Control Valves Maintenance

UTILITIES EQUIPMENT MAINTENANCE
CONTROL VALVES MAINTENANCE
Sec. 4 : CONTROL VALVES MlNTENANCE
LIST O F CONTENTS
PART 1 PREVENTIVE MAINTENANCE
1- INTRODUCTION *
2- PRIOR T O START-UP
3- A F T E R START-UP
PART 2 SHOP O V E R H A U L
1 DECONTAMINATION
2- DISASSEMBLY OF VALVES
3- DISASSEMBLY OFT H E ACTUATOR
4- R E A S S E M B L Y O F T H E V A L V E AND A C T U A T O R
5- T E S T AND A D J U S T M E N T
PART 3 MAINTENANCE GUIDELINES FOR CERTAIN VALVES
1- FIELD MAINTENANCE
1-1 T E S T I N G A N I N S T A L L E D G L O B E V A L V E F O R L E A K S
1- 2 I N S T A L L I N G P A C K I N G IN T H E F I E L D
2- WORKSHOP MAINTENANCE
2- 1 G L O B E V A L V E S
2-1-1 Removing Bonnet
2-1-2 Stem Replacement
2-1-3 Removing Scat Rings
2-1-4 Lapping
2-1-5 Beginning Reassembly
2-1-6 Completing Reassembly
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2-2 C A G E V A L V E S ( T O P E N T R Y )
2-2-1 Introduction
2-2-2 Disassembly & Reassembly
2-3 B U T T E R F L Y V A L V E S
2-3-1 Separating The Valve Body From Actuator
2-3-2 Disc And Shaft Removal
2-3-3 Cleaning And Inspection
2-3-4 Reassembly
2- 4 B A L L V A L V E S
2-4-1 Disassembling A Ball Valve
2-4-2 Inspection And Cleaning
2- 4-3 Reassembling a Ball Valve
3- ACTUATOR WORKSHOP MAINTENANCE
3- 1 D I A P H R A G M A C T U A T O R
3- 1-1 Disassembly
3-1-2 Inspection
3-1-3 Reassembly
3-1-4 Calibration And Checks
3-2 P I S T O N A C T U A T O R S
3-2-1 Piston Actuator Disassembly
3-2-3 Replacing Seals
3-2-4 Actuator Reassembly
3-2-5 Calibration
3-3 E L E C T R I C M O T O R A C T U A T O R
3-3-1 Inspecting The Drive Train
3-3-2 Aligning Motor With The Valve
3-3-3 Adjusting The Limit Switches
LIST OF DRAWINGS
SEC. FIG.
4-2 1 M A N U F A C T U R E R S B E V E L O F 60° O N T H E S E A T R I N G
AND 65° O N T H E P L U G
4-2 2 RE-MACHINED SURFACES OF A REPAIRED VALVE, WITH
B E V E L O F 60° ON T H E S E A T R I N G A N D 59° O N T H E P L U G
4-3 1 C O M P L E T E A C T U A T O R AND V A L V E A S S E M B L Y
4-3 2 S H A F T AND D I S C A S S E M B L Y
4-3 3 BALL CLOSURE ELEMENTS
4-3 4 MOTORIZED ACTUATOR DETAILS
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Sec. 4 : C O N T R O L V A L V E S M A I N T E N A N C E
INTRODUCTION
The control valve is very often the most costly element in a control loop. As a part
of the process stream, it is also the element most likely to cause process down-time in the
event of malfunction. These reasons alone provide the justification for a conscientious
control valve maintenance program.
Control valve maintenance is generally divided into two categories. The first is
preventive maintenance, which involves the installation precautions taken and the inline
follow-up of the valve's performance and environmental deterioration while in service.
The-second is the overhaul of a control valve when it is no longer able to perform
satisfactorily. The latter phase Is generally a shop repair, but in some industries, it is
performed in the pipeline, under controlled shut-down conditions.
Control valve manufacturers provide detailed installation and overhaul

instructions for every type of control valve they produce. This chapter is not intended to
replace these manufacturers' instructions. Instead, it is intended to impart a general
knowledge of control valve maintenance requirements.
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CONTROL V A L V E S MAINTENANCE
PART 1 PREVENTIVE MAINTENANCE
1- INTRODUCTION
Preventive maintenance is a term used to identify a program of scheduled

overhaul, prior to failure. The schedule is usually based on previous knowledge of
performance in a given service and is such, that a maximum* safe in-time is established to
minimize the chance of unexpected breakdown. Repair effected under such a program
for control valves is a shop overhaul, and will be described later in this chapter. Because
of this, the term preventive maintenance is being used here to describe the work, which
should be done during installation and operation to prevent the untimely breakdown of
a control valve, ahead of schedule.
2- PRIOR TO START-UP
The preventive maintenance of a properly specified control valve begins at the time
of installation. While the body and connections of a control valve are indeed rugged
structures, they are not intended to be the means of aligning improperly fitted pipe.
Care must be taken to insure that any stresses caused by improper pipe alignment arc
relieved elsewhere in the pipe system. Pipeline stresses on a control valve may result in
misalignment of the stem, guide, and seat system of the valve and, in the case of a split
body valve, may cause separation of body flanges. This may cause hysteresis leak
through in the seat or flanges and possibly packing leakage.
Every effort should be made to install control valves so that their stems travel in a
vertical plane with the diaphragm housing above the body. If a valve must be installed
with the stem traveling in a horizontal plane support braces should be provided to
support the diaphragm housing. A n unsupported valve may have stem misalignment
resulting in unacceptable hysteresis and packing leakage. Control valves should be
located so they are accessible for periodic inspection and adjustment. Access ladders and
platforms may be used for this purpose.
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Prior to start-up it should be determined if the control valve is to be the collection

point for line trash such as rust weld slag and other foreign objects if so temporary
screens or strainers should be considered for installation immediately upstream. A well
lapped seat may be ruined by one small piece of slag in the valve when the valve is trying
to close. If the process stream may normally contain scale dirt or other hard foreign
matter the installation of permanent-type strainers or filters should be considered. (i
Control valve diaphragm housings are not air consumers. They are howevcV
collectors of liquids and other foreign matter in the air system. A clean dry oil-fr'ê
source of air should be selected to operate the control valve. Valves with positioners Or
booster relays attached are particularly susceptible to failure when exposed to unclean
air systems.
3- A F T E R START-UP
After start-up periodic field inspection of the control valve installation should be
made. The packing will usually require adjustment after a short period in service and
the lubricators will require readjusting. Dusty or dirty conditions may require a plastic
or rubber boot to be placed around the stem to protect the packing gland and/or the
guides in the bottom of the diaphragm housing. Corrosive fume conditions or process
drippings may require additional special protection for the control valve. Plastic bags
are often an easy solution to this problem since they may be used to completely enclose a
valve without affecting its performance. Installation accessories such as lagging or
tracing should be inspected and repaired because these usually have a major effect on a
control valve's performance. '
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Certainly, it is not possible to describe every installation or m-servicc potential
failure situation in this writing. These more common situations provide the basis fo|j a
good control valve preventive maintenance program and, together with the experience
gained in any plant situation, will aid in extending the useful life of a control valve
between overhauls. !
GonJro/X)a/iHis Dltainjimance
CONTROL VALVES jvMAINTENANCE lj.

Sec. 4 : C O N T R O L V A L V E S M A I N T E N A N C E I
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PART 2 SHOP O V E R H A U L V;
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1 DECONTAMINATION ;
The control valve that has been removed from the line for overhaul poses a special
problem to the maintenance organization. This component has been a part of the
process piping and may be contaminated with the process fluid. Certainly, a valve in
water, steam, air, inert has, etc., service is no problem and may be overhauled
immediately, however, many fluids used in modern processing are corrosive, explosive^
radioactive, or, in other ways, hazardous to personnel, or equipment. Such |
contamination must be removed from all process wetted parts of the valve before it can
enter a modern repair shop and before it can be handled by personnel unfamiliar with
such process hazards.
The actual decontamination treatment of the wetted parts will vary, depending on
the nature of the process fluid. Many times, only a thorough water-wash or steaming of
the parts will suffice, while other contaminants may require acid washing or even a
special heat treatment of several hundred degree-hoursâs is the case with some heavji
metal compounds. The required treatment, hi list be determined by someone familiar
with the nature of the contaminant. Facilities for control valve decontamination will
vary, depending on the type of contaminants involved. Location of the facilities should
be chosen so that cross contamination of oth'pj* locations or facilities is avoided. This
usually means a site remote from the operation'and the repair facilities.
Since decontamination applies to the wetted parts of the control valve, disassembly
of the body and bonnet components is required. Facilities for this work must be
provided. These always include lifting and transporting equipment for handling valves
during disassembly. '
A n air supply is essential to stroke the valves (operate the valves) to prevent
further scat damage during stem and plug rcmoyal. A i r is also useful for pneumatic tools
and, in some cases, is needed for health reasons such as breathing air or chemical suit
purging. The need for weather protection will depend upon the need for uninterrupted
use of the decontamination facilities. If weather protection is provided, then good
lighting and ventilation become essential. The need for tanks or vats, heating facilities,
steam hoses and other washing or treating equipment can be determined only after the
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nature of the contaminant is known. Consideration should be given to maintaining
exclusive tool kits and wearing apparel for use at the decontamination site.
Special attention must be given to the selection of the personnel who will do the
decontamination service. Because of th6 generally dirty nature of the wor k, (
decontamination is an undesirable job. It is extremely essential that the employee who is

disassembling a control valve for decontamination, thoroughly understands the control
valve, as well as the nature of the chemical hazards involved, in order to avoid personal
injury. It is also important that the details of construction be understood, to aôid
further deterioration or damage to the control valve during disassembly. Such things as
whether or not bellows seals are involved, whether the plug and stem are removed from
the top or bottom of the body, if the seats are threaded into the body or otherwise
retained, will affect the actual disassembly procedure.
Many expensive bellows* seals, for instance, have been destroyed by unsuspecting
mechanics trying to improperly remove them. It is further essential that the location of
all blind passages in the body or bonnet be known so that they may be thoroughly
cleaned. The precision finished surfaces, such as the stem, plug facing, scat surfaces,'and
guide surfaces, must be protected from-further damage to minimize the overhaul costs.
Skill in the use of special tools, such as packing ring pullers, seat ring extractors or
flange spreaders, is essential to prevent misuse and resulting damage to the valve. ^
When all of the process wetted parts of the control valve are free of contamination,
the valve should be reassembled, finger-tight, to assure that no components are lost
during transit to the repair shop. Prior to shipment to the shop, the valve should be
marked in some obvious manner to indicate that it has been decontaminated.
This procedure aids in preventing a contaminated valve from being delivered to
the repair shop and worked on be unsuspecting personnel. !
2- DISASSEMBLY OF VALVES
The decontaminated control valve should arrive at the repair shop accompanied by
a job card which gives as much information as possible about the valve and its service in
the process.
The first step in the overhaul of a control valve is to mark the actuator connection
orientation, in relation to the body flanges. A complete disassembly is next. This mcjans,
that after separating the actuator from the bonnet, and the bonnet from the bodyj the
actuator is to be disassembled completely. The bonnet and packing gland components
are separated, the plug and stem, as well as the blind head flange, arc removed from the
body.
An inspection of all components should be made at this time to determine the
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extent of repair, reconditioning and replacement that js required. In many cases, all of
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the exposed surfaces of the valve components are rusty and unfit for repainting. These
parts should be descaled before proceeding. Sand blasting equipment is especially good
for this, <?are must be taken, before descaling, to protect all of the machined surfaces
such as flange faces. This protection can be heavy masking tape for sand-blasting, or it
may require a special grease coating if acid washes arc to be used.
After the descaling has been completed, the need for any machine work should be
determined. The body and trim will most likely require the services of a machinist. All of
the flange surfaces should be inspected for damage that would prevent proper gasket
sealing. Generally, such damage will be in the form of scratches or grooves across the
flange face, from the process side to the outside.
Seat rings that are screwed into t'he body should he given special attention to
determine if replacement is necessary. Wire drawing, corrosion and erosion arc usually
the reason for replacing seat rings, other than to change the capacity of the valve. Small
pitting and worn surfaces are usually repaired by machining.
Many manufacturers machine a 60° bevel on the seating edge of the seat ring and
a 65° bevel on the seating edge of the plug, as shown in Fig. 1, This causes the actual seat
contact to be at the top of the bore of the seat ring. This arrangement is satisfactory for
a new control valve, however, a control valve that is in need of repair will often have the
bore of the seat ring, worn non-uniformly. Restoring concentricity would require
enlarging the bore of the seal ring, which will further increase the capacity of the valve,
as well as alter its flow characteristic.
S E C . 4-2 Fig. I M A N U F A C T U R E R S B E V E L O F 60° ON T H E S E A T R I N G

AND 65° O N T H E P L U G
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One solution to this problem, other than discarding an otherwise reusable seat
ring, is to machine a new surface on the face of the seat ring at a 60° bevel, andjto
change the bevel on the plug from 65° to 5 9 ° , as shown in Fig. 2. This causes the seating
contact to change to the top of the seat ring bevel, which can be remachined uniforrnly
without further affecting the valves capacity or the characteristic of the plug seat ring
contact. *
S E C . 4-2 Fig. 2 RE-MACHINED SURFACES O FA REPAIRED VALVE, WITH

. B E V E L O F 60° O N T H E S E A T R I N G A N D 59° O N T H E P L U G
If threaded seat rings are to be replaced, this should be done before any machine
work is done on the body. All too often, forces required to tighten a new seat ring will
cause distortion of the body. Concentricity must be restored or the valve will never close
tightly. Restoration of seat concentricity is best accomplished by using a lathe.
The removal and replacement of threaded seat rings require special tool sets. Most
control valve manufacturers produce sets to fit their valves. Threaded scat rings very
often require some type of thread sealing compound to prevent leakage through the
threaded area. Not only will such leakage prevent tight shut-off of the flow, but the
resulting erosion and wear will also cause irreparable damage to the valve body.
Whenever possible, the valve manufacturer should be consulted for

recommendations of sealing compounds for a particular service. I f the manufacturers
advice is not available, someone familiar with the process chemistry should be consulted
before applying any of the commercially available sealing compounds.
When the necessary machining has been completed, the components arc ready for
painting. Paint specifications for a control valve should be the same as that for other
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machinery in the process line. Proper masking will prevent the paint from being applied
to gasket surfaces. I
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Valve plugs, stems, and seat rings represent some of the most precisely machjncd
parts in the field of instrumentation. The finish on control valve stems is so fine that
replacement with a factory supplied part is the only practical solution to a marred stem
surface. This high polish is required to give the best possible packing seal with a
minimum amount of hysteresis. The plug and seat ring, of course, have to be perfectly
matched, first through precise machining and finally through hand grinding.
Grinding or "lapping" the plug and seat of a control valve requires more skill and
knowledge of the craftsman than any other phase of the overhaul, except perhaps, any
machining that may be required. It must first be determined that the faults in the
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seating surfaces can be economically corrected by lapping rather than requiring

replacement or remachining, if neither has been done. Alignment of the plug to the seat
is absolutely essential for uniform seating. This generally requires that all guides be in
place before the lapping operation begins.
Most of the commercially available valve grinding compound sets, which contain a
coarse and a fine compound, arc satisfactory for control valve lapping. The coarse
compound should be used until a fine, continuous line is produced around the seating
edges of the plug and seat ring. After thoroughly cleaning all of the coarse compound
from the valve, the fine compound should be used to polish this seating seal line.
When the lapping operation has been completed, it is absolutely essential that all of
the grinding compound be cleaned from the valve. Satisfactory flow shut-off and smooth
operation of the plug and stem arc dependent on the alignment of the plug in the seat
ring. Guides are provided to assure excellent alignment. Some valves have guides both
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below and above the seat ring while others are simply top guided. These guides, in order
to accomplish their mission, must be machined to a tolerance close to that of the guide
shoulder on the plug stem assembly. Any corrosion or wear that destroys the close fit
renders the guide useless.
Some guides are threaded into place while others arc pressed into place.
Replacement of threaded guides is straightforward, but pressed guides must be forcibly
removed. Various methods work well for this operation. Press type removal equipment is
preferable, if available, differential heat methods, for expansion of the guide holder and
contraction of the guide, will work. This latter method must be used with care in order
that permanent damage not be done to the guide holder. New guides can usually be
pressed in place with a bench vise.
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3- DISASSEMBLY OFTHE ACTUATOR j
The control valve actuator, after having been completely disassembled, should be
carefully inspected, component by component. Cast steel yokes should be examined for
any signs of cracking since all of the valve stroking force is transmitted through ttyis
component. Corrosion that either weakens or causes misfitting of components is cause
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for parts replacement.
The diaphragm should be examined for any signs of cracking, hardening or
abrasion to indicate possible future failure. The same surface preparation and painting
procedure used on the body components should be applied to the actuator components.
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All threaded parts should have the threads dressed for smooth assembly and
adjustment. It is generally more profitable to discard all diaphragm case bolts and
replace them with new ones. Reverse-acting actuators should have any stem seals
replaced with new ones.
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4- R E A S S E M B L Y O F T H E V A L V E AND A C T U A T O R
Reassembly of the control valve body is a straightforward operation. The chief

points of concern are that gaskets are used of proper size and material and properly
centered, and, that bolts or studs are used of proper size, length and material. When
tightening the bonnet and the blind-head flanges to the body, it is important to tighten
diagonally opposite bolts evenly, to assure an even loading on the gasket, thus
preventing flange leakage.
The valve manufacturers recommendations for proper torque loading of the

