Rosemount Analytical Torque 6x10, Torque 8x14 Operating Manual
HAGAN POWER
POSITIONER
TORQUE TYPE
6x 10 INCH
Instruction Bulletin IB-102-207 Rev. 2
Supercedes II-102.207 dated January, 1985
FISHER-ROSEMOUIIT”ManagingThe Process Better
ROSEMOUNT WARRANTY
Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free
of defects in workmanship or material. Should any failure to conform to this warranty become apparent
daring a period of one year after date of shipment, Rosemount shall, upon prompt written notice from the
purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts.
Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with
respect to the quality of the equipment.
THE FOREGOING WARRANTY IS EXCLUSIVE AND JN LIEU OF ALL OTHER WARRANTIES
OF QUALITY WHETHER WRIT-l-RN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF
MERCHANTABILITY OF FITNESS FOR PURPOSE).
The remedy(ies) provided above shall be purchaser’s sole remedy(ies) for any failure of Rosemount to
comply with the warranty provisions, whether claims by the purchaser are baaed in contract or in tort
(including negligence).
Rosemount does not warrant equipment against deterioration due to environment. Factors such as corrosive
gases and solid particulates can be detrimental and can create the need for repair or replacement as part of
normal wear and tear daring the warranty period.
Equipment supplied by Rosemount Analytical Inc. but not manufactured by it, will be subject to the same
warranty as is extended to Rosemount by the original manufacturer.
PURPOSE
The purpose of this manual is to provide a comprehensive understanding of the Hagan 6 x 10
Power Positioner, components, functions, installation, and maintenance.
This manual is designed to provide information about the Hagan 6 x 10 Power Positioner. We
recommend that you thoroughly familiarize yourself with the Description and Installation section before
installing your power positioner.
The overview presents the basic principles of the power positioner along with the it’s performance
characteristics and components. The remaining sections contain detail procedures and information necessary
for installation and servicing of the power positioner.
Before contacting Rosemount concerning any questions, fast consult this manual. It describes most
situations encountered in your equipment’s operation and details necessary action.
DEFINITIONS
The following defmitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this
publication.
WARNING
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.
CAUTION
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
Highlights an essential operating procedure, condition, or statement.
NOTE TO USERS
The P- number in the lower right comer of the illustrations in this publication are manual
illustration numbers. They are not part numbers, and are not related to the illustration in any technical
manner.
IB-m2-*07
it
TABLE OF CONTENTS
SWtiOU
RosemountWarranty . . . . ..__................_______.......... i
Purpose . . ..___...................................___...__
I.
II.
III.
DESCRIPTION
l-l. Component Checklist of Typical System (Package Contents)
1-2. Model Number Matrix
l-3. System Overview
l-4. Model PP61OTR Specifications
l-5. storage Instruction
INSTALLATION
2-1. Overview
2-2. Special Installation Considerations
2-3. Power Positioner Mounting Instructions
2-4. Air Supply Installation
2-5. Current to Pneumatic Signal Converter (I/P)
Electrical Connections
2-6. Linkage Installation ..__.
REVERSE OPERATION
3-l. Operational Description
3-2. Procedures for Reversing Operation
. . . . . . . .
..... 2-1
...... 2-1
...... 2-1
...... 2-2
...... 2-4
...... 2-4
...... 2-4
Page
1-l
l-l
l-1
l-5
l-5
3-1
3-1
ii
IV.
V.
VI.
VII.
CALIBRATION
4-1. Check Power Positioner Calibration
4-2. Stroke Calibration
4-3. Current to Pneumatic (I/P) Signal Converter Calibration
4-4. Linkage Calibration
TROUBLESHOOTING
5-l. Overview
5-2. Troubleshooting Chart
PERIODIC MAINTENANCE
6-l. Overview
6-2. Maintenance Schedule
6-3. General Cleaning and Lubrication
6-4. Pilot Valve Cleaning and Inspection
6-5. Air Filter Cleaning and Draining
6-6. Diaphragm Cleaning and Inspection
6-7. Cylinder and Piston, Cleaning and Inspection
CORRECTIVE MAINTENANCE
7-1. Overview
7.2. Parts Replacement
...... 4-l
...... 4-2
...... 4-5
...... 4-5
......
