lower limit switch cam assembly (6)
in counterclockwise direction when viewed
from left of positioner. When cam shoe
engages lower limit switch (7), secure cam
assembly (6) to shaft (3) with screws (5).

b. Replacement.

1. Remove power positioner from service.

2. Close supply air shutoff valve. Disconnect
electrical power from positioner.

3. Disconnect limit switch wires from terminals
1 through 8 on buses 2 and 3 in junction

box.

4. Remove nuts (9, Figure 8-2) from studs (8)
and remove studs.

5. Remove lower limit switch (7) and upper
limit switch (4) from bracket.

6. Install new switches on bracket with studs

(8) and nuts (9).

7. Route wires “long same. path as old limit
switches, Connect wires from new switches

to terminal buses 2 and 3 according to

Figure 8-2.

8. Restore electrical power to positioner. Open
supply air shutoff valve.

9. Refer to Section 8-4.a and adjust limit

switches. Return power positioner to service.

B-102-208

8-2

!TEM DESCRIF-TION

1
2 Cam Assembly
3 Shaft
4 Upper Limit Switch
5 SCEWS
6 Cam Assembly
I Lower Limit Switch

8 Stud

9 Nut

10 Nut
11 Washer

screws

PART NUMBER

120090.1633075
6296A90
441157-001
7362C69GO3

120090-1633075
6292A90
7362C69GO3

24-28

VDC

1

2 3 4 5 6 7 8 9 10 1112

N.O. NC.

N.O.

NC. LNG

4-20 MA

II

TB-2

TB-3

PWm5

Figure 8-2.

Limit Switch Exploded View

0%102-208

8-3

8-5. JIEATERPTHEXMOSTAT.

a. Heater Replacement.

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

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

2. Remove terminal cover screws (7, Figure
8-3) and terminal cover (8). Remove

thermostat lead (9) from terminal 1 on
terminal block (12).

3. Remove screws (17) and heater socket (16)

from mounting plate (10). Remove
thermostat lead (15) from heater socket

4. Remove screws (1), lock washers (2), nuts
(4) and thermostat (3) from frame.

5. Install new thermostat (3) with screws (1),

lock washers (2) and nuts (4) on frame.

6. Connect thermostat lead (9) to terminal 1 on

terminal block (12).

2. Remove heating element (18, Figure 8-3)
from heater socket (16) by turning
counterclockwise.

3. Install new heating element (18) into socket

(16).

4. Return power positioner to service

b. Thermostat Replacement.

7. Connect thermostat lead (15) to heater
socket (16) and reinstall heater socket with

screws (17).

8. Install terminal cover (8) with screws (7).

9. Restore electrical power and return
positioner to service.

ITEM DESCRIPTION

1 screw 120093-009 4

PART NUMBER

2 Lock Washer 120114-002
3 Thermostat 153408
4 Nut 120032-004

5 Lock Washer 120114004
6
I
8

9
10
11
12
13

screw
screw

120093-009

120092.1432063
Terminal Cover 114656
Thermostat Lead 181268.162222

Mounting Plate 157030

Terminal Marker Strip
Terminal Block

SCEW

143650.006

181403
120092-1432044

17

1

14 Wire Terminal 157458-001
15 Thermostat Lead 181268-162222
16 Heater Socket 256996
17 screw 120092-1632063
18 Heating Element 153407-001
19 Nut 120032.005

Figure 8-3. Heater/Thermostat Replacement

7

SECTION IX. RECOMMENDED SPARE PARTS

Table 9-1. Recommended Spare Parts for PP814T 8 x 14 Power Positioner.

FIGURE and PART

INDEX No. NUMBER

DESCRIPTION

7-5, 22

l-5, 22

6-6, 14
6-6, 16
6-2, 20
6-6, 8
6-2, 14; 7-1, 3

l-3, I; 6-3, 5
l-4, 30

6-6, 16

6-6, 8

l-4, 30

7-5, 22

l-5, 24

6-6, 14

6-2, 14; 7-1, 3

6-5, 9

l-3, 14
7-6, 12

l-5, 21
7-1, 9; 6-2, 8
7-3, 3
6-2,

11

7-6. 14

7.1, 2

7-5, 23
6-2,

1; 7-1, 1

lA97803GO2

lA97803GO4
lA97803GO5
lA97803G06
lA97803G07
lA97803G08
lA97803G09
lA97803GlO
lA97803Gll
lA97863GOl

183512
243384
342371
7791-021

Spare Parts Kit 8 x 14 Power Positioner

O-ring (120039-016)
O-ring (120039-032)
Gasket (141173.005)

