Baker Hughes Masoneilan VariPak 28000 Series User manual

Masoneilan*
28000 Series VariPak*
Adjustable-CvControl Valves
Instruction Manual (Rev. B)
BHGE Data Classication : Public

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THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE
INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE
PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE (BAKER HUGHES, A GE
COMPANY) AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT
TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN
CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR
REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO
PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION
OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE
WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE
REFERRED TO BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO
THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL
REPRESENTATIONS OR WARRANTIES BY BHGE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY
THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,
TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF BHGE.

Masoneilan VariPak Control Valve Instruction Manual | 3© 2018 Baker Hughes, a GE company. All Rights Reserved.
Contents
1. General .........................................................................................................4
1.1 Spare Parts................................................................................................4
1.2 After Sales Department ...................................................................................4
1.3 Training ...................................................................................................4
2. Operation .......................................................................................................5
2.1 Precise Adjustment of the Varipak 28002 Adjustable-CvValve .............................................5
2.2 Flow Coefficient of Varipak 28001 Single-Lever and 28002 Adjustable-CvValves ...........................5
2.3 Actuator ..................................................................................................7
2.4 Handwheel ................................................................................................7
2.5 Reversing the Valve Action ................................................................................8
3. Installation .....................................................................................................10
3.1 Preliminary Steps.........................................................................................10
3.2 Valve Installation .........................................................................................10
3.3 Pneumatic and Electrical Circuit ..........................................................................11
3.4 Limit Switches............................................................................................11
4. Calibration .....................................................................................................12
4.1 Piston Rod Clevis Adjustment.............................................................................12
4.2 Plug Stem Adjustment....................................................................................12
4.3 Limit Stop Adjustment....................................................................................13
4.4 Varipak 28002 CvAdjustment ............................................................................14
4.5 Positioner Start-Up Pressure Adjustment .................................................................14
5. Maintenance ...................................................................................................14
5.1 Actuator Diaphragm Removal.............................................................................14
5.2 Adding Packing Ring ......................................................................................14
5.3 Disassembly..............................................................................................15
5.4 Reassembly ..............................................................................................16
5.5 Packing Quick Change Method (Only For Valves With Max. CvOf 0.6 To 3.8) ...............................18
5.6 7700P or 7700E Positioner Maintenance..................................................................18
5.7 Maintenance Operations Specific to the 7700E Positioner.................................................19
5.8 Converting a 7700P Positioner (Pneumatic) into a 7700E Positioner (Electro-Pneumatic) ..................20

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Safety Information
Important - Please Read Before Installation
Masoneilan 28000 Series instructions contain DANGER, WARNING,
and CAUTION labels, where necessary, to alert you to safety related
or other important information. Read the instructions carefully
before installing and maintaining your control valve. DANGER
and WARNING hazards are related to personal injury. CAUTION
hazards involve equipment or property damage. Operation of
damaged equipment can, under certain operational conditions,
result in degraded process system performance that can lead to
injury or death. Total compliance with all DANGER, WARNING, and
CAUTION notices is required for safe operation.
CAUTION
CAUTION
WARNING
DANGER
This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
CAUTION
WARNING
DANGER
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could result in
property damage.
Note: Indicates important facts and conditions.
About this Manual
• The information in this manual is subject to change without prior
notice.
• The information contained in this manual, in whole or part, shall
not be transcribed or copied without BHGE’s written permission.
• Please report any errorsorquestions about the information in this
manual to your local supplier.
• These instructions are written specifically for the 28000 Series
control valves, and do not apply for other valves outside of this
product line.
Life Period
The current estimated useful life period for the Masoneilan 28000
Series control valve is 25+ years. To maximize the useful life of
the product it is essential to conduct annual inspections, routine
maintenance and ensure proper installation to avoid any unintended
stresses on the product. The specific operating conditions will also
impact the useful life of the product. Consult the factory for guidance
on specific applications if required prior to installation.
Warranty
Items sold by BHGE are warranted to be free from defects in
materials and workmanship for a period of one year from the
date of shipment provided said items are used according to BHGE
recommended usages. BHGE reserves the right to discontinue
manufacture of any product or change product materials, design or
specifications without notice.
This instruction manual applies to the Masoneilan 28000 Series control
valves.
The Control Valve MUST BE:
• Installed, put into service and maintained by qualified
and competent professionals who have undergone
suitable training.
• Under certain operating conditions, the use of damaged
equipment could cause a degradation of the performance of
the system which may lead to personal injury or death.
• Changes to specifications, structure, and components used
may not lead to the revision of this manual unless such changes
affect the function and performance of the product.
• All surrounding pipe lines must be thoroughly flushed to ensure
all entrained debris has been removed from the system.