......
...... 6-1
......
...... 6-l
...... 6-l
...... 6-l
...... 6-4
...... 6-5
......
......
5-l
5-l
6-1
7-l
7-l
TABLE OF CONTENTS (Continued)
VIII. OPTIONS MAINTENANCE
8-l. Overview _........_...___..........__._...__.__.,,,,__
8-2. AirLock _.____.._........_...._..___..,..._.___....__,,,..,._ 8-l
8-3. Electric Position Transmitter @PT)
8-4. Heatwllwmostat
Ix. RECOMMENDED SPARE PARTS
8-l
8-3
8.3
X.
Figure
l-l.
l-2.
1-3.
2-l.
2-2.
2-3.
2.4.
2-5.
2-6.
2-l.
2-8.
2-9.
2-10.
2-11.
3-1.
4-1.
4-2.
4-3.
4-4.
4-5.
6-l.
6-2.
6-3.
6-4.
7-1.
l-2.
7-3.
l-4.
l-5.
8-l.
8-2.
8-3.
RETURNING EQUIPMENT TO THR FACTORY
INDEX
LIST OF ILLUSTRATIONS
Typical System Package
Power Positioner Operation
Typical Power Positioner Installation
Mounting Dimensions
Cleamnce Requirements
6
x 10 Power Positioner Torque Chart
Air Piping Schematic
Linear Linkage Design
Vertical Arm Travel
Driven Shaft Angular Rotation
Connecting Linkage. Length
Characterized Linear Linkage Design
Cam Bar Shaping
Driven Lever Travel
Reverse Operations
Calibration Flowchart
Stroke Adjustment
Current to Pneumatic Signal Converter
Linear Linkage Calibration
Characterized Linkage Calibration
Lubrication Chat
Pilot Valve Exploded View
Diaphragm Exploded View
Cylinder Exploded View
Air Filter
Pilot Valve
Receiver Exploded View
Cylinder Exploded View
Shaft Exploded View
Air Lock
Air Lock Diaphragm Exploded View
Heaterfllwmostat Replacement
Page
l-l
1-3
l-5
2-l
2-2
2-2
2-3
2-4
2-s
2-6
2-l
2-9
2-10
2-14
3-2
4-l
4-4
4-5
4-6
4-6
6-2
6-3
6-5
6-b
7-l
l-3
l-4
7-6
7-10
8-1
8-2
8-4
LIST OF TABLES
Table
l-1. Model Number Matrix
1-2. Specifications for Model PP61OTR Power Positioner ....................
1-3. Specifications for Recommended Rust Preventive Compound ..............
2-1.
4-1. Device Travel (%)
4-2. Piston Travel (Stroke) Calibration Schedule ...........................
4-3.
5-l.
6-l. Maintenance Schedule ..........................................
9-1.
9-2. Spare Parts for Options (PP61OTR 6 x 10 Power Positioner Only)
9-3.
SystemFlowChart
Direct and Inverse Calibration Signal Pressures ........................
Troubleshooting Chart ..........................................
Recommended Spare Parts for PP61OTR 6 x 10 Power Positioner ...........
Bill of Materials for PP61OTR 6 x 10 Power Positioner ..................
.........................................
............................................
............................................
...........
Page
l-2
1-6
1-6
2-9
4-2
4-3
4-4
5-l
6-1
9-1
9-l
9-2
SECTION I. DESCRIPTION
l-l.
COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS~. A typical
Rosemount 6 X 10 Power Positioner oackaae should
contain the following items shown in-Figure l-l.
1-2.
MODEL NUMBER MATRIX. Use model number
matrix, Table l-l, to verify your style number. The
first part of the matrix dcfmes the model. The last
part defmes the various options and feataxes of the
power positioner. Copy your model number from data
plate located on back of power positioner, into top of
matrix Table l-l. Check your model number against
the features and options of the p0we.r positioner,
making sure the options specified by this number are
on this unit. Use this complete model number for any
comespondcnce with Rosemount.
1-3.
