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
Subtract value marked 11 from step 21.
Press power function key (fl. Enter 0.5. Press inverse sine (INV SIN or
SW).
Write down answer from step 25
and label it 2.
Clear calc”lator. Enter value for bL. Divide value Fran step 28 by 2. Write down answer from step 29
and label it 29. Clear calculator. Enter value fmm step 2.
Subtract value f?om step 2. Multiply answer from step 32 by 2. The value in step 33 is equal to
total angular rotzl of driven lever V,“.
(d) To calculate length of connecting
linkage based on the length of drive lever, driven lever, and the initial offset of both, “se Figure 2-8 and the following relationship:
t= [I,- ~R@s~,+R#x&) ‘+
(R,SfnflI-R@$,)
NOTE
The following known values are used to calculate the length of the linkage I in inches:
L=
Length between drive and driven shaft center lines
R, =
Length of the drive lever (from shaft center to clevis pin center)
rc,=
Length of the driven lever (from
shaft center to clevis pin center)
Angular measurement of drive lever
I% =
from vertical centerline with piston fully extended Angular measurement of driven lever
P2 =
from vertical centerline with damper fully closed
I o.5
Figure 2-8. Connecting Linkage Length
To perform the following procedure, a calculator with basic functions, plus the following scientific functions, is “ecessaly:
Sine Function (SIN) Cosine Function (COS) Square Function (x’)
Power Function (y”) Use the following procedure to
determine 4, the length of connecting linkage in inches:
1 Clear calc”lator,
IB-10%2Q7
2.7
Enter value for b1 and press cosine
2
key (COS).
Multiply answer from step 21 by length of driven lever (RJ.
3 Multiply answer from step 2 by
length of drive lever (R,).
3 Write. down answer from step 2
and label 2.
2 Clear calculator.
Enter value for pz and press cosine
6
key (COS).
1 Multiply answer from step 6 by
length of drive lever (R,).
& Write answer from step 1 down
and label 1. Clear calculator.
2 Add answer from step 8 to value
marked 2. @ Press sqnare key (x3. 11 Write down answer from step g
and label lo.
Write down answer from step 22. and label g. Clear calculator.
Subtract value marked 22 tiom value marked u.
Add answer from step 2 to value
marked~. Press power function key (y”). Enter 0.5 into calculator.
The value in step 27 is eqaal to
length of connectingiige “P “.
Design linkage system by using values for lengths of drive aad driven levers, angular position of both levers from vertical (offsets), and distance between drive and driven levers centers to calcnlate length of lib&age. These values were determined in the previous
steps. 12 Clear calc”lator. 13 Enter distance between drive and
driven shaft (L).
14 Subtract value marked 3 from
step JJ.
.Q Write down answer from step 14
and label H.
6 Clear calculator 12 Enter value for fil and press sine
key (SIN).
u Multiply answer from step 17 by
length of drive lever (R,).
19 Write down answer from step 18
aad label B.
20 Clear calc”lator.
21 Enter vale for fiz and press sine
key (SW.
(e) Close damper to minimum flow
position. Make sore driven lever is at
angle (PJ and drive lever is at angle
(BI).
Cat linkage pipe to length (#). Install
(0
linkage between operating levers.
(g) Check for freedom of movement by
operating power positioner’s manual
lever. Minor adjustments linkage length
can be made by turning pipe to clevis
fitting in or oat as necessary.
Record values on Figure 2-8 for p,, pz,
(h)
P, R,, and R,.
2. Characterized Power Positioner. Determine open and closed positions of
(a)
controlled damper. Install mechanical linkage so the power
(b)
positioner will travel through its ten inch stroke while positioning the damper from minimum to maximum opening.
B-102-207
2.8
DRIVEN
LEVER
CLEVIS
DRIVE
LEVER
POWER
POSITIONER
Install power positioner’s drive
lever at the same angle as the device’s operating lever (El,) with power positioner’s piston fully extended.
MeaSUre distance between operating levers connection holes
(0. Subtract distance of clevis and connection to the damper’s operating lever. Cut pipe to fit this measorement
Install pipe (linkage) between operating arms.
Check for freedom of movement by operating power positioner’s manual lever. Minor adjustments to linkage length can be made by tuning pipe to clevis fdtiag in or out as necessary.
u
Fiire 2-9. Characterized Linear Linkage Design
Measure. length of driven lever
(Figure 2-9) from its shaft center
to center of clevis pin (R,). Attach the linkage clevis to the
power positioner’s drive lever so that distance R, is equal to R,.
Close damper of device to minimum flow position.
Measure angle (63 of device’s driven lever from vertical centerline with damper closed.
Table 2-1. System Flow Chart.
INPUT
SIGNAL
10% 20%
30% 40% 50% 60% 70%
NOTE
Follow calibration procedures carefully. Proper power positioner calibration is essential to accurately shape the cam bar.
(c) Calibrate the stroke of power
positioner. Refer to paragraph 4-1. It is
essential to calibrate carefully.
(d) Measure and record actual flow of
system being controlled starting at zero input signal and increasing signal in
10% increments to 100%. Record these vahm in Table 2-1, System Flow Chart. These values will be used later
to plot the shape of the cam bar.
80% 90% 100%
FLOW
wm
IB-IM-207
2-9
DIMENSION
DIMENSION 6
A
t
- POW13
Figure 2-10. Cam
ROLLER AT BOTTOM
LOCK SCREW
DIMENSION C
Bar Shaping
(g) Near bottom of a sheet of graph paper,
draw a base line (Graph 1). Draw a vertical line near left side of paper. Label this line “% of Input Signal”.
(h) Mark point “A” to right of “% of Input
Signal” line. This point is 10 inches up from base line and at dimension “A’ from “% of Input Signal” line.
(i) Mark point “B” to right of input signal
line. Point “B” is on base line at same distance from “% Input Signal” line as dimension “B”.
(i) Lay cam bar on graph with lock screw
hole at bottom. Point “A” and point “B” as marked on cam bar should line up with point “A” and point “B” as
plotted on graph. Draw a heavy line
thra points “A” and point “B” and label cam bar line.
(e) Measure and record dimensions A, B,
and C as follows:
1 Using air pressure, move piston
and clevis head to bottom of stroke. Mark point that roller touches cam bar. This is point “A” (Figure 2-10).
2. Measure distance from point “A” to face of guide bar to the nearest
1/64th inch. Record thii as
dimension “A”.
2 Using air pressure, move piston
and clevis head to top of stxoke. Mark point that roller touches cam bar. This is point “B”.
4 Measure distance from point “B”
to guide bar to nearest 1/64th inch.
Record this as dimension “B”.
5 Dimension “C” is the distance
between guide bar to center of lock
screw. Measure to nearest 1/64th inch.
(0 Using signal air move piston to bottom of
stroke and remove lock screw (Figure 2-10). Remove compensating bar from positioner.
(k) Refer to Graph 2. Mark input signal
points, in 10% increments, on % of
input signal line at right edge of graph. 0% will be at the top of the graph,
Point A, and 100% will be at the base
he, Point B. Each 10% signal will be one inch apart
(1) Draw a line from each “% Input
Signal” horizontally to cam bar line. From this point of intersection, draw a vertical line to top of graph. Label top of graph “% of Horizontal Roller Travel”.
(m) On base line, label ten points recorded
in step d that represent flow of ten different signal positions. Record these ten flow points along base line between 0 and 100% flow (Graph 3).
NOTE
For this purpose, we used a 100% flow of 7 scfm. At 10% iaput signal we had flow of
18 scfm, at 20% input signal we had flow of 3.1 scfm, etc. These values noted in the example flow chart on Graph 3.
Graph I
% OF
INPUT
SIGNAL
80
Graph 2
: : : : :
From base. line, draw a vertical line at
(a
10% mark of 1.8 up to where a line
would extendhorizontally from 10% “% of Input Signal” scale. Repeat for 20% mark of 3.1 to a line extending horizontally from 20% “% of input signal” scale. Continue in same fashion for others from 30% flow mark to
100% flow mark. Draw a smooth curve thru these points from 0% flow to
100%. Label curve “x”. Draw a straight line from zero flow at
(0)
zero “% of Input Signal” to 100% flow at 100% “% of Input Signal”. Label
curve “y” (Graph 4).
(p) Draw a horizontal line from 10% “%
of Input Signal” at cam bar line to curve “Y”. Draw a line from this point vertically to curve “x”. Draw a line
from curve “x” horizontally back to
10% of “% of Horizontal Roller Travel” line plotted earlier. Place a mark on this 10% line as shown in
Graph 4.
(q) Repeat step @) procedure for 20% thm
90% lines. At each point that intersects
with “% of Horizontal Roller Travel
Line”, put a mark as indicated in Graph 5.
Graph 3
BASE
rNPuT
SIGNAL IN %
Example System Flow Chart
10 20 30 40 50 60
100%
FLOW
(7 SCFM)
PWOIS
70 80 90 100
60
L % OF
Graph 4
i
!ERC
f
ZLOVI
BASE LINE
% OF
INPUT
SIGNAL
50
60
70
kx
I zh%L,T~,
100%
FLOW POW,,
Graph 5
ZERO FLOW
I
\I
IB-102-207
2-13
(r) Connect marks with a smooth curve
thm point “A” to point “B” thru each mark recorded. This will be the required cam bar shape.
(s) Construct a template from the plotted
curve. Mark points A and B on template.
(t) Bend cam bar to match template.
Points A and B on template must align with Points A and B marked on cam bar earlier.
(u) Dtaw tile face of cam bar as necessary
to obtain a smooth carved sarface. Do not remove marked points A and B.
(v) Install am bar on power positioner
with lock screw positioned at point C recorded in step (e). Make sate dimensions for points A and B match
those recorded in step (e): if necessary
adjust position of lock screw to make
dimensions A and B recoTded in step (e).
