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Series 830/831-WP/EX
Operation & Maintenance Manual
Electro-Pneumatic Positioner Model 830/831- WP/EXP
This operation & maintenance manual corresponds to Forbes
Marshall Arca make Electro-Pneumatic Positioner model 830/831.
TEL. : +912027442020
FAX. : +022027442040
Table Of Contents
1.General
3.Salient Features
4.Specifications
5.Principle Of Operation
6.Block Diagram
8.Auto/Manual switch
9. Seat adjuster
12.Trouble shooting
The electro -pneumatic positioner is used in Control Valves with pneumatically operated
actuators. The valve is operated by means of electrical controller or Control Systems With
an control signal of 4 to 20 mA or split ranges of 4~12/ 12~20 mA.
The 830/831 Electro-Pneumatic Positioner converts this control signal into a pneumatic
output in proportion to the lift of the control valve.
This manual contains the information required for the installation & usages of this
equipment. It is addressed to technically qualified & trained person or having relevant
knowledge of instrumentation & control technology.
It must be used in the way described in this manual. Successful safe operation of this
equipment is dependent upon the proper handling, installation, operation & maintenance.
8 3 0 - W P
83 SERIES POSITIONER
0 - NORMAL
1 - WITH FEEDBACK TRANSMITTER
ALWAYS "-"
4. SPECIFICATIONS
Linearity ± 1% of FS
Hysteresis ± 0.2% of FS
Repeatability ± 0.5%
Protection IP 66
Weight 2.8 kg
This equipment works on the force balance principle and uses a flapper/ nozzle & set of springs
to bring the forces under equilibrium at the required valve position with respect to the
signal/command given to it.
When the input signal from the controller is applied to the torque motor, the armature receives a
torque in counter clock wise direction, due to this torque the counter weight/ flapper moves
towards left side and the clearance between the Nozzle & the Flapper increases, due to which,
the back pressure in the Nozzle decreases.
As a result of the above, the exhaust valve of the Pilot Valve moves towards right and the Inlet
Valve “A” opens, thereby the supply air goes to the actuator through port OUT1. The valve
Spindle will move up or down depending up on the actuator configuration (ATO/ATC) and the
Feedback Spring will lengthen or shortens by the movement of Feedback Lever.
When there is a force balance between Feedback Spring tension and the Torque generated by
the Torque Motor, the valve Spindle stays in it’s position.
6. BLOCK DIAGRAM
STABILIZER
/COMPENSATION ACTUATOR
SPRING
b. Connect the wires from the controller, at the terminal block of the positioner. “+” & “-“ signs are
printed at the terminal block of the positioner for the ease of connection. The grounding terminal
should also be connected.
6 Positioner 1 2 3 4 5 6
Positioner
5 Mounting Bracket
Stroke Scanning
4
Lever
3 Threaded Pin
2 Link
1 Lift Indicator
Sr.
No. Part Name
c. Connect the Feedback lever to the Control Valve’s Link mounted on the Valve’s Lift Indicator.
Apply 50% signal ( i.e.12 mA DC) and position the Stroke Scanning Pin/ Positioner in such a way
that that the Feedback Lever is at 900.
d. For best performance the movement of the Feedback Lever should be between +15~200 to –15~200
from the 900 (horizontal position set at 50% signal). Pl. check that, while setting the full stroking
angle, the Feedback Lever should not foul with the stoppers, provided near the Feedback Lever
Connection point on to the Positioner.
e. Position the SPAN le ver as per the actuator function i.e. ATO (Air to Open) or ATC (Air to close),
as explained under
Lock Screw
Lock Screw
OUT2 OUT2
OUT1
OUT1
SPAN Lever Fixing Screw
SUP SUP
AIR
AIR
For changing the position of SPAN Lever, the Lock Screw, should be loosened slightly, to avoid
getting the Feedback Spring damaged. After re-orienting the SPAN Lever to the desired position, the
Lock Screw should be tightened carefully. While changing the position of SPAN Lever, pl. take care
not to stretch the Feedback Spring.
f. Apply, starting signal (4 mA) and turn the Zero setting adjuster, to set the zero setting. (Clockwise
rotation of the adjusting wheel will increase the pneumatic supply to the actuator, to decrease the
supply to actuator rotate the adjuster in CCW direction).
g. Then apply 100% signal (20 mA), if the valve is not taking 100% stroke then slightly loosen the
Lock Screw mounted on the SPAN Lever, rotate the knob on the SPAN lever to achieve the full
stroke position. After setting the SPAN, again check the Zero setting at 4 mA and set if found
disturbed. After setting, carefully tighten the Lock Screw of the SPAN Lever.
The positioner can be set in Split Range also (i.e. 4~12 mA or 12~20 mA), it can be done by doing
calibration as mentioned above.
The Positioner can be by-passed, by the adjustment of “A-M” Screw. The factory setting is for
AUTO mode, however to by-pass the positioner, rotate the “A -M” screw in counterclockwise
direction slowly towards “M” marking on the Pilot Valve (Ref. fig. Under Point no.5
In by-pass mode, the full pr. of the supply air goes to the Actuator. Therefore, pl. be careful to check
the air supply recommended for the actuator. After using the Positioner in manual mode, again rotate
the “A-M” Screw in Clockwise direction towards “A” to go into AUTO Mode. It should be fully
tightened for AUTO Operation.
This is set at the factory at fully tight position and should not be disturbed. Disturbing this screw may
cause positioner malfunctioning.
1. If the quality of the supply air is fouled, then the positioner may not operate normally. Moist air
may damage the Pilot Valve/ Torque Motor and cause Positioner to malfunction/ defunct.
The requirement for a quality air supply can be found in the instrument society of America’s
“Quality Standard for Instrument Air” (ISA-S7.3) or BS 5967:Part 2. Basically, this standard
calls for the following
Particle Size – The maximum particle size in the air stream at the instrument should be no
larger than 3 microns.
Dew Point - The dew point -at line pressure- should be at least 10 0C below the minimum
temperature to which any part of the instrument air system is exposed at any
season of the year.
3. When the fixed orifice is clogged with carbon particle s or others, remove the pilot valve
Auto/Manual changeover screw (built-in fixed aperture) and clean it by inserting a 0.2 wire
(provided at the inside of the Positioner Cover) into the aperture. If it is required to be replaced
with new one, stop the supply pr. and remove the Stopper Screw of the pilot valve.
4. Check the positioner once a year. If any abnormality is observed, contact our works.
5. There should not be any air leakage from the tubing. Use pipe sealant sparingly, only on the
male thread of the tube fittings. A non-hardening sealant is strongly recommended.
1. Do not apply large vibration or impact to the positioner. it causes trouble the positioner must be
handled very carefully during transportation and operation.
2. If the positioner is used under temperature outside of the specifications, the sealing materials
may deteriorate quickly and also the positioner may not operate properly.
3. Do not open the terminal cover at a dangerous position (hazardous area) during operation or
during power conduction.
4. Be sure that the terminal cover and body cover are put on during the operation.
5. If you leave the positioner at the operation site for a long time without using it, put a polythene
cover on it so that the rainwater does not harm it in any way.
6. If the atmosphere is of high temp. Or high humidity, take measures to avoid condensation during
shipment.
7. For proper functioning of the positioner, use only factory authorized replacement parts.
Substitutions of components can impair the performance of the equipment.
8. When the positioner is installed without safety barriers, switch off electrical power supply at its’
source before connecting or disconnecting signal/feedback wiring.
Electronic position transmitter is designed for sensing mechanical position change of Valve Spindle
vis-à-vis signal given to the Positioner. The output is in DC current 4~20 mA. The split range
feedback can also be set with the help of ZERO & SPAN setting.
SPAN
ACTUATOR SELECTION
ZERO SWITCH
ATC ATO
OUTPUT 4 ~20 mA
INPUT (4 ~20 mA) (AT 24 VDC)
1) ZERO Adjustment –
2) SPAN Adjustment –
After adjusting the SPAN, again check the ZERO setting, if required, adjust it.
Note : Adjustment should be done carefully as excessive rotation of the adjustment screw
may damage the adjustment POTs.