Rosemount Analytical PowerVUE 8x14 Operating Manual

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Instruction Manual

IB-102-208P Rev. 1.1 November 2001

PowerVUE

Fan/Damper Actuator Torque Type 8 x 14 with Retrofit Kit Installation Instructions

http://www.processanalytic.com

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ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical repre-

sentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and mainte-

nance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate In- struction Manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without notice.

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

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HIGHLIGHTS OF CHANGES

Effective April, 2001 Rev. 1

PAGE SUMMARY

Throughout Added identity of DVC6000 series digital valve controller where applicable.

1-0 Reidentified digital valve controllers; deleted cam codes in Product Matrix.

1-2

1-3 Updated actuator operation paragraph and illustration for FIELDBUS versions

1-4 Added paragraph 1-5 to reference valve controller specifications.

1-5 and 1-6

2-3 Updated Figure 2-5 to include DVC6000 valve controller identity.

2-4 Updated Figure 2-6 to include dampers.

4-1/4-2 Revised paragraph 4-1 to confine instructions to DVC5000 versions only.

5-1/5-2

7-8

8-4 through 8-6 Added new text of paragraph 8-4, HART Site Programmable Alarm applicable to

I-1/I-2 Updated index.

Added new actuator operation paragraph and illustration for HART versions using DVC6020 model valve controller.

using DVC5020f model valve controller.

Deleted Table 1-3, DVC5000 valve controller specifications and moved balance of Section I text forward.

Revised paragraph 5-1 to reference valve controller manuals for troubleshooting and include new actuator piping diagram (Figure 5-1) for HART versions using DVC6020 model valve controller. Revised piping diagram (Figure 5-2) for FIELDBUS versions to save vertical space. Deleted paragraph 5-2 and Table 5-1.

Added new paragraph 7-8 and Figure 7-4; replacement of DVC6000 electronic unit.

the DVC6000 series controller.

Appendix B

PAGE SUMMARY

1-0 Revised Model Number Matrix.

Appendix A Included revised Appendix A, rev. 1.0.

Added new Appendix B; retrofit instructions to incorporate DVC6000 electronic unit.

Effective November, 2001 Rev. 1.1

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HIGHLIGHTS OF CHANGES

APPENDIX A

Effective November, 2001 Rev. 1.0

Page Summary

iii Added new Model Number Matrix, Table A-1.

iv Relocated Figure A-1 from page A-0 to page iv.

HIGHLIGHTS OF CHANGES

APPENDIX B

Effective November, 2001 Rev. 1.0

Page Summary

iii Added new Model Number Matrix, Table B-1.

iv Relocated Figure B-1 from page B-0 to page iv.

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PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the PowerVUE Fan/Damper

Actuator components, functions, installation, and maintenance.

This manual is designed to provide information about the PowerVUE Fan/Damper Actuator. We recommend that you thoroughly familiarize yourself with the Description and Installation sections before installing your actuator.

The description presents the basic principles of the actuator along with its performance characteristics and components. The remaining sections contain detailed procedures and information necessary to install and service the actuator.

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

DEFINITIONS

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

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

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

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

NOTE

NOTE TO USERS

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

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IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND

INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

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BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten, intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan 75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet moet een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd worden nadat de voedingsspanning werd afgelegd en enkel door getraind onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden door getraind onderhoudspersoneel nadat de voedingsspanning verwijderd werd. Sommige oppper-vlakken kunnen 45 minuten later nog steeds heet aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het handboek te raadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van devolgende standaards: EN61010-1, IEC417 en ISO3864.

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VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande. Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også følges i ikke EUlande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75° C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende kabelaflastning kan etableres.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsituation. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret servicepersonale, når forsyningsspænding er frakoblet. Visse overflader vil stadig være for varme at berøre i op til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i betjeningsmanual for instruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:EN61010-1, IEC417 & ISO3864.

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BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden. Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten te worden.

2. Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels /kappen en aardingen om reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven 75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een adequate verankering van de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats te vinden via een meerpolige automatische zekering (min.10A) die alle spanningvoerende geleiders verbreekt indien een foutconditie optreedt. Deze automatische zekering mag ook voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te voldoen aan een erkende standaard zoals IEC 947.

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder spanning voerende delen bevinden die gevaar op kunnen leveren. Deze beschermdeksels/kappen mogen uitsluitend verwijderd worden door getraind personeel als de spanning is afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het volgende symbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende standaarden: EN 61010-1, IEC 417 & ISO 3864.

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TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive) yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta, elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin paikoilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kunnolla kiinni.

6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min 10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös sisältyä mekaaninen erotuskytkin. Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai katkaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita käyt-töohjekirjasta

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta standardeista: EN61010-1, IEC417 & ISO3864.

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IMPORTANT

Consignes de sécurité concernant le raccordement et l’installation de cet appareil.

Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire aux directives concernant la basse tension. Les états non membres de la communauté européenne doivent également appliquer ces consignes sauf si elles sont en contradiction avec les standards locaux ou nationaux.

1. Un raccordement adéquat à la terre doit être effectuée à chaque borne de mise à la terre, interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre doivent être remis en place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d’alimentation électrique doivent être conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à 75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles afin d’assurer un serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à l’alimentation électrique doit être réalisé exclusivement au travers d’un disjoncteur (minimum 10A.) isolant tous les conducteurs en cas d’anomalie. Ce disjoncteur doit également pouvoir être actionné manuellement, de façon mécanique. Dans le cas contraire, un autre système doit être mis en place afin de pouvoir isoler l’appareil et doit être signalisé comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle IEC947.

7. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des tensions dangereuses sont présentes. Ces capots ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement par un personnel compétent.

8. Lorsque les équipements ou les capots affichent le symbole suivant, cela signifie que des surfaces dangereusement chaudes sont présentes. Ces capots ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement par un personnel compétent. Certaines surfaces peuvent rester chaudes jusqu’à 45 mn.

9. Lorsque les équipements ou les capots affichent le symbole suivant, se reporter au manuel d’instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des standards suivants: EN61010-1, IEC417 & ISO3864.

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WICHTIG

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller Erdverbindungen darf zu keinem Zeitpunkt gestört sein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75 °C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so gewählt werden, daß diese eine sichere Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über mindestens 10 A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die allgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw. unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde. Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis 45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei denen vor dem Eingriff die entsprechenden Kapitel im Handbuch sorgfältig durchgelesen werden müssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren der nachfolgend aufgeführten Standards: EN61010-1, IEC417 & ISO3864.

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IMPORTANTE

Norme di sicurezza per il cablaggio e l’installazione dello strumento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’Unione Europea, salvo quanto disposto dalle vigenti normative locali o nazionali.

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni ed esterni, dove previsti.

2. Dopo l’installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di protezione siano stati collocati e le messa a terra siano collegate. L’integrità di ciscun morsetto di terra deve essere costantemente garantita.

3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245.

4. L’intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un adeguato ancoraggio al cavo.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di alimentazione principale dovrà essere eseguita tramite interruttore automatico (min.10A), in grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi agli standard riconosciuti, quali IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica probabile presenza di elevati voltaggi. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio di contatto con superfici ad alta temperatura. Tali coperchi di protezione devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto alimentazione allo strumento. Alcune superfici possono mantenere temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano il simbolo, fare riferimento alle istruzioni del manuale Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti standard: EN61010-1, IEC417 e ISO3864.

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VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i EØSavtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert av lokale- eller nasjonale standarder.

1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres. Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en mekanisk operert bryter installert, må det være en annen måte å isolere utstyret fra spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate, er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45 minutter etter spenningsforsyning frakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til instruksjonsmanualen for instrukser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder: EN61010-1, IEC417 & ISO3864.

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IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.

As seguintes instruções de segurança aplicam-se especificamente a todos os estados membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE, deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de segurança e terras de protecção. Deve manter-se sempre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma temperatura ambiente até 75º C.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos os condutores de circuitos durante uma avaria. O disjuntor poderá também conter um interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma reconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a existência de tensões perigosas. Estas tampas só devem ser retiradas quando a energia eléctrica tiver sido desligada e por Pessoal da Assistência devidamente treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de existência de superfícies quentes. Estas tampas só devem ser retiradas por Pessoal da Assistência devidamente treinado e depois de a energia eléctrica ter sido desligada. Algumas superfícies permanecem quentes até 45 minutos depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de Funcionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das seguintes normas: EN61010-1, IEC417 e ISO3864.

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IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en aquellos terminales previstos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar las cubiertas de seguridad aasi como los terminales de tierra. Se debe comprobar la integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una temperatura ambiental de 75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma IEC 947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica peligrosa, dicho alojamiento solamente se abrira una vez que se haya interrumpido la alimentacion electrica al equipo asimismo la intervencion sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies con alta temperatura, por tanto se abrira una vez que se haya interrumpido la alimentacion electrica al equipo por personal entrenado para estas labores, y al menos se esperara unos 45 minutos para enfriar las superficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el manual de instrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas EN61010-1, IEC417 & ISO 3864.

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Page 18

VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.

Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så erfordras.

2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord återplaceras. Samtliga jordterminaler måste hållas obrutna hela tiden.

3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller IEC245.

4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC.

5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat kabelförankring.

6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och klart framgå genom markering. Säkring eller omkopplare måste överensstämma med en gällande standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för livsfarlig spänning i närheten. Dessa höljen får endast avlägsnas när strömmen ej är ansluten till utrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast avlägsnas av utbildad servicepersonal, när strömmen kopplats från utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45 minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör instruktionsmanualen studeras för information.

Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera

10.

av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

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Page 21

Section Page

I. DESCRIPTION........................................................................................................................... 1-1

1-1. Component Checklist of Typical System (Package Contents).........................................1-1

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

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

1-4. Model PVD 814 Specifications .......................................................................................1-4

1-5. Controller Specifications .................................................................................................1-4

1-6. Storage Instructions .........................................................................................................1-6

II. INSTALLATION........................................................................................................................ 2-1

2-1. Overview..........................................................................................................................2-1

2-2. Special Installation Considerations..................................................................................2-1

2-3. Actuator Mounting Instructions.......................................................................................2-2

2-4. Air Supply Installation.....................................................................................................2-3

2-5. Linkage Installation .........................................................................................................2-4

III. DVC5000/6000 ELECTRONICS SETUP ............................................................................... 3-1

3-1. Introduction......................................................................................................................3-1

IV. STARTUP CALIBRATION ..................................................................................................... 4-1

4-1. Reverse Relay Calibration (DVC5000 only) ...................................................................4-1

4-2. DVC5000/6000 Calibration.............................................................................................4-1

V. TROUBLESHOOTING ............................................................................................................. 5-1

5-1. Overview..........................................................................................................................5-1

VI. PERIODIC MAINTENANCE .................................................................................................. 6-1

6-1. Overview..........................................................................................................................6-1

6-2. Maintenance Schedule .....................................................................................................6-1

6-3. General Cleaning and Lubrication...................................................................................6-1

6-4. Cylinder and Piston Cleaning and Lubrication ................................................................6-2

6-5. Air Lock Adjustment.......................................................................................................6-4

6-6. Mechanical Linkage Cleaning and Lubrication...............................................................6-4

VII. CORRECTIVE MAINTENANCE ........................................................................................... 7-1

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

7-2. Cylinder Head Gaskets, Piston, and Rod Packing ...........................................................7-1

7-3. Cylinder Replacement......................................................................................................7-3

7-4. Air Lock Diaphragm........................................................................................................7-4

7-5. Transfer Valve .................................................................................................................7-4

7-6. Reverse Relay..................................................................................................................7-6

7-7. DVC5000 Electronic Unit ...............................................................................................7-7

7-8. DVC6000 Electronic Unit ...............................................................................................7-8

7-9. Shaft Bushings.................................................................................................................7-9

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Section Page

VIII. OPTIONS..................................................................................................................................... 8-1

8-1. Overview......................................................................................................................... 8-1

8-2. Limit Switches ................................................................................................................ 8-1

8-3. Heater/Thermostat...........................................................................................................8-3

8-4. HART Site Programmable Alarm (DVC6000 Series Controller only).......................... 8-4

IX. RECOMMENDED SPARE PARTS........................................................................................ 9-1

X. RETURNING EQUIPMENT TO THE FACTORY .......................................................... 10-1

INDEX

APPENDIX A. RETROFIT KIT INSTALLATION INSTRUCTIONS for use with DVC5000 Series

DIGITAL VALVE CONTROLLER

APPENDIX B. RETROFIT KIT INSTALLATION INSTRUCTIONS for use with DVC6000 Series

DIGITAL VALVE CONTROLLER

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LIST OF ILLUSTRATIONS

Figure Page

1-1 Typical System Package .........................................................................................................1-1

1-2 Actuator Operation Diagram - HART Versions using DVC6020 ..........................................1-3

1-3 Actuator Operation Diagram - F

1-4 Typical Actuator Installation ..................................................................................................1-4

2-1 Angular Relationship of Drive and Driven Arms ...................................................................2-1

2-2 Clearance Requirements .........................................................................................................2-2

2-3 Actuator Unit Mounting and Installation (Footprint) Drawing...............................................2-2

2-4 8 x 14 Actuator Torque Chart .................................................................................................2-3

2-5 Air Piping Schematic ..............................................................................................................2-3

2-6 Linkage Installation ................................................................................................................2-4

4-1 Reverse Relay Calibration ......................................................................................................4-1

5-1 Actuator Air Piping Diagram - HART Versions using DVC6020..........................................5-1

5-2 Actuator Air Piping Diagram - F

6-1 Lubrication Chart....................................................................................................................6-0

6-2 Cylinder Exploded View.........................................................................................................6-3

6-3 Air Lock Diaphragm...............................................................................................................6-4

6-4 Mechanical Linkage................................................................................................................6-5

7-1 Cylinder Exploded View.........................................................................................................7-2

7-2 Mechanical Air Lock and Transfer Valve...............................................................................7-5

7-3 Reverse Relay and DVC5000 Electronic Unit Replacement ..................................................7-6

7-4 DVC6000 Electronic Unit Replacement.................................................................................7-8

7-5 Shaft Exploded View..............................................................................................................7-9

8-1 Limit Switch Exploded View..................................................................................................8-2

8-2 Heater/Thermostat...................................................................................................................8-3

8-3 Timing Chart for Flame Safety Application ...........................................................................8-6

8-4 Wiring Diagram for Flame Safety Application.......................................................................8-6

OUNDATION

Fieldbus Versions using DVC5020f................1-3

Fieldbus Versions using DVC5020f ...............5-1

LIST OF TABLES

Table Page

1-1 Model Number Matrix ............................................................................................................1-0

1-2 Specifications for Model PVD 814 Actuator..........................................................................1-5

1-3 Specifications for Recommended Rust Preventative Compound............................................1-6

6-1 Maintenance Schedule ............................................................................................................6-1

9-1 Recommended Spare Parts for PowerVUE Model PVD 814 Fan/Damper Actuator..............9-1

9-2 Recommended Spare Parts for Options

(PowerVUE Model PVD 814 Fan/Damper Actuator Only) ...................................................9-2

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Table 1-1. Model Number Matrix

8 x 14 TORQUE TYPE FLOOR MOUNTED - ORDERING INFORMATION

Select complete model number from the Model Number Matrix.

