Instruction No. 22036 Series 7600 Pneumatic Positioner Instructions Masoneilan Crem Ma Instruction No. 2098 MasoneilanInstallation The essential function of the Series 7600 pneumatic positioner is to make the Camflex valve stroke propor tional to a pneumatic signal from a controller or to modify the natural flow characteristic of the valve itself through the use of a cam, It permits split-ranging of valves, It may be used to reverse valve response to an instrument signal (ie. instrument signal opens or closes the valve) or to provide an increase in response speed. General ‘The Camtlex vaive is installed in the pipe line to operate Jn one of two ways: Airto-Open Air-to-close Flow tending to close Flow tending to open Close on air failure Open on air failure The choice depends on the desired air failure action. This subject is dealt with in Instruction No. 30446. This set of instructions concerns itself only with the Series 7600 pneumatic positioner and how itis mounted on the Camilex vaive. The positioner can operate either by direct action (increasing instrument signal produces an increase in output pressure) or reverse action (increas- ing instrument signal produces a decrease in output pressure) Mounting ‘The positioner is always oriented on the actuator such that the gauge end is nearest the actuator pressure ‘connection, The unit is mounted on the side of 5” and. 62” diameter actuators and the feedback mechanism linkage is connected to the valve lever between the plug shaft and actuator clevis. Two sets of tapped holes ‘are provided on opposite sides of the lower cylinder flange for mounting the positioner using two cap screws and spacers (14). The 3%” diameter actuator is provided with a support bracket (1) on its bottom side to which the positioner is bolted. The feedback mech- anism link is connected to the valve lever below the plug shaft. Feedback Mechanism ‘The relative position of the feedback mechanism parts, i.e. the cam and the lever S/A depends on the following 1, The actuator action (opening or closing with air failure). 2, The size of the actuator (3%4”, 5” and 6%”). 3, The action of the positioner (direct or reverse). When reversing the position of the cam (switching from hole A to hole B or vice versa) it is also necessary to change the position of the bearing lever. In every, cease, the pivot points of the cam and the bearing lever should be on opposite sides of the housing. In this way, the trajectory followed by the contact point of the cam with the ball bearing is constant, whatever the cam position may be. Illustrations on page 5 show, for various combinations of valve action and actuator sizes, .m orientation. Jack mechanis! the required feed inkage ect ate a stroke lever (12), a noes a turnbuckle screw (3), yo tocknuts (5 and 7). The ing to the stroke of othe a and 2”). For al instar each size actuator or cting linkage from the valve yee Sen ith troke lever (12) nT), with Tocknut (5) ad furn- row (0) Mine valve lever. Tighten specie serew (2) withthe stroke tHe connecting screw thread. vis ‘to the stroke lever (12) with clevis Connec i (y and etaning al (1). Serew locke Bin (8), wash urnbuckle serew (2) and complete the rut (7) ont me necting the turnbuckle. One of the assembly PY on turnbuckle has a lett and the other PD tne right hand pitch Hs located on the cylindrically machined end. Conn Connecting link Sus te), a turnbuckle (6) ‘connecting screw dimensions o lever must Ii Install connecting 8°" buckle screw (3) atta focknut (5). Align surnt lever (12) by turning it on Pneumatic Circuit The supply, output and signal connections, at the back of the manifold are tapped ¥4” NPT. The signal and output connections are located directly opposite their respective pressure gauges marked “Instrument” and ‘Output”. The supply connection is also located oppo- site the supply gauge. There is also an exhaust connec- tion with a hex head exhaust plug in it. If the action of the positioner is reversed, then the supply and exhaust connections have to be interchanged. With reverse action, the “Supply” gauge must be re- moved and replaced by a Ye” NPT plug, Since the new ‘supply connection has no gauge opposite, connect the ‘Supply” gauge above to the 77-4 filter regulator using a %” x %” NPT bushing, Mustaine on page 5 show the postions of the con nections for direct and reverse positioner action. The ese of a Mode! 77-4 filter-regulator