particular bolts or studs should be adhered to when tightening the body bolts or studs.
Over tightening will cause excessive elongation, resulting in a weakened flange joint.
The depth of the packing gland should be measured to determine the proper
number of packing rings. Preformed packing rings should be used whenever possible.
These are commercially available in most materials and sizes. Their uniformity assures
the best possible seal in the gland. I f a lantern gland is used, enough rings of packing
should be placed beneath it, to assure that it will mate with the lubrication port in the
gland housing. Packing rings should be inserted one at a time and each should be lightly
tapped into place. Do not pound packing rings.
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Pounding distorts the rings and causes them to lose their resilience. When the
gland has been filled with the predetermined number of packing rings, the follower and
yoke should be installed, finger tight, for hysteresis testingoftheassembledvaIve.lt
should be noted that special packings, such as Chevron sets, and special spring loaded
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glands would be assembled differently. The manufacturers instructions for these special
packings must be followed if a good gland seal is to be expected.
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Reassembly of the actuator should include the application of a suitable lubricant to
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all friction points. These include the stem where it passes through guides and seals, the
spring thrust bearings and retainers, and the spring adjusting nuts.
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5- T E S T AND A D J U S T M E N T
When the reassembly has been completed, the diaphragm case should be leak
tested. This is most easily accomplished by loading the diaphragm chamber with 45 psig
of air (do not exceed the manufacturers rating for the case) and leak testing around the
flange edge with a soap solution. A hysteresis test of the actuator should be made before
it is mated with the body assembly, to determine that there is no binding of components
within the actuator.
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The hysteresis test may be made by attaching a clamp-on arm to the exposed,
movable portion of the stem and by attaching a micrometer gauge to the immovable
yoke or spring barrel. The micrometer gauge must, of course, have as much travel
capacity as the stem. After zeroing the micrometer gauge to the at-rest position of the
stem, record the air loading pressure required to stroke the actuator at every 10%
increment of its travel. Then, while returning the stem to the at rest position, record the
air loading at every 10% increment of travel. !
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Compare the recorded air loading pressures in the two directions, for e'ach
increment of travel. The, differential; pressure between the two readings at each
increment, should not exceed 0.1 psi. Differential pressures greater than 0.1 psi, indicate
an intolerable friction condition, within'the actuator assembly, which must be corrected,
even if complete disassembly and reassembly of the actuator is required.
The assembled and tested actuator may be mated to the valve body with the
hysteresis test equipment attached, because a final assembly hysteresis test will be made
later. When mating the actuator to the body, it is important that the air connections on
the actuator be oriented to the body flanges, exactly as they were before disassembly.
This will allow the valve to be reinstalled into the pipeline, without requiring any
alterations to the field tubing or piping assembly.
The full travel loading pressure, required for any control valve, is a function of the
diaphragm effective area versus the stem loading (the accumulation of the spring
loading and the plug area times the shutoff differential pressure across the plug). Rarely
will these factors result in an ideal 15 psi (30 psi for a 6 to 30 psi control system) full
travel, diaphragm pressure.
If the full travel diaphragm" pressure requirement is less than 12 psi or more th an (
18 psi for a 3 to 15 psi control system (24 psi to 36 psi for a 6 to 30 psi control system),
and if the valve is not normally equipped with a valve positioner, then consideration
should be given to changing either the size of the actuator or the size of the actuator
spring.
When the stroke and spring compression have been properly adjusted, a final
hysteresis check should be made on the actuator. This is done with the packing loose and
with no pressure differential across the valve. This test is to determine that proper
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alignment of all the components has been obtained.
The test should be run on the complete assembly, just as it was run on the
actuator. The hysteresis differential pressure of a properly assembled control valve
should not exceed 0.25 psi under these testing conditions. Higher differential pressures
indicate that binding is occurring somewhere within the inner valve mechanism. The
degree of binding is indicated by the magnitude of the loading pressure differentials
obtained during the test.
Upon completion of a satisfactory hysteresis test, the valve body should be filled
with a test fluid with the stem at mid-travel. The test fluid pressure within the body
should be raised to the maximum process operating pressure and the packing should be
tightened only enough to stop leakage. The stem should be stroked continuously, while
the packing is being tightened, to properly seat the packing and to prevent stem binding.
Note : Special packings previously mentioned should be adjusted according to

the manufacturers recommendations. While the packing is being
adjusted, the body should be examined for external leaks.
Metal-to-metal seated diaphragm control valves are not tight shut-off devices.
They will all leak through the seat to some degree. Most manufacturers design and build
to a shut off condition that will allow no more than 0.1% of maximum flow capacity
leakage at the shut-off position for a double seated valve, and will allow no more than
0.01% of maximum flow capacity leakage for a single seated Valve. These leak rates jjan
be duplicated if reasonable care is exercised during the overhaul of a control valve.
Upon the completion of leak testing, any accessories that were a part of the valve
assembly should be reconditioned and installed on the valve.
Gan/ra/Uafoes DlCainJimanca
PART 3 MAINTENANCE GUIDELINES FOR CERTAIN VALVES
These guidelines are to stress some of the important issues mentioned in Part 1 and
Part 2, and to detail and clarify other issues for different control valve bodies and
actuators.
1- FIELD MAINTENANCE
1-1 T E S T I N G A N I N S T A L L E D G L O B E V A L V E F O R L E A K S
• Check the travel indicator to see what position the valve is in. If the
valve is not closed, call the control room and have it closed. Then check
the travel indicator again to confirm the position of the valve.
• Place a stethoscope probe on the process piping next to the outlet side of
the valve and listen for flow through the valve indicating excessive
leakage. In most cases, the normal amount of leakage for a closed valve
will not be audible through the stethoscope. Therefore, if you hear
sounds other than the sounds normally produced by the system, the
valve is probably leaking. j
• Call the control room and have the valve moved through its full stroke,
from fully closed, to fully opened, to fully closed. In some cases, leakage
may be caused by debris that is wedged between the plug and the seat.
If this is the case, taking the valve through its full stroke may flush out
the debris and correct the problem.
• Reposition the stethoscope probe and listen for leaks again. I f you hear
little or no leakage, the problem may have been corrected by flushing
the valve. If you still hear sounds indicating excessive leakage, follow
your facility procedures to correct the problem.
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1-2 I N S T A L L I N G P A C K I N G IN T H E F I E L D
One part often requiring replacement in globe valves is the packing. I f split-ring
packing is used in the valve, the packing may be able to be replaced in the field without
removing the valve from the process. This procedure usually includes the following steps.
• Check the valve to make sure it has been properly isolated.
• Remove any parts that restrict access to the valve stem, such as the dust
covers and indicator plates.
• Raise any parts that restrict access to the packing flange, such as the
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indicator disc.
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• Remove the packing flange nuts.
• Move the packing flange and packing follower up the stem and secure
them safely out of the way.
• Place a protective cover around the stem, if necessary. A plastic bag can
be used to protect the stem from dirt or process fluid,
• Remove the packing rings, one at a time, with the packing removal tool
Be careful to avoid scratching the stuffing box or the valve body witlj
the tool.
• Insert the new packing rings around the stem and push them into the
stuffing box. Be sure to offset the splits to prevent leakage. t
• Loosen the packing follower and packing flange and lower them back
into position.
• Reinstall the packing stud nuts and tighten them evenly.
• Lower the indicator disc and position it properly.
• Reinstall the dust covers and indicator plates.
After the valve has been put back into service, it may be necessary to adjust the
packing stud nuts. If leakage exists, the nuts may need to be tightened. If the stem does
not move smoothly or docs not move at all, the nuts probably need to be loosened.
GonJrxJDaliHis J/Cunlixiance
2- WORKSHOP MAINTENANCE
2-1 G L O B E V A L V E S
2-1-1 Removing Bonnet
Since the packing in the valve is compressed, the valve stem is held snugly in
place. The stem may be difficult to remove unless the packing is loosened. For
this reason :- j
• Loosen and remove the packing flange nuts.
• Remove the packing flange. Lift the flange straight up fr0m

bonnet to avoid damaging the stem.
Remove the packing follower.
• Before the bonnet is removed from the valve body match

marks should be made on the bonnet and the body to help return
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valve to its position when it is reinstalled in the field.
2-1-2 Stem Replacement
Stems with linear motion trims are to be replaced when they arc found bent
or scored.
2-1-3 Removing Seat Rings
A seat ring removal tool is to be used to loosen the threaded connection

between seat ring and the valve body. T u r n the too using short strokes, until
the seat ring has been loosened completely.
2-1-4 Lapping
The surfaces of the plug and the seat in a globe valve must form a tight seal
to prevent leakage. When sdat and plug arc reconditioned or when a hew
plug, seat or plug and scat are installed, the surfaces are usually lapped to
ensure a good seal, j
Lapping is usually done in several stages. A different grade, of lapping

compound is applied for each stage from coarse to fine until the proper
sealing surface is achieved. The number of stages that are required during
lapping usually depends on the condition of the plug and seat.
i
1
Lapping the parts is done inside the valve. The seat ring is installed in the
valve body and the stem and plug are installed in the bonnet. Sealiilg
compound should be applied to the threads of the seat ring before it is
installed in the valve body so that process fluid can not leak through the
thread and prevent seizing of the scat ring.
Lapping The Plug And Seat
For each stage in the lapping procedure, the plug is turned back and forth
against the seat so that the lapping compound can help the two surfaces mate
properly. The manufacturer will specify the number of strokes and the
turning sequence that are required, as well as the grade of lapping compound
that should be applied for each stage. One lapping procedure involves
lapping the plug and seat at four procedure involves lapping the plug and
scat at four points, 90° apart.
• Note the orientation of the lapping tool before you start.
• Turn the lapping tool back and forth the number of times
specified in the procedure. It is not necessary to press down on the
stem as you are turning. T h e combined weight of the plug, stem,
and lapping tool is sufficient to ensure proper contact between the
plug and the seat.
• Lift the lapping tool and turn the stem 90°. j
• Lower the plug back into the scat.
• T u r n the lapping tool the required number of times in the second

position.
• Repeat the previous steps until the valve stem has been returned
to its original position.
After each stage of lapping has been completed, the plug and scat should be
wiped down thoroughly before the next grade of lapping compound is
applied. This is done for several reasons :
• Lapping compound adheres more easily to a clean surface.
• The used compound will contain small bits of metal from the plug
and scat. These bits of metal could scratch or gouge the scaling
surfaces when the next lapping sequence is performed.
• Most lapping procedures involve going from a coarse grade of

compound to a finer grade of compound. If some of the coarser
GonJroIX)a/tKia Dlttiinltmance I
« fio i
•1)
i
compound were left on the plug and seat, these surfaces could be
lapped too deeply during the next stage.
The valve must be disassembled in order to clean the plug and scat:
® Remove (he body stud nuts. ;
• Lift off the assembly formed by the bonnet, stem and plug, an(l
lapping tool. Be careful not to hit the plug against the inside of the
valve body. '
• Wipe the plug and the scat thoroughly to remove any remaining
lapping compound.
After the plug and seat have been cleaned, the next grade of compound can
be applied to the plug. The valve can then be reassembled for the next
lapping sequence.
It is also important to clean the plug and seat thoroughly after the finajl
lapping sequence has been completed. If lapping compound were left on these
parts, the abrasive in the compound could scratch the mating surface an(I
damage the seal. This could cause leakage when the valve is put back on-line.
!
Use an approved solvent for cleaning.
The plug and seat should be carefully inspected. The sealing surfaces should
look smooth and shiny. Uneven surfaces, grooves, or scratches would indicate
that the parts were not lapped properly. This visual check is usually sufficient
to determine if the lapping procedure has worked properly. Sometimes, a
check called a bluing check is done if it is not obvious that the lapping
procedure has allowed the plug and seat to mate properly. This check
involves placing a special dye on the plug and then moving the plug back and
forth against the seat. If the surfaces of the plug and scat have not been
properly lapped, portions of the dye will remain untouched or uneven.
A bluing check is also sometimes done before lapping to see if lapping is

necessary. Check your facility procedures to see when bluing checks are
recommended.
2-1-5 Beginning Reassembly {
After lapping has been completed and the old packing has been remove^!
from the packing box, thoroughly inspect the packing box and clean it, if
necessary. Your facility procedures may also call for flushing or vacuuming
the valve at this point to remove any dirt or foreign material that
accumulated during the lapping procedure. Now the stem and plug can be
Gon/ra/Z)a/oas DltuinJimance
81
reinstalled in the bonnet and the valve can be reassembled. But, before
beginning, the gasket that is used to seal the connection between the bonnet
and the body should be installed,
i
Control valves arc often designed to use a special type of gasket, called a
spiral wound gasket. This type of gasket is made of several layers of spirally
wound laminated metal strips and filler material. Since spiral wound gaskets
are designed to be very resilient, they usually adjust easily to changesjin
operating conditions and can- usually withstand conditions where they are
exposed to vibration.
The procedure for reassembling a globe valve bonnet and body usually
includes these steps :
• Place the replacement gasket in the gasket groove. Tap the gasjtet
into place with your finger.
• Insert the stem and plug into the bonnet. The top portion ofihe
stem should be properly supported above the bonnet to avoid
damaging the threads.
• Lower the bonnet onto the body and align the match marks. Be
careful to support the stem and plug.
• Lower the stem and plug until the plug rests in the seat.
• Brush antiscizc compound on the threads of the body studs. Make

sure you cover all of the threads on each stud with the compound.
• Place the body stud nuts on the studs.
Torque The Nuts I
The body stud nuts should be torqued to ensure that the spiral wound gasket
will seal properly. Too little torque could cause a poor seal and leakage could
result. Too much torque could excessively deform the gasket.
One method of torquing is to use four stages. Thirty percent of the final
required torque is developed in each of the first three stages, following a
crisscross pattern. The final 10% is developed in the last stage. A clockwise
pattern is used during the final stage to ensure an even torque. It is
important to use the correct torquing pattern. Pressure must be applied
evenly to prevent the gasket from warping. As shown in bellow.
\
GanJra/Ua/t>G.i ^JiCainJonancti
NOTE
Zero the torque wrench before you start,

following the manufacturers procedures.
/a 2\
V 1
M 3] 3
(' )
\ 7
\fi A/
1st Stage 2nd Stage 3rd Stale 4lh Siayo

;
30% 30% 30% 10%
Crisscross Crisscross Crisscross Clockwise
2-1-6 Completing Reassembly

i
After the body stud nuts have been torqued, the remaining parts of the valve
can be installed.
• Place a cover over the threads of the stem to protect the packing
rings as they are installed. Nicks or scratches in the packing could
interfere with its sealing capability.
• Insert only one packing ring at a time. Slip the packing over the
stem and push it into place in the stuffing box with your finger.
• Install the spacer, if one is required.
• Insert the proper amount of packing above the spacer.
• Place the packing follower over the valve stem.
• Install the packing flange,
• Insert the packing flange studs and nuts. Some manufacturers

procedure does not call for tightening the flange nuts at this point.
The packing rings placed over the top of the stem could be split-ring packing.
This type of packing is designed to be split apart so that it can be installed
around the stem. When installing split-ring packing, the splits in the rings
should be offset from each other. This is done to prevent leakage. I f the splits
were lined up, they would form a path for fluid to leak through the packing
assembly. If you are installing split-ring packing during a valve overhaul, (he
GonJrxJ'OaAxit ^JlCainfiumnce
8*V • •'• •
packing should be installed over the top of (he stem to avoid excessive stress
on the rings.
SPLIT PACKING AROUND A STEM
2-2 C A G E V A L V E S ( T O P E N T R Y )
2-2-1 Introduction
The basic parts of a cage valve are similar to those of a globe valve, however
i
there are some differences. Cage valves have an additional part, called the
cage, that helps to guide the movement of the stem and plug. This part is
usually a hollow, metal cylinder.
The valve stem and plug move through the cage as the valve opens and closes.
There are ports in the walls of the cage to allow process fluid to flow through
the valve opening. ;
The seat-ring in a cage valve is normally compressed and held in place b^ the
cage, rather than tightly threaded to the valve body. A gasket is usually
located underneath the seat-ring. This gasket cushions the seat ring and
provide a seal against leakage. The packing assembly in cage valves differs. In
some cage valves, for example, there may be a spring to help compress the
packing and a wiper to clean the stem as it moves through the assembly.
Gan/ra/ZJa/tKzt UittiinJimaiicti -»
2-2-2 Disassembly & Reassembly
The advantage of this valve is that it can be disassembled in the field

(actually in place). The procedure is similar to the globe valve :
• Lift the cage out of the valve body. Hold the cage securely anjJ lift
it straight out of the valve to prevent damage. |
• Remove the gaskets from the top of the cage. |
• Lift out the seat ring. j
• Remove the seat ring gasket.
• Remove the bonnet gasket.
• Clean valve and inspect.
• Repair or replace pails as required.
• Reassemble in reverse order to dismantling. \
Assuming that this valve is fitted with chevron packing ring, the following
procedure should be observed on reassembly. x
• Place a protective covering over the threads of the stem. T£iis is

done to protect the new packing as the rings are lowered over the
stem.
• . Place a new packing ring inside the packing box ring. '
• Lower the packing box ring into the stuffing box.
• Insert the spring and washer into the stuffing box. Springs are
usually used to compress the packing in packing assemblies with
chevron packing. Ij
• Check the procedure to se& which direction t h i packing Ving

chevrons should face,
• Place the bottom packing ring over the si dm. This packing ring is
1
fiat on one side. The flat $ d c faces downward.
• Place the proper number of packing rings over the stem. Make
sure all of the chevrons face in the proper direction.
• Place the top packing ring over the stem, flat side up. The top ring
is usually flat on one side. In this way, the chevron side will seal
the upper area of the stuffing box and the flat side will be eyenly
compressed by the packing follower, jj
GanJi'o/'Oa/iHiJ J/CiinJanancv
» Install the packing follower over the top packing ring.
• Install the packing flange.
© Install the packing flange nuts and tighten them securely.
When chevron packing is used, the flange nuts arc usually tightened during
reassembly. When using other types of packing, the flange nuts are usually
not tightened until the valve is reinstalled in the field.
The actuator is then connected to the valve. The valve shall (if in shop) be
tested hydrostatically and tested for leaks. Calibration of valve as before.
Stem
Top Packing
Packing -
Box R i n g
2-3 B U T T E R F L Y V A L V E S
The stem and plug (called disc) move in a circular or rotary fashion inside the
body. Refer to Figs. 1, for complete actuator and valve assembly and Fig. 2, for shaft and
disc assembly.
2-3-1 Separating The Valve Body From Actuator
• After the disc arm pin has been removed (snap-ring on pin is to he
removed first) and position of the shaft has been marked on the
disc arm, the valve body and shaft can be separated from the
actuator.
• Loosen the clamp screw on the disc arm. This is done to ease
tension on the disc arm and shaft.
• Loosen and remove the retainer nuts on the stuffing box. This also
eases tension on the shaft.
• With the help of another person, remove the valve body and shaft
from the actuator. Pull the body and shaft out straight.
2-3-2 Disc And Shaft Removal
o The disc is often connect to the shaft with shaft pins. These puis,
sometimes, have no; head to hold them in place. When pins are
installed, a head is formed by hitting the top of the pin with a
hammer, in this way a "head" is formed and the pin staysjin
place. This is called peening the pin. Other types of connecting
pins that do not require peening are used on some types of valves.
The head of the peened pin is to be grinded off by the use of

electric or pneumatic grinder and the pin is to be driven out with
a drift punch. If the pin is tapered, care should be taken to drive
pin out in correct direction. .-.
• Discard the pins.
• The disc would slip out of (he seating area if the shaft were
removed first.
S E C . 4-3 Fig. 2 S H A F T AND D I S C A S S E M B L Y
GanJra/X)(l/i>atDifwnjtmanca .
As for previous valves, components of the valve arc to be inspected and

identify parts to be replaced or reconditioned :
• Inspect the seat area for scratches, nicks, hardening, deposits, or

any other damage that would interfere with the seal between the
disc and the scat.
There are four areas where wear often occurs : The two ridges
i
where the disc meets the seat and the two areas where the shaft
penetrates the disc. These should be inspected carefully.
• Remove the seat, if damage is found on a removable scat.
• Check the packing flange, packing follower, and spacer for wear,
• Check the shaft for scratches, nicks, burrs, and bending. Check
the spline on the shaft. I f it is damaged, the parts may not connect
properly and the valve may not operate.
• Inspect the disc for wear and scratches. Check the shaft pin holes
in the disc. If the holes arc deformed in any way, the movement of
the disc and the shaft may be impaired.
• Check the disc arm and disc arm pin for wear.
2-3-4 Reassembly (Assuming lined valve with damaged seat)
• Lubricate liner with approved lubricant and push it into place

around the seating groves in the valve body. Use the fleshy part of
your finger to press the liner in place.
• Lubricate the replacement O-rings for the connecting points

between the disc and shaft and insert O-rings into the O-ring
grooves.
• Install the bottom pieces of the packing assembly onto the shaft,
beginning with the guide bushings. Slide the guide bushing over
the shaft. Then install the spacer over the shaft and finally install
the packing box ring over the spacer.
• Put the shaft into the valve body and push it until the point where
it meets the seat area.
GonJroI'OaliHijUiCiunit'Jitmce •, '
(
89
• Place (he disc into the scat area. The disc should be in the fully
opened, perpendicular position, so there is room to hold and
maneuver it with your finger. Align the holes on the disc where
the shaft comes through with O-ring sealing areas on the seat.
• Hold the disc firmly and push the shaft through the holes on both
end of the disc. Move the shaft until it stops against the end
bearing on the far side of the valve body.
• Move the disc to the closed position, in preparation for tI ic