SYSTEM OVERVIEW.
a.
w. This Instruction Bulletin has been de-
signed to supply details needed to install, operate,
and service the Rosemount 6 X 10 Torque Type
Power Positioner (Figure l-l). The standard
power positioner comes with manual lever,
manual lock, bypass valve, current to pneumatic
signal converter o/p), pressure rcgulator/tilter,
supply air filter, clevis, and dust cover. Options
for the power positioner include electric position
tmnsmitter, limit switches, heater/thermostat, air
lock, and minimum liiit stop. Service instmc-
tions for these options are covered in the appedices to this manual.
b.
Power Positioner Features. The standard model
power positioner includes the following features:
1.
The manual lever provides leverage so
operator can manually change the position of
the device being contilled.
2.
The manual lock allows operator to manually lock the piston and output shaft assembly
in any position. This is done by clamping
the sector with the manual lock handle,
manually shutting-off supply air, and setting
the by-pass valve to open.
ITEM DESCRIPTION
1 Model PP61OTR Power Positioner
2 Air Filter
3 Instruction Bulletin
Fire l-l. Typical System Package
ing manual positioning of device being
controlled.
4.
The current to pneumatic signal converter
(UP) controls signal air to the power posi-
tioner through an electrical signal. Thii
electrical signal can be either a direct 4 to
20 mA signal or an inverse. 20 to 4 mA
signal. The power positioner can be ordered
with out the I/P converter. Without the J/P
converter, an air signal controls the power
positioner. This air signal can be direct or
inverse, and have a range of either 3 to 15
psig or 0 to 30 psig.
5.
The pressure regulator/filter maintains a
stable and filtered air supply to the l/P
converter.
3.
A bypass valve provides a passage between
top and bottom of piston to cqualii air
pressure on both sides of the piston, allow-
IB-102-207
l-1
6.
The supply air filter will remove finely dis-
persed water or oil droplets from the supply
air. Supply air mast be free of oil and water
to prevent pilot valve sticking.
Table l-l. Model Number Matrix.
DESCRIPTION
PNEUMATIC POWER POSITIONER
6 x 10 TORQUE TYPE
FRAME DESCRlPTlON
Standard/Brass Connections ___..............................,............
Lodamss C0”“ecti0”s 2
Manual
Manual and Air Lc&‘Brass Connections ____.__............_.......
Sta”da”vstai”lsss stwl Co”“ecocns
Manual Lockistai”less steel Co”mtio”s
Manual and Air Lo&Stainless Steel Connections _________....
PP610TR
1
3
4
5
6
TYPE INPUT
!
UMIT
HEATER
I
EPT/
STOP
DRIVE SHAFT ASSEMBLY
Right Hand
Left Hand Drive . ..______...............................................
SIGNAL RANGE
515PSlG
O-30 PSIG ..__.___________...............,,,,,...................................
4-20 mA (I/P Mounted and Piped) .._.___...................
LIMIT SWITCH
Selection Based on TYPE
None ...................................................................................
Two Standard (Notes 1 and 6)
Two Standard (Notea 2 and 6) ...........................................
Two Standard (Notes 3 and 6) ...........................................
Two Heavy Duty (Notes 1 and 7) .......................................
Two Heavy Duty (Notes 2 aid 7) .......................................
Two Heavy Duty (Notes 3 and 7) .......................................
HEATER
None ._.______..,.,...._................................,..,,,.......................... 0
117Vac. 150WattHeater ._...__..___.........................,.,,,,,,,,,.. 1
MISCELLANEOUS ACCESSORIES
S&&o” Based on TYPE.
None ...................................................................................
El&ic Pmition Transmitter (See Note 4) .........................
Electric Position Transmitter fSee Note 51
Elecb’ic Position Transmitter Ad Ltmit Stop
(See
Electric Position Transmitter and Limit Stop
(See Note 5) _____._._................................,.,........................
Minimum Limit Stop .._........................................
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
........................................... 1
.........................
Note 4) 3
2
t--
2
3
0
2
3
4
5
6
0
1
2
4
5
NOTES:
(1)
For
(2) For TYF’E Codes 22 and 52.
TYPE Codes 11,X?, Zl, 3,,41,42,51, and 61.