PVD 814 PowerVUE Drive

Code Basic Assembly Type and Connection Material

01 Standard Brass Assembly

02 Standard Stainless Assembly

03 Mechanical Air Lock Brass Assembly

04 Mechanical Air Lock Stainless Assembly

Code Digital Valve Controller

(1)

None

(2)

HART

DVC6000

(3)

Fieldbus

DVC5020f, including Basic Control Suite

(3)

DVC5000f, without Basic Control Suite

Other DVC Style Selected

(4)

Code Limit Switches

01 None

02 2 Std. Limit Switch – SPDT

Code EPT

01 None

Digital EPT and 2 Limit Contacts (HART versions only)

Code Heater Option

01 None

02 Heater/Thermostat 115VAC 150 Watt (Not for use in hazardous areas)

PVD 814 01 02 01 01 02 EXAMPLE

NOTES:

1. Digital Valve Controller (DVC5000/6000) may be supplied by others, but no performance quarantees for accuracy or speeds

DVC5000/6000 Options:

Flameproof cable gland: ½” NPT (aluminum), EExd IIC

Cable entry adaptor (brass): ½” NPT M20 x 1.5 ISO of response are provided. Warranty for DVC5000/6000 will be the responsibility of the provider. Tubing is provided, but is not precut or preformed.

2. Standard arrangement calls for Model DVC6020-516G60, certified to FM as intrinsically safe, and Division 2. Other certifications available. Advanced diagnostics provided.

3. Standard arrangement calls for Model DVC5020f-216, certified to FM as intrinsically safe, and Division 2. Other certifications are available. Advanced diagnostics provided.

4. Designate other DVC5000 model number as a note on order.

5. Alarm.

Default configuration:

HART Filters

Filter Type Option Number

HF210 (cage clamp – normal) HF21N HF210 (cage clamp – reversed) HF21R HF220 (screw terminal – normal) HF22N HF220 (screw terminal – reversed) HF22R HF230 (tiered terminal) HF23 HF240 (DIN rail) HF24D HF240 (DIN rail – pass through – no filter) HF24DP

1 analog output representing actuator travel 3 customer selectable position contacts

1 contact for Field Device Failure Moore HART SPA may be configured in an intrinsically safe arrangement through an IS barrier.

(5)

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Page 25

SECTION I. DESCRIPTION

1-1. COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS). A typical

PowerVUE 8 x 14 fan/damper actuator package should contain the items shown in Figure 1-1.

1-2. MODEL NUMBER MATRIX. Use model

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

1-3. SYSTEM OVERVIEW.

a. Scope. This Instruction Bulletin supplies details

needed to install, operate, and service the PowerVUE 8 x 14 fan/damper actuator.

The standard actuator includes FIELDVUE DVC5000/6000 Series electronics, air lock

capability, transfer valve, supply air filter, clevis, and dust cover. Actuator options include digital electric position transmitter with 2 limit contacts (for HART versions only), limit switches, heater/thermostat, minimum limit stop, and a handwheel/hard mechanical air lock upon loss of plant air.

b. Actuator Features. The PowerVUE actuator is

usually equipped with the following features:

1. The DVC5000/6000 electronic controller is a two-wire instrument and is certified intrinsically safe. It is available with either HART or FOUNDATION fieldbus communications.

2. An optional handwheel/hard mechanical air lock system provides a means of manually changing the position of the controlled device (such as dampers, control valves, and inlet vanes). In the event of plant air loss,



continued operation of the actuator is made possible by the handwheel.

1. PowerVUE Model PVD 814 Actuator

2. Air Filter

3. Instruction Bulletin

NOTE: ILLUSTRATED WITH

OPTIONAL HANDWHEEL.

29330003

Figure 1-1. Typical System Package

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Page 26

Part of the option, a two-position transfer valve, allows simultaneous operation of the air lock, handwheel, and a pneumatic trip valve. In the manual position, the air lock and handwheel are engaged, and the trip switch opens a pneumatic bypass. In the automatic position, the air lock and handwheel are disengaged and the bypass is closed.

(a) The air lock allows the operator to

lock the piston and actuator shaft in any position. Moving the transfer valve to the manual position cuts off the air supply to the air lock diaphragms, allowing a fail-safe air lock to engage. When the transfer valve is in the automatic position, air pressure is returned to the diaphragms, causing the lock to disengage.

final control element (flow control damper, fan inlet vanes, ball valve, etc.).

d. Actuator Operation (HART Vesions using

DVC6020). Refer to the actuator operation dia-

gram in Figure 1-2. In a typical control system operation, the user’s process controller sends a 420 mA input signal directly to the DVC6000 electronic unit inside the actuator. The DVC6000 then positions the actuator according to the desired position indicated by the input signal by converting the input current signal to a pneumatic output pressure. The DVC6000 control sends the output air pressure to the top and bottom of the pneumatic cylinder locking the piston in place. As the actuator shaft rotates to its new position, a cam rotates against a feedback sensor on the DVC6000 electronic unit. The operating arm of the actuator is directly connected to the device control linkage through a clevis.

(b) Placing the transfer valve in manual,

or a loss of plant air pressure, will cause the trip valve to activate the pneumatic bypass, equalizing air pressure across the piston. Manual positioning of the controlled device is then possible.

3. The supply air filter will remove dispersed water or oil droplets from the supply air.

4. The clevis and pin provide a connection from the actuator to linkage, transferring the output arm movement to the device being controlled.

5. A dust and splash-proof NEMA Type 3 enclosure provides protection to the mechanics of the actuator and the DVC5000/6000 electronic unit.

6. The optional heater/thermostat helps prevent the moisture in the actuator air lines from freezing. With the heater/thermostat installed, the actuator can effectively oper-

ate in temperatures down to -10°F (-23°C).

1. Characterizable Outputs. Customized user configurable response modes may be incorporated into the DVC6000 electronic unit.

Refer to FIELDVUE



DVC6000 Series Digital Valve Controller Instruction Manual.

2. Direction of Rotation. The user can configure for direct or inverse acting rotation by switching air tubing on the top and bottom of the pneumatic cylinder.

3. Digital Communications. The DVC6000 valve controller uses 4-20 mA HART communication protocols. All information for setup and diagnostics is transmitted digitally via HART communications. A Rosemount 275 Handheld or similar communicator may be used or a laptop computer with ValveLink Software. Rosemount’s Asset Management Solutions (AMS) offers the ValveLink software as an optional “snap-on” application. Instruments may be accessed individually or multiplexed through an “Interchange” unit, providing continuous access to any number of Rosemount instruments.

c. General Purpose. The PowerVUE 8 x 14

actuator is used to accurately position the user’s

IB-102-208P

4. The actuator’s DVC5000 electronic unit, pneumatic, and mechanical drive devices are safely housed inside a NEMA Type 3 enclosure (dust cover).

1-2

Page 27

AUXILIARY

TERMINALS

DRIVE

SIGNAL

I/P

CONVERTER

TERMINAL

BOX

PRINTED

WIRING

BOARD

PNEUMATIC

RELAY

4–20mA

HART

INPUT SIGNAL

DVC6000

ELECTRONIC

UNIT

FEEDBACK

SENSOR

OUTPUT AIR PRESSURE

SUPPLY AIR

PRESSURE

CAM

Figure 1-2. Actuator Operation Diagram - HART Versions using DVC6020

ACTUATOR

SHAFT

35350001

CYLINDER

PISTON

e. Actuator Operation (F

OUNDATION

Fieldbus

Versions using DVC5020f). Refer to the ac-

tuator operation diagram in Figure 1-3. In a typical control system operation, the user’s process controller sends a fieldbus input signal directly to the DVC5000 electronic unit inside the actuator. The DVC5000 then positions the actuator according to the desired position indicated by the input signal by converting the input current signal to a pneumatic output pressure. The DVC5000 control sends the output air pressure

CAM

ACTUATOR

SHAFT

CYLINDER

FEEDBACK

SENSOR

SENSOR FOR

DIAGNOSTICS

PRESSURE

ADVANCED

AUXILIARY

TERMINALS

to the top of the pneumatic cylinder and the Fairchild reverse relay. The reverse relay then sends the appropriate inverse air pressure to the bottom to the pneumatic cylinder locking the piston in place. As the actuator shaft rotates to its new position, a cam mounted on the actuator shaft rotates against a feedback sensor on the DVC5000 electronic unit. The actuator shaft is connected to the operating arm on the outside of the actuator, which is connected to device control linkage through a clevis.

PRINTED

WIRING BOARD

I/P

4-20 mA

+ FIELDBUS

DVC5000

ELECTRONIC

SUPPLY AIR

PRESSURE

UNIT

INPUT SIGNAL

OUTPUT AIR

PRESSURE

PISTON

Figure 1-3. Actuator Operation Diagram - F

FAIRCHILD

REVERSE

RELAY

OUNDATION

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1-3

RELAY

35350002

Fieldbus Versions using DVC5020f

Page 28

1. Characterizable Outputs. Customized user configurable response modes may be incorporated into the DVC5000 electronic

unit. Refer to FIELDVUE



DVC5000 Series Digital Valve Controller Instruction Manual.

2. Direction of Rotation. The user can configure for direct or inverse acting rotation by switching air tubing on the top and bottom of the pneumatic cylinder.

3. Digital Communications. The DVC5000 controller uses F

OUNDATION

fieldbus communication protocols. All operator interface is via the host computer console. A handheld device will be available in the future.

DAMPERS

BLOWER

CLEVIS

AIR

FLOW

AIR FLOW

LINKAGE

Powe rVUE

ACTUATOR

4. The actuator’s DVC5000 electronic unit, pneumatic, and mechanical drive devices are safely housed inside a NEMA Type 3 enclosure (dust cover).

f. System Considerations. Prior to installation of

the PowerVUE 8 x 14 actuator, check that you have all components necessary to install the system completely.

Once you have verified that you have all components, select the mounting location. A typical installation is illustrated in Figure 1-4. Determine where the actuator will be placed in terms of serviceability, ambient temperatures, environmental considerations, and convenience.

Actuator operating specifications are listed in Table 1-2. For DVC5000/6000 digital valve controller specifications refer to the applicable Digital Valve Controller Instruction Manual. Refer to Section II, Installation, before installing the digital valve controller.

OPERATING

LEVER

AIR

FILTER

SUPPLY

AIR

29330004

Figure 1-4. Typical Actuator Installation

1-4. MODEL PVD 814 SPECIFICATIONS. Table 1-2

contains information about the Model PVD 814 actuator operating characteristics. Use the table to make sure that available conditions are suitable for the actuator before choosing the mounting location.

1-5. CONTROLLER SPECIFICATIONS. Refer to the

applicable DVC5000 or DVC6000 Series Digital Valve Controller Instruction Manual for controller specifications.

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Table 1-2. Specifications for Model PVD 814 Actuator

Signal Requirements

Control Signal Inputs.............................................................................................. 4-20 mA signal with HART or fieldbus

Performance

Positioning Repeatability......................................................................................................... +0.5% of full stroke or better

Full Stroke Time (unloaded) ......................................................................................................................................... 8 sec

Stall Torque ...................................................................................................................................... 4600 ft-lbs (6238 N·m)

Maximum Friction Load................................................................................................................... 1100 ft-lbs (1492 N·m)

Maximum Weight Load .................................................................................................................. 1600 ft-lbs (2170 N·m)

Maximum Load Capability of the Manual Operator ................................................................................... 45 psi (310 kPa)

Air Consumption .................................................................................................................................... 10 scfm steady rate

8-in. Stroke ......................................................................................................................................................... 80° rotation

Environmental Requirements

Ambient Temperature Limits ...................................................................................................... 0° to 120°F (-18° to 50°C)

140°F (60°C) with increased maintenance

Electronics

See DVC5000/6000 specifications in applicable Digital Valve Controller Instruction Manual

Air Supply Requirements

Maximum ........................................................................................................................................ 100 psig (689 kPa gage)

Minimum........................................................................................................................................... 45 psig (310 kPa gage)

Recommended ................................................................................................................................. 100 psig (690 kPa gage)

Fisher-Rosemount has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe. The PowerVUE actuator is a subcomponent of an actuating system, including user-provided items such as linkages, bearings, and dampers. The user must ensure that the entire actuating system is in conformity with the provisions of the European Machinery Directive EC Machinery Directive 89/392/EEC, as amended by Directive 91/368/EEC and Directive 93/44/EEC.