(
insertion of the shaft pins,
• Insert the first shaft pin into the shaft and disc. Push it in place
with a drift punch. When the pin touches the support block under
the valve body, it has been inserted to the proper position. Insert
the second pin same way.
Hit the top of each pin with a ball peen hammer to flatten out the
top edge over the hole in the disc.
• Complete assembly as previously has been done with other valves,
• Test valve.
• Reinstall.
2-4 B A L L V A L V E S
Ball valve move in a rotary fashion. The body of the valve is cylindrical and
resembles a section of pipe. The stem fits into the middle of the valve body, in a
perpendicular fashion. The stem is usually shaped a little different from other valve
stems.
The ball is the closure mechanism for the valve. The ball is usually a sphered-
shaped part with a hole in the middle. The stem fits into an indentation on one side of
the ball. This type of ball is called a full ball. Fig. 3, show this valve and also two other
types of ball closure elements, a characterized ball and an eccentric rotating plug.
GanJro/Z)aAi&t ^Jituiiih'naiice
$0
CHARACTERIZED BALL VALVE E C C E N T R I C ROTATING PLUG
(CROSS-SECTION) VALVE
S E C . 4-3 Fig. 3 BALL CLOSURE ELEMENTS
9/
Gan/ra/T)aftx?j DKtiinJfmaiica
T h e stem seals the area where the stem connects to the ball. Inside the valve, the
ball mates with two circular seats, one on cither end of the valve. These two mating
surfaces provide the major seal for the valve. These seals may have chamfered, or
beveled ridges that the ball fits against. These seals arc often made of rubber. They may
also be made of elastomer or fiurocarbon rcsilent material that help provide tight
shutoff.
O n one end of the valve, there is another seal, called the body seal. This part serves
to provide extra protection against leakage when the valve is in operation. Take note
that, in this type of valve, there are a few different parts that serve to seal the valve in
various places. The body seal and the stem seal are usually called "seals". The seats of
the valve also serve to seal the valve. These seats and seals arc usually all made of lo'w
friction, resilient material so that when the valve is operating the ball and stem can move
with little resistance and the valve can also provide a tight shutoff.
O n the same side of the valve with the body seal, there is usually a part called the
body cap that connects to the process piping when the valve is in operation. Several
parts are located outside of the valve body to guide the movement of the stem.
i
• The bonnet plate and bonnet screws hold the stem in place.
• Check nuts are provided between the bonnet plate and the valve body.
The nuts support the bonnet plate and prevent over tightening of the
bonnet screws.
• The stem bearing cases movement between the metal surfaces of the
stem and the bonnet plate.
• The indicator moves with the stem and shows the position of the stem
when the valve is in operation.
• The retaining ring holds the indicator in place.
An actuator is attached above the retaining ring to move the valve stem when the
valve is in operation. Sonic ball valves do not have packing. The stem seal is used to
protect against leaks. The stem guidance and sealing needed on a ball valve may only
require a simple assembly because the stem is contained within the ball and is riot
exposed to process fluid and air.
2-4-1 Disassembling A Ball Valve
Shop overhauls are sometimes required on ball valves when unsatisfactory

leakage is detected and cannot be fixed by an in-field adjustment.
Unsatisfactory leakage can often be corrected by replacement of the seats and
seals in the valve. ^_
Gan/ra/Ua/tMis DfCainJunance
Make sure (he valve is properly decontaminated, if necessary.
Place the valve in a vi$;f8to support before starting work.
Separate the actuatorlrom the valve.
• Remove the retaining ring on top of the indicator. A retaining

ring removal tool can be used for this step.
• Lift off the indicator.
• Loosen the check nuts. These nuts are used to support the packing
flange and bonnet screws. The nuts have to be loosened before the
bonnet plates and screws can be removed.
• If the valve has an identification tag that is held down by the

check nuts, it can be removed once the nuts arc loosened. Keep
this part in a safe place. It helps to identify the valve.
• Loosen the bonnet screws and remove them.
• Lift off the bonnet plate, and lift out the stem bearing. [
• Lift the stem out. There could be some resistance since the stem is
still being held in place inside the groove on the top of the ball, so
lift it out carefully.
• Lift the stem seal out. Be careful not to scratch the inside of the
valve body. Lifting the seal up evenly and in a level position helps
it come out easily.
• Remove the body cap.
• Take the valve out of the vise.
• Place the valve on the bench. This provides access for the next step
in the disassembly. As the valve is being moved, cover the ends to
keep the ball from slipping out.
• Remove the body seal. A packing removal tool can be used to lift
out the body seal. It will help to get access to the seal if the body
seat underneath it is push down slightly.
• Lift out the first body seat.
• Remove the ball. Y o u may be able to hold the body in one hand
and move the ball with the other hand. It helps to turn the ball so
that the hole inside the ball shows, so it can be gripped. '
• Remove the second body seat.
l
GoiJroIX)aItK'ÔlCainJimaiico ^ - 4 i
93
1
2-4-2 Inspection And Cleaning
As with other control valves, when a ball valve is disassembled, the reusable
parts should be inspected to be sure they are in good shape and can be used
again. '
• Inspect the stem. Look for nicks or scratches that could impair
movement of the valve. Pick the stem up by its flat surface to
avoid damaging the threaded surface.
• Inspect the body cap. Check for damage to the threaded surface.
Damage to this surface could impair the connection of the valve to
the process piping.
• Inspect the ball. It should have a smooth, shiny surface. Nicks,

scratches, or burrs could interfere with the seal of the valve or
could restrict movement of the ball within the valve. Since a large
area of the surface of the ball moves across the scat when the valve
is in operation, the entire surface should be checked. A scratch
could cause an opening in the sealing surface. One small burr
could eventuaHy destroy botli of the seats.
• Check the notch where the stem connects to the ball. Make sure
there is no uneven wear that could cause the stem to be
misaligned.
• Check the body. Pay special attention to the hole where the stem
connects and to the scat area. Look for scratching and uneven
wear.
• Check procedures for the proper cleaning method and materials.
• Clean all reusable parts, including the stem, the ball, the seating
surfaces inside the valve body, the bonnet plate, the stem bearing,
the bonnet screws, the check nuts, and the indicator.
9*
Gaafro/Dafixit Ultainlv.
I
2-4-3 Reassembling a Ball Valve

i
After the parts of a disassembled ball valve have been inspected and cleaned
and replacement parts have been obtained, the valve can be reassembled.
• Check the procedure for any special instructions.
• Place the valve body in a vise for support.
• Lubricate the seat that goes on the side opposite to the body cap
with approved lubricant. The lubricant is used to ease movement
of the ball against the seat when the valve is put back in
operation. The moving parts and the sealing surfaces they move
against are all lubricated before reassembly.
• Insert the lubricated scat into the valve body. Make sure the
chamfered, or beveled, edge of the seat faces toward the inside of
the valve body so that when the ball is installed, the ball meets
with (his edge.
• Lubricate the surface of the ball with approved lubricant. This

helps prevent friction when the ball surface moves against the seat
when the valve is in operation. The lubricant should be one that is
compatible with the process fluid.
• Insert the ball into the valve. Make sure the opening for the stem
is facing toward the opening for the stem in the valve body.
• Insert (he stem into place in the ball. At this point, the stem will be
used to position the ball in the first installed seat. Because of this,
the stem seal is not inserted. The stem will be removed and
inserted again later.
• Turn the stem so that the ball is turned to (he closed position.
When (he valve is in the closed position, the second scat can be
inserted so that the ball fits into the scat.
• Lubricate the second seat.
• Insert the second seat so that (he chamfered edge faces the ball.
Push the seat down until it rests on the ball. i
• Lubricate the body seal,

e.'
• Install the body seal on (op of the seat Place (he chamfered edge
on the body seal away from (he ball.
Gan/rv/'Ua/tHLt DlCaiiih>n<wci>
9*
• Reinstall the body cap. Make sure to get the first few threads
started correctly to avoid cross threading.
• Place the manual handle on the stem and turn it slowly. Gradually
build up to a full quarter turn. This rotates the ball and causes the
Hps of the seats to assume their permanent seal shape against the
ball.
• Remove the handle and the stem.
• Lubricate the stem seal.
• Insert the stem seal with the chamfered edge facing the ball.
• Lubricate the stem. This lubrication helps ease the movement of

the stem when the valve is in operation.
• Reinsert the stem into the valve until it rests on the opening on the
top of the ball.
• Check procedures to see how far down to screw in the check nuts.
Then screw them in.
• Replace the identification tag.
• Insert and tighten the bonnet screws until the heads of the screws
contact the bonnet plate. Do not over tighten these screws. Over
tightening could cause permanent deformation of the stem seal
and destroy its sealing ability.
• Install the indicator over the stem. Make sure the side that is
marked "bottom" faces the valve body, and place it on the side of
the bonnet screws so that when it is turned by a clockwise handle
motion, it will close the valve.
• Install the retaining ring on top of the indicator stop.
• Reinstall the actuator.
• Test the reassembled valve for leaks before reinstalling the valve
in the field.
3- ACTUATOR WORKSHOP MAINTENANCE
3-1 D I A P H R A G M A C T U A T O R
3-1-1 Disassembly
• Remove travel indicator, loosen the spring adjuster and remove it!
• Remove the bolts around upper casing and lift off upper casing.
• Loosen the cap screw that holds the stem assembly together and
remove stem and diaphragm assembly together.
• Remove the range spring. *
• Remove the snap ring from the lower casing. This ring holds the
seal bushing tightly in place within actuator body.
• Remove the seal bushing by pushing it up from inside the actuator

body.
• Remove the large gasket on the actuator body using the proper
scraping tool scrape off the old sealant to loosen the gasket.
3-1-2 Inspection
• Inspect the diaphragm. Look for small tears around the cap screw
hole. Check the molded edges for small cracks that may have
occurred from brittleness due to age or high temperature.
• Inspect actuator stem for scores or scratches, that could prevent

the stem from moving smoothly. Check stem threads for damage
and wear.
3-1-3 Reassembly
• Install new gasket between the yoke and the lower casing . Sealant
shall be applied to the top of the yoke and also to the top of gasket
when put over the yoke. Replace lower housing.
• Before placing the seal bushing into the lower casing, it should be
cleaned and new O-rings are to be fitted on it. O-rings arc to be
lubricated before being installed. Lubricate inside of seal. This
lubricant coats the inner surface and helps to lubricate the
actuator stem. _
T
GimJro/ ()aAx>s UiCainJonanca .*
© Place (he range spring under (he yoke of the actuator.
e Install diaphragm assembly, with new diaphragm if the old onej is

not suitable.
Tighten the casing screws to the torque value specified by the

1
manufacturer. Follow crisscross pattern.
Complete assembly as before.
3-1-4 Calibration And Checks
After calibration, hysteresis check to be done as detailed before.
3-2 P I S T O N A C T U A T O R S
Piston actuators are often used in industrial processes that operate at high process
pressure. The piston actuator makes it possible to use much higher air pressure to
position a valve. Many piston actuator are used with positioners. The positioner helps (o
ob(ain quick and accurate positioning of (he valve stem.
3-2-1 Pislon Actuator Disassembly
• Relieve tension from actuator spring. I f piston actuator does not

have spring, air pressure should be relieved from the cylinder.
• Remove snap ring against out casing, using C-cIamp (if snap ring
is fitted). ,
Remove actuator caver and the spring if the actuator has one. '
e Remove the screws that hold the stem connector onto the piston
rod.
• Remove the stem connector. The connector locks the piston rod
and the valve stem and the valve position indicator.
• Remove the rubber boot from around the piston. The boot
protects (he piston rod from damage.
• Remove the O-ring seal from the piston assembly, using proper
tool.
• Remove the piston assembly by pushing it up from below.
• Remove O-ring from piston rod. Be careful not to scratch the O-
ring grooves with the removal tool.
• Remove the O-ring from the piston. This O-ring seals the body of
the ac(ua(or to the casing.
All parts, specially the stem, O-rings grooves and O-rings are to be cleaned
and inspected.
3-2-3 Replacing Seals
• The new O-rings should be inspected for damage, lubricated with

an approved lubricant and installed.
On the seal plate. Make sure the O-ring is seated correctly in the
groove. The seal plate fits against the piston assembly.
• Clean the piston rod, the small O-ring groove in the piston rod,
and the large groove in the piston assembly.
• Lubricate the piston shaft. This lubricant helps the piston to move
freely.
• Reinstall the piston rod assembly into the body of the actuator.
The lubricant on the stem will help it to slide in smoothly. As the
assembly is reinserted, support it from below with one hand to
control its movement downwards.
• Lubricate and replace the O-ring around the piston assembly.

This O-ring is replaced after the assembly has been reinstalled
because two hands are needed to do the job.
• Reinstall the protective rubber boot over the piston rod. Slide the
boot on straight, being careful not to force it over the piston rod.
• Reinstall the stem connector guide. Line up its open end with the
metal, ridge on the side of the yoke.
3-2-4 Actuator Reassembly
• Reinstall the range spring and spring seat.
• Replace the actuator cover.
• Reinstall snap ring.
• Place a protective cover over the thread of the cap screw. This
cover is used to protect the thread from damage from the O-ring
removal tool.
<
GanJraJDa/txif DiCainhinttncu
• Remove (lie O-ring on the cap screw. Then remove the protective
1
cover.
• Clean the thread and O-ring groove of the cap screw with solvent
and a lint - free cloth.
\ * Replace the protective cover over the threads.
• Lubricate a new O-ring and slide it into place on the cap screw.
Then remove the protective cover.
• Replace the cap screw into the top of the actuator. Tighten the
screw with a box-end wrench.
3-2-5 Calibration '
Calibrate the actuator as for the diaphragm type.
3-3 E L E C T R I C M O T O R A C T U A T O R
The motor moves the valve through a gear train. The gear train usually includes
protective devices, such as limit switches, to provide travel limits in both the open and
the closed valve positions.
When the valve reaches the end of its travel, open or closed, the limit switch breaks
the electrical circuit and the motor stops. Another electrical input signal from the
controller drives the motor back in the opposite direction, and a second limit switch
stops the motor again when the valve has moved fully through its stroke.
If a motor actuator is not driving the valve properly, one possible cause may be
that the limit switches are not adjusted properly. These switches are connected to cams
that can be positioned as required to permit interrupting the electrical circuit to stop the
motor at any point. The cams could be adjusted so that the limit switch stops the motor
when the valve is fully opened or closed.
If the motor continued to drive past the end of the valves travel, damage to the
valve would result or the motor might overheat and burn out. Sec Fig. 4, for detail of
actuator.
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Casino
Slem
Connector
S E C . 4-3 Fig. 4 MOTORIZED ACTUATOR DETAILS
3-3-1 Inspecting The Drive Train
Routine maintenance on electric motor driven actuator include inspection

and lubrication of the gears and drive train. This is to be done at least once a
year. When inspecting the gears, look for broken, damaged, or missing teeth.
Check that the gears mesh together correctly by manually operating the
motor until the gears have moved full circle.
Be sure to use the recommended lubricant. Follow the manufacturers

instruction for lubricating the drive train in an electric motor,
Gin/ra/'Ua/fKzi OiftunhmancQ
(
I
3-3-2 Aligning Motor With The Valve
Proper alignment of the motor actuator and the valve is very important. On
some actuator the alignment can be checked by manually operating the
motor and checking its action on the valve. Manually operate the motor
several times through the full travel range of the valve, opened and closed. Be
sure that the valve opens and closes completely and that there is no
obstruction blocking its movement.
3-3-3 Adjusting The Limit Switches
• Use a multimeter to measure resistance.
• Zero the resistance scale on the multimeter by shorting the two

leads together.
• Attach the limit switch leads from the motor to the leads from the
meter.
• Take the resistance reading from the multimeter scale. Zero

resistance indicates'that the switch is closed. Resistance indicates
that the switch is open. If the switch does not open or close the
circuit fully, adjust the appropriate cam controlling the switch.
• Loosen the small screws in the cam, using a hex wrench.
• Turn the cam slowly clockwise or counter clockwise, as necessary,