(3) For TYPE Codes 32 and 62.
(4) For TYPE Cades 2l,3l, 51, and 61.
Q For TYPE Codes 11,12,22,32,41,42,52,
(6) SPDT Switch Ratings
15 *raps, 125,250, or 480 vat;
l/2 Amp, 125 Vdc.
(7) National Acme DPDT Switch Rat,,,@
VOlf.9
bps
125vae 20
25ovac 10
600 Vat 5
U5Vdc 5
and 62.
IB-1u2-207
1.2
7.
The clevis provides a connection from powcr positioner to liige so movement can be
transferred to the device being controlled.
8.
A dust cover provides a NEMA type 3
enclosure. It is removable and splash proof.
e.
Operational Description. The Model PP61OTR
Torque Type Power Positioner is a pneumatic
driven, double acting piston type power cylinder
in which the operating lever is positioned to a
specific setting for each input signal. The power
positioner is mounted on a steel floor stand. The
unit is covered and protected by a splash proof
metal dust cover. The power positioner is used to
position devices such as inlet vanes, control
valves, and dampers.
1. Automatic Operation. Figure 1-2 depicts a
direct acting power positioner. In thii type
I
PISTON ROD
MANUAL LOCK,
MANUAL LEVER .-
PISTON ’
;1
/
I
/OPERATING ARM
DIAPHRAGM
CALIBRATION SPRING
FROM TOP
TO 801 OF
OF
Fiiure 1-2. Power Positioner Operation
CONNECTING LINK
PILOT VALVE STEM
PILOT VALVE
IB-162-207
t-3
of positioner, a” increase in signal air pressure to the receiver causes the diaphragm to
overcome the tension of the calibration
spring moving the diaphragm downwards.
The downward motion is transmitted to the
pilot valve through a connecti”g link. Thii
positions the pilot valve stem to send supply
air below the piston forcing the piston,
piston rod, and operating arm upwards. Air
from above the piston is exhausted through
the pilot valves exhaust silencer plug.
The upward movement of the piston rod
raises the cam bar. This ca”ses the roller,
riding on the cam bar, to lift the spring
socket increasing pressure on the calibration
spring. The increased pressure on the calibration spring retwns the diaphragm to its
neutral position, closing the pilot valve air
ports. Without additional air, piston movcment is stopped.
As signal air decreases the calibration spring
pressure moves the diaphragm up. The
upward movement of the diaphragm moves
the pilot valve stem up directing air above
the piston. This forces the piston, piston rod,
and operating lever downward. The downward movement of the piston rod, working
through the cam bar and roller, lowers the
calibration spring socket and reduces pressure. on the calibration spring. This
decreased pressure on the calibration spring
returns the receiver’s diaphragm to a neutral
position closing the pilot valve air ports.
2.
Cam Bar. When a linear relationship between input signal and piston position is
desired, the cam bar is straight. The cam bar
can be shaped to produce either a square (9)
shape or a square-root (rx) shape relationship between input signal and operating
lever stroke. Refer to paragmph 2-6b2 for
cam bar shaping.
‘0 20 40 60
loo 80 60 40 20 0
OUTPUT POSITION (%)
80 100
DIRECT (-
INVERSE ( . . . .
Squared Shape Cam Bar. The square
(x2) shape will produce a small output
change for a large input change during
the lower portion of the signal range.
When operating in the upper portion of
the signal range, a small input change
will produce a huge output change.
100 80 60 40 20 0
OUTPUT POSITION (%)
DIRECT (-
INVERSE ( . . . .I
(c) Square-Root Shaped Cam Bar. The
square-root (fx) shape will produce a
relatively large output change for small
input changes during approximately the
fast 10% of signal range. When opersting in the upper portion of the signal
range, a large input change will be
rqdred to produce a small output
change.
SQUARE ROOl
LINEAR(x)
Pccnl5
SQUARE (9)
PM036
(a) Straight Shape Cam Bar. A straight,
non-characterized cam bar will produce
a linear shape (1:l) relationship between the input signal and output
02pO”S~.