Check results by setting 10% increments of input signal from 0% to
100%. The flow must change in 10% increments for 0 flow to 100% flow. For example: with a 100% of 7 SCFM, a 10% input signal will flow at 0.7 SCFM, 20% at 1.4 SCFM, etc.
Adjustments to the cam bar can be made by minor bending or draw fiing.
Figure 2-11. Driven Lever Travel
Set input signal to 0%. Measure distance controlled devices driven lever, Figure 2-11, travels for each
10% increase in input signal: up to
100% input signal. Record these values in Table 4-1, Characterized column as percent of total travel. These values are
necessary for verifying calibmtion.
Set input signal to 0%. Measure distance clevis head travels for each
10% increase; up to 100% input signal.
Measurement should be taken from packing nut to bottom edge clevis
head. Record values measured in Table 4-2, Calibration Schedule D in the
respective columns. These values are
necessary for verifying calibration.
SECTION III. REVERSE OPERATION
3-1. OPERATIONAL DESCRIPTION.
I” reverse acting positioners, the piston and rod operate the same as when setup for direct acting (Figure l-2). The cam bar is reversed top to bottom and the reverse manifold is tomed 90”. The repositioned manifold causes supply air to be directed to the top of piston when signal air pressure is increased and to the bottom of
piston when signal air pressure is decreased. In this case, piston movement is inversely related to the
signal. A falliig signal air pressure raises the piston
and an increasing signal air pressure lowers the piston,
3-2. PROCEDURES FOR REVERSING OPERATION.
To reverse the operation of the cylinder, refer to Figure 3-l and use the following procedures:
a. Reverse Compensating Assemble.
1.
Close the supply air valve.
2.
Set signal air to 0.
3.
Remove screw (1) securing spring clip (2) to
compensating assembly (4). Remove spring clip.
pilot valve (8) and its gasket (9) in the same position as it was when removed, Secure. pilot valve and reverse manifold in place with mounting screws (7).
c. Calibrate Stroke.
1. Disconnect operating lever (12, Figure 3-1) from device being controlled at clevis (13).
WARNING
Use caution when applying supply air to the pilot valve. The air pressure will cause the piston, rod, and operating lever to move
when the piston travels to the top of its
stroke. Personnel injury or damage to e­quipment may occur during sudden applica­tions of compressed air.
2.
Open supply air valve. This will cause piston rod (14) to move to top of its stroke.
Set signal air to minimum.
3.
Using an allen wrench, loosen lock screw (15) holding spring socket (16).
4.
Remove two screws (3) sewing compensat­ing assembly (4) to clevis head (5). Remove compensating assembly.
5. Reinstall compensating assembly (4) in a reversed position with stroke adjustment
scwv (6) at the top. Secure compensating
assembly to clevis head (5) with two screws
(3).
6. Reinstall spring clip (2).
b. Rotate Reverse Manifold.
1. Remove screws (7, Figure 3-1) securing pilot valve (8) and reverse manifold (10) to cylinder assembly (17). Remove pilot valve and reverse manifold.
2. Rotate reverse manifold (10) and its gasket (11) 90” clockwise. The arrow, stamped on
reverse manifold, should point down. Install
4.
Trim spring socket (16) counterclockwise until piston rod (14) starts to move down­ward.
5.
Tam spring socket (16) slowly clockwise until piston rod (14) reaches maximum
position.
6.
Tighten lock screw (15) to hold spring socket (16) fvmly in place.
7.
Set signal air to its maximum amount and check movement of piston rod (14) for fall stroke. The piston rod should just reach bot-
tom of stroke with maximum signal to pilot.
If necessary, tam the stroke adjustment
screw (6) counterclockwiie very slowly until full stroke is reached.
8.
Reconnect operating lever (12) to device being controlled at clevis (13).
IB-102-207
3-l
ITEM
1 2 3 4 5 6 I 8 9
10 11 12 13 14
1.5 lb
17
18
DESCRUTION screw Spring Clip screw Compensating Assembly Clevis Head Stroke Adjustment Screw SCEW
Pilot valve
Gasket
Reverse Manifold
Gasket
Operating Lever Clevis Piston Rod Lock Screw
Spring Socket Cylinder Assembly Packing Nut
3
-3 7-
5
DIRECT ACTING
COMPENSATING ASSEMBLY
3 -
3
6
?I
7
5
-4
6
REVERSE ACTING
COMPENSATING ASSEMBLY
Fire 3-1. Reverse Operations
WlO%207
3-2
PC.2420
SECTION IV. CALIBRATION
4-1.
CHECK POWER POSITIONER CALIBRATION. Use the following promlure to check calibration of power positioner. Figure 4- 1, Calibration Flowchart is provided as a quick reference guide.
NOTE
If cam bar was shaped (characterized),
values of percent output desired must be
recorded upon installation in Table 4-1
Schedule D. This is necessary to check
calibration. If values were not recorded, refer to 2-6b2 and calculate correct
positions using formulas.
a. Device Travel.
1. Measure distance that the controlled device’s driven lever arm travels from 0% signal air to 100% signal air. Record this as total distance.
2. Set signal air to 0%.
OF TRAVEL OF
DEVICE EQUAL TO
CORRESPONDING PERCENTAGE OF
CHECK STROKE
POSITION FOR
EACH PERCENT
OF SIGNAL LISTED
IS PISTON IN PROPER POSITION FOR EACH SIGNAL
AIR PRESSURE?
3. Measure controlled device’s driven lever arm travel from 0% to a 10% signal air. Divide measurement by total distance from step a. Record this as the percentage of output travel for 10% signal air. Measure and record percentage of output travel in the same fashion in 10% increments up to 100% signal air.
4. Compare recorded readings with percent driven lever travel in Table 4-l. Use
respective columns for characterized
systems, linear, square mot, or square cam
bars. If recorded percentages of travel are
equal to those in Table 4-1 the system does not need calibration. If recorded readings do not equal those ia Table 4-1 continue.
checking procedure.
b. Piston Travel.
1. Set signal air to 0%.
2. Measure distance fmm top surface of
packing nut (18, Figure 3-1) to bottom
surface of clevis head (5). Label tbii distance “A”.
CALIBRATE STROKE
AND I/p. REFER TO
PARAGRAPHS 4-2
Fire 4-1. Calibration Flowchart
3. Increase signal to 100%.
4. Measure distance from surface of packiag nut (18) to bottom surface of clevis head (5).
Label this distance “B”.
5. Subtract distance “A” from distance “B”. Thii is total stroke travel of the power positioner. Record this distance as total
stroke travel.
6. Set signal air to 0%.
IB-102-207
Table 4-1. Device Travel (%1.
PERCENT SIGNAL
AIR PRESSURE
0 0 0.0
10 20 30 30 54.8 9.0 40 50 50 70.7 25.0 60 60 77.5 36.0 70 70 83.7 49.0 80 80 89.4 64.0 90
100 100 100.0 100.0
7. Measure the piston travel (stroke) when a 10% signal is sent to the power positioner.
Record this as stroke travel for 10% signal air. Measure and record percentage of output travel in the same fashion in 10% increments up to 100% signal air.
l-
PERCENT DRIVE N LEVER TRAVEL
SQUARE ROOT
LINEAR (x)
10 31.6 1.0
20 44.8 4.0 40
90
Ma
63.25
94.9 81.0
4-2. STROKE CALIBRATION. Use the following
procedures to adjust a power positioner’s stroke. a. Direct Acting Power Positioner.
SQUARE (x3 CHARACTERIZED
0.0
16.0
stroke (paragraph 4-2) and then calibrate I/l’ (paragraph 4-3).
NOTE
Values for characterized stroke measured in inches and percent corresponding to input pressures are recorded in Table 4-2
Schedule D. If values were not recorded, refer to 2-613.2. and calculate correct
positions using formdas.
8. Compare actual stroke movement with
desired stroke movement. Desired stroke movements appear in Table 4-2, Calibration Schedule. Schedule “A” is for a linear cam bar, “B” for a square root cam bar, “c” for a square cam bar, and “D” for a characterized cam bar. If actual stroke of power positioner is equal to desired value in Table 4-2, refer to paragraph 4-5 and calibrate linkage. If it is not equal, calibrate
1. Purge air lines to remove any water or debris.
2. Making sure that by-pass valve is closed, set signal air to minimum stroke position (0%).
Refer to Table 4-3 for percent stroke to
signal air conversion.
3. Loosen lock screw (1, Figure 4-2) holding spring socket (2) in place. Turn spring socket counterclockwise until piston rod (3) begins moving up from bottom of stroke. Turn spring socket slowly clockwise until
piston rod moves to lowest position. Tighten
lock screw.
4. Increase signal air to maximum (100%). Refer to Table 4-3 for percent to signal air
conversion.
o-60 PSig m
0
6 12 18
24 30 36
42
48 54 60
0
6 12 18
24 30 36 42 48 54
60
0
6 12 18
24 30 36 42 48 54 60
0
6 12 18
24 30
36 42 48
54
60
3-15 pstg
3.0
4.2
5.4
6.6
7.8
9.0
10.2
11.4
12.4
13.8
15.0 CP
3.0
4.2
5.4
6.6
7.8
9.0
10.2
11.4
12.4
13.8
15.0
3.0
4.2
5.4
6.6
7.8
9.0
10.2
11.4
12.4
13.8
15.0 CAL
3.0
4.2
5.4
6.6
7.8
9.0
10.2
11.4
12.4
13.8
15.0
Table 4-2. Piston Travel (Stroke) Calibration Schedule.