in the supply circuit 's recommended. t can be mounted on the actuator on We Opposite the positioner, For increased frequency response se atigh capacity air regulator jecommended pneum: eee ere pneumatic piping between filter-regu- jator, Pesitoner and actuator is plastic tubing. with brass connections. Tubing is 4” O10. for the 312” and 3 gous and 36". for the 62” actuator range of the pneumatic psi (207-1094 mbar cr. to1 Keven oat = S18 Maximum allowat e Nonar ar allowable air supply pressure to the posi toner varies acoraing tothe valve size: 2378 (a4 Be forthe 1 5 min valve: {eda vag FOF the 142” (40 mm), 2" (50 mm) and 3” 35 psi (2.4 bar) fo at) for the 4” (100 mm) v 45,psi (3,1 bar) for the 6 (150 uy yaad‘55 psi (3.8 bar) for the 6” (200 mm) valve: fectly. Also, the connections to the positioner should 65 psi (45 bar for the 10” (250 mm) valve be established before instaliing the positioner on the 78 psi (52 bar) for the 12” (300 mm) valve actuator. ‘The supply and connecting circuits must be sealed per- a Lower Cylinder Flange Bearing Lever eter actuator) lex valves (31 (6° and 614” diameter actuators) ‘Series 7600 positioner mounted on 3-12” Camilex valves PARTS REFERENCE Rel. Re Ret. pa Part Name fed Part Name a No. Part Name 7 | Bracket 6 | Tumbuerie 12 | Stoke Lever 2 | Screw (oracket mounting, 7] Nu 13 | Cap Screw ‘ot shown) & | Clovis 14 | Spacer 3 | Tumbuckle Screw 3 | ClevisPin 20 | Washer a | Screw 10 | Flat Washer 21 | Cap Screw 5 | nu 11 | Retaining Cin 3description and operation The operation of the Series 7800 pneumatic positioner is based on the equilibrium of a mechanism subjected to two opposing forces: 1. The force exerted on a diaphragm by the pressure of the pneumatic signal from the control instrument. 2, The compression of a spring, related to movement of the actuator stem through a feedback mechanism. Inthe balanced state, when the pneumatic signal varies, the diaphragm assembly moves. This movement is followed by the pilot plug which is pushed by the pilot spring Movement of the pilot plug alternately connects the ‘output circuit to the supply circuit or the exhaust port, thus moditying air pressure to the actuator. The stroke lever transmits, through the cam, the actuator move- ment to the feedback spring. The actuator stem con- tinues to move until the spring force exactly balances the force of the instrument signal on the diaphragm. In the new balanced state, the vaive plug is positioned in a programmed relationship to the instrument signal Note: The instrument signal must not exceed 22 psi The pilot spring has sufficient force to push the pilot plug against the small diaphragm at instrument signal pressure below 22 psi. Above that pressure the posi- Hioner will not operate. Pilot The pilot is essentially a three-way sliding valve. The plug regulates supply air flow to and from the actuator fo the exhaust port. The position of this plug, governed by the diaphragm, determines the output pressure of the positioner. The positioner action may be reversed by interchanging the supply and exhaust connections land by reversing the position of the cam. Direct Action: Increasing instrument signal pressure produces an increase in output pressure. Reverse Action: Increasing instrument signal pres- sure produces a decrease in output pressure. ay the fe ke ar gine intemediateeaent inthe feedbac as foe lever and the feedback Trachantem between the 8 tnea the relationship. between sonar praie determines tne roll spring, is pros tion andthe control signal, Standard, the valve luo rowtvide rinear of percentage conto characteristics. Bypass Valve During normal opera directly to the diap pressure passes throu actuator The bypass valve permits the positioner to be isolated Tar metntenance while operating the Camilex valve Girectiy with the instrument signal. By turning the nylon Valve to the bypass position (2 red arrow on the valve Shows this. position), the “output” pressure to. the etuator is blocked and the instrument signal passes both to the positioner diaphragm and the actuator. The bypass valve does not block supply pressure to the pilot Theretore, the supply line should be shut off with 2 small hand valve betore disassembling the positioner Note: When a Camtlex valve (because of high pressure drop) uses a supply pressure higher than 20 psi, the 3-18 psi instrument signal may not be sufficient to operate the valve when the