Gasket (141279)
Piston (241282)
Diaphragm (2831A28HOl)
Rod Packing Parts (2831A95GOl)
Cork Gasket (8015-023)
Diaphragm (9351.002)
Diaphragm (9351.003)

Spare Parts Kit 8 x 14 Power Positioner

Piston (241282)

Spare Parts Kit 8 x 14 Power Positioner

Rod Packing Parts (2831A95GOl)

Spare Parts Kit 8 x 14 Power Positioner

Diaphragm (9351-003)

Spare Parts Kit 8 x 14 Power Positioner

Gasket (141173.005)

Spare Parts Kit 8 x 14 Power Positioner

2-211 Buna-n-Rubber O-ring (120039-016)

Spare Parts Kit 8 x 14 Power Positioner

O-ring Buna-n-Rubber #2 (120039-032)

Spare Parts Kit 8 x 14 Power Positioner

Gasket (141279)

Spa Parts Kit 8 x 14 Power Positioner

Cork Gasket (8015.023)

?.eplacement Kit PP814T

Bulletin (I%102.208)
Service Bulletin (SB-102-208-A)

Link (141181-005)
Valve Assembly (142682)
Calibration Spring (142733)
Bracket (242730)
Cylinder Connector (250891)
Air Supply Connector (250892)
Signal Connector (250893)
Exhaust Connector (252592)

Cam(342736)
8 x 14

Compensator 3-15 (442738.007)
3mse, MO,-793 4 lb/can
Pilot Valve
Piston Follower
lonnecting Link

3

15

16

75

50

50

25

50

1
1
1
1
1
1

2

1
1
1
1
1

I

Table 9-2. Spare Parts for Options (PPS14T 8 x 14 Power Positioner Only).

FIGURE and

INDEX No.

8-3, 18
8-3, 3
8-3, 16

8-2, 4 and 7
8-1, 9

S-1, 10

Table 9-3, BiB of Material for PP814T 8 X 14 Power Positioner, includes part numbers and descriptions
that are keyed to Figure and Index Number references. This listing provides information on all basic
PP814T power positioner parts with the exception of hardware.

PART

NUMBER

153407-001

153408
256996
7362C69GO2
7362C69GO3
9885A31HOl
27543 l-007
4505C21GOl
SKI-63580

DESCRIPTION
Heating Element

Thermostat
Heater Socket 1
Electric Position Transmitter
Limit Switches 2
Current to Pneumatic (VP) Converter 1

F’ressure Gauge
Filter Regulator

Check Valves

Diaphragm Valves 2

2.2 Ft. Tank 1
Pressure Switch

Solenoid Valve Mounted and Piped

NOTE

QTY

1
1

1

1
1

2

1
1

Table 93. Bill of Material for PP814T 8 x 14 Power Positioner.

FIGURE and

INDEX No.

6.6, 14;
6-6, 6; l-5,
6-6, 16; 7-5, 25
6-6, 15; l-5, 14
6-6, 4; l-5, 3
6-6, 17; l-5, 27

6-6, 9; l-5, 13
6-6, 18; 7-5, 28
l-5, 9
l-5, 11
l-5, 10
l-5, 23
l-5, 30
6-6, 12; 7-5, 17

1.6, 2; 8-2, 3

l-6, 17-19
l-5, 2; 7-6, 9
l-6, 12
7-6, 14
7-5, 4
7-6, 23
7-6, 22
7-6, 21
7-6, 1
7-1,9

7-3, 3

7-4, 22
7-4, 33
7-4, 30
7-4, 29
7-4, 31
7-4, 40
7-4, 44

6-5, 14
6-5, 13

6-5, 17
6-5, 6
6-5, 7
6-5, 4
6-5, 5
6-5, 8
7-6, 4
7-6, 6
7-4, 47
7-4, 1
7-4, 13
7-4, 12

7-5,

19

8

PART

NUMBER

543383 Stand Assembly

141279 Gasket

142367 Gland Cap
241282
242369 Piston Rod
242370
242405
242407
243252
283lA92HOl
283lA93HOl Male Adapter
283lA94HOl
342371

324312

142645

441157-001 Shaft
6292A90G02 Call3

342375 Cylinder Lever
242730
342736

146009 Clevis Pin
342648 Linkage Lever
243914

174358-004

141193 Tube Sleeve

250892

250893

126198

126172
342316
242406
9351-003

141168-005 Stud
141168-004

357720

157704
141181-003
141181-002 Pin
142616 Fulcrum Block
140914
142675

283lA30HOl

142674
283lA29HOl
2829A77HO3

341183

140895
140903
141187

141176.003 Valve Bracket

DESCRIPTION

Piston

Clevis
Cylinder
Cylinder Head Assembly
Cylinder Stud
Female Adapter

V-Ring Packing
Piston Follower
Lower Cylinder Head
Bearing Block

Bracket
CEllll

Clevis
C&is Pin

Air Supply Connector

Signal Connector

Serial Number Plate
Name Plate
Diaphragm Chamber
Diaphragm Plate
Cupped Diaphragm