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Page 30

1-6. STORAGE INSTRUCTIONS. Use the following

)

guidelines for actuator unit storage.

a. Storage Environment. Store the actuator in a

warehouse environment that maintains the following conditions:

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

2. Relative humidity is below 80%.

b. Preparation for Storage.

Keep Tectyl 506 away from heat, sparks, and open flames. Use with adequate ventilation to cure and to prevent an explosive atmosphere from forming.

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

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

c. Storage Preventive Maintenance. If storing

the actuator unit for more than six months, use the following preventive maintenance guidelines.

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

2. If there is high humidity, place a bag of desiccant into the DVC5000/6000 electronic unit.

3. After removing the actuator from storage, clean and lubricate the unit before installation as follows:

(a) Perform general cleaning and lubrica-

tion per paragraph 6-3.

(b) Clean and lubricate the cylinder and

piston per paragraph 6-4 before installing the actuator.

Table 1-3. Specifications for Recommended Rust Preventive Compound

Approximate air dry time.................................................................................................................................................... 1 hou

Low Temperature Flexibility (90° bend with no flaking or cracking)................................................................. -10°F (-22.5°C

Volatile Organic Content (V.O.C.)................................................................................... 3.24 lbs/U.S. Gallon (400 grams/liter

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

ASTM (See Note 1)

B-117 at 1.3 mils (2 x 4 x 1/8 in. polished steel panels)......................................................................................... 200

DIN (See Note 2)

50021 at 32.5 microns (125 x 200 mm DIN 1623 panels)........................................................................................ 16

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

(2) DIN (Deutsche Industrie Normen)

IB-102-208P

1-6

Page 31

SECTION II. INSTALLATION

2-1. OVERVIEW. The actuator is designed to be in-

stalled upright. The floor stand is bolted to a prepared horizontal foundation. A minimum of 45 psig (310 kPa gage) to a maximum of 100 psig (689 kPa gage) supply air pressure is needed at the mounting location.

2-2. SPECIAL INSTALLATION

CONSIDERATIONS.

a. Foundation. The actuator’s torque is

transmitted to the operating arm of the device being positioned. This torque is also transferred to the actuator’s mass and foundation. To keep the actuator stationary, the foundation must be designed to handle the torque produced. Refer to paragraph 2-3 for detailed foundation requirements.

b. Supply Air. A supply air pressure of 45 to 100

psig (310 to 689 kPa gage), minimum of 2 scfm (0.056 m

/min), is required. An air filter is provided to remove dispersed water or oil droplets from supply air.

c. Linkage Design. Final control components

play a large part in a control system. Special characteristics of the device being controlled affect system response and must be regarded in design and setup of an actuator system. In a normal installation, most users install the linkage with both the drive arm and damper driven arm positioned so that both arms establish an approximate

right angle (90°) to the drive line at mid range of travel as illustrated in Figure 2-1. Refer to paragraph 2-5 for detailed information.

NOTE

The PowerVUE actuator may be set up to use only a portion of its total stroke. Refer to the FIELDVUE



DVC5000/6000 Series Digital Valve Controller Instruction Manual for customization information.

ARM

DRIVEN

90°

DRIVE

ARM

80°

LINKAGE

80°

29330018

Figure 2-1. Angular Relationship of Drive

and Driven Arms

IB-102-208P

2-1

Page 32

36.0

(91.4)

39.0

(99.06)

7.0

(17.8)

52.0

(132)

NOTES: 1. DIMENSIONS ARE IN INCHES WITH

CENTIMETERS IN PARENTHESES.

23.25 (59)

Figure 2-2. Clearance Requirements

2-3. ACTUATOR MOUNTING INSTRUCTIONS.

a. Working Clearance Requirements. Make sure

area is clear of obstructions that will interfere with actuator operation and maintenance. For a standard unit, allow an open area of 52 in. (132 cm) vertically from the foundation, 39 in. (99.06 cm) side to side, and 36 in. (91.4 cm) front to back (Figure 2-2). This will allow for handwheel operation, removal of the dust cover, and unit maintenance.

5.75

(14.6)

5.0

(12.7)

2. SHOWN WITH OPTIONAL HANDWHEEL.

5.19

(13.18)

3.10

(7.87)

23.25

(59.06)

15.19

(38.58)

28.3

(71.88)

13.19

(33.50)

11.00

(27.94)

5.7

(14.48)

29330001

2.19

(5.56)

7.0

(17.78)

b. Location Selection.

1. Select the location for the actuator as near to the device being controlled as possible. Ensure the necessary clearance for operation and maintenance, as specified in paragraph 2-3.a, is available.

2. Refer to Table 1-2 to ensure conditions are suitable for the actuator. Refer to the valve controller manual for environmental conditions required for the electronic unit.

c. Mounting Procedure.

1. Design and Manufacture of Foundation.

(a) Foundation must be able to withstand

at least 5500 ft-lbs (7458 N·m) torque plus 950 lbs (431.3 kg) actuator weight. Refer to Figure 2-3 for footprint dimensions of actuator. Use this footprint as a guide to design the foundation to match the base of the actuator.

NOTE: DIMENSIONS ARE

IN INCHES WITH CENTIMETERS IN PARENTHESES.

Figure 2-3. Actuator Unit Mounting and

Installation (Footprint) Drawing

SHAFT

ROTATION

10-57/64

(27.66)

LEVER AND

INDICATOR MAY BE LOCATED ON EITHER SIDE OF

MACHINE

STANDARD ROTATION

INCREASE OF

LOADING SIGNAL

(35.56)

STROKE

(17.78)

1-1/4 PIPE

THREAD

2.19

(5.56)

29330002

IB-102-208P

2-2

Page 33

(b) Mounting holes in the base are drilled

for 3/4 in. foundation bolts. Decide which foundation material is best suited for your application, steel or concrete, then design and manufacture required foundation.

2. Installation.

(a) Install actuator on foundation with

3/4 in. bolts and standard flat washers.

(b) Make sure actuator is level. Check by

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

mounting bolts and install shims between the actuator and foundation. Continue this process until the actuator is level when 3/4 in. mounting bolts are tightened. This will prevent distortion of the actuator stand.

120

(827)

100

(690)

(552)

(414)

(276)

(138)

SUPPLY AIR PRESSURE psig (kPa gage)

CONTROL

TORQUE

1000

0 2000

(1356)

MAXIMUM TORQUE REQUIRED Ft-Lbs (N·m)

(2712)

3000

(4068)

4000

(5424)

Figure 2-4. 8 x 14 Actuator Torque Chart

STALL

5000

(6780)

6000

(8136)

29330005

(d) If installed on a concrete foundation,

grout foundation with additional concrete to prevent distortion of the actuator stand.

2-4. AIR SUPPLY INSTALLATION. Refer to Figure

2-4 and match the torque load required 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 the 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 actuator will produce for a given supply air pressure before stalling out.

AIR

SHUTOFF

VALV E

USER'S SUPPLY

AIR 45-100 PSIG

(310-689 kPa GAGE)

Figure 2-5. Air Piping Schematic

a. Supply Air Requirements. Operating supply

air pressure range for the PowerVUE actuator is 45 to 100 psig (310 to 689 kPa gage).

b. Supply Air Connection. Basic schematic is

shown in Figure 2-5.

1. Mount bracket for air filter directly on the back of the stand assembly. If this position is unsuitable, mount air filter within 15 ft. (4.6 m) of the actuator.

NOTE

Prior to connecting the supply air line, purge air system until all moisture and debris are blown out.

ACTUATOR

THREADED

3/8 OR 1/4 IN.

AIR

FILTER

NPT FEMALE PIPING PORT

AIR INPUT MANIFOLD

TO TRANSFER VALV E

TO DVC5000/6000

ELECTRONIC UNIT

35350003

IB-102-208P

2-3

Page 34

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 actuator air input manifold. Fittings may be 3/8 in. or 1/4 in. NPT.

2-5. LINKAGE INSTALLATION. In a normal instal-

lation (paragraph 2-2), both the drive and driven arms establish an approximate right angle (90°) to the drive line when at mid-range of travel (Figure 2-1). Because of this, the “ruler/protractor method” for installing linkage is recommended. The linkage described is 1.5 in. (38.1 mm) in diameter. The

installation method is as follows. Refer to Figure 2-6.

a. Position both the drive and driven arms in the

mid-range position. The arms should be parallel to one another.

b. Connect the drive arm to the driven arm with

clevis, clevis pins, and an appropriate length of pipe.

c. Manually adjust the actuator to verify proper op-

eration of the device being controlled.

d. If it is necessary to make a minor length adjust-

ment to the linkage, turn the link pipe in or out at the clevis as required.

Figure 2-6. Linkage Installation

IB-102-208P

2-4

Page 35

SECTION III. DVC5000/6000 ELECTRONICS SETUP

3-1. INTRODUCTION. The DVC5000/6000 electronic

unit has been installed, set up, and calibrated at Rosemount. Additional tuning of the DVC5000/6000 may be required to fit particular applications.

A FIELDVUE DVC5000/6000 Series Digital Valve Controller Instruction Manual has been provided for additional information on the DVC5000/6000 electronic unit. Refer to the following sections in the valve controller instruction manual for specific information.

a. Electrical installation information is contained in

Section 2, Installation.

b. Initial Setup and Calibration, Section 4.

c. Detailed Setup, Section 5.

d. Calibration, Section 6.

e. Maintenance, Section 9.

f. Parts, Section 10.

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Page 36

Page 37

SECTION IV. STARTUP CALIBRATION

4-1. REVERSE RELAY CALIBRATION (DVC5000

only). The PowerVUE actuator uses a Fairchild

Model 25463 reverse relay. The reverse relay provides an output pressure which follows the equation P

= K - PS. Where PO is the output pressure, K is the

spring bias, and P DVC5000 electronic unit. Perform the following procedure to adjust the spring bias during calibration.

is the input pressure from the

CAP NUT

a. Manually position the actuator cylinder off its

end stops.

b. Adjust the supply air to the desired operating air

pressure. It is recommended that the air supply be adjusted to the level likely to be experienced during normal operation.

c. Remove the cap nut from the top of the reverse

relay, Figure 4-1.

d. Loosen the lock nut on the range screw.

e. Turn the range screw until the output gauge on

the DVC5000 reads 50% of the desired operating air pressure.

4-2. DVC5000/6000 CALIBRATION. Refer to the

FIELDVUE DVC5000 or DVC6000 Series Digital Valve Controller Instruction Manual for information on calibrating the DVC5000 or DVC6000 valve controller. Calibration information is contained in Section 6.

RANGE SCREW

LOCK NUT

FAIRCHILD

MODEL 25463

REVERSE

RELAY

29330019

Figure 4-1. Reverse Relay Calibration

IB-102-208P

4-1/4-2

Page 38

Page 39

SECTION V. TROUBLESHOOTING

5-1. OVERVIEW. Refer to the applicable FIELDVUE

DVC5000 or DVC6000 Series Digital Valve Controller Instruction Manual for troubleshooting the actuator electronics. Figure 5-1 shows an air piping diagram for actuators controlled with the DVC6000

SUPPLY

AIR

MECHANICAL AIR

LOCK (NOTE 1)

TRANSFER

VALV E

8 X 14

POSITIONER

CYLINDER

VALV E

ASSEMBLY

(NOTE 2)

4 2

TRIP VALV E

5 1 3

NOTES: 1. UPON LOSS OF AIR PRESSURE, THE TWO AIR LOCK DIAPHRAGMS

CONTRACT. THIS ALLOWS SPRING TENSION TO FORCE THE ENGAGEMENT OF THE MECHANICAL LOCK.

2. THE NUMBERS ON THE VALVE ASSEMBLY REPRESENT ACTUAL NUMBERS VISIBLE ON THE ASSEMBLY.

AIR

MANIFOLD

series valve controller. Figure 5-2 is the air piping diagram for actuators controlled with a DVC5000 series controller. Refer to the applicable diagram as an aid in troubleshooting pneumatic problems.

DVC6000

ELECTRONIC

UNIT

35350005

Figure 5-1. Actuator Air Piping Diagram – HART Versions using DVC6020

MECHANICAL AIR

LOCK (NOTE 1)

TRANSFER

VALV E

8 X 14

POSITIONER

CYLINDER

VALV E

ASSEMBLY

(NOTE 2)

NOTES: 1. UPON LOSS OF AIR PRESSURE, THE TWO AIR LOCK DIAPHRAGMS

4 2

TRIP VALV E

5 1 3

CONTRACT. THIS ALLOWS SPRING TENSION TO FORCE THE ENGAGEMENT OF THE MECHANICAL LOCK.

2. THE NUMBERS ON THE VALVE ASSEMBLY REPRESENT ACTUAL NUMBERS VISIBLE ON THE ASSEMBLY.

Figure 5-2. Actuator Air Piping Diagram – F

SUPPLY

AIR

MANIFOLD

OUNDATION

AIR

DVC5000

ELECTRONIC

UNIT

REVERSE

RELAY

35350006

Fieldbus Versions using DVC5020f

IB-102-208P

5-1

Page 40

Figure 6-1. Lubrication Chart

IB-102-208P

6-0

Page 41

SECTION VI. PERIODIC MAINTENANCE

6-1. OVERVIEW. This section describes preventive

maintenance for the PowerVUE Model PVD 814 Fan/Damper Actuator and common options. Preventive maintenance is necessary at specific intervals to reduce wear and tear on the actuator.