CALIBRATION SCHEDULE “A” - LINEAR CAM BAR
INPUT SIGNAL
O-30 psig
0 3 6
9 12 15 18
21 24
27 30
:RATION SCHEDI
0 3 6
9
12 15
18 21 24 27
­CA
tATION SCHEDUL
30
LIBRATION SCHI - 3DU1
0 3
6
9 12 15
18 21 24 27 30
0
3
6
9
12 15
18 21 24 27 30
Percent of Signal
0%
10% % 30% 40% 50% 60% 70% 80% 90%
100%
“B” - SQUARE R<
0%
10% 20% 30%
40%
50% 60% 70% 80% 90%
10%
1
LE “C” - SOUARE CAM BAR
0% 10% 20% 30%
40%
50% 60% 70% 80% 90%
100%
D” - CHARACTER
0% 10%
20% 30% 40% 50%
60%
70%
80%
90%
100%
Inches
)O
l’CAMBAR
ED CAM BAR
0.M) la0
2.00
3.00
4.00
5.00
6.@3
7.00
8.00
9.03
1om
0.00
3.16
4.48
5.48
6.325
7.07
7.75
8.37
8.94
9.49
10.00
0.00
0.10
0.40
0.90
1.60
2.50
3.60
4.90
6.40
8.10
1oM)
DESlRl
CD STROKE
Percent of Full Stroke
0%
10% 20% 30%
40%
50% 60% 70% 80%
90%
lco%
O.co%
31.60%
44.80%
54.80%
62.25%
70.70%
77.50%
83.70%
89.40%
94.90%
100.00%
0%
1%
4% 9%
16% 25% 36%
49%
64% 81%
100%
IB-102-207
4.3
ITEM DESCRIPTION
1 Lock Screw 2 Spring Socket 3 Piston Rod 4 Lock Bolt
Stroke Adjustment
NOTE
If stroke length needed is less than standard
10 inches, adjustment of stroke adjustment
screw cau decrease stroke length to seven
inches.
Loosen stroke adjustment screw lock bolt (4,
5. Figure. 4-2). Tam stroke adjustment screw
(5) clockwise until piston rod moves downward. Tam screw in opposite direction until piston rod moves to maximum position or to desired length of travel. Tighten lock
bolt (4).
h. Inverse Acting Power Positioner.
1.
Purge air lies to remove any water or
d&is.
2.
Making sure that by-pass valve is closed, set
signal air to maximum (100%). Refer to Table 4-3 for percent to signal conversion.
3.
Loosen lock screw (1, Figure 4-2) holding spring socket (2) in place. Turn spring socket clockwise until piston rod (3) begins moving up from bottom of stroke. Tom
spring socket slowly clockwise until piston
rod moves to lowest position. Tighten lock
SCIZW.
Fire 4-2. Stroke Adjustment
Table 4-3. Direct and Inverse Calibration Signal Pressures.
POWER POSITIONER ACTION
STROKE POSITION
DIRECT INVERSE
PNRUMATIC UP PNEUMATIC I/P
0 - 30 psig 3 - 15 psig O-60 0
0% 0 3 0
100% 30 15 60
4.
Decrease signal air to minimum (0%). Refer
to Table 4-3 for percent to signal conversion.
- 30 3 - 15 0 - 60 psig
Psig psig Psig
30 15 60
0 3 0
LB-N-207
4.4
NOTE
If stroke length needed is less than standard 10 inches, adjustment of stroke adjustment screw can decrease stroke length to SEVEN inches.
5. Loosen stroke. adjustment screw lock bolt (4). Turn stroke adjustment screw (5)
counterclockwise until piston rod (3) moves downward. Turn screw in opposite direction until piston rod moves to maximum position or to desired length of travel. Tighten lock bolt (4).
4-3.
CURRENT TO PNEUMATIC (I/P) SIGNAL
CONVERTER CALIBRATION. Calibrate current to pneumatic signal converter after mounting, changing mounted position, or when loss of control is noticed (refer to Troubleshooting, Section V). Use the following procedures to calibrate the signal converter:
a. Remove plastic caps from “Zero” and “Span”
adjustment holes (Figure 4.3).
NOTE
Make sure the input pressure rating of the power positioner is the same as the pressure rating stamped on the current to pneumatic signal converter.
b.
Set signal value to 4 mA (20 mA if I/p is in an inverse setup) and adjust “zero” screw until output pressure is at 0 psig. Turn SCIW counterclockwise to increase pressure, clockwise to decrease pressure. If output pressure does not change when screw is turned, turn screw counterclockwise until pressure starts to rise.
PRESSURE
GAUGE
Figure 4-3. Current to Pneumatic Signal Converter
4-4. LINKAGE CALIBRATION.
a. Linear
A
Check angular travel of power positioner’s drive. lever at cl&s. Compare this to device’s driven lever angular travel. If angular distances are not the same, use the following
procedure to adjust offset of power positioner’s
drive lever to tbe same angle as tbe device’s driven lever. When adjustment is complete, both operating levers must be parallel with each other.
Measure angle p, from vertical line
extending from shaft hub, to power positioner’s drive lever (Figure 4-4). This is the power positioner’s drive lever offset.
POW23
c.
Set signal value to 20 mA (4 mA if I/p is in an inverse setup). Adjust “Span” screw until output pressure is at 60 psig.
d.
Repeat steps b and c until no further adjustment is needed.
e.
Replace protective caps.
Measure angle b2 from vertical line extending from device lever’s hub, to driven lever of device being controlled. This is the
driven lever offset.
Compare angle PI and angle. bz. Adjust
length of linkage for minor adjustments by threading pipe in or out of clevis. Change
drive lever angle p, for major adjustments.
IB-102-207
4-s
4. Measure length of power positioner’s drive lever (R,) from shaft center to center of clevis pin.
5. Measure length of device’s driven lever (RJ from shaft center to center of clevis pin.
DRIVEN
LEVER
DRIVE _
LEVER
POWER
FOSITIONER
Figure 4-4. Linear Linkage Calibration
b. Characterized. Verify linkage design angles and
length against actual installation. Use the following procedure, Figure 4-5, and adjust angles and lengths as necessary.
6. Compare angle B,, b2, distance P, and
lengths R, and R2 with setup dimensions and angles recorded in Figure 2-8. If setup dimensions and angles were not recorded, use formula’s in Section II to calculate correct design for the positioning system and record on Figure 2-8. Adjust length of linkage for minor adjusbnents by threading pipe in or out of clevis. Change operating arm angle b, for major adjustments.
1. Measure angle /3, from vertical lie extending from shaft hub to power
positioner’s drive lever. Tbii is the power positioner’s drive lever offset.
2. Measure angle b2 from vertical line extending from device lever’s hub to driven lever of device being controlled. This is the driven lever offset.
3. Measure length between connecting levers. This distance is represented by the letter P.
IB-102-207
Figure 4-5. Characterized Linkage Calibration
4.6
SECTION V. TROUBLESHOOTING
5-1. OVERVIEW. Troubleshooting of common problems 5-2. TROUBLESHOOTING CHART. Refer to
is provided for in troubleshooting chart (Table 5-l). Table 5-1. The chti describes common problems, foUowed by tbe related probable cause, and fmally by what action is necessary to correct the defect.
Table 5-1. Troubleshooting Chart.
PROBLEM CAUSE
1. Erratic operation Pilot valve sticking.
Linkage binding or loose.
2. No response from power Manual lock engaged positioner to a signal air pressure change
Air supply shutoff valve closed. Ruptured receiver diaphragm.
3. Power positioner does not Cylinder head gasket leak. remain at set-point; continues to
cycle
Bypass valve air connection loose.
Bypass valve leaking internally.
4. System over shoots or under I/F- out of
shoots set-point calibration.
VP failure.
CORRECTION
Clean or replace pilot valve. Refer to paragraph 6-4 for cleaning proce
dares and paragraph 7-2~ for
replacement procedures. Liige pivot joints corroded, dirty,
or worn. Clean and lubricate or re­place parts.
Disengage manual lock. Open air supply valve. Replace diaphragm. Refer to
pamgraph 7-2d. Replace leaking gasket. Refer to
paragraph 7-2e. Tighten or replace air connection.
Replace bypass valve. Calibrate I/F’. Refer to paragraph 4-3.
Replace I/P per paragraph 7-2b.
Piston stroke travel not properly
set. Cam bar bent.
Pin hole in diaphragm.
5. Sluggish operation Air fdter/separator foU of water,
oil, or sediment. Air fdter dirty.
Ambient temperature is lowe] than the power positioner is designed for.
6. Power positioner operates Device being controlled has a normally but flow that is being
broken valve stem or connection
controlled remains unchanged to the linkage.
ES-102-207
.5-l/5.2
Calibrate stroke travel of piston. Refer to paragraph 4-2.
Replace cam bar. Refer to paragraph 7-2h.
Replace diaphragm. Refer to paragraph 7%.
Drain air filter/separator. Refer to paragraph 6-5.
Replace filter element. Refer to paragraph 7%.
Install power positioner heater.
Repair or replace controlled device.
SECTION Vi. PERIODIC MAINTENANCE
6-1. OVERVIEW. This section describes preventive
maintenance for the Rosemount Model PP61OTR
Power Positioner. Preventive maintenance. is
necessary at specific intervals to reduce wear and tear
on the power positioner.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from alI systems connected to tbe power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
6-2. MAINTENANCE SCHEDULE. Use the
maintenance schedule, Table 6-1, as a guideline for preventive maintenance. The frequency of this maintenance varies directly with plant conditions and operational load on the power positioner. Extremely dusty conditions or high temperahnes will require. more frequent maintenance on the power positioner.
6-3. GENERAL CLEANING AND LUBRICATION.
Clean power positioner’s exterior of all grease buildup with commercial dry cleaning solvent. To lubricate power positioner, refer to Figure 6-1, Lubrication Chart.
WARNING
Clean power positioner in a well ventilated
area. Avoid inhalation of solvent fumes and prolonged exposurt! of skill to cleaning solvent. FoBow alI instructions on the Material Safety Data Sheet (MSDS) of the solvent being used. Severe injury or death may result from improper usage.
6-4. PILOT VALVE CLEANING AND INSPECTION.