Masoneilan VariPak Control Valve Instruction Manual | 5© 2018 Baker Hughes, a GE company. All Rights Reserved.
1. General
These installation, operation, and maintenance instructions apply to Masoneilan VariPak 28000 series control valves. They
also include a parts reference list with recommended spare parts.
IMPORTANT REMARKS
Before installing, operating, or performing maintenance on this equipment, you should read
these instructions carefully and make sure you have understood them.
Work on this equipment should only be carried out by qualified personnel.
Failure to follow the instructions and precautions given in this document could lead to a
malfunction and seriously damage the equipment.
1.1 SPARE PARTS
For maintenance purposes, always use original
Masoneilan spare parts obtained through your local
BHGE representative or Spare Parts Department. When
ordering, always give the references of the original order
for the equipment concerned and, in particular, the number
indicated on the serial plate. (135)
1.2 AFTER SALES DEPARTMENT
BHGE has a highly skilled After Sales Department to assist
customers with start-up, maintenance, and repair of valves
and instruments. Contact your nearest BHGE Sales Office or
Representative.
1.3 TRAINING
BHGE organizes regular training courses in the operation,
maintenance and application of its Masoneilan control valves
and instruments for customer service and instrumentation
personnel. For further details, please contact your local
BHGE representative or Training Department.

6 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
2. Operation
The Masoneilan VariPak microflow control valve features a
very wide range of rated flow coefficients (Cv), from 0.004 to
3.8.
Two types of actuators are available:
- The VariPak 28001 with a single lever, designed for just one
rated Cv. This version is used when enough is known about
the operating conditions when sizing the valve.
- The VariPak 28002 with an adjustable rated Cv. This valve
uses a patented lever system to adjust the rated Cvon site
to suit the actual operating conditions, thereby avoiding
any oversizing in flow capacity. Each plug and seat ring
combination can be adjusted without changing the control
signal.
2.1 PRECISE ADJUSTMENT OF THE VARIPAK 28002
ADJUSTABLE-CvVALVE
The valve is adjusted using a simple, but robust, crossed-
lever system with an adjustable fulcrum. This can be done
easily by hand, either before installation or during operation.
For example, an application requiring a theoretical Cv
of 0.006 could be handled using a VariPak 28002 with a
maximum Cvof 0.010, that can subsequently be calibrated
on site between 0.004 and 0.010.
2.2 FLOW COEFFICIENT OF VARIPAK 28001
SINGLE-LEVER AND 28002 ADJUSTABLE-Cv
VALVES
2.2.1 Plug/seat ring combinations (trim)
Eight plugs and five seat rings are used to make up
the ten available plug and seat ring combinations,
identified by codes from 0 to 9 (see figure 2). The
shape of each plug and the port diameter of the
seat ring can be used to match parts with the table
in figure 2.
The difference between the four plugs in trim Nos.
6 to 9 lies in the angle of the flat machined on the
tip. The same seat ring (3e) and the same spacer (3f)
are used in all four cases (see figure 2).
Use the table in figure 1 to select the plug and seat
ring combination to obtain the Cvvalue or range of
Cvvalues you require.
Trim No.
FLOW COEFFICIENT Cv
VARIPAK
28001
VARIPAK 28002
MIN. RISK FREE MAX.
90.0040 0.0016 0.0020 0.0024 0.0028 0.0032 0.0036 0.0040
80.010 0.004 0.005 0.006 0.007 0.008 0.009 0.010
70.025 0.010 0.013 0.016 0.019 0.021 0.023 0.025
60.050 0.020 0.025 0.030 0.035 0.040 0.045 0.050
50.10 0.04 0.05 0.06 0.07 0.08 0.09 0.10
40.25 0.10 0.13 0.16 0.19 0.21 0.23 0.25
30.6 0.25 0.30 0.35 0.4 0.45 0.5 0.55 0.6
21.2 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
12.3 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3
03.8 1.5 1.9 2.3 2.6 2.9 3.2 3.5 3.8
Figure 1

Masoneilan VariPak Control Valve Instruction Manual | 7© 2018 Baker Hughes, a GE company. All Rights Reserved.
Plug and
seat ring
No. 9
Plug and
seat ring
No. 8
Plug and
seat ring
No. 7
Plug and
seat ring
No. 6
Plug and
seat ring
No. 5
Plug and
seat ring
No. 4
Plug and
seat ring
No. 3
Plug and
seat ring
No. 2
Plug and
seat ring
No. 1
Plug and
seat ring
No. 0
VariPak
28001 Cv0.004 Cv0.010 Cv0.010 Cv0.050 Cv0.10 Cv0.25 Cv0.60 Cv0.2 Cv2.3 Cv3.8
VariPak
28002
Cv
0.004 to
0.0016
Cv0.010
to 0.004
Cv0.010
to 0.004
Cv0.050
to 0.010
Cv0.10
to 0.04
Cv0.25
to 0.10
Cv0.60
to 0.25
Cv1.2 to
0.9
Cv2.3 to
0.9
Cv3.8 to
1.5
Orice Dia.
2 mm
3f 3d
3e Orice Dia.
1.6 mm
Orice Dia.
4.5 mm
Orice Dia.
9.5 mm
Orice Dia.
14.3 mm
3c 3b 3a
2.2.2 Changing the plug and seat ring combination
The plug and seat ring combination can be changed very
easily for trim Nos. 1 to 9 inclusive. Simply replace the
following parts:
- The plug and seat ring (see figures 1 and 2 to select the
combination required for the new Cv).
- The Cvadjustment plate (25) in the case of the VariPak
28002 adjustable-Cvvalve.
- If necessary, the actuator spring (134) (see figure 3 to check
the spring range corresponding to the new Cv.
Plug/Seat
No.
Flow
Coecient Cv
Spring Range (134)
Max. Pressure Supply
Adjustable CvSingle Lever
CI. IV CI. V CI. IV CI. V
m.bar Psi Color Code bar (Psi) bar (Psi) bar
(Psi) ATO ATC
03.8 to 1.5 414
-
1660
6-24 Red 2.1 (30) 2.1 (30) 2.1
(30)
2.8
(40)
12.3 to 0.9
21.2 to 0.5
30.6 to 0.25
40.25 to 1.10
207
-
1035
3-15 Green 1.4 (20) 1.4 (20) 1.4
(20)
1.7
(25)
50.10 to 0.04
60.050 to 0.020
70.025 to 0.010
80.010 to 0.004
90.004 to
0.0016
Figure 3 - Actuator spring ranges and supply pressures

8 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Follow the procedure described in the "Disassembly/
Reassembly" section of the "Maintenance" chapter on
pages 14 to 18.
- Also change the serial plate (135) or correct the
information on the existing plate.
CAUTION
CAUTION
WARNING
DANGER
If the valve in question includes a 1/2" or 3/4"
NPT threaded end, the maximum capacity
of the body is respectively limited to trim
Nos. 9 to 3 inclusive or 9 to 2 inclusive. A trim
No. 9 cannot be installed in a VariPak valve
body designed for a trim No. 0. Likewise, a
trim No. 0 cannot be installed in valve bodies
designed for other trim numbers.
2.2.3 Adjusting the Cvof a Varipak 28002 valve for each
plug and seat ring combination
This is done by moving adjustment knob (24) along
adjustment plate (25) fastened to the top of lever No. 1
(21).
The adjustment plate (25) gives the range of Cvvalues
offered by the selected plug and seat ring combination.
Carry out this adjustment operation as follows:
Figure 4 - Adjusting the Cvof VariPak 28002 valve for each plug/
seat ring combination
- Loosen adjustment knob (24) and slide it along the lever
to the required value. Tighten the adjustment knob again
firmly.
Note:
- This operation entails moving lever No. 2, either
pneumatically (by allowing air into the actuator), or
manually (by pressing piston clevis (140b) with a
screwdriver or similar tool) so that the slides of the two
levers are perfectly parallel.
- It may be necessary to reset the zero to calibrate the
closure point after changing the Cv.
2.3 ACTUATOR
A single actuator allows VariPak valves to act in direct Air-
to-Close (ATC), or reverse Air-to-Open (ATO).
Valve action can be changed with no additional part by
simply shifting:
- the pivot pin and the attachment hole of the positioner
balance spring clamp for the singlelever VariPak 28001
valve,
- the two pivot pins for the adjustable-CvVariPak 28002
valve, then calibrating as required.
Follow the instructions given under "Reversing the valve
action" in paragraph 2.5.
2.4 HANDWHEEL(Figure 5)
The handwheel is an optional feature located on top of the
cover and fitted with a locking lever. Access can be gained
to it directly without removing any other parts. It consists
of a threaded rod, equipped with a handwheel (120) and
a lever arm stop (122). The threaded rod rests freely on
the actuator bracket (108) and is guided through the cover
(110) by handwheel bushing (119). The stop consists of a
block screwed onto the threaded rod. The block is guided
by the actuator bracket (108).
Figure 5

