Pneumatic Positioner

Series 820-PP
Operation & Maintenance Manual
Pneumatic Positioner Model 820- PP
This operation & maintenance manual corresponds to Forbes
Marshall Arca make Pneumatic Positioner model 820-PP.

If you experience any difficulty with the installation or operation

of this equipment, please contact our Customer Support

Manufactured & Marketed by

Forbes Marshall Arca Pvt. Ltd.
A Forbes Marshall Company
A 34/35, H Block, MIDC Estate
Pimpri - 411018
Pune, India

TEL. : +912027442020
FAX. : +022027442040

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 Table Of Contents

1.General

2.Nomenclature/ Model No.

3.Salient Features

4.Specifications

5.Principle Of Operation

6.Block Diagram

7.Installation & Calibration

8.Auto/Manual switch

9. Seat adjuster

10.Maintenance and check

11.Caution and Handling

12.Trouble shooting

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1. GENERAL

The pneumatic positioner is used in Control Valves with pneumatically operated actuators.
The valve is operated by means of electrical controller or Control Systems (through I/P
converter) with a control signal of 0.2~1.0 bar or split ranges of 0.2~0.6 bar & 0.6~1.0 bar.

The 820-PP 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.

2.Nomenclature/ Model No. –

8 2 0 - P P

82 SERIES POSITIONER

0 - NORMAL

ALWAYS "-"

PP - PNEUMATIC TO PNEUMATIC

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3. SALIENT FEATURES

1. There is no change in performance in the range of 5-200Hz of Vibrations.

2. Can be Used for Split Range Application
3. Easy to adjust zero and span & calibrate to the required travel of the valve.
4. Easy to convert from ATO (Air to Open) to ATC (Air to Close) action or vice versa.
5. Easy Feedback connection.
6. Fast and accurate response.
7. Low air consumption.

4. SPECIFICATIONS

Input Signal 0.2~1.0 barg (or SPLIT RANGE)

Supply Pressure 1.4~6 kg/cm2

Air Consumption 3 lpm at 1.4 bar

Air Flow capacity 80 lpm at 1.4 bar

Linearity ± 1% of FS

Hysteresis ± 0.2% of FS

Repeatability ± 0.5%

Air Connection ¼” NPT (F)

Gauge Connection 1/8” NPT (F)

Ambient Temp -20 0C to +80 0C

Protection IP 66

Weight 2.1 kg

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Pneumatic Positioner
820-PP

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5. PRINCIPLE OF OPERATION

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, this pressure makes
bellow to expand thereby exerting force on flapper to move away from the
n o z z l e . T h e c l e a r a n c e b e t w e e n t h e N o z z l e & t h e F l a p p e r i n c r e as e s , d u e t o
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
t h e a c tu a t o r t h r o u g h p o r t O U T 1 . T h e v a l v e S p i n d l e w i l l m o v e u p o r d o w n
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
moment generated by bellow, the valve Spindle stays in it’s position.

When the signal pressure decreases the operation is reversed.

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6. BLOCK DIAGRAM

INPUT BELLOW FLAPPER & PILOT

SIGNAL CHAMBER NOZZLE VALVE
(0.2~1.0 MECHANISM
bar)

STABILIZER
/COMPENSATION ACTUATOR
SPRING

FEEDBACK FEED BACK (OUTPUT )

SPRING LEVER VALVE
STROKE

7. INSTALLATION & CALIBRATION

a. Check that the Pneumatic pipes/ tubing are properly flushed.

b. Connect the pneumatic connections as per the diagram of point 7-e.

c. Connect the Feedback lever to the Control Valve’s Link mounted on the Valve’s Lift Indicator.
Apply 50% signal ( i.e. 0.6 barg) and position the Stroke Scanning Pin/ Positioner in such a way that
that the Feedback Lever is at 90 0.

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

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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 lever as per the actuator function i.e. ATO (Air to Open) or ATC (Air to close),
as explained under

ATC Actuator ATO Actuator

ATC ACTUATOR ATO ACTUATOR

SPAN Lever Fixing Screw

SIGNAL
AIR
SIGNAL
Lock Screw AIR
Lock Screw
SUP
AIR
SUP
OUT2
OUT1

AIR
OUT2

OUT1
SPAN Lever Fixing Screw

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, take care not
to stretch the Feedback Spring.

OUT2 port is not to be used, unless confirmed from works.

f. Apply, starting signal (0.2 barg) 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 (1.0 barg), 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 0.2 barg and set if found
disturbed. After setting, carefully tighten the Lock Screw of the SPAN Lever.

Note - The positioner can be set in Split Range also (i.e 0.2~0.6 barg or 0.6~1.0 barg), as described
under

Split Range 0.2~0.6 barg – Set ZERO at 0.2 barg & SPAN at 0.6 barg for 100% valve travel.
Recheck ZERO after setting SPAN, correct, if found disturbed.

Split Range 0.6~1.0 barg - Set ZERO at 0.6 barg & SPAN at 1.0 barg for 100% valve travel.
Recheck ZERO after setting SPAN, correct, if found disturbed.

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8. By-Passing The Positioner/ ”A-M” Screw -

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.

9. SEAT ADJUSTOR – (Should Not be disturbed)

This is set at the factory at fully tight position and should not be disturbed. Disturbing this screw may
cause positioner malfunctioning.

10. MAINTENANCE AND CHECK

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.

2. The compressed air cleaning/de -humidifying system should be checked periodically.

3. When the fixed orifice is clogged with carbon particles 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.

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11. CAUTION AND HANDLING

1. Do not apply large vibration or impact to the positioner. It causes trouble to the positioner and it
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. Be sure that the body cover is put on during the operation.

4. 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.

5. If the atmosphere is of high temp. Or high humidity, take measures to avoid condensation during
shipment.

6. For proper functioning of the positioner, use only factory authorized replacement parts.
Substitutions of components can impair the performance of the equipment.

12. TROUBLE SHOOTING

PROBLEM CAUSE WHAT TO DO

Too Low or None Supply Pr. Check Supply Pr.

Damaged Bellow Replace Bellow

No Response when
Input Signal is Applied Clean The Nozzle with the
Clogged Nozzle help of wire provided in the
Positioner Cover.
Loose or Wrong Setting of
Correct Setting/ Tighten
Feedback Lever

Correct to the Required

Wrong Orientation of SPAN Switch
Position (Refer Point 7e)
Valve Operates Only
for 0% & 100% Signal Fully tighten the “A -M”
“A-M” Screw is Disturbed
i.e. No Response for in Screw (It has two ‘O- Rings)
between Signals and
Actuator Operates Only Correct the Pneumatic
to ON or OFF Position Wrong Connection of OUT1 & Connection w.r.t. the Position
OUT2 Ports of SPAN adjustment Switch
(Refer Point 7e).

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 PROBLEM CAUSE WHAT TO DO

Leakage of A/M Switch Tighten or Replace ‘O’ Rings

of A/M Switch

OUT PUT Pressure Correct to the Required

Wrong Orientation of SPAN Switch
Raised and Stays, Does Position (Refer Point 7e)
Not Come Down
Clean the Orifice with the
Clogged Fixed Orifice help of Wire, provided in the
Positioner Cover

OUT PUT Pressure is Clean The Nozzle with the

Operated by A/M Clogged Nozzle help of wire provided in the
Switch Only Positioner Cover.

Disturbed Compensation/ Stabilizer Correct the Positioning of

Spring Stabilizer Spring

Hunting is Occurring
Clean The Nozzle with the
Clogged Fixed Nozzle help of wire provided in the
Positioner Cover

Readjust the setting of the

Wrong Setting of Feed Back Lever Feed Back Lever
(Refer Point 7c & 7d)

Wrong ZERO, SPAN adjustment Readjust the ZERO & SPAN

Linearity is not Good
Check the Air Leakage from
the Pneumatic supply OR
Supply Pressure is unstable
Replace the Air Filter
Regulator
Loose Pneumatic connections in the
Check & correct
Actuator or Positioner

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