until the needle on the resistance scale moves. This indicates that
the switch has opened or closed the circuit to the motor.
• Tighten the cam when it has reached the correct position, watch
the meter when tightening the cam to make sure that the
tightening procedure does not trip the switch.
• Repeat the adjustment on the cam for the switch that controls the
valve in the opposite position. This cam is usually turned in the
opposite direction from the first cam.
GaniroIDaftxis fJltuiiihuuincv
1
• I • . , . . . .1
A C T U A T O R S A N D POSITIONERS
- M O T I O N - B A L A N C E POSITIONERS
PREVIEW
YOU WILL LEARN
1. How motion-balance positioners function.
2, JHow to install a motion-balance positioner onto an actuator.
3. H o w t o align the mechanical linkage o f a motion-balance positioner.
REVIEW
Motion-Balance Positioners
I n ' he preceding segments, we worked on a positioner

that operated by the force-balance principle. Other
positioners operate by the motion-balance principle. Motion-balance positioners
Cc t r o l valve positions are also fed back^ to the are usually sidearm
positioner through a series o f linkages to a cam. mounted.
In hotion-balance positioners, the input signal from

the'controller goes to a pressure-to-position converter.
I n he positioner shown on the videotape, the converter
w; a bellows. The graphic on the opposite page
shiAvs the position o f the bellows. ^The input signal
causes the bellows to expand, pushing against one end
o( ji beam. There is a flapper attached to the beam
th»t moves in relation to a nozzle as the beam moves.
Backpressure in the nozzle provides the input to a
sn \[[ relay. The relay o u t p u t is fed to the actuator,
c&Jsing the actuator stem to move and reposition
the control valve.
Movement o f the control valve is fed back to the

positioner through a linkage and a cam. The cam
pi lies against the other end o f the beam and re-
pi itions the flapper in relation to the nozzle. The
m o t i o n caused by this force opposes the m o t i o n
c; |sed by the bellows. The t w o motions balance
e< fh other and an equilibrium is established.
ACTUATORS AND POSITIONERS
The cam determines whether the control valve w i l l

have a linear or a nonlinear relationship to the input
signal. As in the force-balance positioner, the cam
shape determines the valve flow characteristic.
The flapper can be shifted from one quadrant o f

the beam to another. One quadrant is for direct
Flapper Nozzle
action and the other is for reverse action.
Beam
v
Reverse Action Direct Action
Quadrant Quadrant
Installing a Motion-Balance Positioner
When a positioner is installed on an actuator, it is

important to connect the mechanical linkage properly,
The mechanical linkage transmits the position o f the
valve stem to the positioner. The positioner cannot
function correctly i f the alignment o f the linkage
w i t h the valve stem is incorrect. Before installing a
positioner, check the manufacturer's instructions.
The following steps may be used to install a m o t i o n -
balance positioner.
A t t a c h the connector a m i to the valve stem. On

some actuators, the connector arm extends
between the legs o f the actuator yoke. Correct
placement o f the connector arm w i l l help w i t h
the alignment o f the linkage. Tighten the stem
connector nut.
i ;Bolt the positioner onto the actuator body. The

manufacturer's instructions should indicate the
(proper m o u n t i n g holes t o use on the m o u n t i n g
[bracket.
| Place the travel pin in the slot o n the rotary

arm. O n some linkages, the rotary arm swivels
out o f the way. Return i t t o the appropriate
I position before slipping the pin into the slot.
The travel pin should be perpendicular t o the
rotary arm.
| Connect the positioner output t o the actuator

input.
Al [ning the Linkage
The linkage should be aligned w i t h the valve stem.

I n ibis way, the linkage w i l l correctly indicate the Begin alignment with the
pc Ition o f the valve. T o align the linkage, the actuator stem at the
actuator should be positioned at its mid-travel mid-travel position.
pc ition. Beginning alignment at the mid-travel
p( Ition prevents damage to the actuator, linkage,
and cam that might result from improper alignment.
F( ' l o w the manufacturer's instructions. T h e
fo .owing steps may be used for the alignment
procedure.
i
© Connect the positioner air supply line.
9 Connect the positioner input line.
© Set the positioner bypass valve in the bypass

I position.
© A p p l y the specified input. The input w i l l go •

directly to the actuator because the positioner
is on bypass. The i n p u t should be 50% o f the
signal span. A t this value, the valve should be! at
1 the Oiid-travel position.
« Check the travel indicator to determine i f the

I actuator stem is at the mid-travel position.
Adjust the stem position, i f necessary. This can
1
be done by changing the tension on the range
spring o f the actuator.
o Loosen the locknut. Slide the travel pin to the

I Line up the travel pin position specified by the manufacturer. Line'
with the edges of the up the index marks on the positioner linkage
( positioner casing to keep w i t h the marks on the positioner casing to ensure
j it perpendicular. correct alignment. Tighten the locknut.
• A p p l y the input specified by the manufacturer.

This i n p u t w i l l be at one end o f the signal range.
9 Check the travel indicator to determine i f the

actuator stem moved correctly. The stem should
be at either the fully open or the fully closed
position, depending on the input signal.
© Check that the index marks on the positioner

^ linkage arc lined up w i t h the index marks on the
positioner casing. The linkage marks should
line up w i t h either the maximum or the m i n i m u m
rotation marks on the casing, depending on the
input signal.
© A p p l y the specified input. This input w i l l be

at the opposite end o f the signal range.
© Check the travel indicator to determine i f the

actuator stem moved correctly.
© Check that the index marks on the positioner

linkage are lined up w i t h the index marks on the
n e
positioner casing. I f the index marks do not l i
up, the linkage should be readjusted.
# A C T U A T O R S A N D POSITIONERS
}' , " * CAM INSTALLATION A N D PRECALIBRATION ALIGNMENT
PREVIEW
YOU WILL LEARN
1, H o w to select and install a cam in a motion-balance positioner.
2. H o w to begin the precalibration alignment o f a positioner.
REVIEW
Selecting and Installing a Cam
I f a positioner operates w i t h cams, i t is possible to

change the flow characteristic o f the control valve
by changing the cam.
The cams may be marked to indicate the valve's

flow characteristic, the type o f actuator action, and
how the cam should be installed. I t is important
t o install the appropriate cam. Be sure to check
facility procedures and the manufacturer's instruc-
tions for the positioners used in y o u r facility. The
following steps were used t o install a cam i n the
positioner shown on the videotape.
• Disconnect the springs from the beam assembly.

One end o f each spring may be attached to the
casing and need not be detached. Support the
beam assembly as the springs are unhooked.
© L i f t the beam assembly away from the flapper

nozzle. Be careful not to h i t the beam against
the flapper or the nozzle. These parts are easily
(lain aged.
« Remove the cam bolt and nut holding the cam

in place.
© L i f t o f f the cam and spring retainer bracket

together.
© Remove the spare cams from the positioner case.
e Select the proper cam for the desired valve flow

characteristic.
Position the cam correctly © A t t a c h the cam to the spring retainer bracket
according to its markings. and bolt it i n place. Tighten the nut against
the spring retainer bracket.
• Reinstall the beam assembly.
© Connect the springs in the positioner casing to

the beam assembly.
/of
i
I Beginning the Precnlibration Alignment
'}{• The precahbration alignment o f a positioner helps

ensure the correct positioning o f the beam and the
I . flapper and nozzle assembly. These parts should be
• correctly aligned for the valve How characteristic
selected. These parts should be aligned so that- the
control valve will move to fully open and fully close
at each end o f the travel range. The following steps
may be used to begin the precnlibration alignment Follow the manufacturer's
procedure. instructions.
• Remove the beam assembly.
• Loosen the nozzle locknut.
H o l d the nozzle locknut w i t h a wrench. T u r n

the nozzle all the way in to its lowest position.
• Adjust the nozzle to the position specified in Turn the nozzle slowly to
your manufacturer's instructions. prevent damage.
• Tighten the nozzle l o c k n u t to hold the nozzle

in position. This nozzle adjustment should not
change during other alignments on the flapper
or beam.
I - PRECA LIB R A T I O N A L I G N M E N T
PREVIEW
YOU WILL LEARN ?
1. H o w to complete the precalibration alignment o f a motion-balance positioner,
ft
REVIEW
f Precalibration Alignment
ft After the nozzle has been adjusted, the alignment o f

the positioner should be checked for both direct and
reverse action. This w i l l ensure correct operation
i f the action is changed to meet changing process
requirements.
F o l l o w the manufacturer's instructions for the pre-

calibration alignment procedure. The following
steps were used for the motion-balance positioner
shown on the videotape.
• Change the bypass valve from the bypass position

to the positioner position. The input w i l l now
go through the positioner.
• A p p l y an input o f 50% o f the signal range.
• Inspect the flapper and nozzle assembly. L o o k

for any bent or damaged parts that could
prevent the flapper from squarely approaching
the nozzle.
• Inspect and reinstall the beam.

© Adjust the flapper to the zero position on the

beam. This adjustment should be performed
slowly. A screwdriver may be used to turn the
adjustment screw controlling the gears that move
the flapper.
© Loosen the l o c k n u t on the flapper follower

assembly. Adjust the follower screw until the
output pressure is 50% o f the signal range. The
gage needle may oscillate because the flapper
and nozzle alignment may be disturbed by the
adjustment o f the follower screw, causing a
variable output signal.
© Tighten t h e H o c k n u f / o n the flapper follower when

the gage needle lias stabilized.
© Adjust the flapper t o the highest position on the

Check the valve side o f the beam for direct or rey^jse- action,
characteristic no matter whichever has been selected to meet process
how long or short the requirements. This aligns the output signal to
stroke. the m a x i m u m adjustable stroke o f the valve.
//JL.
Adjust the pivot on the bellows w i t h the flapper

at the highest position. The pivot can be
adjusted by loosening the bellows l o c k i n g and
turning the bellows pivot pin. Adjust the
bellows pivot u n t i l the output signal is at 50%
o f the signal range. Tighten the bellows locknut.
Be careful not to hit the

locknut with the wrench.
This could damage the bellows.
• Adjust the flapper to the highest position on the

opposite side o f the beam. I f the first check
was on the direct-acting side o f the beam, the
flapper would be moved to the highest position
o n the reverse-acting side, and vice versa.
• Loosen the locknut on the center pivot pin.

Adjust the pivot pin u n t i l the o u t p u t signal is
at 50% o f the signal range. Tighten the pivot
locknut.
• Recheck the o u t p u t readings at the zero position

and at the direct and reverse action m a x i m u m
positions.
• Make sure the flapper approaches the nozzle

squarely after all the adjustments have been
made.
CALIBRATION
PREVIEW
YOfJ WILL LEARN
1, H o w to calibrate a motion-balance positioner,-.
REVIEW
Calibrating a Motion-Balance Positioner
The precalibration alignment helps ensure that the

actuator and valve move full stroke in response to the
specified i n p u t signal range. Calibration helps ensure The calibration of the
that the positioner w i l l cause the actuator to move positioner affects the action
the valve through its full stroke. of the actuator,
The following steps may be used to calibrate a

motion-balance positioner. The bypass valve should
be set on the positioner setting. Be sure to follow
the manufacturer's instructions for the positioners in
your facility.
• Adjust the flapper to the specified position on

the appropriate side o f the beam. The manu-
facturer specifies a setting that should cover the
stroke length o f most control valves that are
used w i t h the positioner.
• A p p l y the specified input. Increase the i n p u t to Check the instrument gage

50% o f the signal range. for the correct signal
value.
• Check the o u t p u t gage o f the positioner.
I f the gage does not indicate 50% o f the signal range,

check the actuator's travel indicator. The indicator
should show the actuator at the mid-travel position.
I f the stem is not at the mid-travel position, the
height o f the nozzle may need to be adjusted.
I t is also possible that the problem may be caused a

loose linkage. So, before making any adjustments to
the nozzle, check the linkage. I t is a good idea to
check for proper cam installation, a^so.
I f the jinkage and the cam are positioned correctly,

check the actuator stem position at another signal
pressure. Increase or decrease the input to the
highest or lowest value o f the signal range. The)
actuator stem should move to the fully open or fully
closed position. Check the travel indicator. I f the
stem position is incorrect, a zero adjustment may be
required. A zero adjustment on a motion-balance
positioner involves a change in the height o f the
Follow the manufacturer'!; nozzle. The following steps may be used for the zero
instructions. adjustment procedure.
© Loosen the nozzle locknut.
© Adjust the nozzle until the travel indicator shows

that the actuator has moved to the fully open
or fully closed position.
o Tighten the nozzle locknut.
• A p p l y i n p u t pressure at the opposite end o f the

signal range.
© Check the travel indicator for actuator stem

movement to the fully open or fully closed
position.
I f the stem position is correct, the adjustment o f the

nozzle has corrected the zero error. I f the stem
position is still not correct, additional zero adjust-
ments should be made u n t i l the actuator correctly
strokes throughout its travel range in response to
signal pressure.
The actuator stem might move through its full travel ,

range but reach the fully open or fully closed - The numbered position on
positions before the input reaches the t o p or b p t t o m the beam indicates the
o f the signal range. Or, the actuator stem might not length of the stroke.
complete full travel by the time the ends o f the
signal range have been reached. B o t h o f these
problems might be solved by adjusting the flapper to
a higher or lower position on the beam. Reposition-
ing the flapper on the beam w i l l increase or decrease
the travel o f the actuator stem.
When all adjustments have been made, the positioner

and actuator unit can be returned to service.
//6
3582 and 3583 Series
Fisher Controls < Instruction Manual \

s
3532 Series Valve Positioners,
T y p e 35821 V a l v e P o s i t i o n e r , a n d
3533 Series Valve Stem
Position Transmitters
FISHER December 1989 Form 5054
Contents
Introduction 2
Scope of Manual 2
Description 2
Type Number Descriptions 3
Specifications 3
Installation, Mounting,
Connections 5
Installation Of Valve Positioner Or Valve Stem
Position Transmitter 5
Mounting 6
Correct Cam Position 9
Pressure Connections 9
Electrical Connection for Type 3582i
Valve Positioner 10
Installation Of Type 582i Converter 10 CONTROL VALVE WITH
TYPE 3582 POSITIONER
Operating Information 11
Valve Positioner Cam Information 11
Valve Stem Position Transmitter Cam Information .12
Valve Positioner Bypass Operation 12
Input Signal Ranges 13
Valve Positioner Split-Range Operation 13
Reversing Valve Positioner Output-To-Actuator
Action 14
Reversing Valve Stem Position Transmitter Action .14
t' CONTROL VALVE WITH
TYPE 3583 TRANSMITTER
Calibration Of Valve Positioner Or Valve Stem

Position Transmilter 15
Pre-Calibration Alignment 15
Calibration 16
Principle of Operation 16 CONTROL VALVE WITH

3582 Series Valve Positioners 16 TYPE 3582i POSITIONER
Type 3582i Valve Positioner . v 17 Figure 1. Typical Mounting for the 3582 Series, Type 35821,
3583 Series Valve Stem Position Transmitters 17 and 3583 Series Positioners and Transmitters' i
ft?
©Fisher Consols Iniernalionat, Inc. 1989; Ail Righls Heservod
FISHER*
Contents (Cont'd)
Maintenance 17 Replacing Type 582i Converter Cover O-Ring . . . ' .22
Changing the Range Spring 18 Removing the Type 582t Converter j.22
Replacing Gaskets 18 " Reassembling the Type 582i Converter t.22
Replacing Nozzle O-Rings 20 t; •v ••
Replacing the Relay 20 Parts Ordering .'.23
Adjusting the Flapper Pivot 21
Replacing Type 582i Converter Primary O-Ring
and Filter 21 Parts List 23
Introduction Description
Fisher 3582 Series pneumatic valve positioners and the
Type 3582i electro-pneumatic valve positioner (figure 1)
are used with diaphragm-actuated, sliding-stem control \
Note valve assemblies. The pneumatic valve positioners op-
erate from a pneumatic input signal received from a
Only qualified personnel should install, op- control device. In these valve positioners, the pneumatic
erate, or maintain the valve positioner or input signal received from the control device modulates
valve stem position transmitter. If there are the supply pressure to the control valve actuator. Thus,
any questions concerning the instructions these units provide a valve stem position that is propor-
in this manual, pfease contact your Fisher tional to the pneumatic input signal.
s a l e s office or representative before
proceeding.
The Type 3582i is an electro-pneumatic valve positioner, '
consisting of a Type 582i electro-pneumatic converter
installed on a Type 3582 pneumatic valve positioner.
The -Type 3582i valve positioner provides an accurate
Scope of Manual
vaK*a stem position that is proportional to a dc current
This instruction manual Includes installation, operation, input signal. i
maintenance, and parts information for:
ii
The Type 582i electro-pneumatic converter is a modular
unit that can be installed at the factory or in the field.
3582 Series Pneumatic Valve Positioners: Hov/ever, do not plan to install a Type 582i converter on
• Type 3582 and • Types 3582A, C, D, and G an existing positioner until you contact your Fisher sales
office or representative for application assistance. |
T h l Type 582i converter receives the dc current input

Type 3582i Electro-Pneumatic Valve Positioner signal and provides a proportional pneumatic output
signal through a nozzle/flapper arrangement. This noz-
zle pressure provides the input signal to the pneumatic
3583 Series Pneumatic Valve Stem Position valve positioner, eliminating the need for a remote-
Transmitters: mounted transducer.
* Type 3583 and • Type 3583C

The 3583 Series are pneumatic valve stem position
transmitters for use with diaphragm actuators. These
units provide an output signal that is directly proportion-
Type 83L Relay al to the valve stem position.
Please refer to separate manuals for instructions cover-
ing the control valve, actuator, Type 67AFR filter-regula- Please refer to the type number description for a de-
tor, and accessories. tailed explanation of type numbers.
2 i
i
I
Type Number Descriptions Type 35B2i—Valve positioner without bypass; with
Type 582i converter; and with: B supply and outpuj
e following descriptions provide specific information pressure gauges, B automotive tire valves, or B pipe
Jn the different valve positioner or valve stem position plugs
transmitter constructions. If the type number is not *
' now'n, please refer to the nameplate on the positioner, Type 83L—Pneumatic relay included as part of the 3582
or the location of the nameplate, refer to key 25, figure 16. Series valve positioners, the Type 3582i valve position-
er, and the 3583 Series valve stem position transmitters
alve Positioner Type Numbers

i ype 582i—Electro-pneumatic converter with: B supply Valve Stem Position Transmitter Type Numbers
and output pressure gauges, B automotive tire valves, Type 3583—Valve stem position transmitter with supply
j- B pipe plugs. Used for conversion of a 4 to 20 and output pressure gauges
(illiampere input signal to a 3 to 15 psig (0.2 to 1.0 bar)
input signal for the pneumatic valve positioner Type 3583C—Similar to Type 3583 vaive stem position
transmitter except with automotive tire valves in place of
ype 3582—Valve positioner with bypass and instru- pressure gauges
ment, supply, and output pressure gauges
~ype 3582A—Valve positioner without bypass and

ithout pressure gauges
Specifications I
Type 3582C—Valve positioner without bypass and with
Specifications for the valve positioners are shown in
itomotive tire valves instead of pressure gauges
table 1. Specifications for the valve stem position trans-
mitters are shown in table 2.
Type 3582D—Valve positioner with bypass and with
automotive tire valves instead of pressure gauges
Please refer to the unit's nameplate (see figure 2) to
!/pe 3582G—Valve positioner without bypass and with determine the type of positioner or transmitter, supply
Instrument, supply, and output pressure gauges pressure, etc.
Table 1. Specifications for 3582 Series and Type 3582/ Valve Positioners
nput Signal^), Pneumatic Maximuny Steady-State Air Consumption^ * 3
3 to 15 psig (0.2 to 1.0 bar), B 5 to 25 psig For 3582 Series