positioner is. bypassed. Moreover, if the positioner with a high supply pressure is bypassed suddenly, the high pressure in the actuator @ may damage the diaphragm and/or the control instru- ment. Therefore, the bypass valve should be used only if the positioner supply pressure is 20 psi (1, 4 bar) or ‘at most 35 psi (2, 4 bar) tion, the instrument signal passes fhragm and the regulated supply igh the pilot valve to or from the Zero Adjustment The zero adjustment is made with the turnbuckle. When the positioner i installed on the valve and the pneu- matie circuits are connected, apply instrument signal Direct Action irr shim Com Lr Reverse Action wre Exhaust Supply Pressureorientation and connections 3%" Actuators (1°-2” Valves) Direct Positioner Direct Positioner i pit range cams. fo. 495100-172-159 | Te lit range cams. Equal Percentage Cam No. 435100-171-159 1d 694" Actuators (9"-12" Valves) Direct Positioner Direct Positioner GAIT 3 Oh Equal Percer Equal Percentage Cam No. 435100-172-153 Reverse Positioner (eck Linear and bot Linear elt range cams, Equal Percentage Cam No, 435100-171-153pressure required to close the valve, ie. 15 psi (1034 mbar) for a valve that opens on air failure; 3 psi (207 mbar) for a valve that closes on air failure (direction action positioner). Turn the turnbuckle until the plug Seats in the valve, Tighten locknut. Span Adjustment — percentage cams only The point on a percentage cam’s curvature at which the span starts (zero point) determines the length of span. The starting point may shift slightly from one positioner to another. One or two shims, positioned at the ends of the feedback spring assute that, at the zero Point, the feedback roller is always at the exact same Point on the percentage cam, thus establishing the desired span, If @ Mode! 7600 positioner has been factory mounted fon a valve, shims, i any, have been installed and the span permanently adjusted. Only a zero adjustment is maintenance Pilot To clean the pilot subassembly or replace deteriorated paris, place the positioner on “Bypass” and cut the supply air. To minimize maintenance time, it is recom- mended that the entire pilot subassembly (8) be re- placed by a new subassembly, so that the old unit can ‘be worked on when time permits. Disassembly 1. Unscrew the pilot subassembly (8) and disengage it from the body (7). Note: Turn the pilot subassembly while removing it to prevent damage to the O-rings. 2. Remove end plug and withdraw the spring, plug and extension pin. If necessary, use a penetrating oil to free parts, 3. Wipe the parts with a clean soft cloth and blow ‘compressed air through the orifices, Reassembly 1 Install three new O-rings on the pilot spool. Put silicone grease on each O-ring, 2 Replace the extension pin and the plug, counter sunk end first into the pilot spool. The plug should slide into the pilot spool by its own weight. 3. Install the spring in the pilot spool. The end having the smallest diameter must be in contact with the plug. Screw the pilot end plug into the pilot spool 4, Install the pilot subassembly (8) into the body (7), Bypass Valve The bypass valve includes three O-rings (1 & 17) to seal off the air circuits, Disassembly 1. Remove the "Supply", ‘gauges. 2. Remove retaining ring (19) with Tru-Are pliers and remove the bypass valve from the positioner. 3. Remove old O-rings, thoroughly clean the bypass Instrument” and “Output” receaan(e g wo Si, ech 000 toner eapoly instrument signal pressure required connected. @Paive. Turn the turnbuckle until the plug to close valve. Apply instrument signal pressure the 207 BY easly installed by sipping ft ane eeaback spring and the spring button at seats in the required to OP valve is not fully open. a valve and install new O-rings, Put silicone grease fon each O-ring. Reassembly 4. Install the bypass valve in the positioner. Turn it while installing to avoid damage to the O-rings, 2. Be sure that the handle and stop of the bypass valve are positioned on either side of the stopping pin, 3. Replace the retaining ring (19) and gauges. Body Cut the air supply, disconnect the feedback mechanism, linkage at the stroke lever, remove the positioner from, the actuator and disconnect air lines. Disassembly 41. Remove all three pressure gauges, 2. Remove the pilot assembly. 3, Remove cap screws (14) and separate the body sub- assembly from the case subassembly. 