IB-ICC-207
l-4
‘0 20 40 60
100 80 60
OUTPUT POSITION (%)
80 100
40 20 0
DIRECT (INVERSE ( . . .;
Km37
3. Inverse Operation. On inverse acting power
positioners, the cam bar is reversed top to
bottom and the reversal manifold is turned
90”. This causes the supply air to be directed to the top of the piston when signal air
pressure is increased and to the bottom of
the piston when signal air pressure is decreased. In this type of installation, piston
movement is inversely related to the signal-as signal pressure decreases, the piston
raises, as signal pressure raises, the piston
1OUWS.
4. Manual Operation. The power positioner
can be controlled manually through the
manual lever. The movement of this lever
directly controls the position of the device
being controlled. To operate the manual
lever, shut off supply air and open the by-
pass valve.
d. System Considerations. Prior to installation of
your Rosemount 6 X 10 Power Positioner, check
that you have all the components necessary to
make. the complete system installation.
POSITIONER
Once you have verified that you have all the
components, select mounting location. A typical
installation is illustrated in Figure 1-3. De&mine
where power positioner will be placed in terms of
serviceability, available power supply, ambient
temperatures, environmental considerations, and
convenience. Power positioner operating specifications are listed in Table l-2. Become familiar
with Section II, Installation, before. installing unit.
1-4. MODEL PP61OTR SPECIFICATIONS. Model
PP61OTR Power Positioner specifications contain
information about the operating characteristics of the
Figure 1-3. Typical Power Position Installation
power positioner. Use Table l-2 to make sure that available
conditions are suitable. for the power positioner before
choosing mounting location.
Table 1-2. Specifications for Model PP61OTR Power Positioner.
Inputs:
Direct: 4-20 mA/3-15 psig/O90 psig
Inverse: 20-4 mA/15-3 psig/30-0 psig
Performance
Repeatability
Full Stroke Time (unloaded)
Maximum Allowable Cylinder Air Pressure
Supply Air Consumption
Control Torque
Maximum Friction Load
Stall Torque
Outputs
Physical Characteristics
Weight
Dust Cover
Supply Air Input Fitting
Signal Air Input Fitting
Environmental Requirements
Ambient Temperature
Limits:
Without heater
With heater
Relative Humidity
1% of full stroke or better
5 seconds or less
120 psig
1 scfm free air
1050 ft-lbs
450 ft-lbs
1800 ft-lbs
84’ shaft rotation
275 lbs, typical
designed to meet NEMA
Type 3 requirements
l/4 inch NPT female connection
l/4 inch NPT female
connection
40’F to 140°F (4S”C to 60°C)
0-F to 140°F (-17.8”C to 60°C)
operable up to 100% RH
Air Supply Requirements
Operating Air Supply Pressure
Recommended Air Supply Pressure
45 to 120 psig
100 psiz
1-5. STORAGE INSTRUCTIONS. Use the following
guidelines for storage of the power positioner.
a. Storage Environment. Store power positioner in
a warehouse environment that maintains the
following conditions:
1. Ambient temperatures above 45°F (7°C).
2. Humidity below 80% RH.
b. Power Positioner Preparation for Storage. Coat
all non-painted surfaces and exposed metal with a
rust-preventive compound (Tectyl 506 OI a
substitute with similar properties). The specifications for Tectyl 506 are included in Table l-3.
WARNING
CAUTION
Use only approved thinning methods when applying
rust-preventive compounds. Do not apply heat to
compound. Fire or explosion may result. Refer to
manufacture of rust-preventive compound for
specitlc application, thinning, clean-up and removal
instructions.
c. Storage Preventive Maintenance. If storing power
positioner longer than six months, observe the following preventive maintenance guidelines.
1. Cycle cylinder and piston either manually or by air
every 6 months.
Keep Tectyl506 away from heat, sparks, and open
flames and use with adequate ventibxtion. Ventilation is required for cure and to prevent an explosive
atmosphere from forming.
Table 1-3. Sp&tiications for Recommended Rust Preventive Compound.