In normal service, the pilot valve assembly (Figure 6-2) requires cleaning and inspection at intervals of approximately six months, or upon any indication of sticking.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power
positioner. Isolate power positioner from all
systems ccnmected to the power positioner. Severe iojury or death may result from
large torque power positioner is capable
of producing, or from electrical shock.
a. Remove power positioner from service.
I
Time Interval (Approximate) 6 months
6 months
6 months 2 years 2 years
Table 6-1. Maintenance Schedule.
Maintenance Action Perform general cleaning and lubrication. Refer to paragraph 6-3. Clean and inspect pilot valve. Refer to paragraph 6-4.
Clean and drain air filters. Refer to paragraph 6-5. Clean and inspect diaphragm. Refer to paragraph 6-6. Lubricate and clean cylinder and piston assemblies. Refer to paragraph 6-7.
LUBRICATION CHART
f9
GREASE GUN FILLED WITH
MclUBE M&.-793 SEE NOTE 1.
t&LUBE M&-793 SEE NOTE 2.
NOTE 1: USING A GREASE GUN, LUBRICATE
ZERK FIrrINGS AT PISTON ROD CLEVlS PIN, TRUNN!ON SCREW, AND SHAFT ASSEMBLY.
NOTE 2: WIPE PISTON ROD WITH A CLEAN
Figure 6-1. Lubrication Chart
PISTON ROD
CLEWS PIN
TRUNNION SCREW
SHOP TOWEL. APPLY A LIGHT COATING OF t&LUBE MOS 793. WIPE EXCESS
GREASE OFF W&H CLEAN SHOP
TOWEL.
po(xi
IB-102.207
6.2
ITEM
10 11 12 13
DESCRIPTION
1
Stem Assembly
2
Connecting Link
3
Ball Socket Nut
4
Air Supply Tubing
5
Elbow
6
cap screws
7
Reverse Manifold
8
Cylinder Assembly
9
valve cap Exhaust Silencer Plug Pilot Valve Body Pilot Valve Gasket Reverse Manifold Gasket
Figure 6-2. Pilot Valve Exploded View
b.
Carefully hold upper end of pilot valve stem assembly (1, Figure 6-2). Free connecting link (2) from pilot valve stem by turning connecting link
e. Remove valve cap (9), stem assembly (l), and
exhaust silencer plug (10) from pilot valve body
(11).
ball socket nut (3) counterclockwise. e. Disconnect air supply tubing (4) from elbow (5). WARNING d. Remove cap screws (6), that secure pilot valve
and reverse manifold (7) to cylinder assembly
(8). Remove pilot valve and reverse manifold.
Note alignment of pilot valve, arrow on ~cverse
manifold, and cylinder.
CAUTION
Do not use an abrasive for cleaning the valve stem assembly or valve body. Abrasives even as fine as crocus cloth will cause scratches in the stem assembly and air to leak by pilot valve stem assembly.
I&102.207
Clean pilot valve 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 usage.
f. Thoroughly clean pilot valve body (1 l), valve cap
(9) and stem assembly (1) in commercial dry
cleaning solvent. Allow pilot valve to completely
air dry. Do not use abrasive of any kind on stem.
6-3
g. Thoroughly clean exhaust silencer plug (10) in
commercial dry cleaning solvent, making sure it’s exhaust port.9 m open.
NOTE
pilot valve stem and body are a matched set. If eitber b damaged or wora to a non­serviceable condition, entire pilot valve mast be replaced.
h. Inspect stem assembly (1) and pilot valve body
(11). If any signs of wear or damage are found,
replace pilot valve.
is not reaching set points. Refer to Figure 6-3 and “se the following procedure.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to tbe power positioner.
Severe injury or death may result from large torque power positioner B capable of producing, or from electrical shock.
i. Install stem assembly (1) into valve body (11).
Install exhaust silencer plug (10) and valve cap
j.
(9) on pilot valve hody (11).
k. Install reverse manifold (7) and assembled pilot
valve with pilot valve gasket (12) and reverse manifold gasket (13), securing with cap screws
(6). Make sure arrow stamped on reverse manifold (7) is pointing in the direction that the piston rod moves with a” increasing signal air pressure.
1. Carefully hold upper end of pilot valve stem assembly (1). Attach connecting link (2) to pilot
valve stem assembly by tuning connecting link ball socket nut (3) clockwise.
m. Calibrate. stroke of power positioner (refer to
paragraph 4-2).
n. Return power positioner to service.
6-5. AIR FILTER CLEANING AND DRAINING. In
nornxd service, supply air falter and signal air fdter/regulator require draining of water and debris at least every 6 months. The frequeny of thii maintenance will depend on supply system air quality. After installation, drain both falters by slowly opening tilter and filter/regulator petcock valves. Initially drain monthly, gradually increasing time between draining. Schedule periodic draining when filters are approximately l/4 full. Continue draining water and debris at this interval unless plant supply air conditions change. If element in air filter is dirty,
refer to Section WI for replacement procedure.
6-6. DIAPHRAGM CLEANING AND INSPECTION.
Disassemble, clean, and inspect diaphragm assembly
approximately every two years or if power positioner
a. Remove power positioner from service. b. Remove screws (1, Figure 6-3) secwing
diaphragm cover (2) to receiver body (3).
c. Remove zero balance spring (4) from top of
diaphragm.
d. Using a clean shop towel, thoroughly wipe off
any dirt or debris on upper side of diaphragm (5).
e. Visually inspect diaphragm. Replace if nicks,
cuts, or hardened rubber areas (from excess heat) are visible. Refer to Section VII for replacement
procedures.
f. Clean diaphragm cover (2) and zero balance
spring (4) with commercird dry cleaning solvent and allow to air dry.
g. Align the edges of diaphragm (5) with stop ring
(6) to make a” air tight seal. Replace zero
halance spring (4).
h. Making sore the diaphragm is not folded or
pinched, replace diaphragm cover (2) and align
sealing edge of diaphragm cover on top of edge
of diaphragm.
i. Secure diaphragm cover (2) with screws (1).
Tighten all screws hand tight Snug screws down making we that all screws get tightened evenly. Finally complete installation by torquing to 39 foot-pounds (5.39 kg-m), tightening in a” across the diaphragm cover sequence.
j. Test for air leakage around diaphragm cover and
receiver body. Use a leak detector, such as “Snoop”, and apply an air signal to power
positioner. If leak is detected, repair as necessary.
lB-IM-207
6.4
ITEM DESCRIPTION
1 screw
2
Diibmgm cover
3 Receiver Body
4 Zero Balance Spring
5 Diaphragm
6 stop Ring
Figure 6-3. Diaphragm Exploded View
k. Return power positioner to service.
6-7. CYLINDER AND PISTON. CLEANING AND
INSPECTION. Disassemble, clean and lubricate piston and cylinder assembly approximately every two
years. Refer to Figure 6-4 and use the following
procedure.
WARNING
Before performing any maintenance or repair action on power positioner, shut off
supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to the power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
a. Remove paver positioner from service. b. Shot supply air valve and set signal air pressure
to 0 psig. Open bypass valve.
WARNING
Residual air must be bled off of piston cylinder before removal of cylinder head. If
air is not bled off, eye injury may result
Bleed residual air from cylinder through pilot
c.
valve supply air connection.
Remove hex head cap screws (1, Figure 6-4) and
d.
spring clip (2).
e.
Remove hex head cap screw (3), socket head
screw (4), and remove compensating assembly (5) from clevis head (9).
f.
Remove set screws (6) securing clevis head pin (7).
Support cylinder assembly (18) with 2 x 4 inch
g.
board long enough to provide leverage. This will prevent it from tipping over when clevis pin is
removed. Remove clevis pin and move shaft lever (19) out of the way.
IB-m-207
6-S
ITEM DESCRIPTION
1 Hex Head Cap Screw 2 Spring clip 3 Hex Head Cap Screw
4 Socket Head Screw
5 Compensating Assembly 6 Set screws 7 Cl&s Head Pin 8 Clevis Nut 9 Clevis Head
10 set screw 11
Packing Nut
12 Wiper 13 SCWUS
14 Top Cylinder Head 15 Piston Head 16 Piston 17 Top Cylinder Head Gasket 18 Cylinder Assembly 19 Shaft Lever
Figure 6-4. Cylinder Exploded View
I&102-207
6-6
h. Remove screws (13) securing top cylinder head
(14) to cylinder assembly (18).
0.
Screw packing nut (11) onto top cylinder head and secure with setscrew (10).
i. Pulling on clevis head (9), pull piston assembly
and top cylinder head out of cylinder assembly.
Remove and discard top cylinder head gasket
(17).
CAUTION
Do not pull piston and shaft assembly out of cylinder head. Damage to gland bushing and V-packing may occur.
Clean old grease off of piston (16) and piston rod
j.
(15). Wipe with dry cleaning solvent and pack
concave area of piston with McLube MO&793.
k.
With a clean shop towel and commercial dry cleaning solvent, wipe interior surface of cylinder assembly (18). Allow to air dry completely before reassembling cylinder.
1.
Wipe piston rod (15) with a clean shop towel and apply a light coating of McLube MoS,-793. Wipe excess grease off with clean shop towel.
m.
Remove setscrew (10) securing packing nut (11) and remove packing nut. Pack area around wiper
(12) with McLube MO&793.
n.
Replace gland bushing if it appears damaged or was leaking. Refer to Section VII for replacement procedures.
Install top cylinder head (14) and piston assembly
P.
with new top cylinder head gasket (17), onto cylinder assembly (18). Secure top cylinder head to cylinder with screws (13).
Insert end of shaft lever (19) into slot of clevis
9. head (9).
r.
Align holes in clevis head with hole in shaft lever. Drive clevis head pin (7) in securing cl&s head (9) to shaft lever (19). Lock clevis head pin in position with setscrews (6).
s.