4. Remove the diaphragm assembly (6) and the bypass, valve (16) 5. Clean the body (7). Avoid the use of a detergent which might deteriorate the diaphragm (6) or the small diaphragm, Reassembly 41. Replace the bypass valve (16), 2 Position the diaphragm assembly on the case sub- fembly. Secure the body subassembly to the ease 4, jubsssembly with cap screws (14), Inthe plot ase Recon a neh tal the plone connect feedback mechan takage ut the vaive into operation, oe Diaphragm U1 the diaphragm has deteriorated, sembly should be replaced, This’ and pressure gauges. the diaphragm as- requires separation (continued on page 8)il O-Rings Pilot Sub-assembly (8) mes | ot Sp! Extention Pin Pu spring End Plug Recommended spare part numbers o-ring Disphragm Sub-assembly Pio Subassenbiy Reterence No.1 Reterence He Teterence No 8 ‘Quanity — ‘Quantiy— tt ‘Guanty—4 673886099-600 435100-000-299168 495100.004-998 671686-102-680 PARTS REFERENCE Ret Ret art Name i Part Name ae Part Name O-Ring 2 | Washer 720 | Supply Gauge Screw cover) on} Caso sub-assembly 121 | Instrument Gauge Bearing Laver Sub-assombly ada) oa | oval Spina 108} case Subassembly 23 | Screw (eating lever) Diaphragm Sub-assembly oz conciv service) 24 Screw (Gandara) 14 | cap Screw 25 | Cover Disphagm Sb-ssenty 15 | Ven Pig 28 | Sera Piate tor corosvesoracs) 18 | Bypesevabe 21 | Stroke Laver Axis 7 | Body Sub-assembly 17 | O-Ring 28 Range Spring Shim 2 | Piotsuv.assempiy tie | Output cause 30 | Decat mes nescer! © 19 | Retaining Ringof the body and case subassemblies as outlined under Body Subassembly. Small Diaphragm The small diaphragm is held permanently in the body (7). Its eventual deterioration requires replacement of the body. Trouble Shooting The following conditions must exist to ensure satis factory operation of the positioner: 4. The valve must be properly mounted in the line so that the actuator counters the dynamic torque and the valve operates as desired on air failure 2, Supply pressure is adequate for valve operation (reler to installation, pages 2 and 3). 2. Instrument signal pressure must not exceed 22 psi 10 avold reversal of sp00! motion. 4, Correct positioner installation. 5. Correct positioning of the feedback mechanism (linkage, cam, bearing lever, etc) 6, Proper cam selection Split range operation Split ranging permits the operation of two valves in sequence from one 8-15 control instrument signal. The total stroking of each valve occurs with one half the signal, ie. 3-9 psi or 9-15 psi. The following table rument signal and output connections inst Sap: positioner action, Le. direct, must be correct for the or reverse 8, Airtight connections. 9. Correct position of the bypass. in case of malfunction, check following in order given 1 Check the zero adjustment and adjust the turn- buckle if necessary 2, be sure the feedback spring is seated properly on Ae coring button part of lever subassembly (4). The Spring button must freely pivot around its shaft 3, adjust instrument signal pressure from minimum to AeKimum and observe the corresponding gauge. If Tnstrument” gauge reading does not correspond to the signal, the iadphragm and/or small diaphragm may be broken. Replace the defective part 4, Positioner insensitivity may be the result of a stick- ing pilot spool whose movement may be impeded by: 2 Foreign matter such as dirt, metal particles, etc. b. Partial blockage of air passages caused by too ‘much oil in the airlines. . Blocking of vent holes. shows, for example, the plug positions of two valves (both air-to-close action, open on air failure operating in "split-range") with a 3-15 psi instrument signal (207- 1034 mbar. nent Signal No. 1 Valve Plug Position No, 2 Valve Plug Position mbar (3-9 psi) 15 6e 207 Full Open Full Open 414 Half Open Full Open 620 Closed Full Open 827 Closed Half Open 1094 Closed Closed me mS Linear cam Linear spit Equal Percen aast00-108-153 tices Saat aun Percentage cual prcenaae 500-181-189 495100-171-159, ags100-172-153 ‘Cam Types Part ae 495100-166-159 3-9 psi (207-620 m.bar) eee | Linear Linear Split Range Equal Percentage | Equal Percentage 76,11.5 en 8-15 pst (620-1034 m.bar) Fora direc ac Gn an ai-o-close (fal open) valve Fora reverse action postioner ounted onan ai-to-open (al closed) valve, Fora reverse action positioner mounted ‘onan ar-o-close (al open) valve, Fora ditect action positioner mosnted ee 435100-181-153 n positioner mounted a 435100-171-153, 435100-172-153 | 7