(0.3 to 1.7 bar), B 6 to 30 psig (0.4 to 2.0 bar), or 20 Psig (1.4 bar) Supply: 14.0 scfh (0.38 normal
B split range, see table 6 m /hr)
3
I 30 Psig (2.0 bar) Supply: 18.0 scfh (0.48 normal

[nput Signal^, dc Current m /hr)
3
4 to 20 mA dc or split range, see table 6 35 Psig (2.4 bar) Supply: 20.0 scfh (0.54 normal
m /hr)
3
.Output Signal^ For Type 3582i Only

20 Psig (1.4 bar) Supply: 15.8 scfh (0.42 normal
' Type; Pneumatic pressure as required by
m /hr)
3
actuator up to 95 percent of maximum supply

j Action!*); Field-reversible between B direct and
m /hr)
3
I B reverse within the pneumatic valve positioner

35 Psig (2.4 bar) Supply:^.9 scfh (0.59 normal
m /hr)
3
Supply Pressures
Recommended: 5 psi (0.3 bar) above actuator Maximum Supply Air Demand"*
requirement
For 3582 Series and Type 3582I
Maximum: 50 psig (3.4 bar) or pressure rating of
actuator, whichever is lower
m /hr)
3

nput Bellows Pressure Rating' ) 2
m /hr)
3
See table 4 for minimum and maximum pressure 35 Psig (2.4 bar) Supply: 285.5 scfh (8.1 normal
ratings (allowable input signal) for each available m /hr)
3
range spring
- Continued -
3
FISHER
V /
Table 1. Specifications for 3582 Series and Type 3582/ Valve Positioners (Continued)
Performance Hazardous Area Classifications Bulletin for

For 3582 Series specific approvals. Also, refer to the namepiates
Independent Linearity^: ± 1 percent of output shown in figure 2 for the location of positioner
signal span or transmitter classification information and
For Type 3582i Only approval descriptions.
Independent Linearity^: ± 2 percent of output
signal span Housing Classification for Type 35821
For 3582 Series NEMA 3, IEC 529 1P54: Mounting orientation
Hysteresis('): 0.5 percent of span requires vent location to be below horizontal
For Type 3582i Only
Hysteresis^: 0.6 percent of span Pressure Gauges
For 3582 Series and Type 3582i 1-1/2 inch (40 mm) diameter with plastic case
Open Loop Gain (Output Signal)( >: }
and brass connection B triple scale (PSI, fvlPa,
• 100 in the range of 3 to 15 psig (0.2 to 1.0 and bar) or B dual scale (PSI and kg/cm ) 2
bar)
Pressure Connections
• 55 in the range of 6 to 30 psig (0.4 to 2.0 bar)
1/4-inch NPT female
Operating
SupplyInfluences")
Pressure, For 3582 Series Units: Valve Electrical Connection for Type 3582i
travel changes less than 0.25 percent per 2 psi
B 1/2-14 NPT conduit connection
(1.67 percent per bar) change in supply pressure
Supply Pressure, For Type 3582i Units: Valve
Maximum Valve Stem Travel
travel changes less than 1.0 percent per 2 psi
(3.62 percent per bar) change in supply pressure 4-1/8 inches (105 mm); adjustable to obtain
lesser travels with standard input signals
Operative Temperature Limits* ) 1
Characterized Cams
Standard Construction, For 3582 Series and
Type 3582i Units: - 40 to + 160°F ( - 40 to See characterized cams section
+ 71°C)
High-Temperature Construction^), For Types Approximate Weight
3582A and C Only: 0 to + 2 2 0 ° F ( - 18 to 3582 Series Units: 5-1/2 pounds (2.5 kg)
+ 104°C) without gauges Type 3582i: 8 pounds (3.6 kg)
Electrical Classification for Type 3582i

Designed to meet explosion proof and
intrinsically safe applications. Please refer to the
1. This term is deltned in ISA Slandard S51.1-1979. 3. Sclh—standard cubic (eel per hour (60°F and 14.7 psia); normal m'/hr-—normal cubic
2. Do not exceed any of the pressure 01 lemperalure limits In this instruction manual. meters per hour (0°C and 1.01325 bar, absoluie).
Also, any applicable standard or code should not be exceeded.
[FISHER) TYPE 5 8 2 1
SERIAL NO.
( FISHERJ INPUT' ZO mADC MAX. 30 VDC MAX
AMBIEUT UMP< -40 TO 180T ( - « TO 82*C)
o
INSTRUMEriT RANGE
INFORMATION IN THIS PORTION
I T0| | PRESS. OF THE NAMEPLATE DESCRIBES
SAFETY APPROVALS FOR THE
SUPPLY
SERIAL NO.
! M A X . SUPPLY
» PSI
SYSTEM SPECIFIED ON THE
EQUIPMENT ORDER.
KAf* IH U 1 A
POSITIONER OR TRANSMITTER NAMEPLATE TYPE 5821 CONVERTER NAMEPLATE
Figure 2. Typical Namepiates
4
Table 2. Specifications for 3583 Series Valve Stem Position Transmitters
'nput Signal!*) Reference Accuracy*')

4-1/8 inches (105 mm) of valve stem travel; ± 1 percent of output signal span
adjustable to obtain full output signal with lesser
stem travels Operating Influence!*)
Output signal changes 0.23 percent per 2 psig
Output Signal' ' 1
(1.67 percent per bar) change in supply pressure
Type: • 3 to 15 psig (0.2 to 1.0 bar), H 5 to 25
psig (0.3 to 1.7 bar), or H 6 to 30 psig (0.4 to 2.0 Operative Ambient Temperature Limits* ) 1
bar) pneumatic pressure Standard Construction, 3583 Series: - 4 0 to

Action: Field-reversible between direct and + 1 6 0 ° F ( - 4 0 t o +71°C)
reverse High-Temperature Construction^, Type 3583C
only: 0 to + 220 °F ( - 18 to + 1 0 4 ° C )
Output Bellows Pressure Rating (2)
See table 4 for minimum and maximum pressure Pressure Connections
ratings (allowable input signal) for each available Supply and output pressure connections are
range spring '174-inch NPT female
t;
Supply Pressure' ) 1
Maximum Valve Stem Travel
' Recommended: 5 psi (0.3 bar) above upper limit 4-1/8 inches (105 mm); adjustable to obtain full
of output signal range output signal with lesser stem travels
Maximum: 35 psig (2.4 bar) or pressure rating of
connected equipment, whichever is lower Cam
Linear
Maximum Steady-State Air Consumption* ^) 1
I 20 Psig (1.4 bar) Supply. 14.0 scfh (0.38 normal Approximate Weight
I m /hr)
3
5-1/2 pounds (2.5 kg)

I m /hr)
3
j 35 Psig (2.4 bar) Supply: 20.0 scfh (0.54 normal

' m /nr)
3
1. This term is defined in ISA Slandard S51.1-1979. 3. Sclh—-standard cubic feet per hour (60°F and 14.7 psia); normal m /hr—normal cubic
3
i . Do not exceed any ol Iha pressure or temperature limits In this instruction manual.
Also, any applicable slandard or code should nol be exceeded.
meters per hour tO°C and 1.01325 bar, absolute).
tv ..istallation Of Valve Positioner Or output to the actuator. If a Type 67AFR filter-regulator is

specified, it will be integrally mounted to the valve posi-
i Valve Stem Position Transmitter tioner or valve stem position transmitter. For more infor-
mation, please refer to the appropriate section of this
manual.
Note
Note
All valve positioners and valve stem posi-
tion transmitters are shipped with foam rub- In some cases, it is not possible to align j
ber packing material inside the c a s e . and calibrate the valve positioner or valve
Remove the cover (key 33, figure 16) and stem position transmitter at the factory, and
the packing material before attempting to field alignment and calibration is required.
operate the unit. Make sure all vent open- Before putting the valve positioner or valve
ings are clear before installation of the unit stem position transmitter into service, '
and that they remain clear during use. check the operation of the unit to be sure it
has been calibrated. If the valve positioner
or valve stem position transmitter requires
jhen factory mounting of a valve positioner or valve alignment or calibration, please refer to the
em position transmitter is requested, the factory will appropriate calibration instructions in this
mount the unit and will connect the valve positioner manual.
5
TYPE 657, 657MO, 667, 667MO
SIZE 80 UP TO 2 IN (51 mm) TRAVEL
TYPE 657
SIZE 70, 87, UP TO 2 IN (SI mm) TRAVEL
TYPE 513
SIZE 32
TYPE 657, 657HO, 667, 667MO TYPE 650, 656, 657-8
SIZE 100 ALL TRAVEL ALL SIZES
TYPE 657, 657MO, 667, 667MO TYPE 657MO
SIZE 80 2-1/16 TO 3 IN (52 TO 76 mm) SIZE 34, 45, 50, 60
TRAVEL TYPE 657-4, 667-4
TYPE 657MO, 667MO SIZE 70, 87 4 IN (102 mm) TRAVEL
SIZE 70, 87 3-1/16 TO 4 IN TYPE 657, 667
(78 lo 102 mm) TRAVEL SIZE 70, 87 3-1/16 TO 4 IN (78 TO 102 mm) TRAVEL
TYPE 657-4MO, 667-4MO TYPE 6S7MO, 667MO TYPE 667
SIZE 70, 87 4 IN (102 mm) TRAVEL SIZE 70, 67 UP TO 3 IN (78 mm) TRAVEL SlfcE 70, 87, 2-1/16 TO 3 IN (52 TO 78 mm) TRAVEL
Figure 3. Mounting Assembly
If the valve positioner or valve stem position transmitter When mounting a Fisher valve positioner or valve stem
has been ordered separately, disconnected, or removed position transmitter on an actuator by another manufac-
from the actuator, please refer to the appropriate sec- turer, it may be necessary to provide spacers by cutting
tions of this manual. sections from 1/2- or 3/8-inch pipe so that the "X"
dimension matches the value given in figure 6.
Mounting 2. Attach the connector arm (key 48) to the stem

connector so that the connector arm extends through
Key numbers used in this procedure are shown in figure the yoke legs on the side of the lower mounting boss as
3 except where indicated. shown in figures 3 and 4.
1. Mounting parts for Fisher actuators that require

spacers will have the spacers (key 50) included. Type 3. Attach the valve positioner or valve stem position
transmitter to the mounting plate (key 63).
657 and 667 actuators, sizes 70 through 100, with or
without a side-mounted handwheel, use spacers (keys
97 and 102) between the stem connector and the con- 4. Mount the 67AFR regulator:
nector arm (key 48). On all other actuators that use
spacers, place the spacers (key 50) between the mount- © 3582 Series valve positioners and 3583 Series
ing plate (key 63) and the actuator mounting boss. valve stem position transmitters, mount the regulator
Please refer to figure 3. on the integral boss on the bypass block.
6
Table 3. 3582 and 3583 Series Mounting Information
MAXIMUM MOUNTING MOUNTING

TRAVEL MAXIMUM TRAVEL
CTUATOR ACTUATOR TRAVEL ACTUATOR ACTUATOR HOLES
HOLES PIN TRAVEL PIN
5
TYPE SIZE TYPE SIZE SET NO.M)
SET NO.W POSITIONS POSITION! ) 2
Inch mm Inch mm 657 667

r 1 & 513R 20 3/4 19 2 Normal 30 3/4 19 3 4 Normal
32 3/4 19 2 Normal 34 3/4 19 3 2 Normal
30 2 51 4 Inverted 40 1-1/2 38 2 4 Normal
656 40 3-1/2 89 4 Inverted 45 3/4 19 1 4 Inverted
i 60 4 102 4 Inverted 45 2 51 1 1 Normal* ) 3
'-4 Without 50 2 51 1 2 Normal

Sit e-Mounted 70 4 102 3 Inverted 657 & 667 60 2 51 1 2 Normal
Handwheel Without Side 2 51 2 1 Normal
Mounted 70 2- 1/16-3 52-76 3 2 Normal
i '-4 Wilh 102 2
70 4 Inverted Handwheel 3- 1/16-4 78-102 3 1 Inverted
e-Mounted
87 4 102 1 Inverted
Handwheel 80 3 76 2 2 Normal
30 2-1/8 54 3 Normal 2 51 2 2 Normal
34 2- 1/8 54 3 Normal 87 2- 1/16-3 52-76 2 2 Normal
40 3- 1/8 79 3 Normal 3- 1/16-4 78-102 3 1 Inverted
40 3-1/2 89 3 Normal 100 4 102 4 4 Inverted
r- 46 3- 1/8 79 2 Normal 34 3/4 19 2 2 Normal
46 4- 1/8 105 2 or 4 Inverted 40 1-1/2 38 1 2 Normal
47 3-1/8 79 2 Inverted 45 2 51 2 3 Normal
47 4-1/8 105 1 Inverted 657 & 667 50 2 51 3 1 Inverted
60 4-1/8 105 2 Inverted With Side 60 2 51 3 1 Inverted
- 70 4-1/8 105 1 Inverted Mounted 70 4 102 2 2 Inverted
7-4 Wilhout Handwheel 80 3 76 2 2 Normal
70 4 102 1 Normal
Hide-Mounted 3 76 2 2 Normal
87 4 102 1 Normal 87
Handwheel 3-1/16-4 78-102 2 1 Inverted
The Indicated sei number should be considered a reference poinl only, due to the 2. Normal position is shown in figure 2.
variables related lo making up the stem connection. 3. Travel pin position lor Type 667 Is inverted.
HOLES FOR MOUNTING

PLATE TO ACTUATOR
HOLES FOR MOUNTING

POSITIONER TO PLATE
POSITIONER
YOKE
VALVE PLUQ STEM
Figure 4. Isometric View Showing Motion Feedback Figure 5. Mounting Plate Used with 3582 Series Valve
Arrangement and Typical Stem Connection Positioners and 3583 Series Motion Transmitters
* Type 35821 valve positioners, mount the regulator

( I the integral boss that is part of the Type 582i convert- CAUTION
( (housing.
5. The remaining holes in the mounting bracket (figure To avoid equipment damage, be certain the
! .are for mounting the assembly to the actuator. Deter- connector arm will clear the valve position-
i pe from table 3 which set of mounting holes to use, er or valve stem position transmitter case
and attach the unit to the lower mounting pad on the as the actuator moves through its complete
actuator. stroke.
1

FISHER*
X
TRAVEL
STEM 3/8-Inch 1/2-tnch 3/4-Inch
(9.5 mm) Stem (12.7 mm) Stem (19.1 mm) Stem
Inches
1-1/8 or tess 3.19 3.44 3.94
1- 1/2 3.56 3.81 4.31
2 4.00 4.25 4.75
2- 1/2 4.44 4.69 5.19
3 4.88 5.12 5.62
30 MAX.
s
3-1/2 5.31 5.56 6.06
4 5.75 6.00 6.50
Millimeters i
29 or less 81 87 100
30* MAX.
38 90 97 109
51 102 108 121
64 113 119 132
76 124 130 143
89 135 141 154
102 146 152 165
Figure 6. Spacing for Mounting on Other

Than Fisrier Actuators
6. Position the actuator to its mid-travel position, inde-

pendent of the valve positioner, by use of handwheel or
0DEOREE
manual loading regulator. ARM INDEX
MARKS <T}
30 DEGREES < J J
7. Slip the round end of the travel pin (key 60) into the
siot on the rotary shaft arm (key 2).
30 DEGREES C D / \ ' ^h
8. Slide the square end of the travel pin into the pin
holder and pin lock (keys 61,59). Place the pin lock and
ARM AT MID-TRAVEL POSITION
holder into the slot in the connector arm (key 48). Screw
NOTES:
the cap nut (key 62) on loosely.
CD MAXIMUM ROTATION FROM MID-TRAVEL POSITION.
[]f> ALIGN INDEX MARKS AS SHOWN FOR MID-TRAVEL POSITION.
CAUTION Figure 7. Rotary Shaft Arm and Case Index Marks
Never set the travel pin at a setting that is

less than the actual actuator stroke. Setting © If a standard travel pin setting was made (that is,
the travel pin at a setting that is less than with the travel pin setting equal to total actuator travel),
the actual actuator stroke will cause the stroke the actuator to each end of its travel. At each end 0
cam to rotate more than 60 degrees, caus- of travel, the case index marks should be in line with the
ing damage to the cam or other parts. 30-degree index marks on the arm. If the index marks
are not in line, loosen the cap nut (key 62) and make a
lateral adjustment of the travel pin (key 60). After making
9. Check to be sure that the actuator is at its mid-travel this adjustment, tighten the cap nut and re-check the
position. Lift the rotary shaft arm so that the index marks arm at the mid-travel position. If the 0-degree index
on the rotary shaft arm and case indicate the mid-travel marks are not in line, repeat this procedure, j
position as shown in figure 7, or lift the rotary shaft arm
so that the slot In it is parallel with the connector arm © If a special travel pin setting was made (that is, with
(key 48, figures 3 or 4). the travel pin setting greater than total actuator travel),
check the index marks using a procedure similar to that
10. Position the travel pin so that it is perpendicular to for standard settings. The arm will not rotate a full 60
the connector arm and matches the total actuator travel degrees as the actuator Is traveled, and the 30-degree
on the rotary shaft arm. Tighten the cap nut (key 62, index marks on the cam will not reach the case index
figures 3 or 4). marks. If necessary, adjust the travel pin position so that
the 30-degree marks are the same distance from the
11. Check the travel pin setting by the following respective case index mark at each end of actuator
procedures: travel.
Correct Cam Position Failure to provide such protection might

result in personal Injury and equipment
jease refer to figures 13, 14, or 15. damage. J
1. Locate the 1/4-inch NPT "IN" connection in the

Note Type 67AFR regulator. Connect a clean, dry, and non*
corrosive air supply pressure source to the "IN * 1
• For Valve Positioners: The small arrow on connection. <

the valve positioner cam must point in the
direction of stem movement with increasing
actuator diaphragm pressure.
WARNING
o For Valve Stem Position Transmitters:
The arrow on the valve stem position trans- Personal injury or property damage might 1
mitter cam must point up toward the nozzle occur from an uncontrolled process if the
to give increasing output pressure with supply medium is not clean, dry air or non-
downward stem movement; if the arrow corrosive gas. Install a 40 micron filter and >
points down, output pressure wilt decrease suitable equipment to dry the supply medi-
with downward stem movement. um, and establish a maintenance cycle to .
check the filter and equipment. Typically,
If the arrow is pointing in the wrong direc- the filter/regulator supply pressure should |!
tion, use the following procedure to re- - not exceed 250 psig (17.3 bar) at a maxl-
move, reverse, and re-install the cam. •-. mum temperature of 1 5 0 ° F ( 6 6 ° C ) . For
more specific filter/regulator limits, please
refer to the appropriate instruction manual.
|/hen mounting a valve positioner or valve stem position
transmitter, check to see If the correct cam (key 4) or For corrosive media, make sure the tubing
"am position has been selected. To change the cam, and instrument components that contact
nhook the spring (key 38), and remove the cam bolt the corrosive medium are of suitable non-
„ n d nut (keys 6, 45). Remove the cam and spring corrosive material. The use of unsuitable
retainer bracket (key 43). To install the cam, tighten the materials might result in personal injury or !'
ut all the way onto the cam bolt. Attach the cam and property damage due to the uncontrolled
pring retainer bracket with the cam bolt. Tighten the release of the corrosive media.
Jolt to secure the cam. Then, tighten the nut against the
spring retainer bracket. Hook the spring into the spring Supply Pressure Source—The supply pressure should,
gainer bracket. be high enough to permit setting the regulator 5 psi (0.3
bar) above the upper limit of the appropriate pressure
Details on cam characteristics can be found in the range, for example: 20 psig (1.4 bar) for a 3 to 15 psig
nortion on cam information in the section on operating (0.2 to 1.0 bar) range. However, do not exceed the
^formation. maximum allowable supply pressure of 50 psig (3.4 bar)
nor the pressure rating of any connected equipment.;
2. Make the other pressure connections, as described

ressure Connections below:
WARNING Output Pressure—If the valve positioner has been

mounted at the factory, the output of the valve position-
Valve positioners and valve stem position er will be piped to the supply connection on the actuator.
transmitters are capable of providing full If the valve positioner is being mounted in the field]
supply pressure to connected equipment. locate the 1/4-inch NPT valve positioner "OUTPUT"
Supply pressure must never exceed the connection. Run 3/8-inch tubing between the actuatorj
maximum safe working pressure of any supply pressure connection and the "OUTPUT" con-'
connected equipment. nection. The output of a valve stem position transmitter!
generally must be piped to an instrument that indicates
If the source of supply pressure is capable valve stem position.
of exceeding any of the maximum safe
working pressures of connected equip- Instrument Input—A 3582 Series pneumatic valve posi-
ment, take appropriate steps during instal- tioner requires tubing from the control device to the 1/4-.
lation to protect the valve positioner or inch NPT "INSTRUMENT" connection. The factory will
valve stem position transmitter and all con- make th's connection if the control valve assembly is
nected equipment against overpressure. ordered with the control device mounted.
j' 1
3582 and 3583 Series FISHER
The Type 3582i electro-pneumatic valve positioner re-

quires a 4 to 20 milliampere dc current input signal from TERMINAL POSITIONER
BLOCK• HOUSING
the control device. A 1/2-inch NPT conduit connection is
provided for properly wiring electrical installations. For
more information, see the following section. CONTROL ,
DEVICE +
Vent—The screened opening in the back of the case

marked "VENT" should be left open to prevent pressure 0
buildup inside the case and also to provide a drain hole
for any moisture that might collect inside the case. Also
be certain that the exhaust holes in the relay (key 32, 0
figure 16) are kept open.
3. After pressure connections have been made, turn

on the supply pressure and check all connections for
leaks. NOTE:
LL> FOR TROUBLESHOOTING. OR MONITORING OPERATION,
AN INDICATING DEVICE CAN BE A VOLTMETER ACROSS
A 250 OHM RESISTOR OR A CURRENT METER.
Electrical Connection for Type 3582i

Figure 8. Typical Field Wiring Diagram
Valve Positioner
• For explosion-proof applications:

Installation Of Type 582i Converter! )
Personal injury or property damage may
result from fire or explosion if a spark is
introduced into an explosive atmosphere.
To avoid personal injury or property dam- Avoid personal injury or equipment damage
age, disconnect power before removing the from the sudden release of process fluid.
converter cover in an explosive atmo- Before mcnting the Type 582i converter:
sphere. Furthermore, install a suitable con-
duit seal no more than 18 inches (460 mm) © Isolate the valve from the process,
from the converter. Personal injury or prop- o Release process pressure, and
erty damage might result from explosion If o Vent the actuator loading pressure.
the seal is not installed.
• For intrinsically safe installations,

please refer to factory drawings or to in- Note ,
structions provided by the barrier manufac-
turer for proper wiring and installation. Before planning to retrofit an installed 3582
Series positioner, please refer to the posi-
tioner mounting plate illustration shown in
Note
figure 5. Mounting plates with a three-hole
mounting pattern (positioner to mounting
Connect the transducer grounding terminal plate) cannot support a Type 582i convert-
to an earth ground. er. Do not attempt to mount a Type 582i
converter on an existing 3582 Series posi-
1. Locate the 1 /2-inch NPT conduit connection on the tioner which has a three-hole mounting
Type 582i converter case. pattern.
2. Install field wiring through the conduit. For explo-
sion-proof applications, install a suitable conduit seal no
more than 18 inches (460 mm) from the converter. If a 3582 Series pneumatic valve positioner has previ-
ously been installed using a mounting plate with a five-
3. See figure 8. Connect the positive wire from the hole mounting pattern (positioner to mounting plate),
control device to the positive ( + ) terminaf of the con- either at the factory or in the field, it can be upgraded to
verter, and the negative wire from the control device to a Type 3582i electro-pneumatic valve positioner by in-
the negative ( - ) terminal of the converter. Be sure the stallation of a Type 582i converter. To install a Type 582i
unit is properly grounded. converter, please refer to the following instructions.
I. Please eontaci your Flstier sales ollico or representative belore planning lo upgrade
any existing 3562 Series valvo positioner by field installation of a Type B82i electro-
pneurnatlc converter. Also, refer to this sacuon ol the Instruction manual which
describes held Installation ol a Typo 5B2i converter.
too
90 —
eo — — —
2 3 0 70
CAM "7
/
/
60 c CAM /
z SO— /
u
I 40 / CA
BM / _—
JO —
A
a
100 10 20 30 40 SO 60 70 80 90 »0 40 SO 60 TO $0 90 100 i 30 40 iO 60 70 60
I. PERCENT VALVE STEM TRAVEL PERCENT fi-OW PERCENT FLOW
O PERCENT CORRESPONDS 10 .t..r. N
I STRUMENT PRESSURE - FLOW USTfU
i MENT PRESSURE • FLO*
MNIM
I UM DA
I PHRAGM PRESSURE CHARACTERSI TC
I WIH EQUAL CHARACTERSI TC
I WTIH LN
I EAR
PERCENTAGE VALVE PLUG AT WLVE PLUG AT CONSTANT
CONSTANT PRESSURE DROP Sti L>go PRESSURE C«OP
OU&JA
i
figure 9. Cam Characteristic Curves Figure 10. Flow Characteristics with Figure 11. Flov/ Characteristics with
Dillorent Cams and Equal Different Cams and
Percentage Valve Plug Linear Valve Plug
Note 7. Mate the converter and new gasket to the side of ;
the valve positioner case using the alignment pins on the

Inspect the existing valve positioner. Deter- bypass block.
mine the input signal range. It must be 3 to
15 psig. if input signal range is not 3 to 15 8. -Tighten the screws.
psig, please refer to the appropriate sec-
tions of this manual describing input signal 9. Reconnect the pressure connections according to
ranges and how to change the range the instructions given in the appropriate section of this
spring. manual.
Inspect the positioner mounting plate. Be certain 10. Make the electrical connection according to the
t. it the positioner is mounted with five screws to the instructions given in the appropriate section of this
plate. The plate then mounts to the actuator with two manual.
r~rews.
11. Complete the standard calibration procedure de-
Vv ion the positioner is attached to the correct mounting scribed in the appropriate section of this manual.
plate, proceed with the installation by taking the control
\ jve/actuator/positioner package out of service. 12. Return the control valve package to service.
2. Properly vent the actuator loading pressure and the

supply pressure. Disconnect the pressure tubing con-
i jctions to the valve positioner.
3. Locate the two screws (key 105, figures 20 or 21)

holding the bypass block (key 34A, figures 20 or 21) to Instructions for setting the zero and span are found in 1
1 a valve positioner case. Remove the bypass block by the sections on calibration of 3582 Series units and 3583
idnoving the two screws. Save the screws to reattach Series units.
the Type 582i converter.
Remove and discard the existing gasket (key 104,

figures 20 or 21) between the bypass block and valve
Valve Positioner Cam Information
positioner case.
Note
Unpack the Type 582i converter to be installed.
The small arrow on the valve positioner cam
Find the new gasket. Position the new gasket on the must point in the direction of stem move-
|pe 582i converter. See figure 22. Place the existing ment with increasing actuator diaphragm
iJrews (key 105, figures 20 or 21) through the appropri- pressure. If the arrow is pointing in the
ate holes in the Type 582i converter housing and new wro^g direction, remove, reverse, and re-
f sket. install the cam.
/2?
FISHER
•' -
Isolate the control valve and shut off pres- (key 38, figure 16), and remove the cam bolt
sure lines to the valve positioner. Unhook and nut (keys 6, 45, figure 16). Remove the
the spring (key 38, figure 16), and remove cam (key 4, figure 16) and spring retainer
the cam bolt and nut (keys 6, 45, figure 16). bracket (key 43, figure 16). To install the
Remove the cam (key 4, figure 16) and cam, tighten the nut all the way onto the
spring retainer bracket (key 43, figure 16). cam bolt. Attach the cam and spring retain-
To install the cam, tighten the nut all the er bracket. Tighten the bolt to secure the
way onto the cam bolt. Attach the cam and cam. Then, tighten the nut against the
spring retainer bracket with the cam bolt. spring retainer bracket. Hook the spring
Tighten the bolt to secure the cam. Then, into the spring retainer bracket.
tighten the nut against the spring retainer
bracket. Hook the spring into the spring
retainer bracket. The linear cam is the only cam available for the 3583
Series valve stem position transmitter. When referring
When shipped from the factory, 3582 Series valve posi- to figures 9, 10, and 11, use only the cam A reference.
tioners and the Type 3582i valve positioner will be
equipped with three cams, marked A, B, and C. Cam A,
the linear cam, will be installed in the operating position. Valve Positioner Bypass Operation<,
Cams B and C, the characterized cams are attached to
the inside of the case. Type 3582 and 3582D valve positioners are Supplied
with a bypass assembly. Please refer to figure 20.
In figures 9, 10, and 11, the relationship of input signal
span to valve travel can be seen for each cam. In figure
9, the curves are based on 60 degrees cam rotation for " CAUTION
100 percent stem travel. At 50 percent of the input signal *;
span, for example, the valve will have traveled 50 per- Do not use the bypass when the valve posi-
cent with cam A, 68 percent with cam B, and 32 percent tioner is reverse-acting or is in split-range
with cam C. When cam A is the operating cam, the flow operation. In these cases, bypassing the
characteristic of the control valve will be that of the valve positioner will send the input signal
installed valve plug. When either cam B or C is installed directly to the actuator. Such a change will
as the operating cam, the characteristic will be altered affect the desired operation and possibly
so that more or less input change will be required to upset the system. The bypass is used only
create a given change in flow. Figures 10 and 11 indicate when the input signal range is the same as
the characteristic that can be expected with cam A, B, or the valve positioner output range required
C on normally closed control valves. for normal actuator operation.
The extra cams, B and C, are intended to be used for The bypass block (key 34A) is labeled to indicate in what
solving instability problems caused by control valves position the bypass handle (key 34D) should be placed
with nonlinear characteristics and changes in loop gain for valve positioner or bypass operation. With the point-
occur with different flow rates. er of the bypass handle lined up with the small dash
above the word "POSITIONER", the input signal goes
to the valve positioner bellows and the output pressure
of the valve positioner goes to the actuator. With the
Valve Stem Position Transmitter Cam bypass handle pulled forward, the pointer is lined up
Information with the small dash above the word "BYPASS", and the
input signal goes directly to the actuator.
Note
The small arrow on the valve stem position Note

transmitter cam must point up toward the
nozzle to give increasing output pressure A difference between the input and the
with downward stem movement; if the ar- valve positioner output pressure could
row points down, output pressure will de- cause a transient bump in the controlled
crease with downward stem movement. If system when the bypass control is moved
the arrow is pointing in the wrong direction, to "BYPASS."
remove, reverse, and re-install the cam.
Isolate the control valve and shut off pres- With a reverse-acting or split-range valve positioner, it
sure lines to the actuator and valve stem might be desired to lock the bypass handle so the
position transmitter. Unhook the spring bypass cannot be used. To accomplish this, first shut off
12
Table A. Standard Instrument Input Signals and Range Springs

INSTRUMENT ALLOWABLE RANGE RANGE
STANDARD INPUT SIGNAL(')
INPUT SIGNAL SPRING SPRING
SPAN
RANGE Minimum Maximum COLOR PART NUMBER
3-15 psig 12 psig 1 psig f 21 psig
0.2-1.0 bar 0.8 bar 0.07 bar 1.4 bar Silver 1V621727012
4-20 mAt ) a 1 6 mA 2 mA 22 mA
5-25 psig 20 psig 1 psig 30 psig
Green 1V621827012
0.3-1.7 bar 1.4 bar 0.07 bar 2.0 bar
6-30 psig 24 psig 1 pslq 35 psig
- Red 1V621927012
0.4-2.0 bar 1.6 bar 0.07 bar 2.4 bar
t. Minimum and maximum allowable Inpul signals ensure functional operation.
For Typo 3582i. only.
the instrument and supply pressure to the valve posi- Table 5. Split-Range Capabilities
t ner. Then, remove the hex head shoulder screw from
iri
3582 SERIES POSITIONERS
t i center of the handle. Rotate the handle 180 degrees 3 to 15 Psig or 6 to 30 Psig or
&,.d position it between the two lugs cast on the bypass 0.2 to 1.0 Bar 0.4 to 2.0 Bar
block, Replace the shoulder screw. Split Input Signal Input Signal
Psig Bar Psig Bar
3 to 9 0.2 to 0.6 6 to 18 0.4 to 1.2
Two-way
Input Signal Ranges 9 to 15 0.6 to 1.0 18 to 30 1.2 to 2.0
3 to 7 0,2 to 0.5 6 to 14 0.4 to 0.9
5 jindard input signal ranges for valve positioners and Three-way 7 to 11 0.5 lo 0.7 14 to 22 0.9 to 1.5
\ ve stem position transmitters are shown in table 4. 11 to 15 0.7 to 1.0 22 to 30 1.5 to 2.0
TYPE 3582! POSITIONER
To change from one standard range to nnother, it is 4 to 20 Mllllampere
Split
r 'cessary to change the range spring. Please refer to Input Signal
t i instructions for changing the range spring In the 4 to 12
Two-way
maintenance section of this manual. For split-range 12 to 20
operation of 3582 Series valve positioners or the Type 4 to 9.3
< 82i valve positioner, it is not normally necessary to Three-way 9.3 to 14.7
Ci.ange the spring. Please refer to the section below for 14.7 to 20
split-range information.
2. Vary the input signal, observing the span required
to stroke the valve completely.
v 3. Readjust the flapper assembly along the beam until

a l v e Positioner Split-Range Operation full valve travel results from the desired change in input
|e 3582 Series valve positioners and the Type 3582i signal. For example, for a 3582 Series valve positioner
valve positioner are suitable for split-range operations with a 3 to 15 psig (0.2 to 1.0 bar) input signal range
where the input signal, either pneumatic or dc current, spring on a two-way split, a 6 psi (0.4 bar) change should
! Wi a single control device, is split between two or stroke the valve completely.
i.,ore control valves. No additional parts are required to
change an existing valve positioner to one suitable for 4. Apply an input signal equal to the low value of the
; lit-range operation. input signal range. For example, for a 3582 Series valve
positioner with a 3 to 9 psig (0.2 to 0.6 bar) input signal
"I able 5 shows some typical split-ranges for the valve range, set the input signal at 3 psig (0.2 bar).
positioners.
5. Adjust the nozzle (D, figure 12) until the actuator is
\ change to split-range operation, perform the pre- at the starting position (fully up or fully down depending
calibration alignment procedures in the Calibration sec- on the action selected) corresponding to the low input
tion and proceed as follows: signal.
. Move the flapper assembly (key 19, figure 16) along Note
the beam (key 29, figure 16) to increase travel. The
f'-jpper assembly can be positioned by hand or by using The flapper must approach the nozzle
i screwdriver in the slot of the setting adjustment gear squarely at the midpoint value of the input
lu, figure 12). signal range for proper operation.
13,
On some applications where the input sig-

nal span is comparatively small (as found
with split-range applications), the nozzle
adjustment might not be enough to set the
proper starting point. Also, some difficulty
might be experienced in keeping a valve
positioner from unloading when the input
signal continues to increase above the
split-range.
For example, for a 3 to 9 psig (0.2 to 0.6 bar)

input signal range, the input signal could
increase to 15 psig (1.0 bar). Continued
bellows travel due to the increased input
signal over the split-range could drive the
flapper into the nozzle. The impact could
possibly cause misalignment between the
flapper and nozzle. Such a misalignment, in
turn, could affect split-range calibration.
In these c a s e s , an adjustment of the follow-

er assembly screw (A, figure 12) Is required
in addition to the nozzle adjustment to ob-
tain satisfactory results.
Figure 12. Partial View for Beam Leveling and Calibration

\
Note
assembly to tKb opposite quadrant of the beam. Adjust
The 3582 Series valve positioners require a for travel and starting point according to the instructions
relatively small percentage of the instru- outlined in the section on valve positioner calibration.
ment pressure span to obtain full valve
travel. With the travel pin set to equal the
valve travel, the input signal change re-
quired to fully stroke the valve can be re-
Reversing Valve Stem Position
duced to 33 percent of normal input signal Transmitter Action j
change. With the travel pin set to a value
Key numbers used in this section are shown in figure 16
greater than the valve travel, the input sig-
unless another figure is indicated. [!
nal change required to fully stroke the valve
can be reduced to a minimum of 20 percent
The flapper of the 3583 Series vaive stem; position
of normal input signal change.
transmitter is^'always positioned in the reverse-acting
quadrant. See figure 15. To reverse the signal, reverse
the cam as follows: 1
1. Unhook the spring (key 38), and remove the cam

Reversing Valve Positioner bolt (key 6), cam (key 4), and spring retainer bracket (key
43).
Output-To-Actuator Action
No additional parts are required to convert a 3582 2. Tighten'the nut (key 45) all the way onto the cam
Series valve positioner or Type 3582i valve positioner bolt.
from direct acting (an increasing input signal, either
pneumatic or electrical, increases output pressure) to Note
reverse acting (increasing input signal decreases output
pressure) or vice versa. The position of the fiapper The arrow stamped on the cam must point
assembly on the proper beam quadrant (see figures 12, toward the nozzle in order to give increas-
13, 14, or 15) dictates the action. The direct-acting ing output pressure with downward stem
quadrant of the beam is labeled "DIRECT" and the movement. If the arrow points down away
reverse-acting quadrant is labeled " R E V E R S E " . To from the nozzle, output pressure will de-
change the actuator action, simply move the flapper crease with downward stem movement.
14
i. Reverse the cam (key 4) from its original position. other pivot points slightly. Then, repeat the
Attach the cam and spring retainer bracket with the cam original pivot adjustment. Continue this
bolt. Tighten the cam bolt to secure the cam. Then process until the required output pressure
jjhten the nut against the spring retainer bracket. can be attained.
i
4. Hook the spring into the spring retainer bracket.
1. Stroke the actuator in its mid-travel position with a
5. After reversing the cam, complete the calibration of handwheel or a manual loader. Referring to figure 4, lift
„ie unit by following the appropriate instructions. the rotary shaft arm (key 2) so that the index marks on
the rotary shaft arm and case indicate the mid-travel
position as shown in figure 7, or lift the rotary shaft arrri
so-that the slot in it is parallel with the connector arm
Calibration Of Valve Positioner Or (key 48). Then, position the travel pin (key 60) so that it is
perpendicular to the arm and matches the total actuator
J a l v e S t e m Position Transmitter travel on the rotary shaft arm. Tighten the locking nut
(key 62). .
Pre-Caiibration Alignment
Note
| Note
Valve stem travels less than 1-1/8 inches
(29 mm) require that the travel pin be set at !
The following procedures for pre-calibra-

1-1/8 inches travel on the rotary shaft arm.
tion alignment and calibration are applica-
ble for both the 3582 Series and the Type
3582i valve positioners and 3583 Series
2. Refer to figure 16. Loosen the locknut (key 71) and
valve stem position transmitters.
turn the nozzle (key 18) clockwise to its lowest position.
Then screw the nozzle out (counterclockwise) 2 turns
and tighten the locknut.
The purpose of alignment is to ensure the correct me-
chanical position of parts so the valve positioner can be
3. Remove any loading pressure and/or disengage
Calibrated. It is necessary to provide the appropriate any handwheel used to position the actuator. Connect
supply pressure, and you must be able to manually set the necessary tubing from the valve positioner output to
the Input signal at the midpoint of the desired input the actuator pressure connection.
'pignal range.
I 4. Connect the input to the valve positioner and set the
See figure 12. The flapper assembly can be positioned input signal value at midrange. For example, for a 3582
by hand to different settings on the beam assembly or by Series valve positioner with a 3 to 15 psig (0.2 to 1.0 bar)
using a screwdriver in the slot of the nylon adjustment input signal range, set the value at 9 psig (0.6 bar). Then
gear G. apply supply pressure to the valve positioner.
| Note Note
The beam (F, figure 12) is leveled at the For proper operation, the flapper must ap- j
factory prior to shipment. Once the beam is proach the nozzle squarely. Inspect the
leveled, no future leveling should be re- nozzle/flapper alignment. Be sure the flap-
quired unless the pivot pin (C, figure 12) or per is not loose, bent, or twisted.
the locking hex nut (B, figure 12) are
changed or if the bellows assembly or
range spring are replaced or the valve posi- 5. Move the flapper assembly to zero on the beam
tioner is to be set up for split range scale. Loosen the follower assembly screw locknut (key
operation. 19H, figure 18) and adjust the follower assembly screw
(key 19G, figure 18) to yield an output pressure equal to
the mid-point value of the output pressure range. Tight-
To level the beam, proceed as follows: en the locknut.
6. Move the flapper assembly to position 10 on the

Note direct-acting side of the beam scale. Loosen the bellows
assembly locknut (B, figure 12) and adjust the bellows
In the following steps, if it ts not possible to pivot pin (key 30, figure 16) to yield an output pressure
attain the required output pressure when equal to the mid-point value of the output pressure
adjusting a pivot point, adjust one of the range. Tighten the locknut.
15
Table 6, Minimum Travel with Given Pin Position
TRAVEL PIN MINIMUM TRAVEL
POSITION ALONG AVAILABLE
ROTARY SHAFT ARM Inch mm
1-1/8 1/4 6
1-1/2 5/16 8
2 7/16 11
2-1/2 1/2 13
3 5/8 16
4 7/8 22
7. Move the flapper assembly to the left to position 10

on the reverse-acting side of the beam. Loosen the
locknut (C, figure 12) and adjust the beam pivot pin {key
76, figure 16) to provide an output pressure equal to the
mid-point value of the output pressure range. Tighten
the locknut.
8. Repeat steps 5, 6, and 7 to optimize alignment.

Recheck to make sure the flapper approaches the noz-
zle squarely. If it does not, adjust the nozzle and re-level
the beam. After alignment, the valve positioner is ready Figure 13. Schematic Illustration of 3582 Series Positioner
for calibration.
Calibration 5. Repeat steps 3 and 4 until the correct travel is

achieved. (Each time the flapper position is changed
1. Shut off the supply pressure to the valve positioner. according to step 4, it is necessary to repeat step 3 to
Connect or reconnect the necessary tubing from the provide proper zero.) ,
valve positioner output to the actuator supply connec-
tion. Connect the input to the valve positioner and set Table 5 lists travel pin settings and corresponding mini-
the input signal value at midrange. mum valve travel that can be obtained by moving the
flapper assembly toward zero on the beam scale.
2. Move the flapper assembly to approximately posi-
tion 6 in the proper operating quadrant of the beam
(direct or reverse acting), and apply supply pressure to
the valve positioner. The actuator should move close to Principle of Operation
its mid-travel position. If it does not, first check for loose
linkage or improper cam installation. If the beam is not
properly leveled, a minor nozzle height adjustment Please refer to the operational schematics in figures 13,
might be necessary to make the desired input signal 14, and 15.
value correspond to the starting point of travel.
3. Apply an input signal equal to the low value of the

3582 Series Valve Positioners
input signal range. For example, for a 3582 Series valve
positioner with a 3 to 15 psig (0.2 to 1.0 bar) input signal The 3582 Series (the Type 3582 and Types 3582A, C, D,
range, set the input signal at 3 psig (0.2 bar). Loosen the and G pneumatic valve positioners) accept a pneumatic
locknut (key 71, figure 16) and adjust the nozzle (key 18, input signal from a control device. The operational sche-
figure 16) until the actuator moves to the proper end of matic in figure 13 depicts the direct-acting pneumatic
its travel. Changing nozzle position is intended only as a valve positioner.
means of zero trim adjustment. Whenever nozzle posi-
tion is changed, the zero reference point is changed. In a diaphragm-actuated, sliding stem control valve
package with a 3582 Series valve positioner, supply
4. Apply an input signal equal to the high value of the pressure is supplied to the Type 83L relay supply valve
input signal range and observe the actuator travel. If the and fixed restriction. The diameter of this restriction
actuator travel is short of its expected range, increase orifice is less than the diameter of the nozzle, so that air
the travel by moving the flapper assembly to a higher can bleed out faster than it is being supplied when the
number on the beam. If the actuator reaches the end of flapper is not restricting the nozzle.
its desired travel with an input signal less than the high
value of the input signal range, decrease the travel by When the input signal increases, the bellows expands
moving the flapper assembly toward a lower number on and moves the beam. The beam pivots the flapper and
the beam. See figure 12. restricts the nozzle. The nozzle pressure increases and
16
i
Figure 14. Schematic Illustration ol Type 3582/ Positioner
|oves the relay diaphragm assembly to open the supply

prt. Output pressure to the diaphragm actuator in-
creases, moving the actuator stem downward. Stem
movement is fed back to the beam by means of a cam Figure 15. Schematic Illustration of 3583 Series Transmitter
at causes the flapper to pivot slightly away from the
..Lzzle. Nozzle pressure decreases and the relay supply
valve closes to prevent any further increases in output
ressure. The valve positioner is once again in equilibri- 3583 Series Valve Stem Position
on but at a higher input signal and a slightly different
napper position.
Transmitters
3583 Series (Type 3583, 3583C) pneumatic valve stem
|hen the input signal decreases, the bellows contracts position transmitters (figure 15) are mechanically linked
jided by an internal range spring) to move the beam to the valve stem in a diaphragm-actuated, sliding-stem
and to pivot the flapper slightly further from the nozzle. control valve package. A change in the position of the
Nozzle pressure decreases and through relay opera- valve stem changes the output pressure produced by
on, the exhaust port in the relay opens to release the position transmitter. This signal is then piped to a
Japhragm casing pressure to atmosphere, permitting reporting or recording device to indicate valve stem
the actuator stem to move upward. Stem movement is position. ;
' sd back to the beam by the cam to reposition the beam
pd dapper. When equilibrium conditions are obtained, The action of a valve stem position transmitter can be
ute exhaust valve closes to prevent any further de- changed by reversing the internal cam. The valve stem
crease in diaphragm case pressure. position transmitter cam is supplied with an arrow
stamped on one side. The cam can be positioned to
,he principle of operation for reverse acting units is obtain either increasing or decreasing output pressure
similar except that as the input signal increases, the with downward stem motion. If the cam arrow points
diaphragm casing pressure is decreased. Conversely, a toward the nozzle, the output pressure increases; if the
ecreasing input signal causes an increase in the pres- cam points away, the output pressure decreases with
ure to the diaphragm casing. downward stem motion.
Type 3582i Valve Positioner

jhe Type 3582i electro-pneumatic valve positioner (fig-
re 14) accepts a dc current input signal provided to the
Type 582i electro-pneumatic converter attached to the Before attempting maintenance, to avoid
waive positioner. The Type 582i provides the pneumatic personal injury and damage to the process
jiput signal pressure used by the pneumatic valve system caused by an uncontrolled process
Jositioner. or by the sudden release of pressure:
fe" 17
3582 and 3583 Series FISHER
* Isolate the control valve, Changing the Range Spring

• Disconnect the input signal, and
« Shut oft all pressure tines to the valve Key numbers used in this procedure are shown in figure
p o s i t i o n e r or v a l v e s t e m p o s i t i o n 16.
transmitter.
The range spring is inside the bellows assembly. Stan-
For explosion proof applications, discon- dard range spring data is tabulated in table 5. When a
nect power before removing the converter given Input signal range is split to operate two or more
cover in an explosive atmosphere. control valves, it is not normally necessary to change the
range spring. The input signal range lor which the range
spring is suitable can be found stamped on the
CAUTION nameplate.
When replacing components, use only The following steps outline the procedure for changing
components specified by Fisher Controls. the range spring (key 8, figure 16) in a valve positioner or
Substitution with other components may valve stem position transmitter. Unless otherwise noted,
result in the positioner or transmitter no all key number references can be located in figure 16.
longer meeting safety certification require-
ments. Also, always use proper component 1. Unhook the extension springs (keys 27, 77) from
replacement techniques. Improper tech- the beam (key 29).
niques and poor quality repairs can Impair
the safety features of the device. 2. Loosen and remove the two screws (key 13), and
lock washers (key 12) that hold the bellows assembly
Due to normal wear or damage from external sources (key 7) in place.
(such as debris in the supply medium), periodic mainte-
nance or repair of the valve positioner or valve stem 3. Lift out the beam and bellows assembly. Be careful
position transmitter may be necessary. Maintenance of not to lose the small O-ring (key 11).
these units consists of troubleshooting, removal for
inspection, and replacement of component parts. 4. Loosen the machine screw (key 10), and remove the
range spring (key 8).
In case of operational difficulties, the valve positioner or
valve stem position transmitter should first be checked 5. Install a new range spring, making sure the small
to see that adjustments have been properly made. All end of the spring will be against the spring seat (key 9).
pressure lines and connections should be checked for Replace the spring seat and tighten the screw.
leaks.
6. If the O-ring (key 11) is worn or damaged, replace it
with a new one after applying lubricant (key 94). Making
The pneumatic relay and gaskets should also be insure the O-ring is in place, install the bellows assembly,
spected and replaced if necessary. If necessary, the securing it with two mounting screws and lock washers.
relay restriction can be cleaned or replaced. Remove the
restriction assembly (key 9, figure 19). Clean the restric- 7. Install the beam over the pivots and hook the
tion, install a new O-ring (key 14, figure 19) if necessary, springs to the beam.
and replace the restriction assembly.
8. Minor adjustments might be necessary to re-level
Instructions are given below for: the beam as outlined in the manual section describing
the pre-calibration alignment of the valve positioners or
• changing the range spring; the valve stem position transmitters. After leveling the
beam, calibrate according to the appropriate calibration
© replacing gaskets, nozzle O-rings, and the relay; instructions.
• adjusting the flapper pivot;
• replacing the Type 582i converter primary O-ring

Replacing Gaskets
and filter; Key numbers used in this procedure are shown in
figures 20 and 21.
• replacing the Type 582i converter cover O-ring;
A gasket (key 34C) is located behind the bypass handle
9 removing the Type 582i converter; and (key 34D) of the 3582 Series valve positioners or mani-
fold (key 34D) of the 3583 Series valve stem position
© reassembling the Type 582i converter. transmitters.
18
/Sf
Figure 16. Assembly Drawing foe. 3582 and 3583

Series Positioners and Transmitters
19
1. Remove the screw (key 34G), and lift out the bypass
handie or manifold.
2. Remove the gasket.
3. Apply lubricant (key 94, parts list) to both sides of

the gasket when used with the bypass assembly of the
3582 Series valve positioners. Do not apply lubricant to
the gasket when the bypass assembly is not used.
4. Set the new gasket In place on the four locating pins

and replace the bypass handle or manifold. Figure 17. Nozzle Sub-Assembly
The case gasket (key 104) is located between the case

(key 1, parts list) and the bypass block (key 34A) in a
3582 Series valve positioner or a 3583 Series valve stem 6. Reinstall the nozzle onto the nozzle adapter, leav-
position transmitter or the housing of the Type 582i ing the locking nut loose.
converter (key 1, figure 22).
7. Replace the flapper and follower assembly. Inspect
5. Remove the two mounting screws (key 105) that the assembly and make sure the letter "T" on the
hold the bypass block or converter housing to the case flapper is visible.
and remove the unit to expose the case gasket.
8. Refer to the pre-calibration alignment and calibra-
6. Install a new gasket and replace the bypass block tion portions of the Calibration of Valve Positioner or
or converter housing. Valve Stem Position Transmitter section and verify
calibration.
7. Resume operation.
Relay Removal and Replacement

Replacing Nozzle O-Ring Use the following procedure when removing or replac-
ing a relay assembly that required maintenance, or
Key numbers used in this procedure are shown in
when installing a replacement relay assembly listed in
figures 17 and 18 except where indicated.
the parts list. Refer to figure 19 for key number
locations.
1. Remove the two screws (key 19C) that hold the
flapper and follower assembly (keys 19B, 19G) to the
1. For valve positioners using a bypass, direct action,
adjustment arm (key 19A).
and a full-range input signal, move the bypass control to
"BYPASS" and shut off the supply pressure. For all
other valve positioners and valve stem position trans-
CAUTION mitters, isolate the control valve from the system and
shut off all pressure lines.
For proper operation on reassembly, be
careful not to bend or twist the flapper or
nick the nozzle orifice. Note
2. Carefully remove the flapper and follower assembly A difference between input and valve posi-
for access to the nozzle (key 18, figures 16 or 17). tioner output pressure could cause a tran-
sient bump in the controlled system When
3. Loosen the locking nut (key 71), and unscrew the the bypass control is moved to "BYPASS."
nozzle (key 18).
4. Remove the locking sleeve (key 72) from the nozzle

adaptor (key 3). The nozzle adaptor is bonded to the 2. Remove the Type 83L relay (key 32, figure 16) from
positioner case with adhesive (key 96) and cannot be the back of the case by loosening the two mounting
removed. screws (key 10).
5. The O-ring (key 73) on the nozzle adapter can now 3. Reinstall the new relay assembly on the case, mak-
be removed, inspected, and replaced if necessary. Ap- ing sure the O-rings (keys 13, 15) are in place. Secure
ply lubricant (key 93) to the O-ring. with the two mounting screws (key 10).
20
/?£>
t
!

i mi Im i — mi mil ii iii 111 M i n 11 mm 11 hubi i i tinrn-it—nmi - " T r r n m i r n i l I ill I,
I
U. Resume operation by turning bypass lever to the

"POSITIONER" position or by connecting the valve
|ositioner or valve stem position transmitter and control
jalve to the system.
rtelay Maintenance
'^)se the procedure below to repair and replace the relay
Jssembly. Refer to figure 19 for key number locations.
Obtain the relay repair kit listed in the parts list. This kit
provides the parts to be used when repairing the relay
•issembly.
1. Remove the four screws {key 16) and separate the