Before performing any maintenance or repair action on actuator, shut off supply air and any electronic signals to actuator. Isolate actuator from all systems connected to the actuator. Severe injury or death may result from large torque produced by actuator.

Clean actuator in a well ventilated area. Avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning solvent. Follow all instructions on the Material Safety Data Sheet (MSDS) of the solvent being used. Severe injury or death may result from improper use.

6-3. GENERAL CLEANING AND LUBRICATION.

Clean actuator’s exterior of all grease buildup with commercial dry cleaning solvent. To lubricate actuator, use McLube MoS

-793 or equivalent and refer

to Figure 6-1.

6-2. MAINTENANCE SCHEDULE. Use Table 6-1 as

a guideline for preventive maintenance. The frequency of maintenance varies directly with plant conditions and operational load. Extremely dusty conditions or high temperatures will require more frequent maintenance to the actuator.

Table 6-1. Maintenance Schedule

TIME INTERVAL

(Approximate) MAINTENANCE ACTION

6 months

2 years

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

Clean, inspect, and lubricate cylinder and piston assembly. Refer to paragraph 6-4.

Clean, inspect, and adjust mechanical air lock option. Refer to paragraph 6-5.

McLube MoS

-793 can be purchased from

Rosemount Analytical Inc. (P/N 183512) or directly from the manufacturer:

McGee Industries, Inc. 9 Crozerville Rd. Aston, PA 19014

IB-102-208P

6-1

Page 42

6-4. CYLINDER AND PISTON CLEANING AND

LUBRICATION. Disassemble, clean, and lubricate

piston and cylinder assembly approximately every two years. Refer to Figure 6-2 and use the following procedure.

a. Remove actuator from service; shut off or dis-

connect air supply as applicable to system.

b. Position transfer valve to MANUAL position.

Do not scratch piston rod. Use caution when removing and handling upper cylinder head, piston, and piston rod. If piston rod is scratched, actuator will produce lower torque and cause decreased packing life.

4. Carefully remove cylinder/piston assembly from frame.

f. Remove bearing blocks (6) from upper cylinder

head (20).

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

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

c. Loosen upper and lower air hoses (9 and 15).

Allow residual air to bleed through loose connections.

d. Label hoses (9 and 15) “upper and “lower”, re-

spectively. Disconnect hoses from 90° elbows (8 and 16).

e. Remove cylinder/piston assembly as follows:

1. Loosen set screw (1) and remove clevis pin (3). Disconnect cylinder lever (2) from clevis (25).

2. Support cylinder assembly with 2 x 4 in. boards prior to removing nuts (4).

Failure to support the cylinder assembly could result in the assembly falling over, causing severe personal injury. Ensure the cylinder is adequately supported prior to removing nuts.

3. Remove nuts (4), lockwashers (5), and screws (7).

g. Remove, clean, inspect, and lubricate piston as-

sembly as follows:

1. Remove nuts (22). Pull piston assembly and upper cylinder head free of the cylinder. Remove and discard gasket (10).

2. Remove lower cylinder head (14). Remove and discard gasket (13).

3. Remove old grease from piston assembly and piston rod. Clean piston and rod with commercial grade dry cleaning solvent.

4. Inspect piston rod. Pay special attention to the section of rod which passes through rod packing (21). Replace rod if worn, damaged or pitted. Refer to Section VII, Corrective Maintenance, for replacement procedures.

5. Remove screws (24) and gland cap (23).

6. Carefully wipe old grease from rod packing

(21). Remove and replace rod packing if torn or leaking air. Refer to Section VII, Corrective Maintenance, for replacement procedures.

7. Pack area around rod packing with McLube MoS

-793 or an equivalent grease.

8. Reinstall gland cap (23) and secure with screws.

IB-102-208P

6-2

Page 43

1. Set Screw

2. Cylinder Lever

3. Clevis Pin

4. Nut

5. Lockwasher

6. Bearing Block

7. Screw

8. 90° Elbow

9. Upper Air Hose

10. Gasket

11. Piston

12. Cylinder

13. Gasket

14. Lower Cylinder Head

15. Lower Air Hose

16. 90° Elbow

17. Nut

18. Cylinder Stud

19. Piston Rod

20. Upper Cylinder Head

21. Rod Packing

22. Nut

23. Gland Cap

24. Screw

25. Clevis

NOTE: NOT ALL ITEMS IDENTIFIED ARE

AVAILABLE FOR INDIVIDUAL SALE. SEE SECTION IX, RECOMMENDED SPARE PARTS, FOR A LIST OF AVAILABLE PARTS.

Figure 6-2. Cylinder Exploded View

9. Wipe piston rod (19) with a clean cloth. Apply a light coating of McLube MoS

-793

or equivalent grease.

10. Pack piston concave (area A) with McLube MoS

-793 or equivalent grease.

h. Wipe interior of cylinder (12) with a clean cloth

and commercial grade dry cleaning solvent. Inspect cylinder for cracks and scoring and replace cylinder if damaged. Refer to Section VII, Corrective Maintenance, for replacement procedures. Allow cylinder to air dry before reassembly.

i. Reassemble cylinder and piston assembly as

follows:

29330011

2. Lightly lubricate and install new gasket (13) into seal groove on lower cylinder head (14).

3. Position cylinder onto lower cylinder head (14).

4. Install upper cylinder head with piston assembly into cylinder. Ensure elbows (8 and

16) are on the same side of cylinder.

5. Secure upper head to lower head with cylinder studs (18) and nuts (17 and 22).

6. Install bearing blocks (6) onto upper cylinder head.

1. Lightly lubricate and install new gasket (10) into seal groove on upper cylinder head (20).

IB-102-208P

6-3

7. Place cylinder/piston assembly within frame and onto 2 x 4 inch boards for support.

Page 44

8. Secure bearing blocks (6) to frame with screws (7), lockwashers (5) and nuts (4). Remove the 2 x 4 inch board supports.

9. Secure cylinder lever (2) to clevis (25) with clevis pin (3). Secure clevis pin with set screw (1).

10. Install upper air hose to 90° elbow (8).

CLEARANCE BETWEEN ITEMS 1 AND 2 IS BETWEEN 1/8 AND 3/16 IN. (3.18 TO 4.76 MM)

11. Install lower air hose to 90° elbow (16).

j. Resupply air to cylinder and check for air leaks

using a “snoop” type leak detector.

k. Lubricate clevis and bearing blocks using a

grease gun filled with McLube MoS

-793 or

equivalent.

l. Refer to the FIELDVUE DVC5000 or DVC6000

Series Digital Valve Controller Instruction Manual and calibrate the DVC5000/6000 electronic unit. Return actuator to service.

6-5. AIR LOCK ADJUSTMENT. To adjust air lock,

refer to Figure 6-3 and use the following procedure.

NOTE: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE FOR

INDIVIDUAL SALE. SEE SECTION IX, RECOMMENDED SPARE PARTS FOR A LIST OF AVAILABLE PARTS.

1. Worm Gear Sector

2. Worm Shaft

3. Stop Bolt

4. Shaft Bearing

5. Lock Nut

6. Clapper Lever

29330020

Figure 6-3. Air Lock Diaphragm

g. Place transfer valve in MANUAL position and

ensure worm shaft engages with gear sector. If engagement fails to occur, readjust air lock.

h. Return actuator to service.

a. Remove actuator from service and shut off or

disconnect air supply as applicable to system.

b. Position transfer valve to automatic position.

Manually pull clapper lever (6) open. Prop clapper lever to keep open.

c. Measure clearance between worm shaft (2) and

worm gear sector (1). Proper clearance is between 1/8 and 3/16 in. (3.18 to 4.76 mm).

d. If clearance is not in correct range, loosen lock

nut (5) and adjust stop bolt (3) until clearance between worm shaft and gear sector is in range.

e. Tighten lock nut (5).

f. Remove prop from clapper lever (6).

IB-102-208P

6-6. MECHANICAL LINKAGE CLEANING AND

LUBRICATION. Clean actuator’s mechanical link-

age of all grease buildup and inspect for damage and wear every 2 years. Refer to Figure 6-4 and use the following procedure.

a. Remove actuator from service and shut off or

disconnect air supply as applicable.

b. Remove grease from handwheel sprocket (11)

and worm sprocket (2). Inspect sprockets for damage and wear. Replace if required.

c. Remove grease from chain (8). Inspect chain for

damage. Replace if required.

d. Ensure handwheel shaft block (14) is securely

mounted. Tighten if required.

6-4

Page 45

e. Ensure pin blocks (3) are secure. Tighten if

required.

f. Turn handwheel (7) to rotate worm shaft (17).

Inspect worm shaft for damage.

g. Lubricate worm shaft block (5) and handwheel

shaft block (14) using a grease gun filled with MoS

-793 grease or equivalent.

h. Lubricate chain (8) with a light coating of

MoS

-793 grease or equivalent.

1. Nut

2. Worm Sprocket

3. Pin Block

4. Pin

5. Worm Shaft Block

6. Nut

7. Handwheel

8. Chain

9. Handwheel/Sprocket Shaft

10. Key

11. Handwheel Sprocket

12. Cotter Pin

13. Grease Fitting

14. Handwheel Shaft Block

15. Screw

16. Screw

17. Worm Shaft

18. Key Bar

19. Cotter Pin

20. Set Screw

21. Collar

22. Thrust Washer

23. Grease Fitting

NOTE: NOT ALL ITEMS IDENTIFIED ARE

AVAILABLE FOR INDIVIDUAL SALE. SEE SECTION IX, RECOMMENDED SPARE PARTS, FOR A LIST OF AVAILABLE PARTS.

Figure 6-4. Mechanical Linkage

29330010

IB-102-208P

6-5/6-6

Page 46

Page 47

SECTION VII. CORRECTIVE MAINTENANCE

7-1. OVERVIEW. This section describes corrective

maintenance for the PowerVUE Model PVD 814 fan/ damper actuator. If the specific cause of a problem is not known, refer to Section V, Troubleshooting. Spare parts referred to are available from Rosemount. Refer to Section IX of this manual for part numbers and ordering information.

7-2. CYLINDER HEAD GASKETS, PISTON, AND

ROD PACKING. Use the following procedure to

replace the upper and lower cylinder head gaskets, cylinder piston cup, and rod packing.

a. Remove cylinder and piston assembly as

follows:

3. Loosen upper and lower air hoses (21 and 31, Figure 7-1) and allow residual air to bleed through loose connections.

4. Tag hoses (21 and 31) “upper” and “lower”, respectively. Disconnect hoses from 90° elbows (20 and 30).

5. Loosen set screw (1) and remove clevis pin (3). Disconnect cylinder lever (2) from clevis (5).

A loose cylinder may fall over and cause severe personal injury. Before removing bearing block nuts (9), ensure cylinder’s entire weight is firmly supported by 2 x 4 in. boards.

6. Support cylinder assembly with 2 x 4 inch boards prior to removing nuts (9).

7. Remove nuts (9), lockwashers (10), and screws (12).

1. Remove actuator from service. Shut off or disconnect supply air as applicable to the system.

2. Move transfer valve to MANUAL position.

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

Do not scratch piston rod. Use caution when removing and handling upper cylinder head, piston, and piston rod. If piston rod is scratched, actuator will produce lower torque and decreased packing life will result.

8. Carefully remove cylinder/piston assembly from frame.

IB-102-208P

7-1

Page 48

1. Set Screw

2. Cylinder Lever

3. Clevis Pin

4. Grease Fitting

5. Clevis

6. Set Screw

7. Gland Cap Screw

8. Gland Cap

9. Nut

10. Lockwasher

11. Bearing Block

12. Screw

13. Rod Packing (Female Adaptor)

14. V-Ring Packing

15. Rod Packing (Male Adaptor)

16. Nut

17. Upper Cylinder Head

18. Gasket

19. Piston Rod

20. 90° Elbow

21. Upper Air Hose

22. Upper Piston O-Ring

23. Piston Follower

24. Lower Piston O-Ring

25. Piston

26. Stop Nut

27. Cylinder

28. Gasket

29. Lower Cylinder Head

30. 90° Elbow

31. Lower Air Hose

32. Nut

33. Cylinder Stud

NOTE: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE

FOR INDIVIDUAL SALE. SEE SECTION IX, RECOMMENDED SPARE PARTS FOR A LIST OF AVAILABLE PARTS.

29330012

Figure 7-1. Cylinder Exploded View

b. Disassemble cylinder and piston assembly as

follows:

1. Remove bearing blocks (11) from upper cylinder head (17).

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

2. Remove piston assembly and packing.

3. Remove nuts (16). Pull piston assembly and

upper cylinder head (17) free of the cylinder. Remove and discard gasket (18).

IB-102-208P

4. Remove lower cylinder head (29). Remove and discard gasket (28).

5. Remove gland cap screws (7).

6. Move gland cap (8) to access packing.

7. Remove packings (13, 14, and 15).

8. Remove stop nut (26). Remove piston as-

sembly (22 through 25) from piston rod (19).

c. Clean, reassemble, and lubricate the piston and

cylinder assembly as follows:

1. Clean piston rod and inner cylinder with a clean cloth.

7-2

Page 49

2. Spray piston rod and inner cylinder with a

light coating of dry film lubricant (molybdenum disulfide).

15. Install upper cylinder head (17) and piston assembly onto cylinder (27).

16. Install lower cylinder head (29) onto cylinder. Ensure elbows (20 and 30) are on same side of cylinder.

Piston rod threads can damage rod packing, causing leakage. Exercise care when installing packing.

3. Pack new rod packings (13, 14, and 15) with MoS

-793. Carefully place over piston

rod as illustrated in Figure 7-1.