Install compensating assembly (5) to clevis head (9) with socket head screw (4) and hex head cap screw (3). Install spring clip with hex head cap screw (1).
t.
Open supply air valve and test for air leakage around top cylinder head (14). Use a leak detector, such as “Snoop”, and send an air signal to power positioner. If leak is detected, repair as necessary.
Il.
Calibrate power positioner stroke; refer to Section -
IV. Return power positioner to service..
I
SECTION VII. CORRECTIVE MAINTENANCE
7-1. OVERVIEW. This section describes corrective
maintenance of the Rosemount PP61OTR Power Positioner. If specific cause of problem is not known, refer to Section V, Troubleshooting. Spare pats referred to arc available from Rosemount. Refer to
Section VIIJ of this manual for part numbers and
ordering information.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical
supply or electronic signals to power positioner. Jsolate power positioner from all systems connected to the power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
7-2. PARTS REPLACEMENT.
2
a. Air Filter. Regularly inspect disposable filter
elements as needed according to plant air supply quality. If filter element needs to be replaced, new elements are. available. from the factory. Use
the following procedure to replace the filter element.
1. Remove power positioner from service.
2. Open air filter’s drain valve (1, Figure 7-l) and bleed any air pressure and moisture
remaining in the system.
3. Remove air filter’s sump (2) by removing
cap nut (3) and cap nut gasket (4) on top of
air filter. Save cap nut gasket for installation.
4. Remove used filter element (5) by grasping and pulling it downward.
5. Install new fdter element (5). 8. Return system to service.
1
ITEM DESCRIPTION
1 Drain Valve
2 sump
Cap Nut
3 4 Cap Nut Gasket
Filter Element
5 6 Filter Housing
Figure 7-1. Air Filter
6. Install air filter sump (2) on to body. Secure sump with cap nut (3) and cap nut gasket
(4).
7. Open supply air shut off valve and check for leaks.
POW30
b. I/p Converter. Use the following procedure for
replacement of the current to pneumatic signal cO”“ater (I/P).
WARNING
11. Calibrate I/F and return ““it to service. Refer to paragraph 4-3 for calibration procedures.
c. Pilot Valve. Use the following procedures to
replace the pilot valve.
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power
positioner. Isolate power positioner from all systems connected to the power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
1. Remove power positioner from service.
2. Turn electrical signal transmitter off and make sure no voltage or current is being applied to the I/p.
3. Bleed off air pressure through connection of signal tubing to I/P.
4. Remove inlet and outlet piping to I/P.
5. Remove input signal leads from I/p’s screw Co”“ectors. If screw COn”eCtOrs are not installed on I/P, remove IP pigtails from screw co”“ectors.
6. Remove screws securing old I/F’ converter to mounting bracket and discard I/P.
I. Attach inlet and outlet piping to respective
ports on VP.
8. Connect leads to electrical signal wires. For direct acting power positioners connect the positive signal to black lead and negative
signal to white lead. For reverse acting power positioners, connect positive lead to white signal and negative lead to black signal.
9. Install new I/P to same mounting location, securing with screws.
10. Open supply air valves and test for leaks “sing “Snoop” type leak detector.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power
positioner. isolate power positioner from all
systems connected to the power positioner.
Severe injury or death may result from large torque power positioner is capable of producing, or from electriczd shock.
1. Remove power positioner from service.
2. Carefully hold upper end of pilot valve stem assembly (1, Figure 7-2) with pliers. Free connecting link (2) from pilot valve stem assembly by turning connecting link’s hall socket nut (3) counterclockwise.
3. Disconnect supply air tubing (4) from elbow (3.
4. Remove cap screws (6) that secure pilot valve (7) and reverse manifold (8) to cylinder assembly (9). Remove pilot valve and rwerse manifold. Note alignment of
pilot valve, arrow on reverse manifold, and
cylinder.
5. Install reverse manifold (8) and pilot valve (7) with pilot valve gasket (10) and reverse
manifold gasket (11), securing with cap screws (6). Make sure arrow stamped on manifold is pointing in the direction that
piston rod moves with a” increasing signal air pressure.
6. Carefully hold upper end of pilot valve stem assembly (1). Attach connecting link (2) to pilot valve stem assembly by turning connecting link ball socket nut (3) clockwise.
7. Refer to Section N and calibrate stroke of power positioner.
8. Return power positioner to service.
lBlO2-207
7-2
ITEM DESCRIPTION
Stem Assembly
1
Connecting Link
2
Ball Socket Nut
3
4
Supply Aii Tubing 6292A08Hl2
5
Elbow
6
cap screws
7
Pilot Valve
8
Reverse Manifold
9
Cylinder Assembly
10
Pilot Valve Gasket 5057.002
11
Reverse Manifold Gasket
PART NUMBER 6639-003
1791.21
771B867H05 7004lAHO57
6639405 225920 263C3387GOl
125909
Figure 7-2 Pilot Valve
d. Diaphragm and Calibration Spring. Use the
following procedure for replacement of the
receiver’s diaphragm and replacement of
calibration spring. If replacing the diaphragm only, skip steps 6 and 7. If replacing calibration spring only, skip steps 8 and 9.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to the power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
1. Remove power positioner from service.
2. Disconnect signal air tubing (2, Figure 7-3) and remove elbow (1).
3. Remove screws (3) securing diaphragm cover (4) to receiver body.
4. Remove zero balance spring (5) from top of diaphragm.
5. Carefully hold upper end of pilot valve stem assembly (25) with pliers. Free. spring connecting link (12) from pilot valve stem
by tuning ball socket nut (13) counterclockwise.
ITEM DESCRIPTION
1
Elbow 2 Signal Air Tubing 3
SCKW
4 Diaphragm Cover 5 Zero Balance Spring 6 Diaphragm Stud I Diaphragm 8 Stop Ring
9 Shield 10 Nut 11 Ball Socket Nut 12 Spring Connecting Link 13 Ball Socket Nut 14 Compensator Assembly 15 Roller 16 Fillister Head Screw 17 Hex Head Cap Screw 18 Receiver Body 19 TllJIliOIl
20 Tmnion Screw 21 set screw 22 Calibration Spring 23 Spring Washer 24 Spring Nut 25 Stem Assembly
PART NUMBER
771B867HOS 6292AOSH13
1200X8-015
5014-4
175464.348
5290.7 9351-7
5014.019 5015-027
702OOCAB 1A
7791.021
226898
5015.2 120093-031 120088-5013100
5014.6
5015-7
5015.15
120121-001 Refer to Section 9. 5973-7 5015-14
6639.003
Figure 7-3. Receiver Exploded View
6.
Pulling np on diaphragm (7). remove diaphragm and connecting link assembly from the receiver body.
7.
Remove calibration spring (22).
8.
Install new calibration spring (22). Make sure spring washer (23) is in bottom of spring nut (24).
9.
Remove spring connecting link (12) from diaphragm by turning ball socket nut (11) c0lmterc1cckwii.
10.
Remove nut (10) from diaphragm stud (6). Separate diaphragm (7). stop ring (8). and shield (9).
11.
Assemble new diaphragm (7) with stop ring (8) and shield (9). Secure in place with diaphragm stud (6) and nut (10).
12.
Install spring connecting link (12) on new diaphragm assembly securing with ball
socket nut (11).
20. Retmn power positioner to service.
e. Upper Cylinder Head Gasket and Piston. Use
the following procedures to replace upper cylinder head gasket and replacement of the
piston. If only replacing upper cylinder head
gasket, skip steps 8 and 9. If replacing piston, complete entire procedure.
WARNING
Before performing any maintenance or
repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to the power positioner.
Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
1. Remove power positioner from service.
2. Shot off supply air valve and set signal air pressure to 0 pisg. Open bypass valve.
13.
Place diaphragm assembly and connecting
link in receiver so connecting link is aligned with pilot valve stem assembly (25).
14.
Align the edges of diaphragm (7) with the stop ring (8) to make an air tight seal.
15.
Making sure the diaphragm is not folded or pinched, replace diaphragm cover (4) and
align sealing edge of diaphragm cover on top of edge of diaphragm.
16.
Secure diaphragm cover (4) with screws (3).
First tighten screws until hand tight. Then,
snug screws down and finally complete installation by torquing to 39 foot-pounds (5.39 kg-m).
17.
Reinstall elbow (1) and signal air tubing (2).
18.
Teat for air leakage around diaphragm cover and receiver body. Use a leak detector, such as “Snoop”, and send an air signal to power positioner. If leak is detected, repair as necessary.
WARNING
Residual air must be bled off of piston cylinder before removal of cylinder head. If air is not bled off, eye injury may result.
3.
Bleed residual air from cylinder through
pilot valve supply air connection.
4.
Remove hex head cap screw (1, Figure 7-4)
securing spring clip (2) to compensating assembly.
5.
Remove hex head cap screw (8) and socket
head screw (9) and remove compensating assembly from clevis head (16).
6.
Remove set screws (13) sewing clevis head pin (14) in clevis head.
I.
Support cylinder (30) with 2 x 4 inch board long enough to provide leverage. This will
prevent it from tipping over when clevis pin
is removed. Remove clevis pin and move shaft assembly out of the way.
19.
Referring to Section IV and calibrate power positioner.
1%102.207
7-5
8.
Remove hex head cap screws (23) securing top cylinder head (24) to cylinder (30).
PARi--
7CO41AH04R
125783 700208‘4750 7O*lOBC.618 705owL*oP 7omlBU4HE
12015-002 701OilDXO1P 70041AHo5, 701QoDXllP
142326-002
325916
,20083-3118063
125775 6292A85HOl
325912
125907
152507-002
,20039-019
156198
152508-003
120088-50131OC 425918 325914
125782
120110-010
,20,7,-003 22591, 425917 325913
120039-028 225911 425919
120088-5013100
120083-3118063
125775
181829-2250175
126917 225908
,*Om-5013150
Figure 7-4. Cylinder Exploded View
lslO2-207
7-6
9. Polling on clevis head (16), pull piston assembly and top cylinder head out of cylinder assembly.
CAUTION
Do not pull piston and shaft assembly out of cylinder head. Damage to gland bushing aad V-packing may occur.