REQUIREMENTS PROPERTIES
Approximate air dry time 1 hour
Low Temperature Flexibility -10°F (-22.5”C)
(90” bend with no flaking or cracking)
Volatile Organic Content (V.O.C.) 3.24 1bsRJ.S. Gallon
Accelerated Corrosion Tests: (5% Salt Spray (Hours))
ASTM(seeNotel)B-117atl.3mils _.......______.._.__..___. 2000
(2 x 4 x 118 inch Polished Steel Panels)
DIN (see Note 2) 50021 at 32.5 microns 168
(125 x 200 mm DIN 1623 Panels)
NOTES:
(1) ASTM (American Society for Testing and Materials)
(2) DIN (Deutsche Industrie Normen)
2. Perform General Cleaning and Lubrication (paragraph 6.3), and Cylinder and Piston, Cleaning and
Lubrication (paragraph 6-7), before installing
power positioner.
400 grams/liter
SECTION II. INSTALLATION
2-1. OVERVIEW. The power positioner is designed to
be installed upright The floor stand is bolted to a
prepared horizontal foundation. A minimum of 45
psig to a maximum of 120 psig supply air pressure is
needed at the mounting location. The power positioner must be controlled by either an elechicaJ signal
or by an air signal. All wiring must conform to local
and national codes.
2-2. SPECIAL INSTALLATION CONSIDERATIONS.
a.
Foundation. The power positioner’s torque is
transmitted to the operating arm of the device,
this torque is transferred to the mass of the
positioner and its foundation. The foundation
mast be designed to handle the torque produced
to keep the power positioner stationary. Refer to
paragraph 2-3 for detailed foundation require-
ments.
b.
SUPP~V
air pressure of 45 to 120 psig, minimum of 1
scfm, is required. A Nter and regulator should be
provided in the supply line.
c.
Linkaee Design Considerations. Final control
components play a large part in a control system.
Special characteristics of the device being controlled affect system response and most be reganied in design and set-up of a power positioning system.
Air Pressure Considerations. A supply
Flow tests mast be conducted before attempting
to limit damper opening. Testing is necessary to
contii actual damper characteristics and to
ensure control response throughout the entire.
flow range. When installing a new power
positioning system, care must be taken to properly design the system for linkage size and
action. In a properly designed system, a percentage change in control signal will produce the
same percentage change in flow rate. Refer to
paragraph 2-6 for detailed information on design
and installation of a linearized control action
power positioning system.
2-3. POWER POSITIONER MOUNTING
INSTRUCTIONS.
a. Footmint Foundation and
Mounting Requirements.
1.
Foundation Dimensions. Dimensions for
mounting base of stand assembly to foandation are found on Figure 2-1. Four mounting
holes in base are drilled for 3/4 inch foundation bolts.
t-
t-4.625-+-4.6254
Control valvea and damper drives regularly allow
large flow rate changes, compared to valve
movement, near the closed position. Smaller flow
rate changes compared to valve movement occur
near the fully open position. In normal damper
applications there may be no flow rate changes
after damper has reached 70% open. This
characteristic is represented by the following
mathematical equation:
Flow = k (Position)’
k = Constant
This equation means that flow is proportional to
square of valve position. As damper or valve
opens, the rate at which flow changes per valve
position is reduced. As valve or damper closes,
the rate at which flow changes per valve position
is increased.
B-102-207
DIMENSIONS ARE IN INCHES.
Figure 2-1. Mounting Dimensions
2.1
1
14.2!
5
1
ffiter, Figure 2-4. The air filter will remove finely
dispersed water or oil droplets, preventing
sticking of the pilot valve stem.
If your unit is not equipped with an IiF’ signal
converter, a separate signal line must be installed
as shown in Figure 2-4, View B. Tbis signal line
must be either 0 to 30 psig or 3 to 15 psig. Refer
to your model number and model number matrix
(Table l-l) to determine type of air signal
required.
b. Supply Air and Signal Air Connections. Basic
schematics are shown in Figure 2-4. The
installation of the air filter is as follows:
1. Mount bracket for air filter directly on the
back of the stand assembly. If tbis is
unsuitable, mount air filter within 15 feet of
power positioner.
DIMENSIONS ARE IN INCHES.