4. Insert lower end of rod (19) through top of upper cylinder head (17).

5. Carefully press packings (13, 14, and 15) into place.

6. Secure gland cap (8) to cylinder head with screws (7).

7. Replace o-rings (22 and 24) with new lightly lubricated o-rings.

8. Screw piston follower (23) onto piston rod.

9. Place new piston (25) onto piston rod with

machined side of piston facing follower (23).

10. Secure piston assembly to piston rod with stop nut (26).

11. Pack concave area (A) of piston with McLube MoS

-793.

17. Secure upper cylinder head to lower cylinder head with cylinder studs (33) and nuts (16 and 32).

d. Install cylinder/piston assembly as follows:

1. Install bearing blocks (11) onto upper cylinder head.

2. Place cylinder/piston assembly within actuator frame and onto 2 x 4 inch boards for support.

3. Secure bearing blocks (11) to frame with screws (12), lockwashers (10), and nuts (9). Remove the 2 x 4 inch board supports.

4. Secure cylinder lever (2) to clevis (5) with clevis pin (3). Secure clevis pin with set screw (1).

5. Install upper air hose to 90° elbow (20).

6. Install lower air supply hose to 90° elbow

(30).

e. Resupply air to cylinder and check for leaks us-

ing a “snoop” type detector. Repair any leaks.

f. Lubricate clevis and bearing blocks using a

grease gun filled with McLube MoS

-793 or

equivalent.

12. Clean gasket sealing surfaces on cylinder (27) and cylinder heads (17 and 29).

g. Refer to the FIELDVUE DVC5000 or DVC6000

Series Digital Valve Controller Instruction Manual and calibrate the DVC5000/6000 electronic

13. Lightly lubricate and install new gasket

unit. Return the actuator to service.

(18) onto upper cylinder head (17).

7-3. CYLINDER REPLACEMENT. To replace an

14. Lightly lubricate and install new gasket (28) onto lower cylinder head (29).

assembled cylinder, follow the procedures outlined in paragraph 7-2. Step 7-2.a covers cylinder removal, and steps d through g cover installation.

IB-102-208P

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Page 50

7-4. AIR LOCK DIAPHRAGM. Refer to Figure 7-2,

and the following procedure to replace the air lock diaphragm.

a. Remove actuator from service. Disassemble air

lock and remove old diaphragm as follows:

1. Disconnect air line (20) from T-fitting (21).

2. Loosen nut (4) and remove screw (1) and

washer (2) from spring nut (5).

3. Remove air lock stop bolt (47), washer (46), and nut (29).

4. Remove screws (26) from shaft bearing (25) at bottom of worm shaft (51).

5. Remove screws (45) from couplings (37).

6. Swing clapper lever (42) out of the way.

(a) Apply air supply pressure of 30 psi

(207 kPa) to actuator.

(b) Move transfer valve to MANUAL po-

sition.

until clapper lever is held closed by spring (50). Tighten nut (4).

(d) Move transfer valve to automatic po-

sition. If clapper lever does not open, loosen nut (4) and decrease spring tension with screw (1) until clapper lever is fully open. Tighten nut (4) against spring nut (5).

c. Return the actuator to service.

7-5. TRANSFER VALVE. Refer to Figure 7-2 and the

following procedure to replace the transfer valve.

7. Remove screws (39) and remove diaphragm plate (38).

8. Pull on coupling (37) from diaphragm stud (34). Separate diaphragm stud, diaphragm (35), and shield (36).

b. Reassemble and adjust air lock as follows:

1. Assemble new diaphragm (35) with stud (34) and shield (36). Secure together with coupling (37).

2. Place diaphragm assembly in diaphragm chamber (24) and install diaphragm plate (38).

3. Swing clapper lever (42) over diaphragm and install screws (45) into couplings (37).

4. Attach shaft bearings (25) to worm shaft (51) with screw (26).

5. Install air lock stop bolt (47), washer (46), and nut (29).

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

7. Connect air line (20) to T-fitting (21).

8. Adjust air lock spring tension.

a. Remove actuator from service.

b. Remove transfer valve knob (8) from transfer

valve.

c. Remove screws (10) and dust cover.

d. Disconnect supply air line (18) from elbow (17).

Remove elbow from transfer valve.

e. Disconnect air line (20) from adaptor (19). Re-

move adaptor from transfer valve.

f. Remove screws (11) from valve bracket (12) and

remove valve.

g. Install adaptor (19) and elbow (17) on new trans-

fer valve. Install new valve on valve bracket with screws (11).

h. Connect air supply line to (18) to elbow (17).

Connect air line (20) to adaptor (19).

i. Resupply air to actuator and test for leakage

around transfer valve using a “snoop” type leak detector.

j. Reinstall top cover and screws (10). Install trans-

fer valve knob.

k. Return the actuator to service.

IB-102-208P

7-4

Page 51

6 7

12 13

1. Screw

2. Washer

3. Spring Bracket

4. Nut

5. Spring Nut

6. Nut

7. Washer

8. Transfer Valve Knob

9. Seal

10. Screw

11. Screw

12. Valve Bracket

13. Screw

14. Transfer Valve

15. Washer

16. Nut

17. 90° Elbow

18. Supply Air Line

19. Adaptor

20. Air Line

21. T-Fitting

22. Air Line

23. Air Line

24. Diaphragm Chamber

25. Bearing

26. Screw

27. Stud

28. Plug

29. Nut

30. Worm Guide

31. Screw

32. Screw

33. Set Screw

34. Stud

35.

Diaphragm

36. Shield

37. Coupling

38. Diaphragm Plate

39. Screw

40. Spring Connector

41. Nut

42. Clapper Lever

43. Nut

44. Screw

45. Screw

46. Washer

47. Stop Bolt

48. Pivot Pin

49. Screw

50. Spring

51. Worm Shaft

52. Nut

29330013

Figure 7-2. Mechanical Air Lock and Transfer Valve

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Page 52

7-6. REVERSE RELAY. Use the following procedure

for replacement of a faulty reverse relay.

a. Shut off actuator air supply and electronic sig-

nals. If unit has air lock feature, place transfer valve in manual position.

b. Refer to Figure 7-3. Label all air lines for proper

positioning on reassembly.

c. Loosen supply air lines (2) and DVC5000 air

lines (3) to bleed residual air.

d. Disconnect supply air lines (2), DVC5000 air

lines (3), and cylinder air line (4) at fittings (5, 6, and 7).

e. Remove screws (1). Remove reverse relay (8).

f. Remove fittings (5, 6, and 7). Install fittings in

same locations on replacement reverse relay.

g. Install replacement reverse relay (8) on mount-

ing bracket (9) with screws (1).

h. Reinstall supply air lines (2), DVC5000 air lines

(3), and cylinder air line (4) to their proper fittings.

i. Calibrate the reverse relay according to para-

graph 4-1.

1. Screw

2. Supply Air Line

3. DVC5000 Air Line

4. Cylinder Air Line

5. T-Fitting

10. Bolt

11. Washer

12. Nut

13. Supply Air Line

14. Cylinder and Reverse

6. T-Fitting

7. Elbow Fitting

8. Reverse Relay

9. Mounting Bracket

15. Elbow Fitting

16. DVC5000 Electronic Unit

Relay Air Line

29330015

Figure 7-3. Reverse Relay and DVC5000 Electronic Unit Replacement

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Page 53

7-7. DVC5000 ELECTRONIC UNIT. Use the fol-

lowing procedure for replacement of a faulty DVC5000 electronic unit.

roller on cam assembly so position of cam follower arm roller on new unit can be placed in same position.

a. Shut off actuator air supply and electronic sig-

nals. If unit has air lock feature, place transfer valve in manual position.

b. Disconnect any electrical leads to the DVC5000

terminal.

c. Refer to Figure 7-3. Label all air lines for proper

positioning on reassembly.

d. Loosen supply air line (13) and cylinder and re-

verse relay air line (14) to bleed residual air.

e. Disconnect supply air line (13) and cylinder and

reverse relay air line (14) at elbow fittings (15).

NOTE

Before removing DVC5000 electronic unit, note position of cam follower arm roller contacting cam on actuator shaft so cam follower arm roller on new unit can be placed in same position.

f. Remove four bolts (10), washers (11), and nuts

(12) securing DVC5000 electronic unit (16) to mounting bracket (9). Remove DVC5000 electronic unit. Note position of cam follower arm

g. Remove both elbow fittings (15). Install fittings

in same locations on replacement DVC5000 electronic unit (16).

NOTE

Install replacement DVC5000 electronic unit so that the cam follower arm roller contacts the cam mounted on the actuator shaft in the same position as the old unit.

h. Install replacement DVC5000 electronic unit

(16) on mounting bracket (9) with four bolts (10), washers (11), and nuts (12). Ensure cam follower arm roller extending from the bottom of the unit contacts the cam on the actuator shaft in the same position as the old unit.

i. Reinstall supply air line (13) and cylinder and

reverse relay air line (14) to their proper locations.

j. If using ValveLink software, configuration data

can be saved and downloaded from replaced unit.

k. Refer to the FIELDVUE DVC5000 Series Digi-

tal Valve Controller Instruction Manual sections 4 and 6 to calibrate the DVC5000 electronic unit.

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7-7

Page 54

7-8. DVC6000 ELECTRONIC UNIT. Use the fol-

lowing procedure to replace the DVC6000 electronic unit.

a. Shut off actuator air supply and electronic sig-

nals. If unit has air lock feature, place transfer valve in manual position.

b. Disconnect electrical leads to the DVC6000.

c. Refer to Figure 7-4. Label all air lines for proper

positioning on reassembly.

NOTE

Before removing DVC6000 electronic unit, mark contact point of cam follower on cam so cam follower roller can be placed in same position when new unit is installed.

f. Remove four bolts (4), washers (5), and nuts (6)

securing DVC6000 electronic unit (7) to mounting bracket (8). Remove DVC6000 electronic unit. Note position of cam follower arm roller on cam assembly so cam follower on new unit can be placed in same position.

d. Loosen supply air line (1) and cylinder air lines

(2) to bleed residual air.

e. Disconnect supply air line (1) and cylinder air

lines (2) at elbow fittings (3).

g. Remove elbow fittings (3). Install fittings in

same locations on replacement DVC6000 electronic unit (7).

1. Supply Air Line

2. Cylinder Air Line

3. Elbow Fitting

4. Bolt

5. Washer

6. Nut

7. DVC6000 Electronic Unit

8. Mounting Bracket

Figure 7-4. DVC6000 Electronic Unit Replacement

35340007

IB-102-208P

7-8

Page 55

NOTE

Install replacement DVC6000 electronic unit so that the cam follower roller contacts the actuator shaft cam in the same position as the old unit.

h. Install replacement DVC6000 electronic unit (7)

on mounting bracket (8) with four bolts (4), washers (5), and nuts (6). Ensure cam follower arm roller extending from the bottom of the unit contacts the cam on the actuator shaft in the same position as the old unit.

7-9. SHAFT BUSHINGS. Use the following procedure

to replace shaft bushings.

i. Reinstall supply air line (1) and cylinder air line

(2) to their proper locations.

j. If using ValveLink software, configuration data

can be saved and downloaded from replaced unit.

k. Refer to the FIELDVUE DVC6000 Series Digi-

tal Valve Controller Instruction Manual Sections 4 and 6 to calibrate the DVC6000 electronic unit.

a. Remove actuator from service and isolate air to

the unit.

b. Move transfer valve to automatic position and

prop air lock clapper lever open.

c. Remove screws (13, Figure 7-5), sector gear

(14), and key (12) from shaft (20).

Figure 7-5. Shaft Exploded View

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7-9

Page 56

d. Remove screws (10), cylinder lever (11) and key

(12) from shaft (20).

e. Remove screw (5) and linkage lever (4) from

shaft (20).

Loctite sets. This is needed to line up bushings properly. The Loctite will set in approximately 3 minutes. Complete the installation of shaft assembly within 15 minutes from when adhesive was applied.

f. Remove screws (6) and cam mounting bracket

(7) from shaft (20).

g. Pull one end of shaft (20) and remove shaft from

the bushing blocks. Remove spacer (15).

h. Remove grease fitting (18) from bushing block.

i. Break seal by pounding on shaft bushing (19).

Remove shaft bushing from bushing block.

Use caution and appropriate safety equipment when applying Loctite. Make sure all specific instructions on Material Safety Data Sheet (MSDS) are followed. Failure to do so may cause severe eye injury.

Care must be used when applying Loctite primer or adhesive to bushings to make sure it is applied only to the outer surface. Bushing life may be reduced.

NOTE

Bushings are secured to stand assembly with a coating of Loctite applied to the outside of bushings and complete installation of shaft assembly must be completed before

j. Apply Loctite primer (11NA79001A30) to out-

side surface of shaft bushing (19). Allow primer to set for 3 to 5 minutes.

k. After primer has set for 3 to 5 minutes, apply

Loctite adhesive #680 and slide shaft bushing (19) into bushing block within 3 minutes.

l. Insert shaft (20) through both bushing blocks to

align bushings.

m. Allow Loctite to set for 15 minutes. Remove

shaft (20) and drill a 5/16 in. hole into new shaft bushing through the bushing block.

n. Insert shaft through both bushing blocks and

spacer (15) as shown in Figure 7-5.

o. Install cam mounting bracket (7).

p. Install linkage lever (4).

q. Install cylinder lever (11) and sector gear (14)

using keys (30).

r. Remove prop from clapper lever.

s. Refer to Section VI, Periodic Maintenance, and

lubricate actuator shaft bushings.

t. Refer to the FIELDVUE DVC5000/6000 Series

Digital Valve Controller Instruction Manual and calibrate the DVC5000/6000 electronic unit.

u. Return the actuator to service.