Shield

Clapper Lever

Pivot Pin

Valve Lever

Spring
Thrust Plate
End Cover
Gasket
Exhaust Valve Body

SPZiCCX

Sector Gear

Air Lock Spring

Spring Nut

Transfer Valve

QTY

1

2

1
1

I

1
1
1

4

1
1

2

1
1

2

1
1
1
1
1
1
1
1
1
1

1
1
1

1
2
2
2
2
2

1

1

1

1
2

1
1
1
1
1
1
1 ’
1

1
1 ~
1

1

IB-102-208

9-3

Table 9-3. BiB of Material for PP814T 8 x 14 Power Positioner (Continued).

FIGURE and PART

INDEX No. NUMBER

DESCRIPTION

QTY

l-4, 1

7-4, 27
6-7, 16
6-7, 22
6-7, 19
6-7, 5
6-7, 11

6.7, 2
6-7, 1
6-1, 4
6-7, 9
7-4, 23
l-4, 19
6-2, 26

6.5, 1
l-4. 8

7-6. 29

l-4, 21
l-3, 22

7.3, 20
7-3, 11
6-2, 15
l-l,3
6-2, 17
6-2, 21
6-2, 22
6-2, 23
6-2, 20
7-1, 2
l-3, 16
l-3, 24
7-3, 10
l-3, 13
l-3, 14

l-3, 14
7-3, 14

7-3, 8
7-3, 6
7-3,

5

7-3, 4

7.3,

1

242641

142646

343495

142644
152292
141156-003

141156.005
141156-006
152371
141156-002
141156-001

141168.008
252588
252590
252592

141173-010
149904-001
149904-002

343994.001

141173~035

141173.006

141173-009
349918

143234

125368.007

142033
342686
342731

144981.001

8015.023

342693
283lA29HOl

142675
283lA3OHOl
283lA28HOl
243384

142720

142705

7791.021

5015-007

142132

(142733 shown)

142733
161149

(142733 shown)

142129
142680

175464348
242687
9351-002

Spring Bracket
Worm Guide
Handwheel
Handwheel Shaft Block
Sprocket Shaft
Worm Shaft Block
Pin
Worm Sprocket
Collar
Block
Worn Shaft
Bearing
Supply Air-Transfer Valve. Connector

Connector

Pilot Valve-Exhaust Valve Connector

SGII
Right Side Cover
Left Side Cover
Top Cover
Gasket

Felt Gasket

Felt Seal

Cover Assembly

Indicator Disc

connector

Bearing

Follower Arm

Diaphragm Housing

Stud

Cork Gasket

Pilot Valve Manifold

Body

Thrust Plate

End Cover

Diaphragm

Pilot Valve

Spring Nut Cup
Shaft
Connecting Link
Trunnion Ring
Calibration Spring 0-15#

Calibration Spring 0-3&Y
Calibration Spring 3-15#

Diaphragm Seat
Thrust Plate
Zero Balance Spring
Diaphragm Cover
Diaphragm

1
1
1
1
1

2

1
1
1
1
1

2

1
1
1
1
1
1
1
1
2

4

2
1
1
1

1
1

4

1
1
1
1
1
1
1
1
1
1

1
1

1
1

1
1
1
1
1

IB-102-208

9-4

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 Office or Representative before
returning the equipment. Equipment must be
returned with complete identification in

accordance with Rosemount instructions or it will

not be accepted.
In no event will Rosemount be responsible for

equipment without proper authorization and
identification.

b. Carefully pack defective “nit 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.

d. Enclose a cover letter and purchase order and

ship the defective equipment according to
instructions provided in Rosemount Return
Authorization, prepaid, to:

American
Rosemount Analytical Inc.

RMR Department

1201 N. Main Street

Orrville, Ohio 44667

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 standad Rosemount warranty, the defective
unit will be repaired or replaced at Rosemount’s
option, and an operating unit will be returned to
the customer in accordance with shipping
instructions furnished in the cover letter.

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

I8-102-208

lo-l/lo-2

APPENDIX A. LINKAGE INSTALLATION FOR EITHER A

CHARACTERIZED FLOW CONTROL DEVICE, OR A LINEAR FLOW

CONTROL DEVICE.

Linkage installed for a characterized flow control device will
result in rapid flow changes near the closed position. A
linear flow control device will provide linear changes in flow
in relation to changes in control signal.

Characterized flow control device results from linear linkage

and linear power positioner. Linear flow control device
results from characterizing linkage or from characterizing
power positioner.

