User Manual

ManualsBrandsCashco ManualsAccessories for water9540R P/P

I. DESCRIPTION AND SCOPE

Model 9540R is a single acting, compact, force-bal-

ance, pneumatic positioner used together with a

rotary motion adapter baseplate for 90° rotary control

valves. This positioner is utilized to characterize the

relationship between valve stem position and the

system’s control signal. This design is only suitable for

nominal 3-15 psig (.21-1.0 Barg) input signals, or split

range variations thereof.

Each unit comes complete with a set of built-in gauges

within the internals, and a visual stem position indica-

tor; the cover includes a clear see-thru panel to

monitor gauges. Gauges monitor input “SIG” and

output “LOAD”.

The Model 9540R P/P positioner may be utilized as an

alternate to the standard Model 9000R rotary P/P

positioner, with the following current Cashco product

models:

Ranger QCT

Premier EZO

Premier (unlined)

IAS – Instrument Air Supply

PC – Pressure Controller

PCV – Pressure Control Valve

ATO-FC – Air-to-Open, Fail Close

ATC-FO – Air-to-Close, Fail Open

P/P – Pneumatic Input/Pneumatic Output

DIR – Direct Acting

REV– Reverse Acting

SIG – Controller Output Signal

V – Vent

CW – Clockwise Rotation

CCW – Counter-Clockwise Rotation

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-9540R

06-03

MODEL 9540R

P/P - PNEUMATIC POSITIONER FOR ROTARY VALVES

SECTION I

Figure 1: Typical Pressure Reducing Pneumatic

Control Loop – PCV with P/P Positioner

Model 9540R Mounted on a

Cashco Ranger QCT Control Valve

PCV

5-13 psig

3-15 psig

LOAD

DIR.

P1 = 500 psig

ATO-FC

IAS

P/P

SIG

PROCESS

P2 = 100 psig

15-3 psig

IAS

20 psig

REV.

Summary of content (16 pages)