10.
Remove stop nut (28) and washer (27)
securing piston (26) to piston rod (25).
11.
Wipe piston rod (25) and inside of cylinder
liner (31) with clean shop cloth and spray with a light coat of dry fdm lubricant (molybdenum disolfide spray lubricant).
12.
Attach new piston (26) to piston rod with washer and stop not. Pack concave area of
piston seal cup with McLube MoS,-793.
13.
Remove and discard cylinder head gasket
(29).
14.
Using a putty knife, prepare gasket surfaces
of cylinder assembly and cylinder head for
new gasket by removing any old gasket material or dirt. Wipe with a clean shop towel.
15.
Place new cylinder head gasket (29) on cylinder (30), lining up notch in gasket with notch in cylinder assembly.
16.
Align and install top cylinder head (24) and piston assembly onto cylinder assembly.
21. Open supply air valve.
22. Test for air leakage around top cylinder head (24). Use a leak detector, such as “Snoop”, and send an air signal to power positioner. If leak is detected, repair as necessary.
23. Refer to Section IV to calibrate power
positioner.
24. Retam power positioner to service.
f. Lower Cylinder Head Gasket. Use the
following pmcedorea to replace lower cylinder head gasket.
WARNING
Before performing any maintenance or
repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic sigaals to power positioner. Isolate power positioner from all systems connected to the power positioner.
Severe injury or death may result from
large torque power positioner is capable of producing, or from electrical shock.
1.
Remove power positioner from service.
2.
Refer to paragraph 7-2.~ and remove pilot valve.
3.
Remove signal air tubing (2, Figure 7-3) from receiver. Remove hex head cao screws (17) and remove receiver assembly from
CYli”dH.
11.
Secure top cylinder head (24) to cylinder
assembly with hex head cap screws (23).
18.
Align holes in clevis head (16) with hole in shaft lever. Drive in clevis head pin (14), securing clevis head to shaft lever. Lock clevis head pin in position with set screws
(13).
19.
Install compensating assembly to clevis head with hex head cap screw (8) and socket head screw (9). Make sure side bar (12) is resting
against back-up roller (39) in roller bracket (40).
20.
Install spring clip (2) to compensating assembly with hex head cap screw (1).
IB-102-207
7-7
4.
Remove hex head cap screw (1, Figure 7-4) securing spring clip (2) to compensating assembly.
5.
Remove hex head cap screw (8), socket head
screw (9), and remove compensating assembly from clevis head (16).
6.
Remove set screws (13) securing clevis head pin (14) in clevis head.
I.
Support cylinder (30) with 2 x 4 inch board
long enough to provide leverage. Thii will prevent it from tipping over when clevis pin is removed. Remove clevis pin and move
shaft assembly out of the way.
8. Remove set screws (36) locking cl&s pin (37) to bottom cylinder head (34).
17. Install spring clip (2) to compensating assembly with hex head cap screw (1).
WARNING
Before removing lower clevis pin, make sure full weight of cylinder is supported on 2 x 4’s. If not supported loose cylioder may fall over and cause personal injury.
9. Support full weight of cylinder assembly on 2 x 4’s. Drive out lower clevis pin (37, Figure 7-4) and remove cylinder assembly from stand.
10. Set cylinder assembly on its side and remove hex head cap screws (35) securing bottom cylinder head (34) to cylinder assembly. Remove bottom cylinder head (34) and cylinder head gasket (33).
11. Using a putty knife, prepare gasket surfaces of cylinder and cylinder head for new gasket
by removing any old gasket material or dirt. Wipe with a clean shop towel.
12. Install new cylinder head gasket (33) and
bottom cylinder head (34) onto cylinder
assembly. Secure cylinder head to cylinder with hex head cap screws (35).
13. Insert mounting slot on end of bottom cylinder head (34) onto tab of stand
assembly. Make sure full weight of cylinder is supported by 2 x 4’s.
14. Align holes of bottom cylinder head (34) with hole in tab of stand assembly. Drive
lower clevis pin (37) in with punch and hammer. Lock clevis pin in position with set
screws (36).
15. Align holes in clevis head shaft lever. Drive. clevis head pin (14) in, securing clevis head to shaft lever. Lock
clevis head pin in position with set screws
(13).
16. Install compensating assembly to clevis head
with hex head cap screw (8) and socket head screw (9). Make sure slide bar (12) is resting against back-up roller (39) in roller bracket (40).
(19
with hole in
18. Reinstall receiver assembly to cylinder with hex head cap screws (17, Figure 7-3). Reconnect signal air tubing (2).
19. Reinstall pilot valve, refer to paragraph 7-
2.c.
20. Open supply air valve.
21. Test for air leakage around top cylinder head (24, Figure 7-4). Use a leak detector, such as “Snoop”, and send an air signal to power
positioner. If leak is detected, repair as
necessary.
22. Refer to Section IV and calibrate power
positioner.
23. Return power positioner to service.
g. Cvlinder Replacement.
assembled cylinder with a new cylinder follow the procedures outlined in paragraph 7-2.f. Lower Cylinder Head Gasket. Steps 1 through 9 cover cylinder removal, and steps 13 through 23
provide installation procedures.
h. Cam Bar. Use the following procedure to
replace cam bar.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to the power positioner. Severe injury or death may result from large torque power positioner is capable of
producing, or from electrical shock.
1. Remove power positioner from sewice.
2. Remove flat head screw (6, Figure 7-4). washer (5), and hex nut (4) securing cam bar (7) to angle bracket (11).
3. Remove set screw (3) from cam bar (7).
To replace the
4. Place replacement cam bar underneath spring clip (2). Secure cam bar in place with
9. Loosen socket head screw (12) and remove operating lever (11) from shaft (10).
flat head screw (6), washer (5). and hex nut (4).
10. Disconnect shaft (10) from cylinder lever (11) by driving out taper pin (8).
Reinstall set screw (3).
5.
11. While holding cylinder lever (9), slide shaft
6.
Refer to Section IV and calibrate power
(10) out of stand assembly’s bashings (25).
positioner.
12. Using a hack saw, cut a prexwe relieving
Retam power positioner to service.
I.
slit across the inner face of bushings (25).
i. Shaft Bushings. Use the following procedure to 13. Using a hammer and large pooch, drive old
replace shaft bushings.
shaft bushings out of stand.
WARNING
WARNING Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical
supply or electronic signals to power positioner. Isolate power positioner from all systems connected to the power positioner. Severe injury or death may result from
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. large torque power positioner is capable of producing, or from electrical shock.
CAUTION
1.
Remove power positioner from service.
Care most be used when applying Loctite
2.
Remove socket head screws (1, Figure 7-5). lock bridge (3), and lock shoe (4) Tom stand
(26).
primer or adhesive to bushings to make
sore it is only applied to the outer surface.
Bushing life may be reduced.
Remove socket head screws (17) securing
3. lock body (7) to stand (26). Remove lock
MY.
4.
Remove set scTews (13, Figure 7-4) locking clevis head pin (14) in place.
5.
Support cylinder (30) with 2 x 4 inch board long enough to provide leverage. This will prevent it t?om tipping over when clevis pin is removed. Remove clevis pin and move cylinder lever (9, Figure 7-5) away from clevis.
6.
Using manual lever (23), position shaft (10) so taper pin (8) is positioned vertically.
Remove retaining ring (24) and manual lever
1.
(23) from shaft (10).
8.
Loosen socket head screws (18) and remove sector (19) from shaft (10).
NOTE
Bushings are secured to stand assembly with
a coating of Loctite applied on the outside of bushings. Insertion of new bushings and completed installation of shaft assembly most be completed before Loctite sets. This is needed to line up bushings properly. The Loctite will set in approximately 3 minutes. Complete installation of shaft assembly within 15 minutes from when adhesive was applied.
14. Apply Loctite primer (llNA79@2A30), to outside surface of shaft bushings (25, Figure
7-5) and allow primer to set for three to five minutes.
15. After primer has set 3 to 5 minutes, apply Loctite adhesive #680 and slide bushings
(25) in stand assembly within three minutes.
IB-102-207
7-9
220 17
ITRM DFSCRIFTION
1 Socket Head Screw 2 Lock Lever 3 Lock Bridge 4 Lock Shoe 5 Pan Head screw 6 Indicator 1 Lock Anvil 8 Taper Pin 9 Cylinder Lever
10 Shaft 11 Operating Lever 12 Socket Head Screw 13 Clevis 14 Clevis Pin 15 Retaining Ring 16 Grease Fitting 17 Socket Head Screw 18 Socket Head Screw
19 sector 20 Indicator Plate 21
Socket Head Screw 22 Washer 23 Manual Lever 24 Retaining Ring 25 Bushing 26 Stand (Includes 25)
PART NUMBER 7CWlAHOEB
125910 125903
125902 7COlOCDG3N 239613
125904
120107.033 225795 263C385HOl 263C381HOl 70041AHOEP
3159.001
174356.004
120079-010
139656-001 70041AHOEB 70041AHOBP 263C384HOl 239613 70041AHOEB 70500cP1OG
6293C5ffiOl 771B949H25
1111375
425789.002
Figure 7-5. Shaft Exploded View
IB-102.207
7-10
16. Slide shaft (10) into bushing (25) on one side of stand assembly.
21. Install manual lever (23) on shaft searing with retaining ring (24).
17. Lii up cylinder lever (9), aligning hole with shaft (lo), and insert shaft through cylinder
lever and remaining shaft bushing (25). InstaIlalion of shaft into new bushings must occur within 15 minutes after application of Loctite adhesive.
18. Connect shaft (10) to cylinder lever (9) by inserting taper pin (8) with small end pointed towards back of power positioner.