Linkage described is l-l/Z inch diameter pipe.

A-l. LINKAGE INSTALLATION FOR A

CHARACTERIZED FLOW CONTROL

DEVICE.

DRIVEN

LEVER

DAMPER

LINKAGE

a. Measure length of driven lever (R,) on &vice to

be controlled (Figure A-l).

b. Attach the linkage clevis to the power

positioner’s drive lever so that distance R2 is
equal to R,.

c. Close damper of device being controlled to

minimum flow position.

d. Measure angle (l3,) of device’s driven lever from

vertical center line.

e. Install power positioner’s drive lever so its angle

(0,) is the same as the device’s driven lever @,).

f. Measure distance (@) between drive and driven

levers connection holes. Allowing for cl&s
length, cut pipe to tit this measurement. Install
clevises.

g. Install linkage pipe between drive and driven

levers. Check for freedom of movement by
operating power positioner’s handwheel. Make
minor adjustments to linkage length by turning
linkage ClwiS titting in or out as necessary.

CLEWS

DRIVE

LEVER

POSITIONER

Figure A-l. Linear Linkage Design

A-2. LINKAGE INSTALLATION FOR A LINEAR

FLOW CONTROL DEVICE. 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 required at start of power
positioner movement, characterize the linkage system.
This is covered in step a. below.

If this additional starting torque. is not required, a
linear linkage can be installed. The power positioner
cam must be shaped to characterize power positioner.

This is

covered

in step

b.

NOTE

NOTE

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

positioners.

a. Characterized Linkage System.

1. Make Sue. a linear cam is installed to get
linear outputs from power positioner.

2. Figure out how far vertically the operating
lever travels using Figure A-2 and the
following equation:

E

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

R, = Length of drive lever (from shaft

center to clevis pin center) measured
in inches.

e1 = Total angular rotation of drive lever.

If power positioner is at full stroke,
tbk measurement is So”.

PI = Angular measurement of drive lever

from vertical centerline with piston
fulIy extended.

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

-Sine Function (SIN)

-Square Function (x’)
Use the following procedure to determine Y,

the vertical distance travelled by drive lever:

Figure A-2. Vertical Arm Travel

(a) Add value of 8, to value of PI.

(b) Divide answer from step (a) by 2.0.

(c) Enter answer from step (b) and press

sine. key (SIN).
(d) Press square key (x2).
(e) Multiply answer from step (d) by

length of drive lever (R,).
(f) Multiply answer from step (e) by 2.
(g) Write down answer from step (f) and

label it (f) for use later on.
(h) Clear calculator.

(i) Enter value of &.
(j) Press sine key (SIN).

(k) Divide answer from step (j) by 2.0.

(1) Press square key (usually key marked

9).

(I”) Write down answer from step (1) and

label it (1).
(n) Clear calc”lator.
(o) Enter value marked (f) and subtract

value marked (l),
(p) The value in step (0) is equal to

vertical distance travelled by drive
lever “y”.

3. Figure out angular rotation of driven lever.
This is done in terms of drive lever rotation.
The. angular rotation follows Figure A-3 and
the relationship:

NOTE

The following known values are used to
calculate the total angular rotation of the
driven lever; Or

8, =

Total angular rotation of the drive
lever. If power positioner is at full
stroke, this measurement is So”.

R, =

Length of the drive lever (from shaft

center to clevis pin center) measured

in inches.

R2 =

Length of the driven lever (from

shaft center to clevls pin center)

measured in inches.

Angular measurement of drive lever

PI =

from vertical centerline with piston

fully extended.

Angular measurement of driven lever

P, =

from verticzd centerline with damper
fully closed.

Figure A-3. Driven Shaft Angular Rotation

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

-Sine Function (SIN)

-Inverse Sine Function (SIN-I) or

-Square Function (x2)

-Square Root Function (-fx)
Use the following procedure to determine

e*, the angular rotation of the driven lever.

Add value of & to value of 8,.
Enter answer from step (a) and press

sine key (SIN).
Divide answer from step (b) by 2.0.
Multiply answer from step (c) by

length of driven lever (RJ.

(e) Write down answer from step (d) and

label it (d). Clear calculator.

(fl Enter value for length of drive lever

W.

(2) Clear calculator.
(aa) Enter value for p>
(ab) Divide value from steep (aa) by 2

(g) Divide value from step (f) by value

marked (d).
(h) Press square. key (x2)
(i) Write down answer from step (h) and

label it (h) for use later.
(i) Clear calculator.

(k) Enter value for /3, and press sine key

WV.
(1) Divide answer from step (k) by 2.
(“I) Press square key (x2)

(n) Write down answer from step (m) and

label it (m) for later use.

(a) Enter value for pz and press sine key

(SW
(p) Divide answer from (o) by 2.

(ac) Write down answer from step (ab) and

label it (ab). Clear calculator.
(ad) Enter value from step (x).
(ae) Subtract value from step (ab).

(at) Multiply answer from step (ae) by 2.
(ag) The value in step (af) is equal to total

angular rotation of driven lever ‘V2”.

4. Figure o”t length of connecting linkage
based on length of drive lever, driven lever,

and the initial offset of both. Use Figure A-4
and the following relationship:

NOTE

(4) Press square key (x2),
(I) Write down answer from (q) and label

it (q) for later use.
(s) Clear calculator.
(t) Enter value marked (h),
(u) Subtract value marked (m) from value

marked (h).
(v) Add value marked (q) to step (u).
(w) Press square root function key (Jx,.
(x) Press inverse sine @NV SW or SIN’).
(y) Write down answer from step (x) and

label it (x).

The following known values are used to
calculate the length of the linkage in inches;

“Q”.

L = Length between drive and driven

shaft center lines, measured in inch­es.

R, = Length of the drive lever (from shaft

center to clevis pin center) measured
in inches.

R2 = Length of the driven lever (from

shaft center to clevis pin center)
measured in inches.

PI = Angular measurement of drive lever

from vertical center line with piston
fully extended.

PI = Angular measurement of driven lever

from vertical center line with damper
fully closed.

(a) Clear calculator.

(b) Enter value for PI and press cosine

key (COS).

(c) Multiply answer from step (b) by

length of drive lever (R,).

(d) Write down answer from step (c) and

label (c).

(e) Clear calculator.

(f) Enter value for PI and press cosine

key (COS).

DRIVE

LEVER

POWER

POSITIONER

RECORD SETUP DIMENSIONS AND ANGLES USED:
PI-”

82-O

_ INCHES

.!

Rl­Rx-

INCHES
INCHES POWll

Figure A-4. 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 (x2)

-Squax Root Function (Jx,

(g) Multiply answer from step (f) by

length of driven lever (RJ.

(h) Write answer from step (g) down and

label (8). Clear calculator.

(i) Add anwer from step (h) to value

marked (c).
(i) Press square key (x2)
(k) Write down answer from step (i) and

label (i).

(1) Clear calculator.

(m) Enter distance between drive and

driven shaft (L).

(n) Subtract value marked (i) from step

(“0.

(o) Write down answer from step (n) and

label (n).
(p) Clear calculator.
(q) Enter value for 0, and press sine key

(SW

(r) Multiply answer from step (q) by

length of drive lever (R,).

Use the following procedure to determine P,

the length of connecting linkage in inches:

BlOZ-208

(s) Write down answer from step (r) and

label (r).

A-5

(t) Clear calculator.
(u) Enter value for PI and press sine key

mv.

(v) Multiply answer from step (u) by

length of driven lever (RJ.

(w) Write down answer from step (v) and

label (v). Clear calculator.

(x) Subtract value marked (v) from value

marked (r).

(y) Add answer from step (x) to value

marked (n).
(z) Press square root function key (Jx).
(aa) The value in step (z) is equal to length

of connecting linkage “0 “.

Design linkage system by using values for

lengths of drive and driven levers, angular

position of both levers from vertical

(offsets), and distance between drive and

driven levers centers to calculate length of
linkage.

CLEVIS -1

POWER

POSITIONER

5. Close damper to minimum flow position.
Make sure driven lever is at angle (PJ and
drive lever is at angle (PI).

6. Cut linkage pipe to length (0) allowing for
both clevises. Attach clevises and install
linkage between operating levers.

I. Check for freedom of movement by

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

b. Characterized Power Positioner.

1. Measure full travel of device being
controlled from full open to full closed.

Record maximum and minimum positions.

Figure A-5. Characterized Linear Linkage Design

2. Install Linear Linkage.
(a) Measure length of driven lever (R,) on

device to be controlled (Figure A-5).

(b) Attach clevis to drive lever so that

distance R2 is equal to R,.

(c) Close damper of device being

controlled to minimum flow position.

(d) Measure angle (0,) of device’s driven

lever from vertical center line.

(e) Install power positioner’s drive lever so its

1

angle. from vatical center line (0,) is
equal to device’s driven lever angle @,).

(f) Measure distance (0) between drive

and driven levers connection holes.
Allowing for clevis length, cut pipe to

fit this meamrement. Attach clevises.

(g) Install linkage pipe between drive and

driven levers. Check for freedom of
movement by
positioner’s handwheel. Make minor

adjustments to linkage length by
turning linkage clevis fitting in or out
as necessary.

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

operating power

Table A-l. System Flow Chart.

INPUT ACTUAL FLOW

SIGNAL (%) (scfm)

0%
20%
40%

60%
80%

100%

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 A-l.

5. Near bottom edge on a sheet of graph paper,
draw a baseline (Graph 1) 10 blocks long.
Label “% Flow”.

PERCENT

FLOW (%)

r

L

4. Copy “System Flow Chat” (Table A-l.
Measure and record actual flow of system
starting at 0% input signal to power

100

90

80

70

60

%Pu”:

SIGNAL 5o

0 /

BASE LINE

0 20 40 60 80

6. Starting at left edge of baseline, draw a
vertical line 10 blocks long. Label this line

“% Input Signal”.

% CAM

ROTATION

100

% FLOW

Graph 1

% CAM

ROTATION

EASE LINE

0 20 40 60 60 100

Graph 2

RECORD POINTS
IN TABLE 2-Z

BASE LINE

0 20 40

% FLOW

Graph 3

IB-102-208

A-8

60

60 100

Pwo3!3

7.

Starting at right edge of baseline, draw a
vertical line 10 blocks long. Label tbis line

“% Cam Rotation”.

8. Scale. “% Input Signal” line by marking
baseline 0%. Mark 10% point one block
upward. Continue labeling in 10%
increments up to 100%.

13.

From point in step 12, draw a vertical line
downward to meet curve X.

14.

From point in step 13, draw a horizontal line
to “% Cam Rotation” scale.

15.

Repeat process from step 12 through step 14
for 20% to 90% input signal.

9. Scale baseline by marking left end 0%.
Mark 20% point two blocks to right
horizontally. Continue labeling in 20%
increments up to 100%.

16.

Value of “% Cam Rotation” is read where
line in step 14 intersects “% Cam Rotation”
scale. Estimate value by using percentage
scale on left edge of graph. Copy Table A-2
and record values in % Cam Rotation in

10. Plot points on graph (Graph 2) with data
from system flow chat (Table A-l). For

blank column and again in Table 4-1

Characterized column for future reference.
example: Using Table A-l in Graph 2, at a
20% input signal, percent of flow is 35%;
follow 20% input signal line until it

17.

Make a copy of Figure A-6, Cam Shaping.
intersects 35% flow line; place a mark at
tbis point. Repeat this procedure for 40%,
60%, SO%, and 100% input signals, placing

18.

Plot points from Table A-2 on copy of cam

Refer to example in Figure A-7.
marks at each intersection with
corresponding flow line. Connect these
points with a smooth curve starting at a
point with zero % flow and zero % input

19.

Set compass for 0.4375 inch radius and draw

0.875 inch circles using points plotted in

step 18 as cemer.
signal. Label curve X.

20.

11. Draw a straight line from zero point on
curve X to 100% point on curve X. Label
this line curve Y.

Draw a smooth curve

circles that are on same side as cam’s
mounting holes. This is shape of new cam

contour. Make several copies for future

connecting edges of

reference.

12. From 10% increment on “% Input Signal”
scale, draw a horizontal line to curve Y 21. Cut out paper cam leaving new cam contour,
(Graph 3). mounting hole, and slotted hole.

Table A-2. Cam Rotation Points.

Example: Record Values from step (p):

% INPUT SIGNAL % CAM ROTATION

0

10

20
30
40
50
60
70
80
90

100

18.102-208

% INPUT SIGNAL

0

10

20
30
40
50
60
70

80

90

100

A-9

% CAM ROTATION

I I I I I

A-6. Cam

Figure A-7. Characterized Cam Example

22. Line up mounting and slotted holes of paper
cam to mounting and slotted holes of meral
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 curve until no
ridges or imperfections are felt on edge of
curve.

23. 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.

24. Record power positioner characterized action
in Table 4.2, schedule “D”. Use the
following procedure:

(a) Set signal air to O%,

@) Measure distance from top of packing

washer to bottom of cl&s head.

(c) Increase signal air to 10%.
(d) Measure distance from top of gland

cap to bottom of clevis head. Subtract
value in step 2. Record this value as
piston movement in inches for 10%

signal air in Table 4.2.

(e) Repeat steps (c) and (d) for 20% to

90% in 10% increments.

(f) Divide actual distance traveled at each

signal by total distance traveled to
determine percent of full stroke. Enter
percent traveled at each signal in
percent of full stroke column.

APPENDIX B. ELECTRIC POSITION TRANSMllTER FOR

8 INCH x 14 INCH POWER POSITIONER

SECTION I. DESCRIPTION

The Rosemount Electric Position Transmitter Field Retrofit position of the potentiometer to a low level DC current
Kit is designed for installation on the Rosemount 8 x 14 which can be read on a DC milliammeter. The amplifier
Torque Type Power Positioner. It transmits the position of can be set to indicate “zero” with the piston extended or
the piston rod through a mechanical linkage to a
potentiometer. The electric position transmitter converts the

SECTION II. CALIBRATION

retracted.

B-l. AMPLIFIER CALIBRATION.

a. If the zero point of the positioner is with the

piston fully retracted, jumpers Pl and P2 should
be in the Jl and 53 positions. If the zero point is
with the piston fully extended, then move the

jumpers to J2 and 54 position (Figure B-l). The

EFT cover must be removed to access the

jumpers.

SPANn n EE

tu”&-J -

l’ ‘II-I lH----- I-1

111

/-

NOTE

Electric Position Transmitter units are
preset at the factory for reverSe operation
ljumpers in the JUJ4 position).

b. Refer to Figure B-2 for a typical EPT wiring

diagram.

c. Remove two plug buttons (1, Figure B-2) from

the top of the transmitter case.

1 CONFIGURATION CHART 1

JUMPER 1 DIRECT 1 REVERSE

PI Jl
P2 J3

J2

J4

Figure B-l. Jumper and Adjustment Location

NOTE

An ammeter may be connected in series for
amplifier calibration to verify position
indicating meter is giving accurate readings.

With the amplifier power supply on, move power

d.

positioner shaft to zero position. Tune zero

adjustment (as labeled on amplifier cover) until
ammeter indicates 4 mA.

e. Move the power positioner to the opposite end of

its stroke and hme the span adjustment (as
labeled on amplifier cover) for a reading of
20 mA.

f. Replace two plug buttons (1, Figure B-2) in EPT

case.

g. Install power positioner cover and secure with

screws removed at disassembly

POSITION -

INDICATOR

(4-20

mA

AMMETER)

t

+

ITEM DESCRIPTION

1 Button Plugs

2 Amplifier Cable
3 Terminal Block
4 Pan Head Screw

4

3
2 BLACK (-)

WHITE (+)

ITEM DESCRIPTION

5 Lock Washer
6 Terminal Marker

I Terminal Cover
8 Pan Head Screw

Figure B-2. EPT Wiring Installation

2

J/

IB-102-208

B-2

SECTION III. PARTS LIST

ITEM DESCRIPTION

1 EPT
2 spacer
3 screw

4 screw

5 SCiXW
6 Washer
7 Nut
8 Lever Blade
9

10 Mounting Bracket
11 screw
12 Lockwasher

Hex Link

ITEM DESCRIPTION

13 Nut
14 Position Transmitter Bracket
15 screw
16 Clamp
17 SCIW
18 Lockwasher
19 Nut

20 Lever Assembly

21 Positioner Floor Stand
22 Existing Cap Screws
23 Existing Colla Clamp

Figure B-3. EPT Assembly

Table B-l. EPT Retrofit Kit Part No. 7362C69GOL

F’IGURR and PART or

INDEX No. DRAWING No. DESCRIPTION

QTY

B-3, 1 4511C68GOl Electric Position Transmitter
B-3, 2 2832A86HOl
B-3, 3 120103.1932075
B-3, 4 120103.1632025
B-3, 5 120103-1932100
B-3, 6 220197.002
B-3, 7 120033.007 Nut
B-3, 8 7305A21HOl

B-3, 9 172833.001 Hex Link
B-3, 10 7362C62HOl
B-3, 11 120088-3816063 screw
B-3, 12 120114.006 Lockwasher
B-3, 13 120082-008
B-3, 14 7362C63401 Position Transmitter Bracket
B-3, 15 120088-3118100 screw 1
B-3, 16 6292A94HOl

spacer 2

SCE%V
SCKW

SCRW

Washer 1

Lever Blade 1

Mating Bracket 1

Nut 2

Clamp 1

1

1

2

1

2

1

2
2

1

I

B-3, 17 7OOOlOAJ8H screw
B-3, 18 70520ALlOK
B-3, 19 120032-17 Nut
B-3, 20 9884A39HOl Lever Assembly

183504-002
B-l, 1 lB1403.008 Terminal Block
B-l, 2 7OOOlDAJ2P
B-l, 3 7052OALlOF Lockwasher
B-l, 4 143650.005
B-l, 5 114656.005 Terminal Cover
B-l, 6 70OOlDAJ2T

Lockwasher 4

Cable Clamp (Not Illustrated) 4

Pan Head Screw 2

Terminal Marker 1

Pan Head Screw 2

Table B-2. Recommended Spare Parts.

PART or DRAWING No.

4844B27HOl
4516D67GOl

I

Potentiometer, 10 K
Amplifier PC Assembly

4

4

1

1

2

1

DESCRIPTION I

INDEX

This index is an alphabetical listing of parts, tams, and
procedures having to do with the Hagan Model PP814T
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 Adjustment, 6-6
Air Lock Operation, Description, l-l
Air Piping Schematic, 2-4
Air Supply Requirements, 2-3
Automatic Operation, Description, 1-3

B

Bill of Material, 9-3

Bypass Valve, Description, 1-2

C

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

Cam Shaping, A-9
Characterized Cam Example, A-l 1
Clevis, Description, 1-2
Corrective Maintenance, 7-l
Corrective Maintenance, Air Filter, l-2
Corrective Maintenance, Air Lock Diaphragm, 7-5
Corrective Maintenance, Cam, 7-10

Corrective Maintenance, Calibration Spring, 7-3

Corrective Maintenance, Cylinder, 7-10
Corrective Maintenance, Cylinder Head Gaskets, 7-7
Corrective Maintenance, Diaphragm, 7-3
Corrective Maintenance, Pilot Valve, 7-1
Corrective Maintenance, Piston, 7-7
Comctive Maintenance, Rod Packing, l-7

Colrective Maintenance, Shaft Bushings, 7-12

Corrective Maintenance, Transfer Valve, 7-13
Current to Pneumatic Signal Converter, Air Supply, 2-4

Current to Pneumatic Signal Converter, Calibration, 4-5
Current to Pneumatic Signal Converter, Description, 2-4
Current to Pneumatic Signal Converter,

Electrical Connections, 2-4
Current to Pneumatic Signal Converter, Replacement, 8-1
Cylinder Head Gasket Replacement, 7-7
Cylinder Replacement, 7-10

D

Diaphragm Replacement, Air Lock, 7-5
Diaphragm Replacement, Receiver, 7-3
Dust Cover, Description, 1-2

E

Electric Position Transmitter, B-l
Electrical Connections, B-2
Environmental Requirements, l-5

F

Flow Versus Position Formula, 2-l
Formula, Angular Rotation of Driven Lever, A-3
Formula, Linkage Length, A-4
Formula, Vertical Arm Travel, A-2
Foundation, Special Installation Considerations, 2-l
Foundation, Strength Requirements, 2-1

G

Gasket, Cylinder Head, 7-7
Gasket, Pilot Valve, 7-l
General Operation, Description, 1-3

H

Heater Replacement, 8-4

I

Installation, 2-1
Installation, Air Supply, 2-1
Installation, Linkage, 2-5
Installation, Power Positioner Mounting, 2-2
Installation, Special Considerations, 2-1

L

Limit Switch Adjustment, 8-2
Limit Switch Replacement, 8-2
Linkage Design, Special Installation Considerations, 2-l
Lubrication Chart. 6-2

M

Maintenance Schedule, 6-l
Manual Operation, Description, l-4
Maximum Aii Pressure, Cylinder, l-5
Mechanical Linkage, Cleaning and Inspection, 6-10
Model Number Matrix, l-2
Mounting, Foundation Design, 2-1
Mounting, Location Selection, 2-1
Mounting, Working Clearance Requirements, 2-l
Mounting and Installation (Footprint) Drawing, 2-2
Mounting Instructions, 2-2

N

NEMA Rating, 1-2

0

Options, 8-1

P
Paformance Requirements, l-5
Periodic Maintenance, 6-1
Periodic Maintenance, Air Filter, 6-S
Periodic Maintenance, Air Lock, 6-6
Periodic Maintenance, Cylinder, 6-8
Periodic Maintenance, Diaphragm, 6-5
Periodic Maintenance, General, 6-1
Periodic Maintenance, Pilot Valve, 6-3
Periodic Maintenance, Piston, 6-8
Periodic Maintenance, Storage, 1-6
Physical Characteristics, l-5
Power Positioner Torque, 1-5, 2-2

R
Recommended Spare. Parts, 9-l
Regulator (UP) Adjustment, 8-2
Regulator (I&‘) Replacement, 8-l
Returning Equipment to the Factory, 10-l
Reverse (Inverse) Operation, Description, 3-1
Reverse (Inverse) Operation, Procedures, 3-l

S

Signal Requirements, Input, l-5
Specifications, l-5

Stem (Pilot Valve), Cleaning, 6-3
Stem Illustration, 6-3
storage Instruction, l-5
Supply Air, Special Installation Considerations, 2-l
Supply Air Filter, Description, 1-2
Supply Air Shut Off Valve, 2-3

T

Thermostat Replacement, X-4
Torque Chart, 2-3
Troubleshooting, 5-l
Troubleshooting Chart, 5-l

V

Valve, Pilot, 6-3, 7-l

W

Wiring Codes, 2-1
working Clearance, 2-2

1194