IB-102-208P

7-10

Page 57

SECTION VIII. OPTIONS

8-1. OVERVIEW. The options for the PowerVUE

Model PVD 814 fan/damper actuator covered in this section include limit switches, heater/thermostat, and SPA with HART alarm.

8-2. LIMIT SWITCHES.

a. Adjustment.

Before performing any maintenance or repair action on the actuator, shut off supply air and any electrical supply or electronic signals to the actuator. Isolate actuator from all systems connected to the actuator. Severe injury or death may result from large torque produced by actuator.

1. Remove actuator from service, close supply air shutoff valve, and isolate any electrical supply or electronic signals to actuator.

2. Loosen screws (1, Figure 8-1) securing upper limit switch cam assembly (2) to shaft (3).

3. Use manual operator wheel to position linkage lever to desired upper limit stopping position.

4. Rotate upper limit switch cam in counterclockwise direction when viewed from left of actuator. When cam shoe engages upper limit switch (4), secure cam assembly (2) to shaft (3) with screws (1).

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

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

b. Replacement.

1. Remove actuator from service, close supply air shutoff valve, and disconnect any electrical supply and electronic signals to actuator.

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

3. Remove nuts (9, Figure 8-1) from studs (8) and remove studs.

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

5. Install new switches on bracket with studs (8) and nuts (9).

6. Route wires along same path as old limit switches. Connect wires from new switches to terminal blocks 2 and 3 as shown in Figure 8-1.

7. Restore electrical supply and electronic signals to actuator. Open supply air sutoff valve.

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

IB-102-208P

8-1

8. Refer to paragraph 8-2a. and adjust limit switches. Return actuator to service.

Page 58

1. Screws

2. Cam Assembly

3. Shaft

4. Upper Limit Switch

5. Screws

6. Cam Assembly

7. Lower Limit Switch

8. Stud

9. Nut

10. Nut

11. Washer

TB-1

12 8 +

EPT

24-28 VDC

BLACK

WHITE

RED

12 8

N.C.

N.O.

LIMIT SWITCH 1

ACTIVATED WHEN PISTON

IS FULLY EXTENDED

BLACK

WHITE

RED

12 8

N.C.

N.O.

LIMIT SWITCH 2

ACTIVATED WHEN PISTON

IS FULLY RETRACTED

ORANGE

BROWN

N.O.

ORANGE

BROWN

N.O.

PINK

YELLOW

BLUE

7 N.C.

YELLOW

BLUE

7 N.C.

10 11 12

LNG 115 VAC

HEATER

10 11 12

I/P

4-2O MA

TB-2

TB-3

29330021

Figure 8-1. Limit Switch Exploded View

IB-102-208P

8-2

Page 59

8-3. HEATER/THERMOSTAT. Refer to Figure 8-2

and the following procedure to replace the heater/thermostat.

2. Remove heating element (18) from heater socket (16) by turning counterclockwise.

3. Install new heating element (18) into heater socket (16).

Before performing any maintenance or repair action on the actuator, shut off supply air and any or electronic signals to the actuator. Isolate actuator from all systems connected to the actuator. Severe injury or death may result from large torque produced by actuator.

a. Heater Replacement.

1. Remove actuator from service, close air supply shutoff valve, and isolate electronic signals from actuator.

1. Screw

2. Lockwasher

3. Thermostat

4. Nut

5. Lockwasher

6. Screw

7. Screw

8. Terminal Cover

9. Thermostat Lead

10. Mounting Plate

11. Backing Plate

12. Terminal Block

13. Screw

14. Heater Lead

15. Thermostat Lead

16. Heater Socket

17. Screw

18. Heating Element

19. Nut

4. Return actuator to service.

b. Thermostat Replacement.

1. Remove actuator from service, close air supply shutoff valve, and isolate electronic signals from actuator.

2. Remove terminal cover screws (7) 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 (9) from heater socket.

NOTE: NOT ALL ITEMS IDENTIFIED ARE AVAILABLE

FOR INDIVIDUAL SALE. SEE SECTION IX, RECOMMENDED SPARE PARTS FOR A LIST OF AVAILABLE PARTS.

29330017

Figure 8-2. Heater/Termostat

IB-102-208P

8-3

Page 60

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

5. Install new thermostat (3) with screws (1), lockwashers (2), and nuts (4) on frame.

6. Connect thermostat lead (9) to heater socket (16) and reinstall heater socket with screws (17).

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

c. Installation. The SPA is a ¼ DIN electronic

module that can be mounted near the control room in the cabinetry where I/O terminations are located. The SPA should be wired in parallel to the 4-20 mA control signal routed from the control room to the DVC6000.

d. Setup. Install and set up the DVC6000 com-

pletely before setting up the SPA unit. Instructions for setting up the SPA are included in the Moore Instruction Manual, 224-741-00B.

8. Restore electronic signals and return actuator to service.

8-4. HART Site Programmable Alarm (DVC6000

Series Controller only).

a. Overview. The DVC6000 series valve control-

ler includes a cam-driven position potentiometer to provide feedback information about actuator position. The position transmitter is the source of all discrete and absolute position information for the valve controller. The feedback information is transmitted via HART communications from the control room to the DVC6000 controller.

Some users, however, want an independent position feedback to confirm the actuator position. The Moore Industries HART Site Programmable Alarm (SPA) option provides this independent position feedback.

b. Capabilities. The HART Site Programmable

Alarm is provided for customers that want independent confirmation of actuator position. The SPA communicates via HART and can initiate the following actions based on the digital position signal:

Recommended values for this sample setup are as follows:

1. Dip Switch Settings.

Password – no recommendation (user decide) Failsafe/Non-Failsafe – non-failsafe Current Source, Sink, or Voltage – set to Current Source

2. Relay Setup.

Relay #1 – HART alarm:

Set to Primary vs. Secondary Set to Normal vs. Burst Set “Number of variables” to 1 (factory default) Set “Number of Trys” to 1 (factory default) Set “HART Source” settings to:

Bit 7 on Bit 5 off Bit 4 off Bit 3 on Bit 2 on Bit 1 off Bit 0 on

1. Retransmit a single 4-20 mA position signal. Many users want this capability to represent or record the PowerVUE position.

2. Initiate 2 or 3 contact closures based on actuator position.

3. Initiate a contact closure on the loss of HART communications or on a predetermined set of SPA fault conditions.

IB-102-208P

Alarm Source Information, Relays 2,3,4:

Set “Analog Output Source” to PV (process variable) Set “Relay Sources” to PV

Configuring Miscellaneous Options:

Set linearization off – “LINR OFF” Set Scaling to “AUTO” Set Engineering Units to “PCT” Set Source for SPA display to PV Set function of Relay #2 to

“TRIP” vs. “FAULT” Set Upscale/Downscale Drive to “LOW”

8-4

Page 61

Setting Engineering Units:

Set “PCT” for all Smart Scaling – do not use Scaling the HART input – complete this procedure Customizing Input Linearization – do not use Smart Scaling of SPA Analog Output – complete this procedure Trimming the SPA Analog Output – complete this procedure

Configuring the SPA Relays per the “Flame Safety Interface” example:

Alarm #2:

Enter Trip – Set to 95% (input trip is inactive) Deadband – Set to “0” Delay – Set to “0 sec” Hi/Lo Alarm Function – Set for “Hi” Latching – Set to “OFF”

e. Limit Switch Function. Traditionally, limit

switches were tripped upon contact with a cam on the rotary output shaft of the actuator. The lobe of the cam caused switch actuation for 10 to 20% of the rotary travel of the actuator shaft.

The SPA unit receives actuator position data via HART communications and controls two relays based on the digital position signal. (The SPA unit initiates contact closure when the PowerVUE travel is above or below a given position only. Two contact closures are used to confirm a given position or range.)

The following “flame safety interface” example illustrates how to set up the unit for an operation wherein the relay contact closures control an automated boiler light-off system. Refer to the timing chart and wiring diagram shown in Figures 8-3 and 8-4.

1. User wishes to confirm that actuator is above 95% (purge). Contact #2 is normally open and closes at or above 95%.

Alarm #3:

Input Trip – Set 22% (2nd input trip inactive) Deadband – Set to “0” Delay – Set to “0 sec” Hi/Lo Alarm Function – Set to “Lo” Latching – Set to “OFF”

Alarm #4:

Input Trip – Set to 18% (2nd input trip is inactive) Deadband – Set to “0” Delay – Set to “0 sec” Hi/Lo Alarm Function – Set to “Hi” Latching – Set to “OFF”

2. User wishes to confirm that actuator is at 22% of travel (light-off). Contact #3 is normally open and closes below 22%. Contact #4 is normally open and closes above 18%. The two contacts must both be closed in order for the resultant contact to close, confirming actuator position between 18 and 22% (light-off).

Using contacts #1 and #2, any failure within the SPA unit will cause outputs to go to a default value. In this example, all contacts fail to the open position. The contacts are also wired such that a fault can be indicated to the user.

IB-102-208P

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Page 62

PURGE

95%

POSITION

22%

ACTUATOR

18%

RELAY #2 (NO) CLOSED (OPENS BELOW 95%)

Figure 8-3. Timing Chart for Flame Safety Application

BOILER

LIGHT OFF

RELAY #3 (NO) CLOSED (#3 CLOSED BELOW 22%, OPEN ABOVE 22%)

RELAY #4 (NO) CLOSED (#4 CLOSED ABOVE 18%, OPEN BELOW 18%)

TIME

35340007

Figure 8-4. Wiring Schematic for Flame Safety Application

IB-102-208P

8-6

Page 63

SECTION IX. RECOMMENDED SPARE PARTS

NOTE

Refer to FIELDVIEW DVC5000/6000 Series Digital Valve Controller Instruction Manual, Section 10 for parts information for the DVC5000 or DVC6000 electronic unit.

Table 9-1. Recommended Spare Parts for PowerVUE Model PVD 814 Fan/Damper Actuator

FIGURE and

INDEX NUMBER PART NUMBER DESCRIPTION QTY

Not Shown 1A97803G02 Spare Parts Kit 8 x 14 Actuator 1

7-1, 22 O-ring (120039-016) 1

7-1, 24 O-ring (120039-032) 1

7-1, 18 Gasket (141279) 1

7-1, 28 Gasket (141279) 1

7-1, 25 Piston (24128) 1

6-2, 21 Rod Packing Parts (2831A95G01) 1

7-2, 35 Air Lock Diaphragm (9351-003) 2

7-1, 25 1A97803G04 Spare Parts Kit, Piston (241282) 1

6-2, 21 1A97803G05 Spare Parts Kit, Rod Packing (2831A95G01) 15

7-1, 22 1A97803G08 Spare Parts Kit, O-ring (120039-016) 50

7-1, 24 1A97803G09 Spare Parts Kit, O-ring (120039-032) 50

7-1, 18, 28 1A97803G10 Spare Parts Kit, Gasket (141279) 25

6-1 183512 Grease, MoS2-793, 4 lb (1.8 kg) can A/R

7-1, 23 342371 Piston Follower 1

1-1, 3 IB-102-208P 8 x 14 PowerVUE Instruction Bulletin 1

5-1 161433 Pneumatic Trip Valve 1

1-1, 2 372538-002 Air Filter 1

Not Shown 372538-023 Air Filter Element 1

IB-102-208P

9-1

Page 64

Table 9-2. Recommended Spare Parts for Options (PowerVUE Model PVD 814 Fan/Damper Actuator Only)

FIGURE and

INDEX NUMBER

PART NUMBER DESCRIPTION QTY

8-2, 18 153407-001 Heating Element (150 Watt) 1

8-2, 16 256996 Heater Socket 1

8-2, 16 145822 Porcelain Receptacle 1

8-2, 3 153408 Thermostat 1

8-2, 8 114656 Terminal Cover 1

8-2, 10 157030 Mounting Plate 1

8-2, 11 143650-006 Terminal Marker Strip 1

8-2, 11 181404-002 Terminal Marker Strip 1

8-2, 12 181403-002 Terminal Block 1

7-2, 14 141187 Transfer Valve 1

7-2 457829 Air Lock Assembly 1

7-2, 24 342376 Diaphragm Chamber 2

7-2, 38 242406 Diaphragm Plate 2

7-2, 35 9351-003 Diaphragm 2

7-2, 34 141168-005 Stud 2

7-2, 36 141168-004 Shield 2

7-2, 42 357720 Clapper Lever 1

7-2, 48 157704 Pivot Pin 1

7-2, 20 125368-009 Air Line 1

7-2, 22 125368-007 Air Line 1

IB-102-208P

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Page 65

SECTION X. RETURNING EQUIPMENT TO THE FACTORY

10-1. 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 unit in a sturdy box

with sufficient shock absorbing material to ensure no additional damage will occur during shipping.

c. In a cover letter, describe completely:

1. The symptoms that determined the equipment is faulty.

2. The environment in which the equipment was 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 the return of the equipment.

d. Enclose a cover letter and purchase order and

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

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

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

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

IB-102-208P

10-1/10-2

Page 66

Page 67

INDEX

This index is an alphabetized listing of parts, terms, and procedures having to do with the PowerVUE Model PVD 814 fan/damper actuator. Every item listed in this index refers to a location in the manual by one or more page numbers.