PAGE 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-9540R 06-03 MODEL 9540R P/P - PNEUMATIC POSITIONER FOR ROTARY VALVES SECTION I I. DESCRIPTION AND SCOPE Model 9540R is a single acting, compact, force-balance, pneumatic positioner used together with a rotary motion adapter baseplate for 90° rotary control valves. This positioner is utilized to characterize the relationship between valve stem position and the system’s control signal. This design is only suitable for nominal 3-15 psig (.21-1.
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SECTION II II. METHOD OF OPERATION (See Figure 2) The normal factor set position of the bypass switch (3) The positioner operates with the force balance principle: the input signal “SIG” (3-15 psig) acts on the input diaphragm (50). The stroke of the input diaphragm is transferred to the flapper lever (38). The resulting movement of the flapper varies the dynamic pressure at the nozzle (51).
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D. Existing Control Valve Modifications: 1. Refer to IOM-48 or IOM-148 for instructions for the rotary actuators used on Ranger QCT, Premier EZO and Premier (unlined). 2. All indicated Item Numbers that are with respect to IOM-48 or IOM-148 will be in parenthesis and underscored; i.e. (32). All part Item Numbers that are with respect to this IOM-9520R are not underscored; i.e. (32).
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#148 Actuator: (See Figure 3) a. Turn actuator handwheel (58) CW to remove stem windup torque. The linkage from the actuator stem (9) will become slack. May require 1-3 revolutions. This will ease removal of cover plate (13). b. Remove four cap screws (34), two cap screws (31), dial lens (14), travel indicator dial (15), cap screw (32), travel indicator (16), lock washer (55) and pin (51). c. Figure 2.
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21 17 12. As shown in Figure 4, attach the feedback lever (13) onto the positioner unit’s main shaft (17) by hand-tightening socket cap screw (21). DO NOT WRENCH TIGHTEN SCREW (21). 13 Main Positioner Unit 31 13. Remove the two plastic screws in the right side of the main positioner unit where cap screws (11) would be inserted. (See Figure 5.) 14. Begin to set the main positioner unit near its final position on baseplate (26).
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19. Install adapter block (AB) with four O-rings (OR) to main positioner unit, with the connections oriented to the rear. 20. Install tubing fittings with acceptable thread sealant and tubing from the unit’s 1/4” NPT (female) “OUTPUT 1” port of the adapter block (AB) up to the connection port of the actuator casing. NOTE - Thread Sealants: If TFE tape is used, make sure that small pieces of tape will not be “pinched off” and enter the pneumatic internals. (Liquid thread sealants are not recommended.) 21.
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Action ATO-FC Direct N ATC-FO Direct N ATC-FO Reverse U ATO-FC Reverse U Plug Action With Signal Increasing Eckardt Fail Action Position CW to Close CCW to Open Opens Closed U Control Valve Action/Fail Position CW to Close CCW to Open Closes Open U TABLE 2 Positioner CW to Close CCW to Open Opens Closed CW to Close CCW to Open Closes Open w/o Signal Stem Travel Direction N N Changeover Plate Setting TABLE 3 RANGE SPRING SELECTION Input Product "SIG" & Cam psig Character 3-
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RANGER QCT Inner wall of baseplate (26) RANGER QCT X 24 Inner wall of baseplate (26) X 24 =% 24 Signal = max Output Load = max Valve Position = closed Signal = min Output Load = max Valve Position = closed Characteristic: = % Actuator Action: ATC-FO Positioner Action: Direct 31 31 Figure 11 PREMIER EZO or PREMIER RANGER QCT Inner wall of baseplate (26) PREMIER EZO or PREMIER Characteristic: Linear Characteristic: =% 24 24 24 Signal = max Output Load = max Valve Position = open Positi
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SECTION IV IV. BASIC ADJUSTMENTS/SETTINGS A. Required Tools: The following tools are required for the basic adjustment: 1. 2. 3. 4. 5. 6. 7. 8. Screwdriver Open-end wrench - 6 mm Feeler gauge 0.6 mm (.24 in) Two test gauges - 30 psig (for 20 psig max bench range); One test gauge - 30 psig, and one test gauge - 60 psig (for 30 psig max bench range) Manual loader/airset Open-end wrench - 10 mm Needle nose pliers; small #5 Allen wrench (5 mm) (provided) B. Manual Bypass Setting: (See Figure 16) 1.
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SECTION V V. CALIBRATION/ADJUSTMENTS c. A. ZERO and STROKE Setting: (See Figure 17) 1. After settings of Section IV have been completed, place separate manual loaders to supply the positioner with air (“IAS”) and develop a variable 3-15 psig signal (“SIG”) as the input. See Figures 4 and 5. Remove plastic plug (33). Loosen screw (21) securing the feedback lever (13) on the backside of the unit to the main shaft (17) using the #5 (5 mm) metric Allen wrench provided.
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k. If procedures of Step 4. above have been completed, skip Step 5. following, and go to next paragraph V.B. 5. Press the flapper lever (38) several times to the left and right until the flappers are correctly aligned. a. Induce the minimum value of the input signal (“SIG”) using a manual loader. (This corresponds to the start of the valve’s stroke.) b. Turn the zero thumbscrew (39) either CW or CCW until the actuator begins to cause valve stem travel.
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2. DAMPING is factory set, and normally requires minimal/no adjustment. However, if determined as required, DAMPING is adjustable from a minimum-to-maximum ratio of 1:2.5. In its normal factory set position, the damping screw (44) is set approximately flush with the amplifier housing (53); this position is minimum DAMPING . As the damping screw (44) is screwed CW - inwards, DAMPING increases.
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4. The following procedure must be observed in order to achieve a no-feedback adjustment of the ZERO and STROKE setting. a. Press the stroke factor lever (19) against the travel stop pin (20). b. Set the stroke factor thumbscrew (40) to a high stroke factor (approximately 5/64” before the upper stop). 4. Turn the throttle screw (42) in again as far as it goes CW. 5. Turn the limiting screw (43) in as far as it goes CW; then back it out CCW about half a revolution. 6.
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SECTION VII VII. TROUBLE SHOOTING GUIDE 1. Actuator does not respond to applied input signal. Possible Causes A. Amplifier defective B. Pneumatic connections reversed C. Feedback lever not tightened D. Stroke factor lever is loose on the shaft E. Positioner mounted on the wrong side F. Changeover plate in the wrong direction Remedies A1. Replace amplifier (See VI.C.). B1. Check connections. C1. Screw feedback lever tight (See III.D.9.). D1. Tighten shaft. E1.
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REPAIR PARTS KITS Kit A: Includes gaskets, O-rings and small parts. Order P/N 295-08-5-07410-00 Kit B: Replacement pneumatic amplifier. Order P/N 653-75-5-09542-00 APPENDIX A Removal of Model 9000R P/P Positioner 1. Reference Section III.D. Existing Control Valve Modifications, paragraphs 1. and 2. 5. Remove feedback pivot link shaft (74), both spacers (109), and feedback linkage assembly (73). 2. Remove positioner unit (101) by removing four socket cap screw (33). 6.
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Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 FAX (785) 472-3539 www.cashco.com E-mail: sales@cashco.com exportsales@cashco.com Printed in U.S.A.