19. Secure operating lever (11) to shaft with socket head screws (12).
20. Install sector (19) on shaft (10). Tighten socket head screws (18).
22. Install lock body (7) on stand assembly sewing with socket head screws (17).
23. Install lock bridge (3) on stand assembly securing with socket head screws (1). Install lock lever (2) and lock shoe (4).
24. Refer to Section VI and lubricate power
positioner shaft bushings.
25. Refer to Section N and calibrate power
positioner.
26. Retmn power positioner to service.
18-102-207
7.1u7.12
SECTION VIII. OPTIONS
8-l. OVERVIEW. This section of the manual provides
service information on the 6 X 10 power positioner options. These options include an air lock, electric
position transmitter, and heater/thermostat.
8-2. AIR LOCK. The air lock system automatically locks
the power positioner piston and shaft assembly when there is a loss of supply air. When supply air pressure falls below a set value, the air lock diaphragm collapses causing a spring to rotate a lock lever. This clamps the friction plate and locks the piston and shaft assembly.
Upon loss of supply air pressure, the automatic lock can be overridden by turning the air lock release handle (6, Figure 8-1) fully clockwise. The operator must then open the bypass valve and manually position the output shaft. After positioning the output shaft it can be locked in place with the manual lock handle (3).
a. Adjustment.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air and signal air, and disconnect any electrical supply or electronic signals to
power positioner. Severe injury or death
may result from large torque power positioner is capable of producing, or from electrical shock.
1. Remove power positioner from service, close supply air shut off valve. Disconnect electrical power to power positioner.
ITEM DESCRIPTION
1
Lock Shoe 125902 2 Lock Bridge 3 Manual Lock Handle 4
Plunger 131661
5 Air Lock Lever 6 Air Lock Release Handle 231663 7 Lock Nut 70210BC61A
8 set screw 6293A95HOl 9 sector 263C384HOl
Figure 8-l. Air Lock
6. Restore air and electrical power to positioner.
b. Diaphragm Replacement.
PART NUMBER
125903 125910
431666
2. Back off manual lock handle (3, Figure 8-l) allowing lock shoe (1) to bottom against lock bridge (2).
3. Back off lock nut (7).
4. With air lock lever (5) disengaged (in vertical position), adjust set screw (8) so that
lock plunger (4) just clears back face of sector (9).
5. Tighten lock ““t (7) and turn manual lock handle (3) so that lock shoe (1) just touches front face of sector.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air and signal air, and disconnect any electrical supply or electronic signals to power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
1. Remove power positioner from service, close supply air shut off valve. Disconnect electrical power to power positioner.
PART NUMBER
131671 431666 7o1ooDxocP
7-210BC.418 7050ocL10P 70041AH077
132090
131677 70041AH0BD
231678 9351-002
131676 231673 231679 7cmocR105
7oc4L‘woEF
Figure 8-2. Air Lock Diaphragm Exploded View.
2. Remove springs (1, figure S-2) from air lock lever (2).
3. Disconnect air tubing (19) from elbow (18).
4. Loosen jam nut (4) and unthread socket head screw (6) from air lock lever (2).
5. Remove hex head screw (3) to disconnect lock lever from diaphragm assembly.
6. Remove socket head cap SCI~WS (16) and lockwashers (15). Remove diaphragm assembly from power positioner.
7. Remove socket head screw (9) and diaphragm plate (10). Remove assembled diaphragm from diaphragm chamber (13).
8. Holding coupling (7) with a wrench unscrew diaphragm stud (12).
9. Assemble new diaphragm (11) with diaphragm stud (12) and diaphragm washer
(8). Holding diaphragm stud securely with a wrench tighten coupling (7) against diaphragm washer (8).
10. Place assembled diaphragm into dia­phragm chamber (13) and install diaphragm plate (10).
11. Install diaphragm assembly onto power positioner and reconnect air line tubing (19).
12. Connect air lock lever (2) to coupling (7) with hex head screws (3).
13. Thread socket head screw (6) into air lock lever (2) and secure into place with jam nut
(4). Reinstall springs (1).
lF-102-20,
8-2
8-3.
ELECTRIC POSITION TRANSMITTER (EPT). For information on the EPT for PP61OTR Power Positioner, refer to IE-102.207A. Field Retrofit Kit Electric Position Transmitter.
8-4.
HEATER/THERMOSTAT. The heater/thermostat helps prevent freezing of moisture or condensate in power positioner supply and signal air lines. This
allows the pilot valve to operate better in temperatures below freezing. With the heater/thermostat installed the power positioner can effectively operate in temperatures down to -10°F
(-23.3”C). Operation below this ambient temperature is not recommended.
a. Heater Replacement.
WARNING
Before performing any maintenance or repair action cm power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
3.
Remove screws (4), washers (5), nuts (6), and heater (7) from bracket (8).
4.
Install new heater. Connect black heater lead
(1) to terminal 1 and white heater lead (2) to
terminal 4 on terminal block (3).
b. Thermostat Replacement.
WARNING
Before performing any maintenance or repair action on power positioner, shut off supply air, signal air, and any electrical supply or electronic signals to power positioner. Isolate power positioner from all systems connected to power positioner. Severe injury or death may result from large torque power positioner is capable of producing, or from electrical shock.
1. Remove power positioner from service, close supply air shut off valve, and isolate electrical power from power positioner.
2. Remove thermostat leads (9 and 10, figure 8-3) from terminals 2 and 3 on terminal
block (3). Remove ground lead (13).
1. Remove power positioner from service, close supply air shut off valve, and isolate electrical power from power positioner.
2. Remove heater leads (1 and 2, Figure 8-3) from terminals 2 and 4 on terminal
block (3).
3. Remove screws (ll), washers (12), and thermostat (14) from bracket (8).
4. Install new thermostat. Reattach ground lead
(13).
5. Connect thermostat leads (9 and 10) to terminals 2 and 3 on terminal block (3).
HEATER POWER SUPPLY
120 “AC, 60 HZ, 150 w
T.S. SCREW SIZE NO. 5
15
rLNG’
\ !!!
THERMOSTAT
TG SCREW FOR
VIEW A -
ITEM DESCRIPTION PART NUMBER
1
Heater Lead (Black)
6292A22605
2 Heater Lead (White) 6292A22606 3 4
Terminal Block screw 7O@llDAJSQ
181403-co8
5 Washer 220197-w 6
Nut
120033-007
I Heater 153407-001
8
Bracket
45llC13HOl
9 Thermostat Lead N/A 10 Thermostat Lead N/A 11
screw
7000lDAJ8G 12 Washer 70520ALlOH 13 Ground Lead 6292A22607 14 15
Thermostat Jumper
6292Al lGO1
145131-001
Figure 8-3. Heater/Thermostat Replacement
-3
A
SECTION IX. RECOMMENDED SPARE PARTS
Table 9-l. Recommended Spare Parts for PP61OTR 6 x 10 Power Positioner.
FIGURE
INDEX No.
7.4, 20 7-4, 32 7-4, 26 7-2, 11 6-4, 17 l-4, 22 7-4, 29 6-2, 13
7-3, I
7-3, 5 75464.226 7-3, 5 6154 7-5, 19 63C384HOl
7-7 63C386GOl 6-2, 6 639-005 7-3. 12 791-021
and
‘ART NUMBER BESCRIPTION
A97809GOl
A97809GO3
A97809GO4
A9781OGO5
A9781OGO6
A9781OG06
pare Pats Kit 6 x 10 Power Positioner
O-Ring (120039-019) O-Ring (120039.028)
Piston Assembly (125782)
Reverse
Chicago
Block V-Packing (152508-003) Cylinder Head Gasket (225911) Gasket (5057.002) Diaphragm (935 l-007)
, pareParts Kit
Piston Assembly (125782)
spare Parts Kit
Block Vee Packing (152508-003)
spare Parts Kit
Rawhide Wiper (152507.002)
spare Parts Kit
Diaphragm (9351.002)
spare Parts Kit
Cylinder Head Gasket (225911) Calibration Spring 0 - 30 psig Calibration Spring 3 15 psig Sector Shaft Assembly Pilot Valve Assembly
1 Spring Connecting Link
Manifold Gasket (125909)
Rawhide
Wiper (152507-002)
QTY
1 1 1 1 1 1 1 1 1
5
15
15
15
15
1 1 1 1 1 1
Table 9-2. Spare Parts for Oplions (PP610TR 6 x 10 Power Positioner Only).
FIGURE and INDEX No. PART NUMBER DESCRIPTION I OTY
145822 Heater Receptacle
8-3, 7 153407-001 Heater
4511C68GOl Electric Position Transmitter Assembly
5505A52H06 O-Ring Gasket
8-3, 14 6292AllGOl
8741-001 8-1, 4 131661 Air Lock Plunger 8-1, 1 125902 8-2, 1 131671 Air Lock spring 8-2, 8 131677 Air Lock Diaphragm Washer 8-2, 11 9351.002
Thermostat Aluminum Micro-switch
Air Lock Shoe
Air Lock Diaubragm
10
10
1 1 1
5
1 1
5
2
5
FIGURE and INDEX No.
NOTE
Table 9-3, Bill of Material for PP610TR 6 X 10 Power Positioner, includes part numbers and descriptions that are keyed to Figure and Index Number references. Tbis listing provides information on all basic PP405TR power positioner parts with the exception of hardware.
Table 9-3. Bill of Material for PP61OTR 6 X 10 Power Positioner.