Actuator Features, 1-1 Actuator Mounting, 2-2 Actuator Operation, 1-2, 1-3 Actuator Options, 1-1, 1-2 Actuator Piping Diagram, 5-1 Air Filter, 1-2 Air Lock, 1-2 Air Lock, Adjustment, 6-4 Air Piping Schematic, 2-3 Air Supply Installation, 2-3 Air Supply Requirements, 1-5, 2-3

Calibration

DVC5000/6000 Electronic Unit, 4-1

Reverse Relay, 4-1 Clearance Requirements, 2-2 Clevis, 1-2 Corrective Maintenance

Air Lock Diaphragm, 7-4

Cylinder Replacement, 7-3

DVC5000 Electronic Unit, 7-7

DVC6000 Electronic Unit, 7-8

Heater/Thermostat, 8-3

Reverse Relay, 7-6

Shaft Bushings, 7-9

Transfer Valve, 7-4

Handwheel, 1-1 Heater/Thermostat, 1-2

Installation

Air Supply, 2-3 Linkage, 2-4 Special Considerations, 2-1

Linkage Cleaning and Lubrication, 6-4 Linkage Design, Special Installation Considerations, 2-1 Linkage Installation, 2-4 Lubrication Chart, 6-0

Maintenance Schedule, 6-1 Mechanical Air Lock, 1-1 Model Number Matrix, 1-0 Mounting Instructions, 2-2

Package Contents, 1-1 Periodic Maintenance

Cylinder, 6-2 General, 6-1 Piston, 6-2

Recommended Spare Parts, 9-1 Reverse Relay, 4-1

Digital Communications, 1-2 Direction of Rotation, 1-2 DVC5000/6000 Electronic Unit, 1-1, 1-2

Signal Requirements, 1-5 Site Programmable Alarm, 8-4 Specifications, Actuator, 1-5 Specifications, Rust Preventative Compound, 1-6 Storage Instructions, 1-6

Electronic Unit Replacement, DVC5000, 7-7 Electronic Unit Replacement, DVC6000, 7-8 Environmental Requirements, 1-5

IB-102-208P

Transfer Valve, 1-2 Troubleshooting, 5-1

I-1/I-2

Page 68

Page 69

Appendix A PowerVUE FAN/DAMPER ACTUATOR TORQUE TYPE 8 x 14 for use with DVC5000 Series DIGITAL VALVE CONTROLLER

RETROFIT KIT INSTALLATION INSTRUCTIONS

Instruction Bulletin IB-102-208P Rev. 1.0

Page 70

Page 71

Section Page

A. RETROFIT KIT INSTALLATION INSTRUCTIONS...........................................................A-1

A-1. Forward...........................................................................................................................A-1

A-2. Component Checklist......................................................................................................A-1

A-3. Overview.........................................................................................................................A-1

A-4. Mechanical Installation...................................................................................................A-2

A-5. DVC5000 Electronic Setup ............................................................................................A-7

A-6. Calibration ......................................................................................................................A-7

LIST OF ILLUSTRATIONS

Figure Page

A-1 PowerVUE 8 x 14 Retrofit Kit..................................................................................................iv

A-2 Retrofitted PowerVUE 8 x 14 Actuator .................................................................................A-1

A-3 8 x 14 Actuator (with Side Panels) ........................................................................................A-2

A-4 Air Tubing and Positioner System (Pre-retrofit)....................................................................A-3

A-5 Component Removal .............................................................................................................A-4

A-6 PowerVUE Component Installation.......................................................................................A-5

A-7 Air Piping Diagram (with Mechanical Air Lock Option)......................................................A-6

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Page 73

Table A-1. Model Number Matrix

PowerVUE Retrofit Kit - ORDERING INFORMATION

Select complete model number from the Model Number Matrix.

8 x 14

(1)

(2)

PVD 468R

PowerVUE Drive

Code Model

01 4 x 5

Code Digital Valve Controller

(3)

None

(4)

DVC6000

HART

Fieldbus

(5)

DVC5000, with Basic Control Suite

(5)

DVC5000f, without Basic Control Suite

Other DVC Style Selected

(6)

Code EPT

00 None

Digital EPT and 2 Limit Contacts (HART versions only)

PVD 468R 02 02 01 EXAMPLE

NOTES:

1. Performance and specifications may vary from the published

specifications, depending on the age of the Hagan fan/damper actuator and the quality of the DVC5000/6000 installation. Setup and calibration is the responsibility of others. Faichild reversing relay is included with or without (selection of) DVC5000.

2. Some rilling and tapping required. Existing covers may be

modified in the field or a precut back cover can be selected (reference P/N 4851B28G01).

3. Digital Valve Controller (DVC5000/6000) may be supplied by

others, but no performance quarantees for accuracy or speeds of response are provided. Warranty for DVC5000/6000 will be the responsibility of the provider. Tubing is provided, but is not precut or preformed.

4. Standard arrangement calls for Model DVC6020f-516G60,

5. Standard arrangement calls for Model DVC5020f-216, certified to FM as intrinsically safe, and Division 2. Other certifications are available. Advanced diagnostics provided.

6. Designate other DVC5020/6020 model number as a note on order.

7. Utilizes Moore Industries Site Programmable HART Alarm.

Default configuration:

1 analog output representing actuator travel 3 customer selectable position contacts

1 contact for Field Device Failure Moore HART SPA may be configured in an intrinsically safe arrangement through an IS barrier.

DVC5000/6000 Options:

Flameproof cable gland: ½” NPT (aluminum), EExd IIC Cable entry adaptor (brass): ½” NPT M20 x 1.5 ISO

certified to FM as intrinsically safe, and Division 2. Other certifications are available. Advanced diagnostics provided.

(7)

½” NPT, PG 13.5

IB-102-208P

iii

Page 74

ROSEMOUNT

NOTE:

PowerVUE Retrofit Subassembly

PowerVUE RETROFIT SUBASSEMBLY INCLUDES DVC5000 ELECTRONIC UNIT, REVERSE RELAY, MOUNTING BRACKET, MOUNTING BLOCKS, HARDWARE, AND CONNECTING AIR FITTINGS.

2. Flexible Air Line Tubing Roll, Fitted Air Lines, Fittings and Connectors

Cam Assembly

Figure A-1. PowerVUE 8 x 14 Retrofit Kit

4. Trip Valve

5. Side Panels (With Cutouts)

6. PowerVue 8×14 Actuator Instruction Bulletin with Retrofit Kit Installation Instructions

29330022

IB-102-208P

Page 75

APPENDIX A. RETROFIT KIT INSTALLATION INSTRUCTIONS

A-1. FORWARD. This appendix addresses how to

replace an existing Hagan mechanical, pilot valve type, positioner system with a PowerVUE system. Removal, installation, and setup procedures are included. After completing this conversion, refer to the base sections of this instruction bulletin for future reference. The retrofit package includes a full instruction bulletin for the 8 x 14 PowerVUE Actuator. This instruction bulletin provides important information including startup, calibration, troubleshooting, and spare parts.

NOTE

The instruction bulletin for your existing power positioner (pre-retrofit) should be kept on file. Although Rosemount/Hagan continues to improve products and update instruction bulletins, the outdated instruction bulletin may still provide useful information.

A-2. COMPONENT CHECKLIST. A typical Power-

VUE 8 x 14 Actuator Retrofit Kit should contain the items shown in Figure A-1.

NOTE: ILLUSTRATED WITH

HANDWHEEL / MECHANICAL AIR LOCK OPTION.

A-3. OVERVIEW. The Rosemount PowerVUE 8 x 14

Actuator Retrofit Kit is designed for installation on the Hagan 8 x 14 Torque Type Power Positioner. The retrofit allows a 4-20 mA or fieldbus input signal sent by a user’s process controller, to be received by the DVC5000 electronic unit. The DVC5000 electronic unit converts the input signal to a pneumatic output pressure which is sent to the top of the power cylinder and the reverse relay. The reverse relay sends the appropriate inverse air pressure to the bottom of the power cylinder locking the piston in place. A retrofitted PowerVUE 8 x 14 Actuator is shown in Figure A-1.

29330023

Figure A-1. Retrofitted PowerVUE 8 x 14 Actuator

IB-102-208P

A-1

Page 76

A-4. MECHANICAL INSTALLATION.

Before performing any retrofit actions on the actuator, isolate the actuator from all electrical and pneumatic systems. Severe injury or death may result from the large torque produced by the actuator.

2. Open the drain cock on the air filter to exhaust the air supply from the actuator.

3. If the unit is equipped with a transfer valve, place the transfer valve in the manual position (Figure A-2).

4. If leaving the unit in place during the retrofit, remove the side panels with the exception of the panel on the side of the operating lever.

a. Remove Actuator from Service.

NOTE

It is recommended that the actuator be decommissioned and moved prior to retrofitting the unit. Decomminssioning and moving the unit will allow the removal of all covers, making component removal and installation much easier.

It is possible to complete the retrofit with the actuator in place. If the unit is to remain in place, use the “manual mode” of operation and remove all covers with the exception of the operating lever side cover.

1. Remove the actuator from service. Isolate the actuator from the air supply by disconnecting the air supply or closing the supply air shutoff valve (as applicable to the system). Isolate electrical power and electronic signals to the actuator.

OPERATING

LEVER

TRANSFER VALVE

Figure A-2. 8 x 14 Actuator

(with Side Panels)

29330024

IB-102-208P

A-2

Page 77

b. Remove Pneumatic Positioning Components.

NOTE

The limit switch assembly may be removed or reused. If removed, leave the outer cam saddle to serve as a thrust bearing.

The limit stop is not affected by the retrofit.

2. Remove tubing and elbow fittings from the pneumatic cylinder.

3. Turn the handwheel counterclockwise to expose the pilot valve stem.

4. Unscrew the valve stem and separate the stem from the connecting link.

The heater/thermostat option is not affected by the retrofit.

The air lock option is not affected by the retrofit.

1. Disconnect and remove tubing from the diaphragm/spring assembly, pilot valve, and pilot valve manifold, Figure A-3.

TRANSFER VALVE

HANDWHEEL

SHAFT

CAM

ASSEMBLY

NOTE:

ILLUSTRATED WITH HANDWHEEL/

MECHANICAL AIR LOCK OPTION.

DIAPHRAGM/

SPRING

ASSEMBLY

5. Remove cam assembly (1, Figure A-4) from shaft (2).

6. Remove the diaphragm/spring assembly (3) from the frame.

7. Remove the pilot valve/pilot valve manifold (4) from the frame.

CONNECTING

LINK

29330025

PNEUMATIC

CYLINDER

ELBOW

FITTING

ELBOW

FITTING

PILOT

VALV E

STEM

PILOT VALVE

MANIFOLD

Figure A-3. Air Tubing and Positioner System (Pre-retrofit)

IB-102-208P

A-3

Page 78

1. Cam Assembly

2. Shaft

3. Diaphragm/Spring Assembly

4. Pilot Valve/Pilot Valve Manifold

Figure A-4. Component Removal

c. Install PowerVUE Components.

NOTE

Before installing any PowerVUE retrofit components on the unit, ensure pneumatic cylinder piston is completely down.

1. Ensure pneumatic cylinder piston is completely down.

2. Install cam assembly to shaft, Figure A-5. Leave screws loose so cam rotates on shaft for later adjustment.

3. Hold up PowerVUE retrofit subassembly to bearing blocks and mark position of mounting blocks, Figure A-5.

29330026

Ensure weld splash does not damage actuator shaft, grease fittings, mounting hardware holes, or any other actuator components.

4. Remove mounting blocks from PowerVUE retrofit subassembly and weld to bearing blocks in marked positions. Ensure weld splash does not damage actuator components.

5. Install PowerVUE retrofit subassembly to mounting blocks with two allen screws provided.

IB-102-208P

A-4

Page 79

BEARING BLOCK

CAM

ASSEMBLY

MOUNTING

BLOCK

MARK POSITION OF MOUNTING BLOCK ON BEARING BLOCK ALONG EDGE (BOTH SIDES).

Powe rVUE

RETROFIT

SUBASSEMBLY

Figure A-5. PowerVUE Component Installation

6. Adjust cam assembly on actuator shaft so that the surface of the cam contacts DVC5000 follower arm roller squarely. Rotate the cam assembly so that the DVC5000 follower arm just retracts slightly. Tighten cam assembly to actuator shaft.

d. Install PowerVUE System Air Tubing.

NOTE

ACTUATOR

SHAFT

DVC5000

FOLLOWER ARM

ROLLER

1. Install fitted air supply line (1, Figure A-6) to bottom T-fitting (2) between DVC5000 and reverse relay, and air manifold.

2. Install elbows (3) and fitted air lines (4) to top and bottom of positioner cylinder.

NOTE

Trip valve has air fittings pre-installed in port 4, port 5, and side as installation aid.

29330027

Prior to connecting supply air to the actuator, purge the air system to remove all moisture and debris.

3. Install top fitted air line (4) to T-fitting in port 4 on top of trip valve. Install bottom fitted air line (4) to T-fitting in port 5 on

Fitted air lines may be copper or stainless

bottom of trip valve.

steel depending on specific kit order.

IB-102-208P

A-5

Page 80

TRANSFER

VALV E

MECHANICAL

AIR LOCK

(NOTE 2)

TRIP

VALV E

REVERSE

RELAY

ILLUSTRATION DEPICTS TUBING

NOTES:

ELECTRONIC

DVC5000

UNIT

1. CONNECTION POINTS. ACTUAL ROUTING MAY APPEAR DIFFERENT.

ILLUSTRATION DEPICTS MECHANICAL AIR LOCK OPTION.

VALVE ASSEMBLY NUMBERS 1 THROUGH 5 REPRESENT ACTUAL NUMBERS VISIBLE ON THE ASSEMBLY.