Figure 2-2. Clearance Requirements
2. Strength Requirement. Foundation must be
able to withstand 1050 ft-lbs torque plus 250
pounds weight. Mount power positioner to
the foundation with 3/4 inch bolts.
b. Working Clearance Requirements. Make sure
area is clear of obstructions that will interfere
with operation and maintenance. Allow adequate
clearance (34.25 inches from foundation
vertically, 41.25 inches front to back) for removal
of dust cover and for full travel of operating and
manual levers (Figure 2-2).
2-4. AIR SUPPLY INSTALLATION. Using Figure 2-3,
match the torque load needed to position your device
to the “maximum torque required” axis along the
bottom of the graph. From this point, move vertically
up to the control torque curve. From the point that
intersects control torque curve, move horizontally to
the left scale labeled “supply air pressure”. This is the
minimum supply air required to develop the required
control torque. The stall torque curve represents tbe
maximum amount of torque the power positioner will
produce for given supply air pressure before stalling
out.
a. Air Llle Requirements. Installation of air filter
is necessary for proper power positioner
operation. A manual shutoff valve should be
installed in the air supply line before the air
NOTE
Prior to comvxting supply air line or signal
air line, purge air systems until all moisture
and debris are blown out
2. Purge air supply system and connect air
supply line to the air filter inlet. Run a
second line from the air filter outlet to the
power positioner supply air inlet connection.
All fittings are l/4 inch NPT.
3. Purge signal air line and connect to signal
air connection on power positioner.
120
100
80
s”EiLy
PFIESES~FIE 6o
40
20
0
MAXIMUM TORQUE REQUIRED
(FT.LSS)
Figure 2-3. 6 x 10 Power Positioner Torque Chart
POW06
18-102-207
2-2
REGULATOWFILTER
SHUTOFF
VALVE
CONNECTION
6
x 10 POWER
POSITIONER
VIEW A
POWER POSITIONER WITH CURRENT TO PNEUMATIC SIGNAL COVERTER (I/P)
SUPPLY AIR
>120
PSIG
l/4-16
CONNECTION
NPT
+--‘5tvhFT---+
AIR
FILTER
:I3 TO PILOT VALVE
l/4-18
COCK
CONNECTION
VIEW B
POWER POSITIONER WITH PNEUMATIC CONTROL SIGNAL
Figure 2-4. Air Piping Schematic
NPT
6 x IO POWER
POSITIONER
2-5. CURRENT TO PNEUMATIC SIGNAL
CONVERTER (I/P) ELECTRICAL
CONNECTIONS. Connect electrical signal input to
I/F’ converter and calibrate if necessary, refer to
paragraph 4-3 for calibration procedures. The
connections most be made by screw terminals. If the
I/P has pigtail leads instead of screw terminals, the
connection must be made at a terminal block. Gage of
wire required is 18 gage signal wire. The signal that
wiU control the W should have a range of 4 to 20
mA at a voltage of 24 vdc.
a. Direct Acting. Connect positive signal to black
lead and negative signal to white lead.
h. Reverse Acting.. Connect positive signal to
white lead and negative signal to black lead.
2-6. LINKAGE INSTALLATION. lnstxdl liige for
either a characterized flow control device, or linkage
for a linear flow control device. Linkage described is
pipe (l-1/4 inches diameter), maximum length is 21
feet, 9 inches.
a. Linkage Installation for a Characterized Flow
Control Device.
DRIVE
LEVER
POWER
POSITIONER
1. Measure length of driven lever (Figure 2-5)
on device to be controlled (R,).
2. Attach the linkage clevis to the power
positioner’s drive lever so that distance & is
equal to R,.
3. Close damper of device to minimum flow
position.
4. Measure angle (6,) of device’s driven lever
from vertical.
5. Inslall power positioner’s drive lever so its
angle l$ is the same as the device’s driven
lever (0,).
6. Measure. distance (p) between operating
levers connection holes. Cut linkage pipe to
fit this measoremenr allow for clevis length.
7. Install pipe (linkage) between operating
levers, check for freedom of movement by
operating power positioner’s manual lever.
Minor adjustments can be made to linkage
length by turning linkage clevis fitting in or
out as “L?ceSsary.
