July 2001 Type 3590, S, & ST

Type 3590, S, & ST Electro–Pneumatic Valve

Positioners
(Obsolete Product)
Obsolete products may not be manufactured again in tronic components. Post-sale documents (such as in-
any Fisher location under any conditions. Rec- struction manuals) will be available on CD Rom and
omended spare parts availability is guaranteed for 10 the Fishweb. Pre-sale documents (such as bulletins)
years after the last production on manufactured trim for obsolete are not included on the Fishweb or CD-
replacement parts and 5 years of best effort on die ROM.
cast parts, elastomers, buyout components, and elec-

Fisher and Fisher-Rosemount are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc.
All other marks are the property of their respective owners.

EFisher Controls International, Inc. 2001; All Rights Reserved

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express
or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

For information, contact Fisher:

Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 128461

Printed in U.S.A.

Safety Instructions
Supplemental Safety Instructions for Fisher
Controls Products
Provided for product type:
Types 3590, S, and ST
Form 2403
January 1976
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Maintenance Scheduling . . . . .
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve Actuators . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruments, Switches, and Accessories . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
The attached instruction manual or other documenta-
tion is no longer in active circulation. The attached is
Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher
Controls International, Inc. or Fisher-Rosemount Systems, Inc.
All other marks are the property of their respective owners.
EFisher Controls International, Inc. 1995; All Rights Reserved
Instruction Manual
Form 5370
April 1995
provided to you from our files to assist you in opera-
tion or maintenance of the product.
Please read these safety warnings, cautions, and
instructions carefully before using the product.
These supplemental instructions cannot cover every
installation and situation. The installation, operation,
and maintenance of this product should only be per-
formed by persons who are qualified through training
or experience. If you have any questions concerning
installation, use, or maintenance of this product, con-
tact your Fisher Controls sales office or sales repre-
sentative before proceeding.
All Products
1
1
1
Specifications
1 This product was intended for a specific range of ser-
1 vice conditions–pressure, pressure drop, process and
2 ambient temperature, temperature variations, process
2 fluid, and possibly other specifications. Do not ex-
2 pose the product to service conditions or vari-
3 ables other than those for which the product was
3 intended. If you are not sure what these conditions
3 are, contact your Fisher Controls sales office or sales
3 representative for assistance. Provide the product
3 serial number and all other pertinent information that
4 you have available.
4
4 Inspection and Maintenance Schedules
4
All products must be inspected periodically and main-
4
tained as needed. The schedule for inspection can
5
only be determined based on the severity of your ser-
5
vice conditions. Your installation might also be subject
6
to inspection schedules set by applicable governmen-
tal codes and regulations, industry standards, compa-
ny standards, or plant standards.
Parts Ordering
Whenever ordering parts for older products, always
specify the serial number of the product and provide
D102116X012
Safety Instructions
all other pertinent information that you can, such as
product size, part material, age of the product, and
general service conditions. If you have modified the
product since it was originally purchased, include that
information with your request. Because of the care
Fisher Controls takes in meeting all manufacturing re-
quirements such as heat treating, dimensional toler-
ances, etc., use only replacement parts manufactured
or furnished by Fisher Controls or parts meeting Fish-
er Controls’ specifications.
Control Valves
Installation
WARNING
D Personal injury or equipment dam-
age caused by sudden release of pres-
sure or bursting of parts may result if
the valve assembly is installed where
service conditions could exceed the lim-
its given in the applicable product litera-
ture, the limits on the appropriate name-
plates, or the mating pipe flange rating.
Use pressure-relieving devices as re-
quired by government or relevant indus-
try codes and good engineering practic-
es. If you cannot determine the ratings
and limits for this product, contact your
Fisher Controls sales office or sales rep-
resentative before proceeding.
D If hoisting the valve, use a nylon
sling to protect the surfaces. Carefully
position the sling to prevent damage to
the actuator tubing and any accesso-
ries. Also, take care to prevent people
from being injured in case the hoist or
rigging might slip. Be sure to use ade-
quately sized hoists and chains or
slings to handle the valve.
D Personal injury could result from
packing leakage. Valve packing was
tightened before shipment; however, the
packing might require some readjustment
to meet specific service conditions.
D Many rotary shaft valves are not
necessarily grounded to the pipeline
when installed in a flammable, hazard-
ous, oxygen service, or explosive atmo-
spheres. An explosion is possible, due
to the discharge of static electricity from
the valve components. To avoid person-
2
al injury or property damage, make sure
that the valve is grounded to the pipe-
line before placing the control valve as-
sembly into service. Use alternate shaft-
to-body bonding, such as a shaft-to-
body bonding strap assembly .
CAUTION
When ordered, the valve configuration
and construction materials are generally
selected to meet particular pressure,
temperature, pressure drop and con-
trolled fluid conditions. Since some
body/trim material combinations are lim-
ited in their pressure drop and tempera-
ture ranges, do not apply any other
conditions to the valve without first con-
tacting your Fisher Controls sales office
or sales representative.
Maintenance
WARNING
Avoid personal injury or property dam-
age from sudden release of process
pressure or uncontrolled movement of
parts. Before performing any mainte-
nance operations:
D Disconnect any operating lines pro-
viding air pressure, electric power, or a
control signal to the actuator. Be sure
the actuator cannot suddenly open or
close the valve.
D Use bypass valves or completely
shut off the process to isolate the valve
from process pressure. Relieve process
pressure from both sides of the valve.
Drain the process media from both
sides of the valve.
D Vent the pneumatic actuator load-
ing pressure and relieve any actuator
spring pre-compression.
D Use lock-out procedures to be sure
that the above measures stay in effect
while you work on the equipment.
D Many valve parts that are moving
can injure you by pinching, cutting, or
shearing. To help prevent such injury,
stay clear of any moving part.).
D Never apply pressure to a partially
assembled valve.

D To avoid personal injury or proper-
ty damage caused by uncontrolled
movement of a valve bonnet, loosen the
bonnet by following these instructions:
Do not remove a stuck bonnet by pull-
ing on it with equipment that can stretch
or store energy in any other manner.
The sudden release of stored energy
can cause uncontrolled movement of
the bonnet. Loosen bonnet nuts
approximately 1/8 inch (3 mm). Then
loosen the body-to-bonnet gasketed
joint by either rocking the bonnet or
prying between the bonnet and body.
Work the prying tool around the bonnet
until the bonnet loosens. If no fluid
leaks from the joint, proceed with bon-
net removal.
D As you remove parts, such as valve
shafts, other parts, such as disks can
fall from the valve body. To avoid injury
from falling parts, be sure to support
parts as you disassemble the valve.
Control Valve Actuators
Installation
WARNING
To avoid personal injury and property
damage caused by bursting of parts and
to avoid parts damage, malfunction of
control valve, or loss of control of the
process caused by excessive pressure,
do not exceed the maximum pressures
or temperatures for this actuator, as giv-
en in the applicable product literature or
on the nameplate. If you cannot deter-
mine the limits for this product, contact
your Fisher Controls sales office or
sales representative before proceeding.
Operation
WARNING
When moving the actuator stem or shaft
with loading pressure applied, use cau-
tion to keep hands and tools out of the
actuator travel path. Personal injury and
property damage is possible if something
Safety Instructions
is caught between the actuator stem and
other control valve assembly parts.
Maintenance
WARNING
Avoid personal injury or property dam-
age from sudden release of process
pressure or uncontrolled movement of
parts. Before performing any mainte-
nance operations:
D Disconnect any operating lines pro-
viding air pressure, electric power, or a
control signal to the actuator. Be sure
the actuator cannot suddenly open or
close the valve.
D Use bypass valves or completely
shut off the process to isolate the valve
from process pressure. Relieve process
pressure from both sides of the valve.
Drain the process media from both
sides of the valve.
D Vent any pneumatic pressure from
the actuator and relieve any actuator
spring pre-compression.
D Use lock-out procedures to be sure
that the above measures stay in effect
while you work on the equipment.
D To avoid personal injury due to the
sudden uncontrolled movement of
parts, do not loosen the stem connector
cap screws when the stem connector
has spring force applied to it.
D Never apply pressure to a partially
assembled actuator unless all pressure-
retaining parts have been installed prop-
erly.
Regulators
Installation
WARNING
D Personal injury, equipment dam-
age, or leakage due to escaping gas or
bursting of pressure-containing parts
might result if this regulator is overpres-
sured or is installed where service
3
Safety Instructions
conditions could exceed the limits for
which the regulator was designed, or
where conditions exceed any ratings of
the adjacent piping or piping connec-
tions. To avoid such injury or damage,
provide pressure-relieving or pressure-
limiting devices (as required by the ap-
propriate code, regulation, or standard)
to prevent service conditions from ex-
ceeding those limits.
D Additionally, physical damage to a
pilot-operated regulator could break the
pilot off the main valve, causing person-
al injury and property damage due to
escaping gas. To avoid such injury and
damage, install the regulator in a safe
location.
D A regulator may vent some gas to
the atmosphere in hazardous or flam-
mable gas service. Vented gas might ac-
cumulate and cause personal injury,
death, or property damage due to fire or
explosion. Vent a regulator in hazardous
gas service to a remote, safe location
away from air intakes or any hazardous
location. The vent line or stack opening
must be protected against condensation
or clogging.
Maintenance
WARNING
Avoid personal injury or damage to
property from sudden or uncontrolled
release of pressure, gas, or other pro-
cess fluid. Before starting to disas-
semble, isolate the pilot or regulator
from all pressure and cautiously release
trapped pressure from the pilot or regu-
lator. Use gauges to monitor inlet, load-
ing, and outlet pressures while releas-
ing these pressures.
4
Relief Valves
Installation
WARNING
Personal injury, equipment damage, or
leakage due to escaping gas or bursting
of pressure-containing parts may result
if the relief valve or backpressure regu-
lator is installed where its capabilities
can be exceeded or where conditions
exceed any ratings of the adjacent pip-
ing or piping connections. To avoid this,
install a relief valve or backpressure reg-
ulator where:
D Service conditions are within unit
capabilities,
D Service conditions are within appli-
cable codes, regulations, or standards
requirements.
Additionally, physical damage to the re-
lief valve or backpressure regulator
could break the pilot off the main valve,
causing personal injury and property
damage due to escaping gas. To avoid
such injury or damage, install the unit in
a safe location.
When used in relief valve service, a relief
valve and pilot both exhaust gas. ln haz-
ardous or flammable gas service, person-
al injury, death, or property damage may
occur due to fire or explosion of vented
gas that has accumulated. To prevent
such injury or damage, provide piping or
tubing to vent the gas to a safe location.
The exhaust piping must be designed
and installed to guard against excessive
flow restriction. This piping must be pro-
tected against condensation or anything
else that could clog it.
Operation
WARNING
For safety during shutdown, vent valves
are required immediately upstream and
downstream of the main valve on a
backpressure or bypass installation.
Maintenance
WARNING
Avoid personal injury or damage to
property from sudden or uncontrolled

release of pressure, gas, or other pro-
cess fluid. Before beginning disassem-
bly, carefully release all pressures. Use
a gauge to monitor relief (inlet) pressure
while releasing it.
Instruments, Switches, and
Accessories
Installation
Actuator-Mounted Accessories
WARNING
Avoid personal injury or property dam-
age from sudden release of process
pressure or bursting of parts. Before
mounting the product:
D Disconnect any operating lines pro-
viding air pressure, electric power, or a
control signal to the actuator. Be sure
the actuator cannot suddenly open or
close the valve.
D Use bypass valves or completely
shut off the process to isolate the valve
from process pressure. Relieve process
pressure from both sides of the valve.
Drain the process media from both
sides of the valve.
D Vent the pneumatic actuator load-
ing pressure and relieve any actuator
spring pre-compression.
D Use lock-out procedures to be sure
that the above measures stay in effect
while you work on the equipment.
All Instruments, Switches, and Accessories
WARNING
D The instrument is capable of sup-
plying full supply pressure to connected
equipment. To avoid personal injury
and equipment damage, make sure the
supply pressure never exceeds the max-
imum safe working pressure of any con-
nected equipment.
D Personal injury or property damage
may occur from an uncontrolled pro-
Safety Instructions
cess if the supply medium is not clean,
dry, oil-free, and noncorrosive gas. In-
dustry instrument air quality standards
describe acceptable dirt, oil, and mois-
ture content. Due to the variability in na-
ture of the problems these influences
can have on pneumatic equipment,
Fisher Controls has no technical basis
to recommend the level of filtration
equipment required to prevent perfor-
mance degradation of pneumatic equip-
ment. A filter or filter regulator capable
of removing particles 40 microns in di-
ameter should suffice for most applica-
tions. Use of suitable filtration equip-
ment and the establishment of a
maintenance cycle to monitor its opera-
tion is recommended.
D For corrosive media, make sure the
tubing and instrument components that
contact the corrosive media are of suit-
able non-corrosive material. The use of
unsuitable materials might result in per-
sonal injury or property damage due to
the uncontrolled release of the corrosive
media.
D If a flammable, toxic, or reactive
gas is to be used as the supply pressure
medium, personal injury and property
damage could result from fire or explo-
sion of accumulated gas or from contact
with toxic or reactive gas. The instru-
metn or instrument/actuator assembly
does not form a gas-tight seal, and
when the assembly is in an enclosed
area, a remote vent line, adequate ven-
tilation, and necessary safety measures
should be used. A remote vent pipe
alone cannot be relied upon to remove
all hazardous gas.
D If a remote vent is required, vent
line piping should comply with local
and regional codes and should be as
short as possible with adequate inside
diameter and few bends to remove ex-
haust gases to a ventilated area.
D Personal injury or property damage
can result from the discharge of static
electricity. Connect a 14 AWG (2.08
mm2) ground strap between the instru-
ment and earth ground when flammable
or hazardous gases are present. Refer to
national and local codes and standards
for grounding requirements.
D Personal injury or property damage
can result if a suitable conduit seal is
not installed. For explosion-proof ap-
5
Safety Instructions
plications, install the seal no more that Drain the process media from both
18 inches (457 mm) from the instrument sides of the valve.
when required by the nameplate.
D Vent any pneumatic pressure from
the actuator and instrument and relieve
Operation any actuator spring pre-compression.
With instruments, switches, and other accessories that D Use lock-out procedures to be sure
are controlling valves or other final control elements, it that the above measures stay in effect
is possible to lose control of the final control element while you work on the equipment.
when you adjust or calibrate the instrument. If it is
necessary to take the instrument out of service, ob-
serve the following warning before proceeding. Instruments Mounted on Tank or Cage

WARNING WARNING

Avoid personal injury or equipment For instruments mounted on a tank or

damage from uncontrolled process. displacer cage, release trapped pressure
Provide some temporary means of con- from the tank and lower the liquid level to
trol for the process before taking the a point below the connection. This pre-
instrument out of service. caution is necessary to avoid personal
injury from contact with the process fluid.

Maintenance
Instruments With a Hollow Displacer or Float
WARNING
WARNING
D To avoid personal injury caused by
a fire or explosion, remove electrical For instruments with a hollow liquid lev-
power before opening instrument cov- el displacer, the displacer might retain
ers or removing the instrument in a haz- process fluid or pressure. Personal in-
ardous area. Do not apply electrical jury and property might result from sud-
power to the instrument, with the covers den release of this pressure or fluid.
removed, while in a hazardous area. Contact with hazardous fluid, fire, or ex-
D Provide some temporary measure plosion can be caused by puncturing,
of control to the process before taking heating, or repairing a displacer that is
the instrument out of service. retaining process pressure or fluid. A
displacer that has been penetrated by
Before performing any maintenance op-
process pressure or fluid might contain:
erations on an actuator-mounted instru-
ment or accessory: D pressure as a result of being in a
D Disconnect any operating lines pro- pressurized vessel
viding air pressure, electric power, or a D liquid that becomes pressurized
control signal to the actuator. Be sure due to a change in temperature
the actuator cannot suddenly open or
close the valve. D liquid that is flammable, toxic, cor-
rosive, or reactive
D Use bypass valves or completely
shut off the process to isolate the valve Handle the displacer with care. Consid-
from process pressure. Relieve process er the characteristics of the specific pro-
pressure from both sides of the valve. cess liquid in use.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or
implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

For information, contact Fisher Controls:

Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 0512
6
Printed in U.S.A.
 Types 3590,-S, and -ST

Fisher Controls Instruction Manual

Type 3590,-S, & -ST
Electra-Pneumatic Valve
Positioners

January 1976 Form 2403

SCOPE OF MANUAL

This manual includes installation, operating, and

maintenance instructions and parts lists for Type 3590,
3590s. and 3590ST positioners and Type 93H relays. Refer
to separate instruction manuals for information concerning
the valve, actuator, Type 67FR filter-regulator, and
accessories.

INTRODUCTION

Type 3590, 35905, and 3590ST electro-pneumatic valve

positioners are designed for use in electronic control loops in
which the final control element is pneumatically operated.
The positioner receives a direct-current input signal and con-
velfs it to the required pneumatic output signal pressure.
producing a valve stem position that has a linear relationship
to the input signal. The three types are similar except that
the Type 3590 positioner is CSA listed es explosion proof
and the Type 3590s and 3590ST positioners are FM, UL. or
CSA listed as intrinsically safe. See table 3 for electrical Figure 1. Type 3590 Positioner Mounted on Fisher
classifications. Type 657 Pneumadc Diaphragm Actuator
 Types 3590, 4, and -ST
,““,1 ,.
NPUT SIGNALS * 4
? to 20 mA dc. . 10 to 50 mA dc MAXIMUM SUPPLY
(Type 3590 only). or split range
using a portion of the 4 to 20 or 10
to 50 mA dc input signal (see
“Split-Range Operation” section)
NTERNAL RESISTANCE
4 to 20 mA dc Input Signal: 300
IF POSITIONER TDRQUE ztl5ohms
ADTDR 10 to 50 mA dc Input Signal: 70
f5 ohms
KITPUT SIGNAL ? Type: Pneumatic pressure range as
required to produce from 7/l 6 to
4-116 inches valve plug travel
Action: Type 3590 is field revers-
ible between . direct and . reverse
(Types 3590s and 3590ST are
available with either direct or
reverse action but cannot be
reversed in the field)
;UPPLV PRESSURE
? Recommended: 5 psi higher than
upper range limit of required
diaphragm pressure range
Maximum: 50 psig
IAXIMUM STEADV- 20 psig Supply Pressure: 0.4 scfm
TATE AIR CDNSUMPTIDN* 35 psig Supply Pressure: 0.6 scfm
rks. ,OrnI are demd in SAMA Standdrd WC zo.1.iB,J.
Table 2. Valve Sfroking Time
..&,“..~“*‘L,“,,.,
20 psig Supply Pressure: 4.3 scfm
AIR DEMAND 35 psig Supply Pressure: 7.0 scfm
PERFORMANCE+ Valve Stroking Time: See table 2
Reference Accuracy:* & 1.254
of OUtpUt span (actuator travel)
Independent Linearity:’ fl% o
OUtpUt span ~actuator travel)
Dead Band:* 0.025% of o”tpu’
span (actuator travelJ
Hysteresis:’ 0.40% of output spar
kJctuator travelJ
Open Loop Gain:* 60
Frequency Response:’ Gain is
attenuated 3 dB at 0.65 Hz with a
20 psig supply pressure and output
of positioner piped to a size 40
Fisher Type 657 pneumatic dia-
phragm actuator
OPERATIVE AMBIENT -4oto +15ooF
TEMPERATURE*
ELECTRICAL See table 3
CldSSlFlCATlDN
APPROXIMATE
WEICNT 10 pounds ipositioner only)

Table 3. Elecrrical
INSTALLATION
Positioner Mounting
When the positioner is furnished with an actuator, the
factory will mount and align the positioner. If the positioner
1s ordered separately. or if it has been removed for
maintenance, mount the positioner as follows. Figures 2 and
3 illustrate the manner in which the positioner should be
mounted on Type 657 direct-acting or Type 667 reverse-
acting diaphragm actuators. respectively.
Note in figures 2 and 3 that the positioner arm (key 21.
figure 81 extends from the right side of the positioner for
direct-acting actuators and from the left for reverse-acting
actuators. If the arm does not extend from the proper side.
remove two machine screws (key 22, figure 81. remove and
w-install the arm on the opposite side, and secure with
machine screws before proceeding.
Key numbers used in the following steps are shown in
figures 2 and 3 except where indicated.
1 Types 3590, 4, and -ST 1
C/assif;car;ons
1. Make certain that the proper mounting parts are provid-
ed. When mounting the positioner on other than Fisher ac-
tuators. it may be necessary to provide spacers by cutting
sections from 3/8-inch or l/Z-inch pipe to attain dimension
“X” between the maximum and minimum values shown in
figure 4.
2. Attach connector arm (key 76) to the actuator stem
connector, aligning the connector arm perpendicular to the
positioner mounting pad. Do not allow the actuator stem to
rotate.
3. Bolt the positioner to the mounting plate (key 93).
4. The mounting plate includes several sets of mounting
holes for use with various actuators as shown in figure 5.
Determine the appropriate mounting hole set to bs used for
a given actuator from table 4. Bolt the mounting plate to the
lower mounting pad of the actuator with cap screws (key
96).
5. Using the cap screw and washer (keys 78 and 791. at-
tach connector arm block (key 77) to connector arm. Do not
tighten cap screw (key 781. Refer to table 4 to determine if
connector arm block is to be mounted in the standard or
3
Types 3590, 4, and -ST

Figure 2. Positioner Mounted on Type 657 Diaphragm Actuator

4 4.12 5.75 4.38 5.00 4.88 6.50

Figure 4. Actuator-Valve Positioner Spacing for Other Than Fisher Acfuators


reversed position. Connector arm block positions are shown
in figures 2 and 3.
6. Proceed with the following sections.
Turnbuckle Assembly and Alignment
Key numbers used in the following procedure are shown in
figures 2 and 3 except where indicated.
To avoid damaging the mechanical feedback
linkage. do not apply an input signal or supply
pressure to the positioner until all steps in this
section have been completed.
1. Assemble the following parts of the turnbuckle
assembly: turnbuckle rod (key 80). turnbuckle pivot (key
811, turnbuckle (key 82). hex nut (key 831, and upper clevis
(key 84). Attach turnbuckle assembly to connector arm
block (key 77).
2. Remove cover from back of positioner and loosen lock-
ing screw (key 29, figure 81.
3. Using the adjustment gear (key 26, figure 8). set the
adjustment clamp (key 25, figure 8) so its V-notch indicator
shows the maximum actuator travel.
Never make this setting less than maximum
actuator travel. or damage to the mechanical
feedback linkage may result.
 Types 3590, 45, and -ST
4. Tighten locking screw (key 29, figure 8).
5. To connect turnbuckle:
a. On Type 657 direct-acting diaphragm actuators
with no signal pressure applied, the actuator spring will re-
tain the actuator stern and attached connector arm (key 76)
in the highest posifions. With the positioner installed as
shown in figure 2. the arm (key 21. figure 61 will be at the
upper limit of travel. Adjust the turnbuckle (key 82) to the
length required to connect the upper clevis to the arm
without repositioning either the arm or the connector arm.
Attach the upper clevis to the arm using the pin and E-rings
(keys 85 and 86).
b. On Type 667 reverse-acting diaphragm actuators
with no signal pressure applied. the actuator spring will
retain the actuator stem and attached connector arm (key
76) in the lowest positions. With the positioner installed as
shown in figure 3. the arm (key 21, figure 81 will be at the
lower limit of travel. Adjust turnbuckle length to l/2 inch
+,I8
-,, longer than the length required to connect the upper
clevis (key 841 to the arm without moving the arm.
NOt.2
If this adjustment results in less than l/Cinch
engagement of the turnbuckle threads. use the
turnbuckle at its maximum length (allowing l/4-
inch engagement of the turnbuckle threads).
Move the arm up to the upper clevis, and attach the upper
clevis to the arm with the pin and E-rings (keys 85 and 86).
6 . Slide the connector arm block in the connector arm slot
to position the turnbuckle assembly to be approximately ver-
tical (parallel with actuator stem) when viewed from the side
as in the drawing on the right in figure 4. Tighten cap screw
(key 781 to secure the assembly.
1 CAUTION 1
To avoid damage to the mechanical feedback
linkage, be certain that the turnbuckle rod (key
80) moves freely on the turnbuckle pivot (key
81). If binding occurs, adjust position of connec-
tor arm block in connector arm slot.
7. Using a manual loading regulator or handwheel. posi-
tion the actuator to the midtravel position.
8. Adjust turnbuckle until the feedback rod (key 16. figure
8) is parallel with the travel arm assembly (key 19. figure 8)
as shown in the drawing on the right in figure 8.
9. Lock turnbuckle with lock nut (key 83). This adjustment
should remain unchanged for any additional adjustment
operations.
10. Make electrical and pneumatic COnneCtiOnS per the
following sections. then proceed to the “Operating Ad-
justments” section.
Electrical Connections
The electrical connections are made in the positioner case. A
3/4-inch NPT conduit connection is provided in the bottom
of the case. Use a suitable conduit seal for hazardous
locations. The wires that carry the input signal from the con-
troller are connected to the terminal strip (key 46. figure 9).
The terminal strip is marked “+” and “-” to indicate the
positive and negative terminals.
For a direcr-acting positioner (i.e.. increasing current
produces an increasing output pressure). connect the
positive wire from the controller to the positive terminal of
the positioner and the negative wire to the negative ter-
minal.
For a reverse-acting positioner (i.e.. increasing current
produces a decreasing output pressure). connect the
positive wire from the controller to the negative terminal and
the negative wire to the positive terminal.
Note
Action of Type 35905 and 3590ST positioners
is not field reversible. If the input signal wire
connections on these types are reversed. the
positioner will not operate.
Output Pressure Connection
Connect 3/8-inch tubing from the pressure connection in the
diaphragm case (Type 657 actuators1 or top of the yoke
(Type 667 actuators) to the l/4-inch tapped hole in the
positioner marked “OUTPUT.“This connection will be made
at the factory if the positioner is shipped mounted on a con-
trol valve.
Supply Pressure Connection
Connect 3/8” tubing from the l/4-inch connection marked
“OUT” on the Type 67FR filter-regulator to the l/4-inch
tapped hole in the positioner marked “SUPPLY.” This con-
nection will be made at the factory if the filter-regulator and
positioner are factory mounted.
Supply Source
Connect available supply source to the l/4-inch connection
marked “IN” on the Type 67FR regulator. Normally this
regulator should be set to supply air to the positioner at a
pressure 5 psi higher than the upper limit of the output
pressure range. Maximum inlet pressme to the Type 67FR
regulator is 250 psig. Maximum supply pressure to the
positioner is 50 psig.

The positioner is capable of applying its full
supply pressure to the actuator. Therefore, max-
imum supply pressure must not exceed the
pressure rating of the actuator. or damage to the
actuafor and personal injury may result.
Vent
The screened opening in the side of the case marked
“VENT” should be left open to prevent a pressure buildup in-
side the case and also to provide a way to purge the case. If
it is necessan/ to pipe away the vent, remove the screens in
the case and relay vents. Use a line size of at least 3/8-inch
pipe or l/2-inch tubing in the case vent. Place a pipe plug in
the relay vent.
OPERATING ADJUSTMENTS
Make the zero and span adjustments as indicated below.
Key numbers used in this procedure are shown in figure 8.
1 CAUTION 1 below.
To avoid damage to the mechanical feedback
linkage, make sure the section “Turnbuckle
Assembly and Alignment” has been performed
before applying input signal or supply pressure
to the positioner or actuator.
1. Apply supply pressure to the positioner.
2. Check actuator starting point by applying the lower
range limit of the input signal (upper range limits for reverse-
acting positioners). Adjust the zero screw as necessary to
position the actuator et its starting point. The zero screw is
located et the side of the positioner. The cover (key 13) must
be moved to expose the zero screw.
3. To adjust the span, apply the upper range limit of input
signal llower range limit for reverse-acting positioners).
Observe the actuator travel to determine that the actuator is
et the opposite end of the travel achieved in step 2 and et
full travel. If Lees than full travel results, increase travel by
loosening the locking screw (key 29) and rotating the adjust-
ment gear (key 26) to move the adjustment clamp (key 25)
toward a larger number on the travel scale. If the travel set-
ting is greater than maximum actuator travel, and the ac-
tuator achieves full travel with less than the upper range
limit of the input signal (more than the lower range limit for
reverse-acting positioners), decrease travel by moving the
adjustment clamp toward a smaller number on the travel
scale.
1 T y p e s 3 5 9 0 , 4, a n d -ST 1
Travel settings less than maximum actuator
travel may result in damage to the travel arm
(key 191 if the feedback arm (key 161 contecte
the travel stop before actuator travel is com-
plete. (In figure 8. the travel stop appears es a
circle between the travel arm and the Type 83H
relay.) If it is necessary to make a travel setting
slightly less than maximum actuator travel, vary
the input signal very slowly while observing the
travel arm (key 16). Turn off the input signal if it
appears that the arm will contact the stop before
actuator travel is complete. A travel setting that
is less than maximum actuator travel may be
made only if the travel arm does not contact the
stop at full actuator travel.
4. Repeat steps 2 and 3 until the correct travel is achieved.
SPLIT-RANGE OPERATION
Split-range operation of the positioner can be accomplished
using either of Tao methods~ es described in steps 1 and 2
Zero and span adjustments are required after
performing either procedure; refer to the
“Operating Adjustments” section.
1. Change the feedback spring from full range to half or
quarter range (see table 5). With the half- or quarter-renge
feedback spring. an input signal change equal to one-half or
one-quarter. respectively, of the full input signal span will
cause a full change in positioner output. For example, using
the half-range spring in an equal two-way split with a 4 to
20 milliamp signal. one control valve would be set to stroke
completely on 4 to 12 milliamps, while the other valve
would stroke on 12 to 20 milliamps.
Change the feedback spring es follows:
a. Shut off supply pressure and input signal to
positioner.
b. Unscrew positioner cover (key 5, figure 8). Unhook
feedback spring (key 30. figure 81 from feedback lever (key
15. figure 81 and spring anchor (key 51. figure 91.
c. Replace the desired spring. Use care to avoid
damaging spring when installing.
7
 Types 3590, 4, and -ST

Table 5. FeedbackSnrinos

2. With any feedback spring, split the input signal equally

or in various ranges using the charts in figure 6 to obtain the
correct travel sening. Proceed as follows:
To avoid damage tp the mechanical feedback
a. Calculate “f.” the percent of full input signal with linkage, “ever use a travel sening less than the
which it is desired to stroke the valve fully. For example, if a maximum actuator travel.
positioner with a standard 4 to 20 milliamp input signal is to
stroke a valve 3 inches with a” input signal of 4 to 16
milliamps. the calculation would be:

f=
12mA
= y$- (1001
= 75%
b. Use the appropriate chart in figure 6 to determine
the valve travel setting required for the split-range
application. For the example given above, use the full-range
spring chart for part number 1 V4139 42082. Enter the chart
at a valve travel of 3 inches. Move upward tp intersect with
the line marked “f = 7596” Move horizontally from this
intersection and obtain a travel setting of 4. Thus, it is
possible to operate a valve having 3 inches of travel with an
input signal of 4 to 16 milliamps. using the full-range
feedback spring, if the travel setting is at 4 on the scale.
REVERSING POSITIONER
ACTION
Note
Action of Type 3590s and 3590ST positioners
is not field reversible. If the input signal wire
connections on these types are reversed, the
positioner will not operate.
No additional parts are required to convert a Type 3590
positioner from direct acting to reverse acting, or vice versa.
To change the action, simply reverse the input wires. After
changing the action, it is necessary tp adjust the zerp
sening: follow the instructions given in the “Operating
Adjustments” section.

8
 pressure in the relay. The decreased pressure on the relay
diaphragm decreases the output pressure to the Type 657
PRINCIPLE OF OPERATION actuator diaphragm, permitting the stem to move upward.
Stem movement is fed back to the armature by the
mechanical feedback linkage and feedback spring, which
Refer to the operational schematic in figure 7. increasing the
causes the armature to rotate toward the nozzle. A further
input signal to the coils rotates the armature of the torque
decrease in nozzle pressure is stopped. and additional
motor about the fixed torsion rod and covers the nozzle. The
actuator stem movement is’ prevented. The positioner is
resulting nozzle restriction produces an increased pressure in
once again in a steady-state condition.
the relay.
Reverse-acting positioners operate in a similar manner.
The incresed pressure on the relay diaphragm forces the
except that when the input signal increases, the output
exhaust valve plug down. As the exhaust valve plug moves
pressure from the relay decreases. Conversely, a decreasing
down, the exhaust valve plug stern pushes the supply valve
input signal increases the output preawre.
plug stem to open the supply valve plug and increase output
pressure to the actuator diaphragm. In response to large
input signal increases, the exhaust valve plug closes. and the
exhaust valve plug stem continues to move through the MAINTENANCE
exhaust valve plug to open the supply valve plug and
increase the output pressure. The overlapped opening of the
exhaust and supply valve plugs determines the gain of the
relay. Adjustment of the overlapped opening of these plugs
is made at the factory, and the relay seat ring assembly is
sealed in position to lock the adjustment. To avoid personal injury and damage to the
process system. isolate the control valve from
The increased pressure to the Type 657 actuator diaphragm the system, shut off input signal and supply
moves the actuator stem downward. Stem movement is fed pressure, and release pressure from the control
back to the armature by the mechanical feedback linkage valve and actuator before attempting any
and feedback spring, which causes the armature to rotate disassembly or repair.
away from the nozzle. A further increase in nozzle pressure
is stopped, and additional actuator atem movement is In case of operational difficulties, check the positioner for
prevented. The positioner is once again at a steady-state the following items:
condition but at a higher input signal and a new actuator
sfem position. 1. Proper zero and span adjustments for travel of valve:
see the section “Operating Adjustments”
When the input signal decreases, the armature rotates about
the fixed torsion rod and uncovers the nozzle. decreasing the 2. Controller output reaching the positioner
 Types 3590, 4, and -ST
3. Leaks in pressure lines and connections
4. Leaks in pneumatic relay, its diaphragm, and O-rings.
Leaks in torque motor O-ring lkey 57. figure9) and manifold
O-ring (key 9A. figure 81
5. Metal chips in the air gap between the armature and
the pole pieces in torque motor assembly will limit armature
travel and reduce the flux across the air gap, which will
shorten the span and cause erratic operation. Blow out any
chips with low-pressure air.
6. Open dripwell petcock of the Type 67FR filter-regulator
periodically to drain moisture.
Torque Motor
The torque motor assembly, which consists of permanent
magnets. pole pieces, torque motor mounting plate, etc..
should never be disassembled because the level of mag-
netism in the magnets will decrease, and will not return upon
reassembly. Consequently, it will not be possible to obtain
proper span. If it is known that the torque motor is faulty.
replace the entire motor with a new one and return the
faulty torque motor to the factory for repairs. Figure 9 shows
the torque motor and associated parts. Shaded key numbers
indicate the parts that must not be disassembled from the
torque motor. Do not attempt repairs on the torque motor
assembly.
Relay Repairing and Cleaning
Shaded key numbers in figure 10 indicate parts that are not
available es replacement parts. If it is necessary to replace
parts other than the diaphragm (key 4) and O-rings (keys 13.
14. 15, and 171, purchase a complete relay assembly ae a
spare part. To replace the diaphragm and O-rings or to clean
the relay, proceed as follows. Key numbers used in this
procedure are shown in figure 10.
Do not attempt to adjust the valve plug in the
seat ring assembly (key 71, to dissassemble the
seat ring assembly. or to remove the seat ring
assembly from the body (key 1). Performing any
of these operations will disturb the relay
adjustment made at the factory. This adjustment
cannot be made in the field, and the relay will
not function properly if the adjustment is
disturbed. Purchase a complete relay if
replacement is required.
1. Unscrew two mounting screws (key 101 and remove
relay from positioner.
2. Remove four screws that hold the three body sections
together.
3. Separate the sections: body assembly (key 11, relay
base (key 21. and cap ikey 31.
4. Use care to avoid losing O-rings
5. The diaphragm (key 4). diaphragm head (key 5). relay
spring (key 6). washer (key 8). spring washer (key 91. and
shim washers (key 18) can all be separated. Use care to
avoid losing the shim washers.
6. Unscrew the nozzle adaptor assembly (key 16).
7. With the relay disassembled, check all parts for wear. If
necessan/. clean the fixed restriction with a 0.016~inch
diameter or smaller wire. The fixed restriction is located in
the nozzle adaptor assembly (key 16).
8. If the relay is to be cleaned, use only a solvent that will
not damage the nitrile O-rings.
9. Reassemble using a new diaphragm and O-rings where
required. Follow the assembly drawing in figure 10, paying
particular attention to the positioning of the diaphragm so
that all holes line up properly. Also, the three body sections
should be positioned eo that the lug on the outside of each
section is in line with the others. Install and tighten four
screws to complete the assembly.
10. Install two mounting screws (key 10) and replace
relay on positioner case. making sure the,O-rings (keys 14
and 15) are in good condition and in place.
Replacing travel Arm Assembly
If the travel arm assembly (key 19. figure 8) has been
damaged. replace it as follows. Key numbers used in this
procedure are shown in figure 8 except where indicated.
1. Shut off and disconnect positioner pressure lines.
For applications requiring an explosion-proof
positioner. open the input signal circuit before
disconnecting the electrical conduit connection
from the positioner. The positioner is not
explosion proof if the input circuit is live and the
conduit connection is disconnected.
Disconnect conduit connection from positioner. Remove
positioner cover (key 5) and disconnect input signal wires
from terminal strip.
2. Remove rear cover from positioner.
3. Remove one E-ring (key 86, figures 2 and 31 from upper
clevis (key 84, figures 2 and 3). Pull clevis pin (key 85.
figures 2 and 31 out of clevis.
 Types 3590, 4, and -ST

4. Three cap screws secure the positioner to the mounting b e n t a t a r i g h t a n g l e t o t h e s p r i n g a x i s contacts the
plate (key 93, figures 2 and 3). Unscrew the mounting plate projection on the back of the positioner.
cap screw located near the bottom of the positioner and the
To ensure proper spring installation, rotate the travel arm a
mounting plate cap screw located nearest the actuator.
few degrees counterclockwise (when viewed from back of
Loosen, but do not remove, the remaining mounting plate
positioner) around the pivot formed by the cap screw (key
cap screw. Using the cap screw as a pivot, rotate the
20). If the spring is properly installed, it will be possible to
positioner away from the actuator to expose the rear of the
rotate the arm counterclockwise against spring torque. and
positioner.
the spring will return the travel arm clockwise against a stop.

5. Unscrew two machine screws (key 22) and remove arm

10. Attach arm (key 21) with two machine screws (key
(key 21).
22).

6. Unscrew and remove cap screw (key 20). Remove

11. Rotate positioner back into place and secure with
travel arm. spring (key 231, and adjustment block assembly
three mounting plate cap screws.
(key 24).

12. When connecting the arm (key 211 to the upper clevis
7. Unscrew machine screws (keys 28 and 29) to release
(key 84, figures 2 and 3). refer to the “Turnbuckle Assembly
adjustment block. adjustment clamp. and gear (keys 24,25,
and Alignment” section for instructions. When making
and 261. Inspect these pans; replace with new pans if
electrical and pressure connections, refer to the appropriate
“eCSSCiW.
sections of the “Installation” section.

Making certain that the travel increments on the travel arm

Re-adjust the positioner per the “Operating Adjustments”
will be visible through the V-notch opening in the clamp.
section.
assemble the gear, block assembly, and clamp to the new
navel arm.

8. Slide spring (key 23) onto the hub of the travel arm.
Make certain the end of the spring that enends parallel with
the spring axis is inserted into the mating hole in the travel
arm.
9. When installing the travel arm and spring on the
positioner. make certain the feedback rod (key 16) makes
contact with the knife-edge surface on the gear assembly
(key 26). Also make certain that the end of the spring that is
SERIAL NUMBER
When corresponding with the sales representative about this
equipment, always state the serial number of the unit. The
serial number is stamped on the nameplate (key 7. figure 8).
When ordering replacement parts. also specify the complete
eleven-character part number of each part required as
shown in the following parts list.

PARTS LIST

15

16
Torque motor and relay 17
18
p a r t s f o r w h i c h n o part
numbers appear are not 19
field replaceable and must 20
not be removed. Order a 21
22
complete torque motor or
relay if replacement of
these parts is necessav.
 Figure 8. Positioner Assembly

KSY KW osrtiption
30 Torque Motor
35
37
31’ 38
32’
33 39
40
41
Type 83H Relay
33.1
42

43
44
45
46

47
48
49
SO
51

33.2 52
53
34 54

12
 Types 3590, 4, and -ST

‘ppq

Figure 10. Type 83H Relay

 1 Types 3590, 4, and -ST 1

Key
82

Universal Mounting Parts

83

84
 Type 3590s

Fisher Controls intrinsically Safe Loop Schematics

wpe 3590s
Electro.Pneumatic
Valve Positioner

December 1994 Form 5358

Loop Schematics
This document includes loop schematics required for wir-
ing of intrinsically safe installations. If you have any ques-
tions, contact your Fisher Controls sales representative or
sales office.

CSA Schematics
Type 3590s

CSA Schematics (Continued)

 Type 3590s

FM Schematics

3
Type 3590s

[FISHERY Fisher Controls