DVC5000

ELECTRONIC

UNIT

MECHANICAL AIR

LOCK (NOTE 2)

TRANSFER

VALV E

PNEUMATIC

CYLINDER

VALV E

ASSEMBLY

(NOTE 3)

4 2

TRIP

5 1 3

VALV E

AIR

MANIFOLD

SUPPLY

AIR

Figure A-6. Air Piping Diagram (with Mechanical Air Lock Option)

REVERSE

RELAY

29330028

IB-102-208P

A-6

Page 81

Severe personal injury is possible. Do

not attempt to cut flexible air tubing while supporting by hand. Place tubing on a suitable surface prior to cutting. Failure to take proper precautions can lead to blade slippage and serious injury.

NOTE

Ensure each section of flexible air line is of adequate length prior to cutting it from the roll of tubing.

4. Place flexible tubing on a suitable surface and cut adequate lengths of air line from the roll.

7. Install flexible tubing (9) from fitting on left side of trip valve to T-fitting (10) on bottom of mechanical air lock.

8. If the retrofit resulted in an open line leading from the transfer valve, remove the line and plug the open port on the transfer valve.

A-5. DVC5000 ELECTRONICS SETUP.

a. Introduction. Initial setup of the DVC5000 has

been performed at the factory. Refer to Sections 4 and 5 of FIELDVUE DVC5000 Series Digital Valve Controller Instruction Manual for any additional tuning that may be required for particular applications.

A-6. CALIBRATION.

5. Install flexible tubing (6) from top T-fitting (7) between DVC5000 and reverse relay to T-fitting (5) in port 5 on bottom of trip valve.

6. Install flexible tubing (8) from fitting on output side of reverse relay to T-fitting (5) in port 4 on top of trip valve.

a. Reverse Relay Calibration. Refer to paragraph

4-1 to calibrate the reverse relay.

b. DVC5000 Calibration. Refer to sections 4 and

6 of FIELDVUE DVC5000 Series Digital Valve Controller Instruction Manual to calibrate the DVC5000 electronic unit.

IB-102-208P

A-7/A-8

Page 82

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Page 83

Appendix B PowerVUE FAN/DAMPER ACTUATOR TORQUE TYPE 8 x 14 for use with DVC6000 Series DIGITAL VALVE CONTROLLER

RETROFIT KIT INSTALLATION INSTRUCTIONS

Instruction Bulletin IB-102-208P Rev. 1.0

Page 84

Page 85

Section Page

B. RETROFIT KIT INSTALLATION INSTRUCTIONS........................................................B-1

B-1. Forward...........................................................................................................................B-1

B-2. Component Checklist......................................................................................................B-1

B-3. Overview.........................................................................................................................B-1

B-4. Mechanical Installation................................................................................................... B-2

B-5. DVC5000 Electronics Setup........................................................................................... B-7

B-6. Calibration ......................................................................................................................B-7

LIST OF ILLUSTRATIONS

Figure Page

A-1 PowerVUE 8 x 14 Retrofit Kit.................................................................................................iv

A-2 Retrofitted PowerVUE 8 x 14 Actuator ................................................................................ B-1

A-3 8 x 14 Actuator (with Side Panels) .......................................................................................B-2

A-4 Air Tubing and Positioner System (Pre-retrofit)................................................................... B-3

A-5 Component Removal ............................................................................................................B-4

A-6 PowerVUE Component Installation..................................................................................... B-5

A-7 Air Piping Diagram (with Mechanical Air Lock Option) .....................................................B-6

IB-102-208P

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Page 86

Page 87

Table B-1. Model Number Matrix

PowerVUE Retrofit Kit - ORDERING INFORMATION

Select complete model number from the Model Number Matrix.

8 x 14

(1)

(2)

PVD 468R

PowerVUE Drive

Code Model

01 4 x 5

Code Digital Valve Controller

(3)

None

(4)

DVC6000

HART

Fieldbus

(5)

DVC5000, with Basic Control Suite

(5)

DVC5000f, without Basic Control Suite

Other DVC Style Selected

(6)

Code EPT

00 None

Digital EPT and 2 Limit Contacts (HART versions only)

PVD 468R 02 02 01 EXAMPLE

NOTES:

1. Performance and specifications may vary from the published specifications, depending on the age of the Hagan fan/damper actuator and the quality of the DVC5000/6000 installation. Setup and calibration is the responsibility of others. Faichild reversing relay is included with or without (selection of) DVC5000.

2. Some rilling and tapping required. Existing covers may be modified in the field or a precut back cover can be selected (reference P/N 4851B28G01).

3. Digital Valve Controller (DVC5000/6000) may be supplied by others, but no performance quarantees for accuracy or speeds of response are provided. Warranty for DVC5000/6000 will be the responsibility of the provider. Tubing is provided, but is not precut or preformed.

4. Standard arrangement calls for Model DVC6020f-516G60,

5. Standard arrangement calls for Model DVC5020f-216, certified to FM as intrinsically safe, and Division 2. Other certifications are available. Advanced diagnostics provided.

6. Designate other DVC5020/6020 model number as a note on order.

7. Utilizes Moore Industries Site Programmable HART Alarm.

Default configuration:

1 analog output representing actuator travel 3 customer selectable position contacts

1 contact for Field Device Failure Moore HART SPA may be configured in an intrinsically safe arrangement through an IS barrier.

DVC5000/6000 Options:

Flameproof cable gland: ½” NPT (aluminum), EExd IIC Cable entry adaptor (brass): ½” NPT M20 x 1.5 ISO

certified to FM as intrinsically safe, and Division 2. Other certifications are available. Advanced diagnostics provided.

(7)

½” NPT, PG 13.5

IB-102-208P

iii

Page 88

ROSEMOUNT

PowerVUE RETROFIT SUBASSEMBLY INCLUDES DVC6000 ELECTRONIC UNIT,

NOTE:

MOUNTING BRACKET, MOUNTING BLOCKS, HARDWARE, AND CONNECTING AIR FITTINGS.

1. PowerVUE Retrofit Subassembly

2. Flexible Air Line Tubing Roll, Fitted Air Lines, Fitting and Connectors

3. Cam Assembly

Figure B-1. PowerVUE 8 x 14 Retrofit Kit

4. Trip Valve

5. Side Panels (With Cutouts)

6. PowerVUE 8x14 Actuator Instruction Bulletin with Retrofit Kit Installation Instructions

35350008

IB-102-208P

Page 89

APPENDIX B RETROFIT KIT INSTALLATION INSTRUCTIONS

B-1. FORWARD. This appendix addresses how to

NOTE

B-2. COMPONENT CHECKLIST. A typical Power-

VUE 8 x 14 Actuator Retrofit Kit should contain the items shown in Figure B-1.

NOTE: ILLUSTRATED WITH

HANDWHEEL / MECHANICAL AIR LOCK OPTION.

B-3. OVERVIEW. The Rosemount PowerVUE 8 x 14

Actuator Retrofit Kit is designed for installation on the Hagan 8 x 14 Torque Type Power Positioner. The retrofit allows a 4-20 mA or fieldbus input signal sent by a user’s process controller, to be received by the DVC6000 electronic unit. The DVC6000 electronic unit converts the input signal to a pneumatic output pressure which is sent to the top or bottom of the pneumatic cylinder, positioning and locking the piston in place. A retrofitted PowerVUE 8 x 14 Actuator is shown in Figure B-1.

35350009

Figure B-1. Retrofitted PowerVUE 8 x 14 Actuator

IB-102-208P

B-1

Page 90

B-4. MECHANICAL INSTALLATION.

2. Open the drain cock on the air filter to exhaust the air supply from the actuator.

3. If the unit is equipped with a transfer valve, place the transfer valve in the manual position (Figure B-2).

4. If leaving the unit in place during the retrofit, remove the side panels with the exception of the panel on the side of the operating lever.

a. Remove Actuator from Service.

NOTE

OPERATING

LEVER

TRANSFER VALVE

Figure B-2. 8 x 14 Actuator

(with Side Panels)

29330024

IB-102-208P

B-2

Page 91

b. Remove Pneumatic Positioning Components.

NOTE

The limit switch assembly may be removed or reused. If removed, leave the outer cam saddle to serve as a thrust bearing.

The limit stop is not affected by the retrofit.

2. Remove tubing and elbow fittings from the pneumatic cylinder.

3. Turn the handwheel counterclockwise to expose the pilot valve stem.

4. Unscrew the valve stem and separate the stem from the connecting link.

The heater/thermostat option is not affected by the retrofit.

The air lock option is not affected by the retrofit.

1. Disconnect and remove tubing from the diaphragm/spring assembly, pilot valve, and pilot valve manifold, Figure B-3.

TRANSFER VALVE

HANDWHEEL

SHAFT

CAM

ASSEMBLY

NOTE:

ILLUSTRATED WITH HANDWHEEL/

MECHANICAL AIR LOCK OPTION.

DIAPHRAGM/

SPRING

ASSEMBLY

5. Remove cam assembly (1, Figure B-4) from shaft (2).

6. Remove the diaphragm/spring assembly (3) from the frame.

7. Remove the pilot valve/pilot valve manifold (4) from the frame.

CONNECTING

LINK

29330025

PNEUMATIC

CYLINDER

ELBOW

FITTING

ELBOW

FITTING

PILOT

VALV E

STEM

PILOT VALVE

MANIFOLD

Figure B-3. Air Tubing and Positioner System (Pre-retrofit)

IB-102-208P

B-3

Page 92

1. Cam Assembly

2. Shaft

3. Diaphragm/Spring Assembly

4. Pilot Valve/Pilot Valve Manifold

Figure B-4. Component Removal

c. Install PowerVUE Components.

NOTE

Before installing any PowerVUE retrofit components on the unit, ensure pneumatic cylinder piston is completely down.

1. Ensure pneumatic cylinder piston is completely down.

2. Install cam assembly to shaft, Figure B-5. Leave screws loose so cam rotates on shaft for later adjustment.

3. Hold up PowerVUE retrofit subassembly to bearing blocks and mark position of mounting blocks, Figure B-5.

29330026

Ensure weld splash does not damage actuator shaft, grease fittings, mounting hardware holes, or any other actuator components.

4. Remove mounting blocks from PowerVUE retrofit subassembly and weld to bearing blocks in marked positions. Ensure weld splash does not damage actuator components.

5. Install PowerVUE retrofit subassembly to mounting blocks with two allen screws provided.

IB-102-208P

B-4

Page 93

Figure B-5. PowerVUE Component Installation

6. Adjust cam assembly on actuator shaft so that the surface of the cam contacts DVC6000 follower arm roller squarely. Rotate the cam assembly so that the DVC6000 follower arm just retracts slightly. Tighten cam assembly to actuator shaft.

d. Install PowerVUE System Air Tubing.

NOTE

Prior to connecting supply air to the actuator, purge the air system to remove all moisture and debris.

Fitted air lines may be copper or stainless steel depending on specific kit order.

1. Install air supply line (1, Figure B-6) to Tfitting (2). Connect air supply line between DVC6000 and air manifold.

2. Install elbows (3) and fitted air lines (4) to top and bottom of pneumatic cylinder.

NOTE

Trip valve has air fittings pre-installed in port 4, port 5, and side as installation aid.

3. Install top fitted air line (4) to T-fitting in port 4 on top of trip valve. Install bottom fitted air line (4) to T-fitting in port 5 on bottom of trip valve.

IB-102-208P

B-5

Page 94

Figure B-6. Air Piping Diagram (with Mechanical Air Lock Option)

IB-102-208P

B-6

Page 95

Severe personal injury is possible. Do

not attempt to cut flexible air tubing while supporting by hand. Place tubing on a suitable surface prior to cutting. Failure to take proper precautions can lead to blade slippage and serious injury.

NOTE

6. Install flexible tubing (7) from T-fitting (5) on top of trip valve to port B (bottom port) of DVC6000.

7. Install flexible tubing (8) from fitting on left side of trip valve to T-fitting (9) on bottom of mechanical air lock.

8. If the retrofit resulted in an open line leading from the transfer valve, remove the line and plug the open port on the transfer valve.

Ensure each section of flexible air line is of adequate length prior to cutting it from the roll of tubing.

4. Place flexible tubing on a suitable surface and cut adequate lengths of air line from the roll.

5. Install flexible tubing (6) from top T-fitting (5) to port A (top port) of DVC6000.

B-5. DVC6000 ELECTRONICS SETUP. Initial setup

of the DVC6000 has been performed at the factory. Refer to Sections 4 and 5 of FIELDVUE DVC6000 Series Digital Valve Controller Instruction Manual for any additional tuning that may be required for particular applications.

B-6. CALIBRATION. Refer to Sections 4 and 6 of

FIELDVUE DVC6000 Series Digital Valve Controller Instruction Manual to calibrate the DVC6000 electronic unit.

IB-102-208P

B-7/B-8

Page 96

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Page 97

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller's direct control.

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Instruction Manual

IB-102-208P Rev. 1.1 November 2001

PowerVUE Fan/Damper Actuator

PowerVUE

Pa rt n o . _______________ Se ria l n o. _______________ Or d er n o. _______________

Emerson Process Management

Rosemount Analytical Inc. Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.

1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

Fisher-Rosemount GmbH & Co.

Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd.

Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount

Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Rosemount Analytical PowerVUE 8x14 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

HIGHLIGHTS OF CHANGES

PURPOSE

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

SECTION I. DESCRIPTION

SECTION II. INSTALLATION

SECTION III. DVC5000/6000 ELECTRONICS SETUP

SECTION IV. STARTUP CALIBRATION

SECTION V. TROUBLESHOOTING

5-1. OVERVIEW. Refer to the applicable FIELDVUE

SECTION VI. PERIODIC MAINTENANCE

SECTION VII. CORRECTIVE MAINTENANCE

7-9. SHAFT BUSHINGS. Use the following procedure

SECTION VIII. OPTIONS

SECTION IX. RECOMMENDED SPARE PARTS

SECTION X. RETURNING EQUIPMENT TO THE FACTORY

INDEX

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS