`

USERS MANUAL
This users manual corresponds to the

Control valve model series 100,140,160. Pneumatic Positioner 820. Actuator series U - series and MSA Multi Spring Actuator FM Pressure Controller model 902.

Manufactured & marketed by

FORBES MARSHALL A 34/35, MIDC Industrial Area, H Block, Pimpri, Pune 411 018 INDIA. TEL.: 91(0) 20 7442020 FAX. : 91(0) 20 7442040 E-MAIL : vsales@forbesmarshall.com WEB SITE : www.forbesmarshall.com

FORBES MARSHALL

Dear User,

Thank you for purchasing the FM Control Valve. To maximize your benefits from this product, we request you to read this manual thoroughly before installing the valve. A record of the product maintenance history should be kept every time our service representative visits you.

If you experience difficulty with the Installation or operation of this Equipment, please contact our nearest Customer Service Representative

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Whats Inside
FM CONTROL VALVE
1. 2. 3. 4. 5. 6. 7. 8. About The Product Drawing of the Product Principle of Operation Getting Started Before First Startup Commissioning the Product Maintenance Assembly Tips Addition of packing rings Replacement of Packing Rings Replacement of Seat Replacement of Plug Recommended Spares Frequently Faced Problems 8 9 18 18 19 19 20 20

9.

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PNEUMATIC POSITIONER 820.

1. About the Product a. General Description b. Specifications c. Dimensional Drawing d. Technical Data e. Operating Principle 2. Getting Started a. Installation & Commissioning 3. Operation & Maintenance a. Basic Functions 40 b. Calibration & Adjustment of Stroke 44 4. Trouble Shooting 45 49 39 34 35 36 37 38

5. Positioner part list

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ACTUATOR
1. Universal Diaphragm Actuator a. About the Product b. Principle of Operation c. Getting Started d. Installation e. Commissioning the Product f. Reversibility of Actuator

52 55 57 58 59 60

Exchange of Spares Mounting succession Recommended Spares

2. Multi Spring Actuator a. About the Product b. Principle of Operation c. Getting Started d. Installation e. Commissioning the Product f. Reversibility of Actuator g. Part List of MSA Actuator 64 65 66 67 68 69 70

3. Actuator Trouble Shooting

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PRESSURE CONTROLLER
1. About The Product a. General Description b. Specifications c. Operation Principle d. Codification 2. Getting Started a. Installation b. Mounting Instruction For Pressure Controller c. Pressure Controller Part List d. Commissioning 3. Operation and maintenance a. Basic Function 4. Trouble shooting 88 90-92 81 82 85 86 76 78 80

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FM CONTROL VALVE

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1. ABOUT THE PRODUCT:

Specifications and Model Numbers 1 0 1 P 1 NUMBER OF STEPS FOR PARABOLIC PLUG PERFORATED PLUG (L) LOW NOISE CAGE (LK) LOW NOISE DISC (LS) TRIM TYPE P :1 OR SEVERAL STEPPED PARABOLIC PLUG L :1 OR SEVERAL STEPPED PERFORATED PLUG LK :1 OR SEVERAL STEPPED LOW NOISE PLUG LS :1 OR SEVERAL STEPPED LOW NOISE DISC BONNET TYPE 1 :STANDARD TOP FLANGE 2 :TOP FLANGE WIYH DOUBLE GLAND PACKING 3 : TOP FLANGE WITH COOLING FINS 4 :TOP FLANGE WITH BELLOW SEALING 7 : STD. TOP FLANGE & PRESSURE BALANCING 8 : TOP FLANGE WITH COOLING FINS & PRESSURE BALANCE PRESSURE CLASS 0 :NOMINAL PRESSURE CLASS(#); #150,#300 TOP GUIDED PLUG 1 :NOMINAL PRESSURE CLASS(3); #600,#900 TOP GUIDED PLUG 4 :NOMINAL PRESSURE CLASS(#); #300 TOP & BOTTOM GUIDED PLUG 6 :NOMINAL PRESSURE CLASS(#); #600, #900 TOP & BOTTOM GUIDED PLUG

SINGLE SEAT CONTROL VALVE

This manual is applicable to the following valve model nos.: 100, 140 & 160 The code nos are given above.
For ex. : Valve with model no. 1 0 1 L 2 : SINGLE SEAT CONTROL VALVE NOMINAL PRESSURE # 600-900 STANDARD TOP FLANGE WITH TWO STEP PERFORATED PLUG.
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2. DRAWINGS OF THE PRODUCT:

Following are the sectional drawings elaborating salient features of FM control valves. These are two different series distinguished by 3-flanged and 4flanged design of FM bodies. The index of drawings is as follows:

NO. DWG NO.

VALVE TYPE

1 2 3 4 5 6 7 8

I/A I/B I/C I/D II/A II/B II/C II/D

CONTROL VALVE SERIES 141 ON/OFF VALVE SERIES 141 ON/OFF AND CONTROL VALVE SERIES 141 WITH SOFT SEATING TOP FLANGE WITH COOLING FINS SERIES 143 CONTROL VALVE SERIES 101 ON/OFF VALE SERIES 101 ON/OFF AND CONTROL VALVE SERIES 101 WITH SOFT SEATING TOP FLANGE WITH COOLING FINS SERIES 143

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7 12 11 10 13 9 16 2 14 17 8 15 6 5 4 1

16 14 3
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO. BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL PLUG SEAT BOTTOM FLANGE TOP FLANGE VALVE BODY DESCRIPTION

17

CONTROL VALVE-SERIES 141

FIG. I/A
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7 12 11 10 13 9 16 2 14 17 8 15 6 5 4 1

16 14 3
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO. BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL PLUG SEAT BOTTOM FLANGE TOP FLANGE VALVE BODY DESCRIPTION

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ON/OFF VALVE SERIES 141

FIG. I/B
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7 12 11 10 13 9 16 2 14 17 8 6 15 5.1 5.2 5.3 5.4 4 1 16 14 3

17 16 15 14 13 12 11 10 9 8 7 6 5.4 5.3 5.2 5.1 5 4 3 2 1 I.NO. BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL LOWER PART O-RING UPPER PART SPRING DOWEL PIN PLUG SEAT BOTTOM FLANGE TOP FLANGE VALVE BODY DESCRIPTION

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CONTROL AND ON/OFF VALVE SERIES 141 WITH SOFT SEATING FIG. I/C

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7 12 11 10 13 9

16 2 14 17 8 15 6 5 4 1

16 14 3 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO. BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL PLUG SEAT BOTTOM FLANGE TOP FLANGE VALVE BODY DESCRIPTION 17

TOP FLANGE WITH COOLING FINS SERIES 143 FIG. I/D

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7 12 11 10 13 9 16 2 14 17 8 15 6 5 4 1

17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO.

BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL PLUG SEAT TOP FLANGE VALVE BODY DESCRIPTION

CONTROL VALVE-SERIES 100

FIG II/A.

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7 12 11 10 13 9 16 2 14 17 8 15 6 5 4 1

17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO.

BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL PLUG SEAT TOP FLANGE VALVE BODY DESCRIPTION

ON/OFF VALVE SERIES 101

FIG. II/B

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7 12 11 10 13 9 16 2 14 17 8 6 15 5.1 5.2 5.3 5.4 4 1 5

17 16 15 14 13 12 11 10 9 8 7 6 5.4 5.3 5.2 5.1 5 4 3 2 1 I.NO.

BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL LOWER PART O-RING UPPER PART SPRING DOWEL PIN PLUG SEAT BOTTOM FLANGE TOP FLANGE VALVE BODY DESCRIPTION

CONTROL AND ON-OFF VALVE SERIES 101 WITH SOFT SEATING

FIG. II/C

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7 12 11 10 13 9

16 2 14 17 8 15 6 5 4 1

16 14 3 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO. BOLT NUT GUIDE BUSH GASKET SLOTTED NUT GLAND NUT GLAND FOLLOWER GLAND PACKING RINGS BOTTOM RING SPRING DOWEL PIN SPINDLE BALL PLUG SEAT BOTTOM FLANGE TOP FLANGE VALVE BODY DESCRIPTION 17

TOP FLANGE WITH COOLING FINS SERIES 143 FIG. I/D

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3. PRINCIPLE OF OPERATION:
The Control Valve type mentioned above are according to ANSI B 1634. They reduce the pressure/ flow by single step or multi step parabolic plug or perforated plug. By changing the valve lift (plug position) the annular area between the plug and seat changes, which in turn changes the flow. The flow characteristics is determined by the profile or the size and orientation of the holes in case of perforated plug. At zero lift (closed position of the control valve) the plug taper rests on the tapered edge of the seat and thus provides metal to metal closing. In case of multi-step parabolic plugs, only last step has taper; which rests on the seat in closed position.

4. GETTING STARTED:
Installation
The place of installation should be selected to have sufficient valve accessibility around the valve for dismantling & repairs. Valve size 6 and above should have sufficient space above the valve to mount a chain pulley block. When valves are mounted in raised position platform should be provided at least on one side of the valve. The valve with flanged ends can be directly installed in the pipeline with flanges. The valves with welded ends can be directly welded in the line. In both cases following points must be considered: a) The valve should be in a horizontal position, with valve spindle in vertical position as shown in cross-section drawings of valves in next section. b) The upstream & downstream of the valve should be properly supported to avoid excessive stress on the valve body. c) On upstream & downstream of the control valve there should be a straight flow at least 10x valve size (in mm) without any interruption by stop valves, elbows. d) To avoid longer breakdown of the plant a bypass should be installed.

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5. BEFORE FIRST STARTUP:

All the main lines as well as the pneumatic lines are to be thoroughly flushed before first commissioning. Following points must be taken care during flushing of these lines: a) During flushing flanged control valves should be taken off the line and replaced by a spacer i.e. spool piece. b) If the valve is welded in the line all internal parts including top and bottom flanges have to be removed and top & bottom flanges should be blanked with specially ordered blanked flanges. Dismantling and assembling of the valve internal should be carried out as per procedure given in TROUBLE SHOOTING. c) If the flushing is done with the assembled valve inline the valve must be dismantled & cleaned thoroughly after flushing. Special attention to be given to all hollow spaces and gaps. d) Parts which have been corroded by the pickling /cleaning process have to be repaired or replaced. Specially take care of probable leftover of pickling fluid in stuffing box area.

6. COMMISSIONING THE PRODUCT:

Please refer to drawing no I/A to I/D and II/1 to II/D. At the first startup, the gaskets (14) may leak due to setting. If so the nuts (16) should be tightened equally and evenly. Also there may be leakage through gland packing (10) due to setting of packing rings by pressure and temperature effect. Therefore, tighten the gland nut (12) slightly. This tightening of gland nut must be done just sufficient to stop leakage. Excessive tightening will increase friction between packing rings (10) and spindle (7) will result in bad control quality. Control valve in steam line with high temperature should be slowly heated up before startup to avoid thermal shocks.

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7. MAINTENANCE:
GENERAL
The valve spindle (7) must be kept clean in places with bad environmental conditions. The cleaning should be done when the valve spindle is in the up most position.

ROUTINE MAINTENANCE
As a part of routine maintenance it is only necessary to retighten the gland nut (12) if any leakage through gland packing starts. Also it may be necessary to tighten the nuts (16) on top and bottom flanges if the gasket (14) leak due to changing pressure and temperature.

8. ASSEMBLY TIPS:
ADDITION OF GLAND PACKING RINGS
If, the leakage cannot be stopped, by re-tightening of the gland nut it will be necessary to add one or two packing rings. For this the valve should be pressure-less and drained. Remove the lift indicator coupling. Take the actuator spindle in uppermost position and lock it there. Unscrew the gland nut and lift the gland follower (11) out. Graphite rings can now be slipped over the spindle and pushed down in stuffing box with the help of gland follower (11). Endless pure graphite rings can also be carefully cut in two halves and laid around the spindle so that the broken faces match again. Push down the ring in the stuffing box with the help of gland follower. In this case the lift indicator coupling need not be removed.

REPLACEMENT OF GLAND PACKING RINGS

The valve must be pressure-less and drained. Dismantle the lift indicator coupling between valve and actuator spindle. Unscrew the slotted nut (13) and actuator can now be taken out. Now loosen the nut (16) of top flange. Unscrew th0e gland nut (16) & gland follower (11) can be lifted up. Care should be taken while lifting removing top flange especially in steam & hot gas piping as slight leakage in any stop valve can pressurize the control valve. After ensuring that the valve is pressure-less the top flange along with the plug-spindle assembly can be completely taken off
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the body. Take out the old packing rings (10) with the help of a hook. Also take the bottom ring (9) out of the stuffing box. Clean all the parts of stuffing box including all the threading. Also clean the top flange in the guide bush (15) area and gasket (14) area. Smear all parts with Molykote HSC or molybdenum disulfide grease. In some special cases say with inflammable fluids this grease cannot be used due to chemical reaction. Clean gasket-seating area in body. Use a new gasket (14). Apply Mo-S2 grease to gasket also. Carefully place the plug spindle assembly on seat (4). Place the top flanges on the valve body. Smear bolt threads with Mo-S2 grease and tighten the nuts equally and evenly. Insert bottom ring (9) in stuffing box bore. Push packing ring around the valve spindle. Take care that the oblique cuts on the rings are staggered. Finally assemble the gland follower (11) and gland nut (12). Connect valve spindle with the actuator spindle using lift indicator and start the process. (Refer to commissioning the product).

REPLACEMENT OF SEAT

The seat is replaceable as it is screwed in the body. Actuator, Top flange, Plug & Spindle assembly should be dismantled according to previous section. A special tool can be used to unscrew the seat. Smear the threads of the new seat with Mo-S2 grease (with the exception of some special fluids). Screw in the new seat with the special tool. Reassemble the seat as explained in REPLACEMENT OF GLAND PACKING RINGS. For screwing & unscrewing of the seat, especially in case if larger valve size it is recommended to use pneumatic tools.

REPLACEMENT OF PLUG

Dismantling actuator top flange and plug spindle assembly as described in REPLACEMENT OF GLAND PACKING RINGS. It is recommended to replace complete plug spindle assembly instead of plug assembly. Assembly of new plug spindle can be done as described above.

RECOMMENDED SPARES

It is recommended to keep following spares in stock: 1. Seat and plug spindle assembly. (Part no. 4,5 and 7.) 2. Set of gaskets. (Part no. 14) 3. Set of gland packing rings. (Part no. 10)
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**

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)

12) 13) 14)

No foreign material should enter the line. No Sulfur or corrosive material should enter SS 410 tubing. Check the direction of valve as per arrow marking on body and side flange. Every time the valve is disassembled, calibration must be done. The valve should be mounted in vertical position only. Other wise the forces due to weight of mountings will come on the trim. No hammering or anything that will distort the original shape/design of any of FM product should be done on trial basis. Air quality is very important for any valve operation. Please keep it checking intermittently. In case of PRDS valves water quality should also be controlled. Strainers can be inserted if required before the water control valve. Ensure correct air tubing connections. The valve should be mounted safe so that, it remains free from water, fluids, etc. accumulating on its outer surface. Any measuring gauge should be inserted only after minimum 1 m from valve that it gives correct reading on steady flow. * For Roboter controlled valves this is very significant. Avoid mishandling to prevent damage of delicate parts and mountings like gauges. It is always recommended to have valve supports placed at site for bigger valves. Refer the manual while changing the spares

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9. FREQUENTLY FACED PROBLEMS

Q1]
A] A1.1]

How to assemble or disassemble valve?

Valve assembly procedure: Refer the Data Sheet; ensure that all components received as per the same. Read the additional description carefully and take note of any special recommendations like degreasing, etc. Deburr and clean all the components. Clean and dry plug, spindle with air. a] b] c] Plug and spindle assembly: Hold the plug in the vice using Aluminum or soft pads. Drop the ball of correct diameter into the top bore of the plug. Screw the spindle until it touches the ball. Check the fitting by removing the plug-spindle assembly from the vice and holding it horizontal in quick successions. If the spindle is not tight the ball will make a sound. Then tighten the spindle. Again hold the plug in vice using Aluminum or soft pads and remove spindle and ball. Apply Molycote HSC to ball and spindle threading and tighten fully, as explained above. Drill diameter 4mm hole in the plug assembly and fit the dowel pin in the assembly. Use correct drilling jig for above purpose Check the plug for true on either lathe or on V-block and using dial gauge. Clean the top flange and bottom flange in the tank and rinse with water and then dry with air. Press fit the guide bush, ensuring that the edges are not damaged. Punch holes using the punch on the top flange around the guide bush. Hold body in fixture (up to 50 NB) and dry with air. Rotate the body such that bottom flange is facing upwards.
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A1.2] A1.3] A1.4]

d] e] f] g] A1.5]

A1.6]

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A1.7]

Apply Molycote HSC on the gasket face and on both sides of the gasket. Fit the bottom flange on the body and tighten evenly/squarely. A1.8] Now reverse the body such that the top flange is now upside.

A1.9]

Apply molycote on seat threads and taper portion. Ensure that there is no damage to the seat-taper in the body. Match the seat and body taper first using color by lightly screwing the seat inside the body. Using proper tightening tools and pneumatic gun. Apply Molycote HSC on the gasket face and both sides of the gasket. Place the plug-spindle assembly in the body and slide down the top flange on to the body. Tighten the top flange evenly/squarely. Place bottom-ring in the top flange and add glandpackings. Compress the gland packing by fitting the gland follower and tightening the gland nut. For valves up to 50NB, check for seat leakage on the bench rig using pneumatic supply. Apply force on the spindle using toggle clamp. Check for leakage by isolating the air supply and observing the pressure drop on the gauge and soap-water solution. Carry out lapping (360 degrees). If there is leakage, then retest the valve. All valves should be tested for seat leakage on the hydraulic test bench after mounting Actuator. Actuator mounting: Mount the actuator on the support and tighten the screw. b] Place the actuator on the top flange and tighten the slotted nut using the special spanner. The actuator spindle should be lifted slightly and couple with the valve spindle using lift-indicator
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A1.10] A1.11]

A1.12]

A1.13]

A1.14]

A1.15] a] c]

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d] A1.16]

Set the Actuator (as per Data Sheet) by tightening the adjustment bolt. All valves to be tested hydraulically. The valve assembly should be mounted on the test bench. The spindle should be raised fully either by hand or by actuator. The valve should be filled with water and all air should be vented from the valve. This is done, by loosening the gland nut. The valve should be pressurized depending upon its class as per the chart displayed in the testing area. For IBR approved valves, the testing pressure should be minimum twice of the working pressure as per the IBR schedule. The valve should be pressurized for minimum of 60 seconds for sizes up to 200NB and 180 seconds for 250NB. The hydraulic test should always be carried out in the unpainted condition. The hydraulic seat leakage test should be done, by closing the valve and pressurizing the inlet side of the valve. The seat leakage pressure should be as per the VDS and amount of leakage shall be compared with the seat leakage chart for permissible leakage displayed in the assembly area. If the leakage is more than that specified in the chart, lapping should be done. Note all recordings. (Including the corrective action.)

A1.17]

A1.18]

A1.19]

Q2]
A2.1] A2.2] A2.3]

How to mount actuator on the valve?

Fix actuator support on the valve body. Fix the actuator (as per the requirement i.e. air to close/ air to open) on the support and valve body assembly. Fix lift indicator to the actuator spindle.

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Q3]
A3.1] A3.2] A3.3] A3.4] A3.5] A3.6] A3.7a) b) c) d) e) A3.8] A3.9]

What is the sequence of other mountings?

Fix Positioner link to lift indicator and mounting bracket. Fix threaded pin on Positioner and Positioner on the valve assembly. Fix AFR bracket. Fix gauge group. Fix AFR on AFR bracket. Fix the ferule. Cut the tube. Flatten the tube. Mark for bending. Bend the tube. Fix the tube to the actuator, Positioner and valve. Fix the arrow after deburring. Do the calibration.

Q4]
A4.1] A4.2] a] b] c] d] e]

How to do the valve hand-wheel assembly?

Deburr and clean all the components. For air to open assembly: Assemble supporting disc and Teflon disc in bush well with lock ring. Assemble bush with hand-wheel support. Lock using M8 grub screw. Press fit dowel pin with clamp rings. Assemble hand-wheel, castle nut on the spindle. Pass spindle through the bush and spindle clamp ring with spindle by locating the dowel pin in the slot provided on the support.
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f] a] b] c]

Pass spindle through the hand-wheel once for checking. For air to close assembly: Assemble threaded bush with support and lock using M8 grub screw. Assemble threaded nut, lock nut and castle nut with spindle. Pass spindle through bush. Check by passing spindle through bush.

**

How to flush the valve?

Before charging any steam-line or any of the piping of Pressure Reducing and / or De-superheating Stations and /or before taking control valves to auto or manual mode the line must be thoroughly flushed. However the method of flushing defers as per the type of valve connections. Let us see one by one. a] 1] For flanged type of valves: After all type of fabrication work is over, the total valve with body is to be dropped. (I.e. to be taken out of the line is kept wrapped at a place away from the line to avoid any damage from the flushing media being following on it.) Now the line can be charged with the operating media i.e. steam, water, etc. as per the application may be. If the media is to be prevented from wastage a spool-piece can be assembled at the place of FM valve otherwise it is better to charge the line open to atmospheric pressure and high velocities, so that all the weld spots, foreign particles, rust in the line is washed away. This procedure can be followed for 20-30 minutes. For better results and assurance flushing can be repeated for 3 to 4 times. For butt-welded valves: For butt welding TIG [Tungsten Inert Gas Method should be adapted at the root. This avoids oxidization and slag problems. Stress relieving should be done at all inlet and outlet welding places.
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2]

3]

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3]

After all these precautions for flushing the line the whole valve assembly should be taken out of the welded body. The procedure is as follows: 3.1] Open the valve up to 15 20% by means of the hand-wheel or air. 3.2] Now the nut and bolts connecting the body and top flange can be diagonally unscrewed with equal torque. The top-flange assembly or say the bonnet assembly should be taken out vertically upward only and not side-ways. 3.3] Now the line can be charged with the operating media i.e. steam, water, etc. as per the application may be. It is better to charge the line open to atmospheric pressure and high velocities, so that all the weld spots, foreign particles, rust in the line is washed away. This procedure can be followed for 20-30 minutes. It is recommended to replace the seat with the dummy seat [which is provided with the valve and has maximum kV in its size and pressure class] before flushing.

Q5]

What are various torque values for assembling?

THREAD SIZE M8 M10 M12 M16 M20 TORQUE MOMENT N-m 10 16 30 70 100

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Q6]
6.1] 6.2] 6.3] **

What to do if the seat is not coming out of the body? Proper tool has to be fabricated for this purpose. Heat the seat only using gas flame. This is to be done to relieve stresses due to various operating parameters and rusting between seat and body. Suddenly put cold water on the seat and immediately unscrew using the special tool.
In such cases it is always recommended not to do anything on trial basis and call our service engineer.

Q7]

What to do if the valve output is pulsating, i.e. the valve is hunting?

The valve may hunt in operation and at rest also. Reasons for hunting: a. Presence of oil, dust, foreign material in the pistoncylinder assembly of Positioner. b. Over tightening of gland. c. Air leakage in actuator or air tubing. d. In case of valve with silencer basket. The basket might have shifted from its place i.e. its screws are loose or the basket might have damaged. Effects: a. Valve not functioning. b. Pulsating output. c. Plug/seat may even (in case if severe hunting) break. Remedies: a. Air should be free from oil, dust, and moisture. b. Open piston-cylinder assembly (ref. Pos. manual 2.2) and clean with thinner or any fluid that will not affect the material of o-rings, etc. c. Check for consistency of air supply. d. Make loose the gland by unscrewing the gland nut slightly. Clean the spindle. Apply lubricant to the spindle surface. e. Arrest the air leakage in tubing. Put Teflon tape at ferrule.
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7.1]

7.2]

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f.

g.

Take care that any Sulfur fumes or caustic acid does not enter the tubing. When there is such material used in the plant for any purpose it is safer to use SS 316 tubing. For silencer basket valves tighten the basket screws, and in case of damage to basket itself replace it with new one.

Q8]

If the valve is passing, or say due to any other reason need arises to check the seat leakage, then how to do it?
Ensure that the valve is fully closed and there is no signal from the actuator. Pass the flow medium through the valve inlet. Check for output through the valve. Measure at the flowmeter/drain at outlet. Compare with the allowable values. If the valve is butt-welded the take the measuring opening the line after the spool piece next to the control valve.

8.1] 8.2] 8.3] 8.4] 8.5]

Q9]

If the valve with pressure balance rings passes heavily what are the possible reasons?
The possible reasons are as follows: a) Pressure balance ring has worn out. b) Foreign material stuck at the plug-seat interface. c) Passing through seat and body. d) Due to loss of stiffness of springs in actuator. e) Oil or dust in Positioner. f) Disturbed zero setting.

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Q10]
10.1]

If the pressure balance ring is damaged then how to replace it?

In this case the plug-spindle assembly is to be taken out. Follow strictly as given: a. b. c. d. Open the valve 15%. Lock the hand-wheel to prevent further opening. Remove the tubing, Positioner and all other mountings. Disassemble the lift indicator. Unscrew the nut bolts (diagonally) holding the body and top/bonnet. Lift the actuator top vertically up. It should be done neatly ensuring the movement of spindle to be perfectly vertical without touching anything. Now keep the removed assembly such that the plug does not touch the ground or catches any foreign material. Unscrew the Allen bolts of the plug.

e. f.

Q11]

If leakage found in soft seated valve i.e. valve with plug having two halves, and the o-ring of plug found damaged then how to replace it?
First of all find out the reason for leakage as follows: a) Give 4-ma signal to Positioner. The output of Positioner should be zero and the valve should be perfectly close. If it not like that then Positioner troubleshooting is to be done. b) Valve might have been lifted manually by handwheel close it. c) While servicing the coupling i.e. lift indicator is not fitted properly. Re-couple it properly as follows: 1. Remove coupling. Insert spacer ensuring that the plug is completely seating on the seat. Re-couple. d) Plug might have damaged. If it is the case:
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e)

If it is standard parabolic single piece plug then for small damage, lap the plug and check for leakage and if severe damage is found then the plug is to be changed. 2. If it is soft-seated plug, then it has two halves as bottom cone and top cone and an o-ring between both of them. This o-ring gets damaged. Replace that with new. The seat might have damaged. In this case take a small cut from the degree at the bore of seat towards periphery. Ensure that the cut only removes the affected material and not goes further. Take care to flush the valve every time it is disassembled and no foreign material enters the valve.

1.

**

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FM PNEUMATIC POSITIONER MODEL 820

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1. ABOUT THE PRODUCT:

a. General Description:
The Positioner acts according to the force balance principle and proportionally controls the position of the control valve. By changing the cam curve the signal v/s stroke characteristics of the Positioner can be changed. The direct/reverse function of the Positioner; can be selected by, changeover switch position & cam side. Further alternatives are also foreseen, for operating with input signal split range. The unit is also provided with gauge group. The mounting of control valve is made according to NAMUR.

FIG. 1

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Specifications:
Basic type no. 820 x x x x x x

Required

Input signal a. 0.2-1.0 bar b. 0.0-20.0 bar c. 4.0-20.0 bar Air Supply a. 1.2-6.0 bar b. 1.6-6.0 bar c. 1.8-6.0 bar d. 2.0-6.0 bar e. 3.0-6.0 bar f. 4.5-6.0 bar g. 6.0 bar Air Filter Regulator a. with AFR b. without AFR Bypass a. With bypass b. without bypass Gauge group a. With gauge-group b. Without gauge-group Action d. Direct action r. Reverse action Model number 820. Pneumatic 824. Electro-Pneumatic 827. Electrical

Special design: For stroke ranges, less than 10 mm and more than 100 mm for cam angle 90, by mounting an I/p module the Pneumatic Positioner may be changed to an Electro-pneumatic one at any time.

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TOTAL VIEW OF POSITIONER WITH GAUGES:

120

220 132

M8

60 137

120 1/4" NPT

M8

30 30

220 132

21

60 137

Main Dimensions of Positioner 820

30 30
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d. Technical Data:
Input Split range Output Air supply pressure Open loop gain Internal air consumption Air capacity Hysterisis Threshold response Pressure Vibration stability Operating temperature Direction of control effect [Factory setting is direct acting.] Connection Stroke range Weight Protection class : : : : : : : : : : : : : : : : : 0.2-1.0 bar 0.2-0.6 & 0.6-1.0 bar 0-air supply pressure max 6 bar max 100 @0.5 m^3/h (0c, 1 bar Abs) 5m3/h (0c, 1 bar abs) at 1.4 0.7 % of range 0.5% of range Dependence on air supply 0.1%/0.1 bar deviation 10sg DIN89011 -20 to +60 c Field reversible NPT 20-100 mm basic unit- 1.7 KG Gauge set- 0.5 KG IP 54

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e. Operation Principle:
As already mentioned the Positioner acts on the force balance principle (fig iii). The pneumatic signal fed into the input I exerts a force on the diaphragm in the diaphragm chamber (5). This force is compared with the feedback force of the spring (10). In balanced condition the Positioner remains in steady condition. When the input pressure increases the piston lever (8) is deflected upwards and the piston (4) is lifted. Now, the supply air flows through the output O into the pneumatic actuator, whereby the valve actuator spindle is displaced (in present case downward). The initial spring tension of the spring (10) is increased via the stroke scanning lever (16). This happens until the spring force balances the diaphragm force (i.e. steady condition). The actuator stroke thus follows the input signal according to the shape of the cam. In case of falling input signal the effect on valve stroke is reversed. The piston moves downward, turns off the supply air and ventilates the actuator via the exhaust hole in change over switch. Thereby the Actuator changes its position towards the original position.

output 0

I Ventilation A S

Valve

16

10

20

13

11 FIG. III

Single -acting positioner

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2. GETTING STARTED:
a. Installation & Commissioning:
Before connecting and adjusting the Positioner the action of the output signal and the signal/stroke coupling (position of cam), i.e. the control characteristics should be checked. In case every thing is in accordance with the requirements the connecting & adjusting exercise can be started otherwise a change of curve or an inversion, be made. Depending upon the cam side N or I, visible on the installed cam (13) the spring wire (54) is set into the link (52), according to fig. IV. The link (52) prepared this way is fixed to lift indicator (71) with two no of socket head screws M6 (57). The stroke screw is set on the desired lift marking on the scanning lever. Thereafter, the mounting bracket (51) is fixed to the Positioner with two no of hex. Screw (55). Then the mounting bracket (51) and the Positioner are placed in such a way, that the cylindrical part of the stroke adjustment screw (53) grips into the slot of the link (52). Finally the mounting bracket (51) is fixed to the support (74) using a hex screw M8 (55) and spring washer (67). Fig VI shows the mounting arrangement. Unevenness of the casting at the yoke (74) causing an inclination of the mounting bracket (51) and thus of the Positioner can be compensated with the oblong holes for the Positioner fixing on bracket.

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3. OPERATION & MAINTENANCE:

a. Basic Functions:

Split range: Split ranges are used in cases such as two different control valves are to be controlled by a single controller operating in different ranges. Then one valve would operate in input range of 0.2 to 0.6 bar and the other in the range of 0.6 to 1.0 bar. To identify the different springs (10) for the split range we have marked them with the following colors: RED corresponds to 0.2 to 0.6 bar Yellow corresponds to 0.6 to 1.0 bar Direct/ reverse action: for changing action of Positioner (ref fig IX) which is stuck inside the cover. Depending upon the required action (direct or reverse) and also on the type of actuator (air to open and air to close) the changeover switch (6) or the cam (13) side or both of them must be changed. The changeover switch can be turned into other position by slightly loosening its clamping screw. However before inversion of cam all the air connections have to be pressure-free in order to hang the feedback spring (10) out of the eye of the feedback lever (11) by means of a screwdriver. Now, the clamping screw (35) of the cam is entirely drawn out, the cam removed, turn and set it again with the desired curve downward. Subsequently, the clamping screws have to be tightened again and the feedback spring set in again.

1. Calibration adjustment of stroke: before changing curve all air-connections have to be pressure-free in order to hang the feedback spring out of the eye of the feedback lever by means of a screwdriver. Thereafter the clamping screw of the cam is placed in again with the desired curve downward and carefully fixed with the clamping screw. Finally the feedback spring must be hung again. The correct choice of curve can be made using the middle part of the adjustment table (fig IX).

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For Cam Side N

For Cam Side I

Position of Spring Wire in the Carrier

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52

54

57 53 56 58

51

55

67

NAMUR mounting parts

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N
3

Input and Output increasing

I
2

Input increasing, Output decreasing

I
2
3

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b.

Callibration And Adjustment Of Stroke

The lower part of the connections and adjustment table (inside the cover) indicates the air connections of the single acting and double acting Positioner. After doing the connection the adjustment of the stroke can be made. For this the input signal is first adjusted to 50% corresponding to 0.6 bar at signal range 0.2 to 1.0 bar. In case the stroke scanning lever (16) is not in horizontal position, the adjusting screw for zero setting (20) is to be displaced accordingly. In case of horizontal position of the stroke-scanning lever the lift indicator (fig 71) points to the center of the stroke. Otherwise the fixing screw (55) of the mounting bracket (51) must be displaced accordingly and the screw is tightened again. By variation of input signal now both end positions of the valve stroke must be entered. Both input signals at the end position have to differ from each other by exactly 0.8 bar (for instance valve shut 0.15 bar valve 100% open 0.95 bar). In case of variation from this required position, the stroke adjustment screw (53) is loosened and moved within the slot of the stroke-scanning lever to increase or decrease the value as required. Afterwards the stroke adjustment screw is fixed again and the pressure difference of the end positions is checked. If necessary the procedure is repeated. After having made the required adjustment to get the pressure difference of the input signals the adjustment screw for zero setting (20) can be adjusted in such a way that the locking position (closed) of the valve corresponds to the desired input pressure (0.2 or 1.0 bar). In the above example the adjustment screw should be slightly tightened in order to reach 0.2 bar as the locking position pressure. We have described the stroke position for the most usual version only: Output signal increasing input signal i.e. change-over-switch at N and cam side I characteristic to curve no. 1 input signal range 0.2-1.0 bar corresponding to 0%-100%.

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4. TROUBLE SHOOTING:
1. How to calibrate valve with Positioner?

1.1] Make pneumatic connections as shown on the plate pasted inside the Positioner cover. 1.2] Ensure that there is no leakage at joints. Also check ferrule for damage. Put Teflon on the Ferrule if damaged. 1.3] Set the desired AFR pressure as mentioned on the plate. 1.4] Open the cover [47] by removing all screws [48](4no.s) 1.5] Ensure that air is dry and free from oil/dust. To check the quality, of air drain the AFR by pressing the drain-valve at the bottom of AFR. If there is any oil or dust stop the next procedure and ensure supply of quality air. 1.6] Set the stroke adjustment screw [53] as per the valve lift number given on the scale on the stroke scanning lever [16]. 1.7] Give signal of 4mA from I/P to the Positioner. Ensure 0.2 kg is available, in the topmost pressure gauge. Check the valve lift. It can, be seen on the scale by the lift indicator at the coupling between valve and actuator. 1.8] If the valve lifts, bring it back to zero lift position (valve fully closed) by brining the zero adjusting screw (20) at zero setting. 1.9] Give signal of 20mA from I/P to the Positioner. Ensure 1 kg is available. Check the valve for fully open condition. If it is not fully open; then make it by adjusting the stroke adjusting screw [53]. 1.10] Again, check for zero setting and full lift setting alternately by repeating the above procedure. 1.11] Finally the valve should automatically close at 4mA signal and be full open at 20ma signal. Achieve check the valve at intermediate input signals for its corresponding lift. 1.12] If still, desired results are not achieved, bring the valve to full close position by loosening the slotted screw [29]. (Check the position of piston-lever [8] by twisting it up and down. This helps in adjusting the zero setting by removing any misalignment of piston inside the cylinder.) 1.13] If the valve is still short of travel, unscrew the threaded pin [17] fully, put a washer and retighten it. * The signal from I/P should be completely cut while removing the threaded pin; otherwise the diaphragm assembly will burst.
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1.14] Reassemble in the reverse manner. 2] If Positioner is, out of calibration what needs to be checked/replaced? 2.1] Diaphragm chamber assembly: Open the Positioner cover as discussed in above problem. Connect full signal of 20ma from I/P. Spray soap solution on the diaphragm chamber assembly. *Ensure the soap solution does not enter the piston cylinder assembly. If there is any puncture in the diaphragm because of which the valve is out of calibration; then the diaphragm chamber assembly is to be, changed with new FM Positioner diaphragm chamber assembly. (Because, only diaphragm cannot be changed.) If there is any leakage around the O-rings [21], then these can be, replaced separately. 2.2] Piston-cylinder assembly: Remove spring [10]. Remove screws [30](3 numbers), [17] and washer [33]. Lift the diaphragm chamber assembly [5] carefully so that the piston [4] is visible and comes up. Check for dust and remove it. Observe piston. If there are scratches on its surface, replace both the piston and cylinder. 2.3] Gaskets: Apply soap solution on the gasket [18] surface. Check for bubbles giving maximum supply. If it is leaking then, remove, the screw [31], remove the change-overswitch [13]. Check for tear on the gasket surface, if there is tear replace the gasket, if not then press it at its place applying some lock-tight place the change-over-switch on its surface and tighten the screw [13] properly. It would have been loose earlier. Also, check all other screws, sir-clips for tightness. Check for play between the stroke scanning lever [16] and shaft [14]. 2.4] Check bearings. If jammed, replace with new. 2.5] Ensure cam is rolling properly on the roller with its curve passing smoothly over the roller surface. 2.6] Check and tighten the zero-adjustment screw [20].

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3]

How to know the Positioner diaphragm assembly leakage?

3.1] Diaphragm chamber assembly: Open the Positioner cover as discussed in above problem. Connect full signal of 20ma from I/P. Spray soap solution on the diaphragm chamber assembly. *Ensure the soap solution does not enter the piston cylinder assembly. If there is any puncture in the diaphragm because of which the valve is out of calibration; then the diaphragm chamber assembly is to be, changed with new FM Positioner diaphragm chamber assembly. (Because, only diaphragm cannot be changed.) If there is any leakage around the O-rings [21], then these can be, replaced separately.

4]

How to change the valve characteristics using the cam and switches?

4.1] Disassemble the Positioner cover as discussed earlier. Find the current characteristics on the plate stuck inside the Positioner housing. *Suppose the characteristics are linear and are to be changed to equal percentage. The plate will be showing like the figure. 4.2] Remove screws (m6x12). Remove cam. See on the label. As per that, select the curve and side of the cam and set, such that the selected curve rests on the roller and reassemble.

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5]

How to change the direct/reverse action of Positioner? Let us first understand what is direct action or reverse action. Direct action: Is when the O/P of the Positioner increases, with the I/P given to it through the I to P increases. Reverse action: is when the O/P of the Positioner decreases, with increase in I/P to it given by I to P converter or vice-versa. In case of Positioner, input is the signal in ma given by I to P converter and the O/P is the supply air. Let us assume that the present action of Positioner is direct and we want to change it to reverse. Proceed as per the steps given bellow:

5.1] Take out the Positioner cover and remove the air supply as usual. 5.2] Refer the plate inside the Positioner. 5.3] Watch the Fig. No. [2] in the chart given. 5.4] Remove the spring carefully. 5.5] Unscrew [35]. Pullout the cam [13]. Unscrew [31]. Pullout the change-over-switch [6]. Now the gasket [18] is exposed. Please do not remove this gasket. Suppose now the N mark, on the change-over-switch [6] is on the reference mark on the Positioner housing.

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5. POSITIONER PART LIST :

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FM PNEUMATIC ACTUATOR 1. U-SERIES 2. MSA SERIES

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About The Product:

DRAWINGS OF THE PRODUCT

22 21 20 19 18 17 16 15 14 13 12 10 11 6 7 8 9 5 4 3 2 1 27 28 29 30 23 24

25 26

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO.

SPRING DIAPHRAGM PLATE DIAPHRAGM DIAPHRAGM COVER LOCK NUT WASHER BUSH SCREW STAR WASHER HEX. NUT SOCKET SCREW HEX. NUT LIFT INDICATOR LIFT PLATE SUPPORT DESCRIPTION

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 I.NO.

HEX. BOLT HEX. NUT WASHER HEX. BOLT RIVET NAME PLATE SOCKET SCREW CAP SLIDE BEARING SUPPORTIING DISC TEFLON WASHER SPRING HOUSING SPRING PLATE ADUJUSTMENT BOLT SPINDLE DESCRIPTION

ACTUATOR-AIR TO OPEN FIG.

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22 21 20 19 18 17 16 15 14 13 12 10 11

23 24

25 26

27 28 29 30 6 7 8

9 5 4 3 2 1

15 SPRING DIAPHRAGM PLATE 14 DIAPHRAGM 13 12 DIAPHRAGM COVER 11 LOCK NUT 10 WASHER BUSH 9 8 SCREW STAR WASHER 7 6 HEX. NUT 5 SOCKET SCREW 4 HEX. NUT LIFT INDICATOR 3 LIFT PLATE 2 1 SUPPORT DESCRIPTION I.NO.

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 I.NO.

HEX. BOLT HEX. NUT WASHER HEX. BOLT RIVET NAME PLATE SOCKET SCREW CAP SLIDE BEARING SUPPORTIING DISC TEFLON WASHER SPRING HOUSING SPRING PLATE ADUJUSTMENT BOLT SPINDLE DESCRIPTION

ACTUATOR-AIR TO OPEN FIG.

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9 11 10 12 13 14 15 16 17 18 19 20 21 22 5 4 3

23 24 29 28 27

26 25

30 6 7 8

2 1

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO.

SPRING DIAPHRAGMPLATE DIAPHRAGM DIAPHRAGMCOVER LOCK NUT WASHER BUSH SCREW STAR WASHER HEX. NUT SOCKET SCREW HEX. NUT LIFT INDICATOR LIFT PLATE SUPPORT DESCRIPTION

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 I.NO.

HEX. BOLT HEX. NUT WASHER HEX. BOLT RIVET NAME PLATE SOCKET SCREW CAP SLIDE BEARING SUPPORTIING DISC TEFLON WASHER SPRING HOUSING SPRING PLATE ADUJUSTMENT BOLT SPINDLE DESCRIPTION

ACTUATOR-AIR TO CLOSE
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FIG. B

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9 1

2 12 7 6 5 13 8

4 3 13

11 10
13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO. GRUB SCREW LOCKNUT HEX. BOLT DOWEL PIN SPLIT PIN SUPPORT BUSH TEFLON DISC LOCK RING SPINDLE CLAMPING RING HAND WHEEL CASTLE NUT DESCRIPTION

HAND WHEEL-AIR TO OPEN

FIG.

9 1

2 12 7 6 5 13 8

4 3 13

11 10
13 12 11 10 9 8 7 6 5 4 3 2 1 I.NO. GRUB SCREW LOCKNUT HEX. BOLT DOWEL PIN SPLIT PIN SUPPORT BUSH TEFLON DISC LOCK RING SPINDLE CLAMPING RING HAND WHEEL CASTLE NUT DESCRIPTION

HAND WHEEL-AIR TO OPEN

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FIG.

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b. Principle Of Operation:
(REF. FIG. ) The universal diaphragm actuators are operated by compressed air. The air is admitted in the diaphragm cover (28), which deflects the diaphragm (32), which in turn moves the actuator spindle (37) which compresses the springs between the diaphragm plate (38) and spring plate (33). By removing air from diaphragm cover, the spring expands which results in the movement of the spindle in opposite direction. Thus the actuator spindle actuated one way by air and other way by spring. _____________________________________________________

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c. Getting Started:
General Instructions:
The name plate (39) on the actuator contains the data concerning the valve and actuator. When ordering spare parts always mention the application number marked on the nameplate. On reversing the actuator or changing the operating conditions check the data on the nameplate, if necessary order new nameplate with corrected data. After replacing the spare parts make sure that the joint between the diaphragm cover (28) and the spring housing (46) and o-ring are (26) tight. Also check that lift and initial spring tension are correctly adjusted. Diaphragm (32) can withstand temperature from 30c to +100c. To increase life of diaphragm in case of high temperature, we recommend to provide a heat protection and in case of temperature below -10c to provide dry air. The mounting position of actuator is vertical on top of the valve. For other mounting position please consult us. The diaphragm cover (28) has a connection of NPT for actuator size U-O/U-I and of NPT for sizes U-III/U-V. The air tubing, which supplies air to the actuator must have minimum 6 mm inner diameter. (8 mm OD x 1 mm thick).

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d. Installation:
The actuator offers easy mounting of Positioner, Roboter, air filter regulator and limit switch. The spring housing (46) has two tapings of (M8) in front. The support (55) is constructed according to NAMUR principle and provides two tapings of M8 for mounting accessories. The hand-wheel arrangement is a separate subassembly, which can be mounted at any time. On air failure, remove the hand-wheel lock (6) from the lower hole of the hand-wheel (11/17) and put it into the hole at the upper end of the hand-wheel spindle. In case of air to close arrangement (valve opened on air failure) to open the valve turn the hand-wheel (1) clockwise. In case of air to open arrangement (valve closed on air failure) to open turn the hand-wheel anti-clockwise. Attention: Before changing to automatic service with air, turn hand-wheel (1) to uppermost position and replace hand-wheel lock to lower hole of spindle.

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e.

Commissioning Of U-Series Actuator:

The initial tension of spring (38) can be adjusted so that different operating conditions in the valve can be adapted to the available spring ranges. The air pressure given to the actuator must be sufficient to start the spindle movement. If the required pressure for starting the spindle movement is above or below the desired starting signal (say 0.2 bar) it can be corrected by turning the adjustment bolt (42) until the starting signal and start of spindle movement correspond. The spring tension (i.e. starting signal) can be increased by turning adjustment bolt (42) clockwise and decreased by turning adjustment bolt (42) anti-clockwise.

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f. Reversibility Of The Actuator:

The actuator is constructed in such a way that it can be reversed at any time without additional parts and thus the valve can changed from air to open to air to close and vice versa. This can be achieved as follows: Unscrew screws (2 no.) and remove cap (22). Unscrew bolts (4 no). The diaphragm cover (28) and spring housing (4^) bolted together can be mounted in reverse sense (i.e. upside down) on the support (55). Tighten all 4 bolts (21) and also assemble cap (22) by tightening 2 screws (23). If the diaphragm cover (28), is on top the increasing signal pressure effects a downward movement of the actuator spindle (37). If the diaphragm cover (28) is below the top, the increasing signal pressure effects an upward movement of the actuator spindle (37). The hand-wheel arrangement is designed for one action only. For reversing the hand-wheel arrangement with diaphragm cover below, part no 7,8,9,10,11,15,16 & 17 are required. However for hand-wheel arrangement with diaphragm cover on top part no 4,5,11,14 & 18 are required.

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ACTUATOR TIPS:

The actuator has enormous spring force, especially in case of reinforced springs. It is not possible to release the spring totally by adjustment bolt (42) in every case. Therefore, use the mounting aid. The mounting aid consists of long hex bolts and special nuts as shown in the drawing. _____________________________________________________

Exchange of spares:

The mounting shows the mounting proceedings for the two actuator-versions O (air to open) and S (air to close) and for the different spare parts. Proceed with the mounting step by step as given. (refer mounting plan.)

Mounting successions:

At first remove only 2-2 nuts and bolts (34 & 36) symmetrically as shown in the drawing. Replace these with the mounting aids and tighten. Now loosen and remove all nut and bolts (34 & 36). Loosen the mounting aids slowly and evenly, so that the diaphragm cover and spring housing separate, releasing the spring tension. Now actuator can be further dismantled and spare parts can be replaced as per mounting plan. The re-assembly follows in reverse succession. _____________________________________________________

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TYPE-UI

TYPE-UIII

TYPE-UV

M10 x 150, ISO IN mm. M8 x 75, ISO IN mm. SCREW DESIGNATION

145 75 A

133 65 B

11 9 D

17 13 SW

M10 150 UIII & UV M8 M 75 L UI TYPE

NO. AND DISTRIBUTION OF THE MOUNTING AIDS. FIG.

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PART LIST OF U SERIES ACTUATOR:

SR. NO. CODE A2007103 A2007105 A2007107 A2007109 A2007118 A2007119 A2007120 A2007121 A2007122 A2007123 PART NAME SPRING HOUSING UI-20/30 ACTR DIAPHRAGM PLATE UI ACTR DIAPHRAGM COVER UI ACTR SPRING PLATE UI ACTUATOR

SPINDLE UI-ACTUATOR DIAPHRAGM (UI) ACTR ADJUSTMENT BOLT UI ACTUATOR BUSH UI ACTUATOR TEFLON DISC UI ACTUATOR SLIDE BEARING UI MATL. TAURUS TFE(60 PERCENT BRONZE FILLED PTFE) A2007127 SUPPORTING DISC UI ACTUATOR A2007140 NAME PLATE FOR ACTUATOR A2007141 ATTENTION LABEL A2007150 SPRING UI-20 STD A2007152 SPACER A2007155 SUPPORT UI-20 MACHINED A2007156 LIFT PLATE (UI 20) A2007157 LIFT INDICATOR UI-20 ASSLY MACHINED A2007158 LIFT INDICATOR UI MACHINED A2026411 O RING 16 ID X 3.5 SEC.DIA. A6007139 INSERT M8 FOR UI/UIII QTY.-4 A6007143 INSERT M10 UI SPRING HOUSING/4 UI DIAPHRAGM COVER/4 A6020379 ALLEN SCREW M8X35LG GR 12.9 MAKE-TVS BLUE ZINC PLATED A6020500 LOCK NUT M20X1.5LG GR 4 A6020539 HEX NUT M 8 GR.4 A6020575 STAR WASHER M20 MS ZINC PLATED A6020582 PLAIN WASHER M20 STEEL ZN PLATED ANSIB18.22.1.1965.R1975 A6020739 HEX NUT M8X1.25X30L ZINC PLATED A6020997 BOLT HEX HEAD M10X25L GR 4.6 A6060043 BOLT HEX M8X30 GR.4.8 A6096303 HEX. NUT M4 GR.4 A6096305 BOLT CH/HD M4X16L GR.4.8 A6096306 PLAIN WASHER M4 ZN/PL. (ID = 4.3) A6096308 STAR WASHER M4 CHEM/BL A6096334 PLAIN WASHER M8 MS ZINK/PL **** FOR CODES OF U-III AND U-V ACTUATOR USE A20072__ & A20074__ RESPECTIVELY IN PLACE OF A20071__
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2.

MULTI SPRING ACTUATOR

a. About The Product:

DRAWINGS OF THE PRODUCT

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b. Principle of Operation:
(REF. FIG.) The Multi-Spring Actuators [MSA] are operated by compressed air. The air is admitted in the actuator housing (11), which deflects the diaphragm (9), which in turn moves the actuator spindle (6) which compresses the springs between the diaphragm plate (4) and actuator plate (1). By removing air from diaphragm cover, the springs expand which results in the movement of the spindle in opposite direction. Thus the actuator spindle actuated one way by air and other way by springs.

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c. Getting Started: General Instructions:

The nameplate on the actuator contains the data concerning the valve and actuator. When ordering spare parts always mention the application number marked on the nameplate. On reversing the actuator or changing the operating conditions check the data on the nameplate, if necessary order new nameplate with corrected data. After replacing the spare parts make sure that all the joints especially between the actuator cover (1) and the actuator housing (11) and o-ring are (28) tight. Also check that lift and initial spring tension are correctly adjusted. Diaphragm (9) can withstand temperature from 30c to +100c. To increase life of diaphragm in case of high temperature, we recommend to provide a heat protection and in case of temperature below -10c to provide dry air. The mounting position of actuator is vertical on top of the valve. For other mounting position please consult us. The diaphragm cover (1) has a connection of NPT for actuator size MSA-I and of NPT for sizes MSA-II/III. The air tubing, which supplies air to the actuator must have minimum 6 mm inner diameter. (8 mm OD x 1 mm thick.)

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d. Installation:
The actuator offers easy mounting of Positioner, Roboter, Air Filter Regulator and Limit Switch. The spring housing (11) has two tapings of (M8) in front. The support (22) is constructed according to NAMUR principle and provides two tapings of M8 for mounting accessories. The hand-wheel arrangement is a separate subassembly, which can be mounted at any time. In case of air to close arrangement (valve opened on air failure) to open the valve turn the hand-wheel (1) clockwise. In case of air to open arrangement (valve closed on air failure) to open turn the hand-wheel anti-clockwise. Attention: Before changing to automatic service with air, turn hand-wheel (30) to uppermost position.

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e.

Assembly Instructions For MSA Actuators:

*
1] 2]

Actuator assembly:
Ensure all parts are deburred, clean and lubricated. Assemble diaphragm plate (7), diaphragm (9), diaphragm plate and guide assembly, sequentially, on the spindle (3). Ensure that o-ring (8) is in position. Tighten lock-nut (10) on to the spindle. Assemble the boss base (17), to diaphragm housing (11) ensuring o-rings (18) & (20) and slide bearing (38) in the place. Lubricate spindle assembly; insert it from top in the diaphragm housing assembly till the end. Align assembly bolt holes of the diaphragm with that of diaphragm housing. Place selected type and quantity of springs (3) on the diaphragm plate (7) duly guided it the bottom as per drawing. Position spring cover (1) on diaphragm housing, align assembly bolt holes. Insert two long assembly bolts M8 x 30 diametrically opposite and tighten nuts by one turn alternatively till all the bolts of standard M8 x 25 size can be inserted properly and can be nuts engaged. Replace two numbers M8 long bolts by standard M8 x 25 bolts. Tighten all bolts partially till fully tightened up to torque level of 10 N-m. Establish pneumatic connection at (11) the base of actuator housing. Pressurize assembly and check for ease of spindle movement, lift (should be at least 2 mm more than specified) and leakage from joints (raise supply pressure to 5 bar). Assemble nut cover along and cap plastic at respective places.

3] 4]

5] 6] 7]

8]

9]

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Actuator and Support Assembly:

1] Place the actuator on the top of actuator support, locate plug in the hole provided on top of face of the support. Tighten nut-spindle on boss base ensuring its location in the step provided in the support. This ensures alignment of valve and actuator spindle. Tighten nut-spindle fully using C-spanner.

2] * 1] 2] 3]

FM vale and Actuator assembly:

For Air to Open operation, ensure that the valve spindle is completely down and plug is sitting tight on the seat. Place actuator-support on the valve top flange taking guidance of the step on valve top flange. This ensures alignment of valve and actuator spindle. Clamp two halves of the lift indicator, carefully aligning the split threads of the indicator with that of spindle.

f. Reversibility Of MSA Actuator:

The actuator is designed in such away that it can be reversed at any time without additional parts and thus valve can be changed from Air to Open to air to Close and reverse. This can be done in following sequence: a. Remove nut cover (15)/hand-wheel assembly from actuator cover (11). b. Remove lock nut (14) from top of spindle (6). c. Remove spindle off the actuator assembly from bottom side. d. Remove boss base from actuator housing. e. Insert spindle from top of the actuator aligning in the guide-diaphragm plate (5). Tighten lock nut on the spindle. f. Assemble boss-base, along-with o-rings and slide bearing on actuator cover.
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Tightening Torque Moments:

THREAD SIZE TORQUE MOMENT N-m

M8 M10 M12 M16 M20

10 16 30 70 100

Spring Location (on the spring plate over the boss):

*Initially take any boss as no. 1 and count from that.
NUMBER OF SPRINGS LOCATION

2 3 4 6 >6

1.4 1,3,5 2,3,5,6 1 to 6 1 to 6 and in above sequence

g. PART LIST OF MSA ACTUATOR: Refer Fig. On Pg 64

SR NO. CODE PART NAME

A2007119 A2007156 A2007158 A2007223 A2026419 A2026421 A2098001 A2098002 A2098004 A2098005 A2098013 A2098016 A2098017 A2098018 A2098020 A2098022

DIAPHRAGM
LIFT PLATE LIFT INDICATOR SLIDE BEARING O RING 20 I.D. X 3.5 C/S O RING I.D.13 X 2.5 C/S SPRING COVER O RING 26 I.D. X 5 C/S NITRILE RUBBER SPRING WASHER M8 LOCK NUT M12 NUT-SUPPORT M/CED MSA1 DIAPHRAGM PLATE M/CED MSA1 GUIDE DIAPHRAGM PLATE SS410 SPINDLE M/CED SS410 MSA1 SUPPORT-DIAPHRAGM PLATE SS410 BRACKET AFR MOUNTING MSA
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DIAPHRAGM HOUSING M/CED MSA1 MAT LS PLUG VENT 1/4 NPT MS ELECTROPLATED PLUG BLIND 1/4 NPT MS ELECTROPLATED BOSS BASE SS410 MSA1 MACHINED. SUPPORT ACTUATOR MSA1 (UI 20) MACHINED A20980356/7/8/9 SPRING TYPE A/B/C/D/E A2098041 PLATE PRODUCT C.V. --- --A2098042 PLATE ATTENTION --- --A6020539 HEX NUT M 8 GR.4 A6060045 HEX BOLT M8 X 25L GR. 4.8 A6060046 HEX. BOLT M8X35L GR. 4.8 A2007122 TEFLON DISC A2007127 SUPPORTING DISC A2007176 HANDWHEEL A2007180 PIN LOCK HANDWHEEL (R-TYPE) A2098006 HANDWHEEL SUPPORT SS410 AIR TO OPEN A2098007 HANDWHEEL SPINDLE SS410 AIR TO OPEN A6020516 HEX LOCK NUT M20 GR.4 ZINC PL A6020929 GRUB SCREW M6X20L

A2098025 A2098026 A2098027 A2098028 A2098029

3.
1]

TROUBLE SHOOTING
How to reverse actuator with or without hand-wheel? Open the valve till its 10% opening giving signal of around 6 mA or manually using hand-wheel. Unscrew the coupling. Disassemble the lift indicator and remove the hand-wheel assembly by unscrewing the grub screw (35), hand-wheel support (36) and hand-wheel assembly (30) in anti-clockwise direction. Remove all the tubing. Remove Positioner and accessories if any. Unscrew the spindle nut (21); remove any two apposite nut bolts of the actuator and insert two no. Long bolts
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1.5] 1.6] 1.7] 1.8]

1.9] **

[M8] size. This is for avoiding accident that might happen due to initial compression of springs. Unscrew all the remaining nut-bolts diagonally. Remove the cover (1), springs (3). Pull out the diaphragm plate assembly with the spindle (6). Hold the spindle in vice in the slots at its bottom. Unscrew lock nut (10), remove diaphragm plate (4), diaphragm (9), o-ring (8), Diaphragm plate support (7). Assemble all above parts from diaphragm plate support (1), as shown in the air to close diagram. It is essential to order boss base (17), with two o-rings (20) and slide bearing (19) and air to close hand-wheel assembly as shown or if the actuator is without handwheel then nut cover (2). Assemble the diaphragm plate assembly into the cover (1) as shown in figure air to close. Tighten the spindle nut (21). Do all the tubing to the actuator housing (11) in the vent provided (27). a) There are certain changes to be made in Positioner/Roboter as the case may be. these are explained in the respective manuals. How to check diaphragm failure and air leakage? Give 6 Bar air supply at air inlet (27).

1.10] 1.11] 1.12] **

2] 2.1]

2.2] Put soap solution near boss base assembly (17). All the joints, Spindle and cover interface and diaphragm clutching (periphery) and check for bubble. No leakage is allowed. In case of leakage tighten the joints or change the o-rings with respect to the area of leakage.

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3] 3.1]

How to change capability?

and

increase/decrease

force

Force capabilities can be changed, by increasing number or type of springs. This is for MSA-I actuator. In case of U-series, turn the adjustment bolt clock-wise till the desired lift position of valve spindle is achieved at higher air pressure. In case further force capabilities are required, change the spring type to re-enforce from standard and if already re-enforced is used then go for higher sized actuator. 4] How to adjust (using coupling) the valve lift with the actuator lift? Change the position of end of valve spindle in the coupling and adjust its distance with the actuator spindle such that the valve completes its travel.

4.1]

5] 5.1] 5.2]

How to check the spring range? Give air pressure to the actuator slowly. Note the pressure reading when the actuator spindle starts moving. Suppose the spring range is 0.2 to 1.0 bar. The actuator spindle starts moving at 0.2 bar and attends maximum lift at 1 bar. If any deviation in this is found then couple the actuator spindle with the valve spindle at the required lift. How to mount various accessories on the actuator? Mounting the Positioner: Mount the Positioner on, the support on inlet side of the valve at opposite side of air inlet of the actuator. Fit the Positioner link on lift indicator. Fit the Positioner mounting bracket to the Positioner. Fit the threaded pin in to stroke scanning lever depending upon valve size. Fit the Positioner support/yoke.
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Mounting Position Transmitter: Fit the Positioner link of Positioner link on the opposite side of Positioner. Mount the bracket to Position Transmitter. Fit the stroke-scanning lever to shaft, which is extruding out of the Transmitter. Fit the threaded pin to stroke scanning lever depending upon size of valve. Mount the Position Transmitter, on support on opposite to Positioner on the other leg of support. AFR/ALR/Booster Relay/I to P/ Solenoid Valve: Mount the bracket on actuator by loosening any of the actuator cover bolt nearest to the Positioner and accessories to be connected to it to save tubing length. Fit the AFR/ALR on the bracket. Limit Switches: Mount the limit switches on its bracket using screws/nuts. Mount the bracket on the hand-wheel support using M8x20 mm size bolt. After mounting proper tubing as per plan is to be made. Ensure Zero Leakage.

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FM VALVE MOUNTED PRESSURE CONTROLLER

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1.
a

ABOUT THE PRODUCT:

General Description:

This Valve Mounted pressure controller is a yet solid one for direct mounting to the control valve and direct impulse connection for various pressures including vacuum and absolute pressures. It has the following outstanding characteristics: 1. 2. 3. Separate interchangeable measuring units. In-built supply air restrictor and output damping throttle. Reversal of action without additional parts.

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Specifications:
: 0.02 To 400 Bar : 0.05 To 3 Bar : 0-1 Bar Low Pressure : 1.4 Bar : 0.2-1 Bar : See Fig. No. B : <0.02% Of Medium Set Point : <0.033% Of Medium. Set : <1.1% Of Medium Set Point

Measuring Range Absolute Pressure Vacuum Supply Air Pressure Control Pressure Set Point/Actual Value Speed Of Response Range Reversal Range Point Hysterisis Range

Dependence On Supply Pressure : <0.4% Per 0.1 Bar Air Consumption : 300 NL/hr On Y=0.6, Z=1.4, Nozzle=Dia. 0.2 : 40 Sec. Up/ 5 Sec Down Nozzle 2, Actuator UI-30 140 Sec Up/20 Sec Down Nozzle 2, Actuator UIII-60.

Valve Speed

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Operation:

Ref. Fig.

The pressure to be controlled, x, which is acting on the measuring unit (bellows, diaphragm, etc.) is compared to a set point spring, w. Any deviation in x alters the valve diaphragm pressure y at the nozzle, altering the flow to the actuator and thereby the lift. This alteration in lift is fed back to the controller via the adjustable spring R.

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2.

GETTING STARTED:
a. Installation:

The pressure control valve should be stored in its original packing until it is mounted. The storage area must be dry and clean. After mounting the valve should be supplied with control air, this is best protection against fouling and corrosion. The protection caps of the valve openings, of the filter and regulating valve and of the pressure controller have to be taken off. If there are conservatives in the spindle area of the valve, they have to be removed carefully. The diaphragm control valve is mounted vertically standing up with actuator on top. The mounting place has to be easily accessible. Maximum allowable temperature is 80 degrees centigrade. The impulse connection is taken at about 1-2 m after the control valve. The point of pressure taking has to be provided with a stop valve, so that in case of troubles you can get the measuring system free of pressure. Pressure tapping from a vertical line where the point of tapping is above the measuring chamber is ideal. In this case the measuring line can remain filled, and the possibility of air inclusion cam be eliminated. With viscous media the tapping point has to be provided with a separating vessel as to avoid delays in pressure transmission. The separating vessel should be mounted as near as possible to the tapping point.
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b. Mounting Instruction For Pressure Controller Before connecting the air supply to the air filter and regulator, the newly laid airline should be carefully blown out to line and it should be examined for any possible leakages.

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c.

Pressure Controller Part List :

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d.

Commissioning The Product:

Ref. Fig. G:
On start up the required air-supply is adjusted, at the AFR. The supply pressure should be about 0.5 bar higher than the maximum operating pressure of the connected control actuator. (See nameplate: CONTROL RANGE). The air is checked for moisture, dirt, etc. by operating the drain valve. The set-point spring (30) is relieved (-) by turning the nut anticlockwise direction. The operating pressure Y now increases up to maximum value and control valve closes. The Control Valve can, now be started as follows. Open the impulse valve slowly de-aerating the measuring chamber. Tighten slowly the Set-point spring (+) until the valve begins to open. Set the spring tension to the desired set pressure. If controller oscillates, the measuring chamber must be de-aerated again. If this does not improve the situation, the proportional range has to be enlarged by feedback-spring (21). If the controller remains unsteady, screwing in the damping throttle can damp the control pressure Y to the Diaphragm chamber. (16) After start up the following service has to be done. Examine if hand-wheel is in end position and secured by lock pin. Slightly tighten stuffing box nut to avoid leakage of media. Tighten all nuts on valve.

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3.
a.

OPERATION AND MAINTENANCE:

Basic Functions:

PRESSURE REDUCING CONTROLLER:

The FM valve pressure reducing controller works as a pressurereducing valve. If the set pressure value is surpassed, the control valve closes and reduces the pressure. Air is supplied at pressure Z which is to be free from dust, oil and water of at-least 4 Bar. The supply pr. to Roboter. Z1 is adjusted on the Air Filter Regulator (1). The supply air reaches the nozzle flapper system through the constant restrictor (18). The flapper (25) at the nozzle lever (26) covers the nozzle (9) more or less depending upon the pressure deviation at the bellows (35). This in turn changes the control pressure y supplied to the actuator. The air supply is limited to a fixed value by the fixed throttle (18) so that with open nozzle, the pressure goes towards zero and the actuator can assume the failsafe position as determined by the spring. (In the given fig. Actuator is mounted in air to close position) At the outer end of the lever (26), an adjustable feedback spring (21) is connected. By blocking some spring threads, the feedback force can be changed depending on the lift position of the control valve. If the feedback spring is tightened, the proportional range is widened and the control loop is attenuated. If the feedback spring is loosened, the proportional range is shortened and the control loop reacts more sensitively and may even tend to vibrate. The output signal y can be dampened by a damping throttle (16). The set-point spring (30) secures the lever (26) in its bearing and counteracts the force on the impulse pressure, X, at the measuring system. The bellows assembly consists of the below (35) and the thrust bolt (29). Depending on the impulse pressure X at the bellow (35), the distance between nozzle and flapper is changed and thereby the control pressure Y. Referring to Fig H, when impulse pressure increases the lever moves upwards, nozzle closes, control pressure increases and valve closes. On decreasing impulse pressure X, the lever moves down, nozzle opens, control pressure decreases and valve opens. The set value of the spring W can be adjusted by a nut (33) by tightening & releasing the spring tension (30) .On the cover this tightening or loosening is marked as "+" or "-" respectively. If set88

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point spring is tightened (+) control pressure Y decreases, set value W increases. If set point spring is loosened (-), control pressure increases, set value W decreases. The air supply is limited to a fixed value by the constant fixed throttle (18) so that; it opens nozzle the pressure goes towards zero and the actuator can assume the fail-safe position as determined by the spring. (In the given fig. The Actuator is mounted in air to close position). At the outer end of the lever (26) an adjustable feedback spring (21) is connected. By blocking some spring threads, the feedback force can be changed depending on the lift position of the control valve. If the feedback spring is tightened, the proportional range is widened and the control loop Is attenuated. If the feedback spring is loosened, the proportional range is shortened and the control loop reacts more sensitively and may even tend to vibrate. The output signal V can be dampened by a damping throttle. (16). 2.2 The set-point spring (30) secures the lever (26) in its bearing and counteracts the force on the impulse pressure, X, at the measuring system. The bellow assembly consists of the bellow (35) and the thrust bolt (29). Depending on the impulse pressure X at the bellow (35), the distance between nozzle and flapper is changed and thereby the control pressure V. Referring to Fig. No. 1, when impulse pressure increases the lever upward, nozzle opens, control pressure decreases and valve opens. The set value of the spring W can be adjusted by a nut (33) by tightening or releasing the spring tension (3.0) On the cover this tightening & loosening is marked as "+" respectively. If set-point spring is tightened (+) control pressure y decreases, set value W increases. lf set-point spring is loosened (-), control pressure increases, set value W decreases.

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4.

TROUBLE SHOOTING:

In case there is trouble in starting, the valve can be operated in any position by means of the hand-wheel It is to be noted that after manual operation, the hand-wheel should always be set back into end position and locked by means of a lock pin. In case of Viscous media the application of a separating vessel is necessary, the installation should be arranged as showing Fig numbers' (a) & (b). The lines have to be, arranged with a slope of 1: 10 so that the enclosed air bubbles can go up to the de-aeration points. Before start-up the impulse lines, controller and separating vessel should be carefully filled with a separating, liquid (e.g. Barium Chloride or Glycerin) .It has to be observed that the least possible air enters into the system. Then the valve is to be carefully opened. The media exerts pressure on the separating liquid in the separating vessel and the system is once more de-aerated. This is very important as the air bubbles rise in the measuring system and cause oscillation.

Q1] How to change springs and bellows? Remove the cover [6] by unscrewing the M5x10L screws [2](4 noose). Unscrew the hex-nut [33]. Take-out the bearing [32]. Take-out the spring [30] and spring-plate attached to it [28]. Turn the notches using Plyer; ensure that the notches are not damaged. Now take out the spring and replace with new. For bellow: 3.5] remove the cover [6] by unscrewing the M5x10L screws [2](4 nos.). Unscrew the Allen-bolt (M8x35) [20] 4nos. Remove the bellow chamber assembly [37]. Replace bellow with new one. Fix the new bellow by tightening Allen-bolt (M8x35) [20].

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Q2] How to adjust Roboter settings for given valve lift? Check what is the set pressure of valve check the action of Roboter. Suppose the valve is 80#150. Observe on the VDS. The set pressure and the action of Roboter are given on it. Suppose the action is reverse acting down stream control and set pressure is 4.5 bar. Also check spring and bellow size as per the VDS. Remove the cover [6] by unscrewing the M5x10L screws [2](4 nos.). Take out the ball bearing [32], hex nut [31], set point spring [30]. Polish the flapper [25] with smooth polish paper and needle file and hit the contact screw [29] by soft headed mallet/hammer to make the nozzle [9] impression on flapper [25]. Check for impression. If not there, on the flapper r then repeat above steps. Give air supply to AFR. Adjust the pressure of the air between (3-3.5 bar). Rotate the hex nut [31] in clockwise direction so that the valve opens fully [i.e. 30 mm for given valve. Check the pipeline for air leakage by spraying soap solution near all the joints. There must not be any leakage. Rotate the hex nut [31] in anti-clockwise direction until the valve is 50% open i.e. 15mm. Check the double arm lever [ ] to be horizontal. If not then by rotating the adjustment lever [ ] make the double arm lever horizontal. Rotate the contact screw [29] making it touch the bellow [44]. Again, rotate it 1 [1.5 mm] rotation of contact screw. Now the valve should be completely close. [If not the Roboter is to be replaced completely.] Apply set pressure 4.5 bar through siphon. If siphon is not used then bellow might get burst. To check the bellow chamber is completely filled observe the flowing medium coming out at the air vent port. Now tight the air vent screw [39]. Rotate the hex nut [33] up to 50 % opening of the valve. Increase the set pressure 4.5 bar till the valve is fully closed. Ensure output pressure [p1] on the gauge [13] to
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be zero or less than operating control range of valve. Note that pressure. Then decrease the pressure [p2] bellow 4.5 bar. Do it until the valve gets open fully. Apply set pressure 4.5 bar and ensure the valve is 50% open. To check smooth operation of the valve we should check the proportionate band. {= (P1-p2)/(set pr. X 100)} this formula should give result between 10 % to 40 %. Q3] How to change the nozzle? Remove the cover [6] by unscrewing the M5x10L screws [2](4 nos.). Unscrew the hex-nut [33]. Take-out the bearing [32]. Take-out the spring [30] and spring-plate attached to it [28]. Remove the flapper lever [26]. Unscrew the (m4x40) screw 2nos. [7]. Take out the traverse [12] and traverse head assembly [8]. Unscrew the nozzle [9] and replace with news. Assemble in reverse as above steps. Recalibrate.

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