Figure 18. Flapper Sub-assembly (Key 19)
jelay base {key 1), exhaust block {key 2), output block
assembly (key 4), and relay cap (key 3) by inserting a
casting lug are properly aligned. Place the relay base
screwdriver between the external casting lugs and
(key 1) on the diaphragm with proper casting lug
twisting.
alignment.
'2. Remove the diaphragm (key 8), diaphragm assem-
10. Insert the four screws (key 16) into the relay base
bly (key 7), spring (key 12), inner valve (key 6), gasket
(key 1), and tighten evenly in an "X" pattern.
jkey 5) and spring (key 11).
11. Install the two relay mounting screws (key 10) and
^3. Remove the nozzle and adapter assembly (key 9)
install the relay assembly to the positioner case.
and remove the O-rings {keys 14, 19). The restriction
hole in the nozzle and adapter assembly is 0.020 inches
12. Apply supply pressure to the positioner case and
to.51 mm) in diameter. Clean the hole with solvent.and
check the relay assembly for leaks with soap solution.
blow dry with air. If the hole is plugged, insert a wire in
the hole. Then, clean with solvent and blow dry with air.
bo not enlarge the hole. Adjusting the Flapper Pivot
4. Apply lubricant (key 20) to the O-rings (keys 14,19) Key numbers used in this procedure are shown in figure
before reinstalling the nozzle and adapter assembly into 18.
the relay base. Do not over tighten.
1. Loosen the two screws (key 19C).
5. Fold the diaphragm assembly (key 7) over and push
it through the exhaust block (key 2). 2. Tighten the pivot pin (key 19L) by compressing the
upturned ears of the arm support (key 19K). Tighten the
screws (key 19C) and make sure the flapper (key 19B)
6. Invert the relay cap (key 3) and install the spring (key does not rub on the supports. ;
A1). Place the gasket (key 5) on the relay cap, properly
'aligning the holes and the flat locating tab of the gasket
3. The flapper should be snug, but not constricting to
with the holes and casting lug of the relay cap. Set the
pivot action. I
inner valve (key 6) on the spring.
i
J 7. Place the output block assembly (key 4) on the Replacing Type 582i Converter Primary
gasket. Ensure the casting lugs and holes are properly
O-Ring and Filter
aligned. The inner valve will protrude through the valve
'seat insert of the output block assembly. Install the Key numbers used in this procedure are shown in figure
Isprlng (key 12). 22.
8. Orientate the diaphragm assembly (key 7) on the 1. Locate and remove the nozzle restriction adaptor
.exhaust block (key 2), and place both parts onto the assembly (key 4).
'output block assembly (key 4), inserting the spring (key
12) on the guide of the exhaust port. Ensure the casting 2. Inspect and replace, if necessary, the O-rings (keys
ilugs are properly aligned, 5, 6). Apply lubricant (key 15) to the O-ring before
i replacing.
' 9. Place the diaphragm assembly (key 7) on the ex-
haust block (key 2). Ensure the diaphragm tab and 3. Inspect and replace the filter cartridge (key 23).
s 21
FISHER 3
Replacing Type 582s Converter 4. Disconnect the supply tubing, output tubing, and
electrical conduit from the converter.
Cover O-Ring
Key numbers used in this procedure are shown in figure 5. If necessary, remove the Type 67AFR regulator by
22. removing the two screws (key 13). Then, remove the
regulator from the converter assembly. Inspect the
1. Unscrew and remove the converter housing cap O-ring (key 3) and replace if necessary. Apply lubricant
(key 2). Inspect and replace the O-ring (key 8), if neces- (key 15) to the o-ring before replacing.
sary. Apply lubricant (key 15) to the O-ring before
replacing. 6. Remove the two screws (key 11) holding the Type
582i converter to the valve positioner case. Remove the
converter from the valve positioner case (key 1, figure
Removing the Type 582i Converter 16). Inspect the gasket (key 20) and replace it if
necessary.
During the following converter removal procedures,
please refer to figure 22 for key number locations.
Reassembling the Type 582i Converter

CAUTION During the following converter reassembly procedures,
please refer to figure 22 for key number locations.
The converter module should never be dis-
assembled because the magnetism In the 1. If the Type 582i converter was removed from the
coils will decrease permanently. If mainte- valve positioner, install a new gasket (key 20) between
nance attempts indicate a faulty converter the converter housing and the valve positioher case.
module, replace the module or return the Attach the converter housing to the valve positioner
unit to your Fisher sales representative or case with the screws (key 11) and tighten the screws,
sales office.
2. If the l/P module was removed from the Type 582i
Note converter, reinstall the l/P module in the converter
housing.
To check the operation of the l/P module,
remove the pipe plug (key 12, figure 22), 3. Reinsert the two screws (key 9) and tighten them.
and connect a pressure gauge. When the
module is tested with a 20 psig supply 4. If other valve positioner components are removed,
pressure, the pressure output at a 4-milH- please refer to the appropriate reassembly procedures
ampere input signal should read 2.3 to 3.5 and assemble the valve positioner completely.
psig (0.16 to 0.24 bar). For a 20 psig supply
pressure, the pressure output at a 20-milli- 5. Reconnect the supply tubing, output tubing, and
ampere input signal should read 14.0 to conduit to the valve positioner.
15.5 psig (0.96 to 1.07 bar).
6. Reconnect the wiring to the terminal block. Recon-
nect the grounding wire to the housing ground screw
1. Turn off the input signal to the converter. Release all (key 10) and replace the cap (key 2).
supply pressure from the valve positioner.
2. Remove the cap (key 2), and disconnect the fielo!- Note
wiring from the terminal block. Disconnect the ground-
ing wire from the external ground screw (key 10). To check the operation of the l/P module,
remove the pipe plug (key 12, figure 22),
3. To remove the l/P module, remove the two screws and connect a pressure gauge. When the
(key 9), and pull the module out of the housing. Inspect module is tested with a 20 psig supply
the O-ring (key 6) and replace it, if necessary. Apply pressure, the pressure output at a 4-milli-
lubricant (key 15) to the O-ring before replacing. ampere input signal should read 2.3 to 3.5
psig (0.16 to 0.24 bar). For a 20 psig supply
a. If it is necessary to remove the entire Type 582i pressure, the pressure output at a 20-milli-
converter from the Type 3582i valve positioner, continue ampere input signal should read 14.0 to
with steps 4 through 6. Or, 15.5 psig (0.96 to 1.07 bar).
b. If replacing the l/P module only, obtain a replace-

ment l/P module fisted in the parts list and refer to the 7. Plug the output connection and apply 35 psig (2.4
procedures to reassemble the Type 582i converter. bar) to the supply pressure connection.
22
If it is necessary to replace either extension

ING spring (key 27 or 77, figure 16), check the
springs being used in the valve positioner
Do not exceed 35 milliamperes of current or valve stem position transmitter. If one of
' applied to the converter module. Higher the springs has a red color code and the
current values may damage the converter other has a yellow color code, either spring
, module. could be replaced independently. If the
I springs being used to not have color codes,
'8. Apply a 20 milliampere dc current input signal to the both springs must be replaced.
converter.
Part numbers in the following parts list are
9. Check for leaks using a soap solution or other for the new-style parts.
solution compatible with nitrile. Check any components
which were disassembled or disconnected.
Note
Parts in the following list are common to

both the 3582 Series valve positioners and
the 3583 Series position transmitters, un-
less identified by specific type or series
•Parts O r d e r i n g number.
i serial number is assigned to each valve positioner or

valve stem position transmitter and is stamped on the Parts Lest
nameplate. Always refer to this number when corre-
sponding with your Fisher representative regarding
Ipare parts or technical Information, When ordering 3582 Series Valve Positioners,
parts, also give the eleven-digit part number shown in
jhe following parts list.
Type 3582i Valve Positioner, and
3583 Series Valve Stem
i
Position Transmitters
Note
Depending upon the date manufactured,

these valve positioners and valve stem po- Parts Kits
sition transmitters will be equipped with Repair kit for positioner/transmitter (kit contains
one of two styles of rotary shaft assemblies keys 11, 16, 17, 33B, 34C. 34H. and 73. Note:
(key 2, figure 3) and cams (key 4, figure 16). This kit also contains keys 18C and 18E lor 3580
and 3581 Series) {for standard temperature j
the new rotary shaft assembly has six index applications only) ' R3580X00022
marks on the arm (see figure 7), and the Repair kit for Type 83L Relay '
tapped hole in the opposite end of the shaft {kit contains keys 5, 6, 7, 8, 11, 13. 14, 15, and 19)
is located in the center of the end of the For Relays with std. const. R83LX000012
shaft. The old rotary shaft assembly has no For Relays with hi-temp. const. R83LX000022
Replacement kit lor Type 83L Relay
index marks, and the tapped hole is offset (kit contains keys 10, 13. 15, 32)
from the center of the shaft. If replacement For 3582 Series, std. const. R3580XRS012
of the shaft assembly is required, a new For 3582 Series, hi-temp. const. R3580XRH012
shaft assembly can be used to replace an For 3583 Series, std. const. R3580XRS022
old shaft assembly. When Installing a new
shaft assembly, also install a new-style
cam and a new spring retainer bracket (key Positioner/Transmitter (figure 16)
43, figure 16).
The new-style cams have slotted mounting Key Description Part Number
holes; the old cams have round mounting
holes. New-style cams can be used with an 1 CASE ASSEMBLY 1188556X012
2' SHAFT ASSEMBLY* ', SST/steel
1
old rotary shaft, but old cams cannot be For travel up to 2-1/8 inch (54 mm) 15A9609X012
used with a new rotary shaft. For travel up to 4-inch {102 mm) 15A9609X022
FISHER"
Key Description Part Number

3 NOZZLE ADAPTOR, SST 12A2613X012
4* CAMIM, SST
CAM A (For all types) 45A9614X012
CAM B (For all except Types 3583, 3583C) 45A9615X012
CAM C (For all except Types 3583. 3583C) 45A9616X012
5 MACHINE SCREW, pi steol

(3582 Series only, not shown) 1A769028982
6 CAM BOLT. 416 SST 12A2616X012
T BELLOWS ASSEMBLY, brass 12A7360X012
6' RANGE SPRING, pi steel (also see table 5)
3 to 15 PSI (0.2 to 1.0 bar) 1V621727012
5 to 25 PSI (0.3 to 1.7 bar) 1V621827012
6 to 30 PSI (0.4 to 2.0 bar) W621927012
9 SPRING SEAT, aluminum 12A7355X012

to MACHINE SCREW, pi steel 1B285628982
11* O-RING
Nilrile (std. const.) 1F463606992
fluoroetasiomer (hl-temp. const.) 1N571406382
12 LOCKWASHER, pi sleel (2 req'd) 1H322328982
13 MACHINE SCREW, pi steel (2 req'd) 1A3294X0022

18* NOZZLE, SST Figure 19. Type 03L Relay Sub-Assembly (Key 32)
3582 Series 12A9840X012
35B3 Series 12A9841X012
19' FLAPPER SUB-ASSEMBLY 13A1451X012 Key Description Part Number
19A ADJUSTMENT ARM, pi steel 2V606625182
35 PIPE PLUG, pi sleel
198 FLAPPER. SST 13A1314X012 Req'd when gauges are not used:
19C MACHINE SCREW, pi steel (2 req'd) 1V605628982 3 req'd for Type 3582, 3582A
19D FLAPPER ARM, aluminum 23A1318X012 1 req'd for Types 3583, 3583C 1D829328982
36 OUTPUT GAUGE, DUAL SCALE
19E MACHINE SCREW, pi steel (2 req'd) 1A345028982
Types 3582, 3582G. 3583
t" 0-30 psig/0-2 kg/cm* 11B4040X042
19F FLAPPER SPRING. SST
13A1316X012 0-60 psig/0-4 kg/cm* 11B4040X052
19G FOLLOWER ASSEMBLY, 416 SST/nylon 1K375B000A2
19H HEX NUT, pi steel 1A330328982 36 OUTPUT GAUGE. TRIPLE SCALE
19J LOCKWASHER, pi steel 1H267128982 Types 3582, 3582G. 3583
0-30 psig/0-0.2 MPa/0-2 bar 11B4040X012
19K ARM SUPPORT, SST 0-60 psig/0-0.4 MPa/0-4 bar 11B4040X022
13A1315X012
19L PIVOT PIN, 440C SST 13A1317X012 37 SUPPLY GAUGE, DUAL SCALE
20' SETTING ADJUSTMENT GEAR, nylon 2U905206162 Types 3582, 3582G. 3583
21 FLAPPER ASSEMBLY RETAtNEH, SST 2U905336012 0-30 psig/0-2 kg/cm* 11B404OXO42
0-60 psig/0-4 kg/cm 2
11B404OXO52
23 MACHINE SCREW, pi steel (2 req'd) 1A345028982
25 NAMEPLATE. aluminum 37 SUPPLY GAUGE, TRIPLE SCALE
psig or psig/kPa 1J968711032 Types 3b82. 35S2G, 3583
kg/cm 2
11A9819X012 0-30 psiy/0-Q.2 MPa/6-2 bar 11B4040X012
kPa 13A7478X012 0-60 psig/0-0.4 MPa/0-4 bar 11B4040X022
bar 14A1991X012 38' EXTENSION SPRING, pi sleel 12A2937X012
26 SELF TAPPING SCREW, steel (2 req'd) 1C941928982 39 SHIPPING STOP (not shown) 1V451706992
27' EXTENSION SPRING!'), 42 HEX NUT, pi steel (2 req'dj 1A573528982
pi steel, yellow color code 14A8214X012
43 SPRING RE1AINER SRACKST, SST 25A9611X012
28 MACHINE SCREW, pi steel (3 req'd) 1H736528982 44 GEAR MOUNTING PLATS, aluminum 12A2611X012
29' BEAM SUB-ASSEMBLY 12A8869X022 45 LOCKING NUT, aluminum 12A2618X012
30 BELLOWS PIVOT PIN, SST 12A7357X012 46 INSTRUMENT GAUGE, DUAL SCALE
32 TYPE 83L RELAY—See "Type 83L Relay" section 0-30 psig/0-2 kg/cm 2
of this parts list (3-15 psig/0.2-1.0 kg/cm* ranges) 11B4040X042

0-60 pslg/0-4 kg/cm 2
33 COVER ASSEMBLY (5-25 psig/0.4-1.8 kg/cm ranges) 2
For all typos, plastic 17A7682X012 (6-30 psig/0.4-2.0 kg/cm* ranges) 11B4040X052
16 INSTRUMENT GAUGE, TRIPLE SCALE

0-30 psfg/0-0.2 MPa/0-2 bar
Note (3-15 psiy/20-100 kPa/0,2-1 bar ranges) 11B4040X012
0-60 pslg/0-0.4 MPa/0-4 bar
Bypass block assembly (key 34) and parts are listed (5-25 psig/35-170 kPa/0.3-1.7 bar ranges) 11B4040X022
later In this parts list. Non-bypass block assembly (also (6-30 psig/40-200 kPa/0.4-2 bar ranges) 11B4040X022
key 34) and parts are listed following the bypass block 47 TEST CONNECTION
assembly and parts. (3 req'd for Types 3582C, 3582D)
(2 req'd for Type 3583C) ' 1N908899012
24 ' r i e a s ,
» feat) Hie nole al the beginning of ihe Pails l i s ! section.'

Control Valves Maintenance

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Control Valves Maintenance

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UTILITIES EQUIPMENT MAINTENANCE

CONTROL VALVES MAINTENANCE

Sec. 4 : CONTROL VALVES MlNTENANCE

PART 1 PREVENTIVE MAINTENANCE

PART 3 MAINTENANCE GUIDELINES FOR CERTAIN VALVES

CONTROL VALVES MAINTENANCE

Control valve manufacturers provide detailed installation and overhaul

PART 1 PREVENTIVE MAINTENANCE

Preventive maintenance is a term used to identify a program of scheduled

GanJra/Da/vas DjCimJt. t."

Prior to start-up it should be determined if the control valve is to be the collection

CONTROL VALVES jvMAINTENANCE lj.

decontamination is an undesirable job. It is extremely essential that the employee who is

S E C . 4-2 Fig. I M A N U F A C T U R E R S B E V E L O F 60° ON T H E S E A T R I N G

S E C . 4-2 Fig. 2 RE-MACHINED SURFACES O FA REPAIRED VALVE, WITH

Whenever possible, the valve manufacturer should be consulted for

seating surfaces can be economically corrected by lapping rather than requiring

3- DISASSEMBLY OFTHE ACTUATOR j

Reassembly of the control valve body is a straightforward operation. The chief

The valve manufacturers recommendations for proper torque loading of the

Note : Special packings previously mentioned should be adjusted according to

CONTROL VALVES MAINTENANCE

PART 3 MAINTENANCE GUIDELINES FOR CERTAIN VALVES

• Check the valve to make sure it has been properly isolated.

• Reinstall the packing stud nuts and tighten them evenly.

• Lower the indicator disc and position it properly.

• Reinstall the dust covers and indicator plates.

2-1-1 Removing Bonnet

• Loosen and remove the packing flange nuts.

• Remove the packing flange. Lift the flange straight up fr0m

Remove the packing follower.

• Before the bonnet is removed from the valve body match

2-1-2 Stem Replacement

2-1-3 Removing Seat Rings

A seat ring removal tool is to be used to loosen the threaded connection

Lapping is usually done in several stages. A different grade, of lapping

Lapping The Plug And Seat

• Note the orientation of the lapping tool before you start.

• Lift the lapping tool and turn the stem 90°. j

• Lower the plug back into the scat.

• T u r n the lapping tool the required number of times in the second

• Lapping compound adheres more easily to a clean surface.

• Most lapping procedures involve going from a coarse grade of

® Remove (he body stud nuts. ;

A bluing check is also sometimes done before lapping to see if lapping is

2-1-5 Beginning Reassembly {

• Brush antiscizc compound on the threads of the body studs. Make

• Place the body stud nuts on the studs.

Torque The Nuts I

Zero the torque wrench before you start,

1st Stage 2nd Stage 3rd Stale 4lh Siayo

2-1-6 Completing Reassembly

• Install the spacer, if one is required.

• Insert the proper amount of packing above the spacer.

• Place the packing follower over the valve stem.

• Install the packing flange,

• Insert the packing flange studs and nuts. Some manufacturers

SPLIT PACKING AROUND A STEM

The advantage of this valve is that it can be disassembled in the field

• Remove the gaskets from the top of the cage. |

• Lift out the seat ring. j

• Remove the seat ring gasket.

• Remove the bonnet gasket.

• Clean valve and inspect.