PART NUMBER DESCRIPTION
QTY
l-5, 25
l-5, 16 l-5, 26
3-2, 17 74, 30 7-4, 34 l-4, 24 7-4, 31 l-4, 29
1.4, 32 l-4, 21 l-4, 18
1.4, 22 l-4, 19 l-4, 20 l-4, 25 l-4, 26 7-4, 12 l-4, 16 l-4, 40 l-4, 38 7-4, 39
l-5, 10 7-5, 9
l-5,
8
7-5, 16
1-2 7-3, 4 l-3, 5 l-3, 6 7-3, I l-3, 8 l-3, 9 l-3, 10 l-3, 12 7-3, 14
425789 Stand Assembly
1111375 Bushing 2 126198 Serial Number Plate 139656-001 Grease Fitting 2
425789.002 Stand 1 6295A68HOl Air Supply Label
6295A68H02 Signal Input Label 263C387 Cylinder Assembly 1 425917 Cylinder 425919 Bottom Cylinder Head 425918 Top Cylinder Head 325913 225911 Cylinder Head Gasket
120039.028 O-Ring 156198 Gland Bushing
125901 Stuffing Box Nut 1
152508.003 Block V-Packing
152501-002 Wiper
120039-019 O-Ring 1 325914 Piston Rod
125182
325916 325912 Clevis Head 225908 Roller Bracket
181829.2250175 Oroove Pin 1
126917 Back-up Roller 263C386 Shaft Assembly 263C385HOl Shaft 225195 Cylinder Lever
120107.033 Taper Pin
139656.001 Grease Fitting
314610.003 Receiver 5014-4 Diaphragm Cover
115464.348
5290-I Diaphragm Stud 9351-7 Diaphragm
5014-019 stop Ring
5015.027 Shield IOZOOCAB 1A Nut, 318 - 16 Hex 7791-21 Spring Connecting Link 226898 Compensator Assembly
Cylinder Liner
Piston
Side Bar
Zero Balance Spring
1
1
1 1
1 1 1 1
2
1 1
1 1
1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Table 93. Bi of Material for PP610TR 6 X 10 Power Positioner (Continued)
FIGURE and INDEX No. PART NUMBER DESCRIPTION
QTY
l-3, 15 l-3, 18 7-3, 20 7-3, 23 l-3, 24 l-2, I l-2, 8 l-2, 11 7-3, 22 l-3, 22
l-5,
11 l-5, 13 l-5, 14 l-5, 15 l-4, 14
l-3, 2 l-2, 4 l-4, I l-4, 11 l-4, 2
l-5, 19 l-5, 23
l-5, 24 l-5, I 8-1, 4
l-5, 3 l-5, 4
l-5. 2
4-3
I-l l-l, 5
5015-Z Roller
5014-6 Receiver Body
5015.15 Tnmnion Screw 5913-I Spring Washer 5015-14 Spring Nut
6639.005 225920
125909 Reverse Manifold Gasket 115464-226 Calibration Spring (0 - 30 psig)
16154 Calibration Spring (3 - 15 psig) 263C381HOl operating Lever 3159-001 Clevis
114356-004 Clevis Pin
120019-010 Retaining Ring
125115 Clevis Head Pin 426151 Cover Assembly
126154 Strike 6292A08H13 Tubing (Signal Air) 6292A08H12 Tubing (Air Supply)
12015-002 Cam Bar
14236.002 Angle Bracket (Cam Bar)
125183 263C384HOl sector 6293C50GOl Manual Lever
lllB949H25
125904 Lock Anvil
131661 Plunger
125903
125902 Lock Shoe
125910 Lock Lever
126109 6293AllHOl By-pass Valve
239613
139612 Pointer 241-96-6080 31253X-002 312538-023
Pilot Valve Reverse Manifold
Spring Clip
Retaining Ring
Lockbridge
By-pass Indicator
Indicator Plate
IIF Converter Air Filter Filter Element
1 1
1 1 1 1 1 1 1 1 1 1
1 2 2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
B-102-207
9.3/9-4
SECTION X. RETURNING EQUIPMENT TO THE FACTORY
10-l. If factory repair of defective equipment is required,
proceed as follows: a. Secure a retnrn authorization from a Rosemount
Analytical Sales Office or Representative before returning the equipment. Equipment must be rehrned 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 insure that no additional damage will occur during shipping.
e. In a cover letter, describe completely:
1. The symptoms from which it was determined that the equipment is faulty.
2. The environment in which the equipment has been operating (housing, weather, vibration, dust, etc.).
3. Site from which equipment was removed
4. Whether warranty service or nonwarranty service is requested.
5. Complete shipping instructions for return of equipment.
d. Enclose a cover letter and purchase order and
ship the defective equipment according to instructions provided in Rosemount Return Authorization, prepaid, to:
Rosemount Analytical Inc. RMR Department
1201 N. Main Street
Omiie, Ohio 44667
EWOp~ll
Rosemount b-eland
Equipment Return Repair Dept. Site 7 Shannon Industrial Estate Co. Glare Ireland
If warranty service is requested, the defective unit will be carefolly inspected and tested at the factory. If failure was due to conditions listed in the stamimd 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 covez letter.
For equipment no longer under warranty, the equipment will be repaired at the factory and rehnned as directed by the purchase order and shipping inshuctions.
IELm-*
10.l/10-2
INDEX
This index is an alphabetized listing of parts, terms, and
procedures having to do with the Hagan Model PP61OTR
Torque Type Power Positioner. Every item listed in this index refers to a location in the manual by one or more page numbers.
A
Air Lock Adjustment, 8-l
Air Lock Diaphragm Replacement, 8-1 Air Lock Operation, Description, 8-l Air Piping Schematic, 2-3 Air Supply Requirements, 1-6, 2-4 Automatic Operation, Description, 1-3
B
Bypass Valve, Description, l-l
C
Calibration Check, 4-1 Calibration, Current to Pneumatic Signal Converter, 4-5 Calibration, Linkage, 4-5 Calibration, Stroke, 4-2 Calibration, Quick Reference, Flowchart, 4-l Calibration, Reverse Acting Power Positioner, 3-1 Calibration Spring Part Numbers, 9-l Cam Bar Shaping, 2-8 Characterized Cam Bar Example, 2-12 Clevis, Description, 1-3 Corrective Maintenance, l-l Corrective Maintenance, Air Filter Element, 7-l Coi~ective Maintenance, Calibration Spring, 7-2 Corrective Maintenance, Cam Bar, 7-8 Corrective Maintenance, Current to Pneumatic
Signal Converter, 7-l Corrective Maintenance, Cylinder, 7-5 to 7-8 Corrective Maintenance, Diaphragm, 7-2 Corrective Maintenance, Pilot Valve, 7-2 Current to Pneumatic Signal Converter, Air Supply, 2-2 Current to Pneumatic Signal Converter, Calibration, 4-S Current to Pneumatic Signal Converter, Description, l-l Current to Pneumatic Signal Converter, Electrical
Connections, 2-4 Current to Pneumatic Signal Converter Electrical
Connections, Direct Acting, 2-4 Current to Pneumatic Signal Convexter, Replacement, 7-l Current to Pneumatic Signal Converter, Reverse
Acting, 2-4 Cylinder Head Gasket Replacement, 7-5 to 7-7 Cylinder Replacement, 7-8
D
Diaphragm Replacement, Air Lock, 8-l Diaphragm Replacement, Receiver 7-2 Dust Cover, Description, 1-3
E
Environmental Requirements, 1-6 Electrical Connections, 2-4
F
Flow Verses Position Formula, 2-1 Formula, Angular Rotation of Driven Lever, 2-6 Formula, Linkage Length, 2-7 Formula, Vertical Arm Travel, 2-5 Foundation, Special Installation Considerations, 2-l Foundation, Strength Requirements, 2-2
G
General Operation, Description, 1-3 Gasket, Cylinder Head, 7-5 to 7-8 Gasket, Pilot Valve, 6.1, 7-2
I Installation, 2-l
Installation, Air Supply, 2-2 Installation, Linkage, 2-4 Installation, Power Positioner Mounting, 2-l Installation, Special Considerations, 2-1
L
Linear Cam Bar, Outputs, 14 Linkage Design, Special Installation Considerations, 2-1 Linkage, Material, 2-4 Linkage, Maximum Length, 2-4 Lubrication Chat, 6-2
M
Maintenance Schedule, 6-1 Manual Lever, Description, l-l
Manual Lock, Description, l-1 Manual Operation, Description, l-5 Maximum Air Pressure, Cylinder, 1-6 Model Number Matrix, l-2 Mounting and Installation (Footprint) Drawing, 2-l Mounting, Foundation Design, 2-l
Mounting Instructions, 2-1 Mounting, Location Selection, 2-l
Mounting, Working Clearance Requirements, 2-2
N
NFMA Rating, 1-6
0
options, 8-l
P
Package Contents, l-l Performance Requirements, 1-6
Periodic Maintenance, 6-l Periodic Maintenance, Air Filters, 6-4 Periodic Maintenance, Cylinder, 6-S Periodic Maintenance, Diaphragm, 6-4 Periodic Maintenance, General, 6-1 Periodic Maintenance, Pilot Valve, 6-1 Periodic Maintenance, Piston, 6-S Periodic Maintenance, Storage, 1-S Physical Characteristics, 1-6 Power Positioner Torque, 1-6, 2-2 Pressure Regulator, Description, l-l
S
Signal Requirements, Input, 1-6 Signal Requirements, Output, 1-6 Specifications, 1-6 Square-Root Cam Bar, Outputs, 1-4 Squared Cam Bar, Outputs, l-4 Supply Air Filter, Description, l-l Supply Air, Special Installation Considerations, 2-l Supply Air Shut Off Valve, 2-2 Switch Ratings, DPDT, 1-2 Switch Ratings, SPST, l-2 Stem (Pilot Valve), Cleaning, 6-l Stem, Illustration, 6-3 storage Instluctions, 1-s
T
Troubleshooting, S-l Troubleshooting Chart, S-l
V
Valve, Pilot, 6-1, 7-2
R
Recommended Spare Parts, 9-l Reverse (Inverse) Operation, Description, l-5, 3-l
W
working Clearances, 2-2 Wiring Codes, 2-l
Loading...