Pwme
Figure 2-5. Linear Linkage Design
b. Linkage Installation for a Linear Flow Control
Device. Linear flow control devices require a
characterized control system. This can be
accomplished by either characterizing linkage or
the power positioner.
If greater torque is required at start of power
positioner movement, characterize the linkage
system. This is covered in step 1.
If this additional starting torque is not required,
a linear linkage can be installed; the power
positioner cam bar must be shaped to characterize
the power positioner. This is covered in step 2.
NOTE
Linkage installation described in thii section
of the manual are for direct acting power
positioners.
1. Characterized Linkage System.
IB-102.207
2-4
Sine Function (SIN)
Square Function (x’)
Use the following procedure to
determine Y, the vertical distance
travell.xl by drive lever:
1 Add value of 8, to value of &.
2 Divide answer from step 1. by 2.0.
3 Enter answer from step 2. aad press
sine key (SJN).
\ DRIVE
LEVER
POWER
POSITIONER
Figure 2-6. Vertical Arm Travel
(a) Make sore a straight cam bar is
installed to get linear outputs from
power positioner.
(b) Figure out how far vertically the
operating lever travels using Figure 2-6
aad the following equation:
NOTE 14 Clear calculator.
4 Press square. key (x”,.
2 Multiply answer from step 2 by
length of drive lever (RI).
6 Multiply answer from step 5 by 2.
z Write down answer from step 6
and label it 6 for use later.
& Clear calculator.
2 Enter value of pP
a Press sine key (SIN).
.lJ Divide answer from step jQ by 2.0.
12 Press square key (asaally key
marked x3.
12 Write down answer from step 12.
and lab4 it 12.
The following known values are used to
calculate the vertical distance travelled by
the drive lever
“Y”-
, .
R, = Length of the drive lever (from shaft
center to clevis pin center)
Total angular rotation of the drive
Cl1 =
lever
Angular measurement of drive lever
PI =
from vertical centerline with piston
fully extended.
To perform the following procedure, a
calculator with basic functions, plus the
following scientific fanctions, is
necessary:
IF-102-207
2-s
u Enter value marked fi aad subtract
value marked 12.
16 The value in step u is equal to
vertical distance travelled by drive
lever “Y”.
(c) Since we know how far angularly the
drive lever will move, determine the
angular rotation
of driven lever
interms of drive lever rotation. The
angular rotation follows Figure 2-7 aad
the relationship:
DRIVE
LEVER
use the following procedure to
determine O,, the angular rotation of
the driven lever.
1 Add value of PI to value of 8,.
2. Enter answer from step 1. and press
sine key (SIN).
3 Divide answer from step 2 by 2.0.
4 Multiply answer from step 3 by
length of driven lever (&).
2 Write down answer from step 4
and label it 2. Clear calculator.
6 Enter value for length of drive
lever (Rd.
1 Divide value. from step 6 by value
marked 5.
8 Press square key (x3.
Figure 2-7. Driven Shaft Angular Rotation
NOTE
The followiag known values are used to
calculate the total angular rotation of the
driven lever, 8,:
8, = Total angular rotation of the drive
lever
R, = Length of the drive lever (from shaft
center to clevis pin center)
& = Length of the driven lever (from
shaft center to clevis pin center)
f& = Angular measurement of drive lever
from vertical centerline with piston
folly extended
bt = Angular measurement of driven lever
from vertical centerline with damper
fully closed.
To perform the following procedure, a
cakxlator with basic functions, plus the
following scientific functions, is
lN%Xssary:
Sine Function (SIN)
Inverse Sine Function (SIN’) or (INV
SIN)
Square Function (x3
Power Function (y”)
2 Write down answer from step 8
and label it 5 for use later.
g Clear calcolator.
11. Enter value for PI and press sine
key (SW.
12 Divide answer from step 11 by 2.
12. Press square key (x”).
14 Write down answer from step .lJ
and label it 13 for later use.
u Enter value for a and press sine
key (SW.
16 Divide answer from u by 2.
12 Press square key (x2).
B Write down answer from u and
label it ,lJ for later use.
19 Clear calcllhtor.
20 Enter value marked &
21. Subtract value marked 13 tiom
value marked 8.
m-102-207
2.6
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