Masoneilan VariPak Control Valve Instruction Manual | 9© 2018 Baker Hughes, a GE company. All Rights Reserved.
When the handwheel (120) is turned clockwise, the stop
(122) moves up the threaded rod, compressing the spring
(134) and raising lever No. 2 (22) (VariPak 28002) or (113)
(VariPak 28001). This closes the valve if the valve is equipped
with a direct-action actuator (Air-to-Close) and opens the
valve if it is equipped with a reverse-action actuator (Air-to-
Open).
The valve can be returned to automatic mode (neutral
position), by turning the handwheel counterclockwise until
the stop (122) comes into contact with the bracket (108).
Note: During this operation, the compression is released
when the stop (122) moves away from the lever (22) (VariPak
28002) or (113) (VariPak 28001). Continue the operation until
a slight tension reappears, then tighten the handwheel lock
(121).
VariPak actuators are equipped with a limit stop. This
consists of parts (180) and (181), and is designed to prevent
damage to the plug and seat ring assembly and/or the plug
stem in the event of handwheel or actuator overstroke.
Note: The limit stop is not used with air-to-open valves fitted
with a handwheel, and must be screwed down at the bottom
of the piston.
2.5 REVERSING THE VALVE ACTION
(Figures 5, 6, 26, 27 and 29)
CAUTION
CAUTION
WARNING
DANGER
The valve must be isolated and pressure
vented before disassembly.
A. Loosen and remove cover (110). On valves equipped
with a handwheel, loosen cover screw (109), back off
handwheel lock (121), and turn handwheel (120) counter-
clockwise to release cover (110).
B. Adjust the signal so that the valve closes. Change the
signal slightly so that the plug just moves off the seat
ring. On the VariPak 28002 adjustable-Cvvalve, set the
adjustment knob (24) to the minimum Cvsetting.
C. Loosen locknut (103) and, using a screwdriver, turn the
plug stem one and three-quarter turns counter-clockwise.
Shut off the signal and the supply pressure. Slightly
tighten locknut (103) against the clevis.
D. Unlock nut (117) and completely loosen screw (116).
Unhook spring (114) from spring clamp (115).
2.5.1 VariPak 28001 single-lever valve
E. Remove retainer clips (112b) from pin (18), and remove the
pin from lever (113) and plug clevis (104a).
Note: This operation will be simplified by relieving the load
exerted on the plug clevis by the conical compression spring
(106). To do this push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112a) from the pin (105)
and disengage it to uncouple the lever (113) from the
bracket (108).
G. Refit the levers (113) making sure that the pin (105) is
fitted into the correct holes in the lever and bracket for
the new action of the actuator (see figure 6). Fit the spring
clamp (115) into the corresponding lever hole.
Note: Ensure that the clevis is correctly positioned before
fitting the lever on the bracket.
H. Couple the plug stem clevis (104a) to the lever (113)
following the normal reassembly procedure (step I. in the
"Reassembly" section). Then follow the same procedure as
for the VariPak 28002 adjustable-Cvvalve as from step L.
2.5.2 VariPak 28002 adjustable-Cvvalve (2 levers)
E. Remove retainer clips (112b) from each of the two pins
(184) and remove pins from lever (113) and plug clevis
(104a).
Note: This operation will be simplified by relieving the load
exerted on the plug clevis by the conical compression spring
(106). To do this push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112a) from pin No. 1 (105)
and disengage it to uncouple lever No. 1 from bracket
(108). Loosen adjustment knob (24) and slide it to the
maximum Cvsetting. Disengage the smooth end of the
adjustment pin (23) from the groove in lever No. 2 while
removing lever No. 1.
G. Drive out pin No. 3 (18) and remove lever No. 2 (22) from
the bracket.
H. Remove the two screws (26) and refit Cvadjustment plate
(25) after turning it round to comply with the new action.
I. Refit levers No. 1 and 2 in sequence, making sure that
pins (105) and (108) are fitted into the correct holes in the
levers and bracket for the new action of the actuator (see
figure 6).

10 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Note: Ensure that the clevis is correctly positioned before
tting the lever No. 1 on the bracket (108).
J. Reset adjustment knob (24) to the minimum Cvposition.
K. Couple plug stem clevis (104a) to lever No. 1 following the
normal reassembly procedure (step L. in the "Reassembly"
section).
L. Hook spring (114) in the appropriate hole in spring clamp
(115) (see gure 6).
M. Admit supply and signal pressures and complete
calibration. Ret cover (110) using the two screws (109).
If the valve is equipped with a handwheel, ret the cover
and turn the handwheel clockwise so that it engages in
lever arm stop (122). Tighten cover screws (109).
N. Put the valve back into service.
Note:
- When replacing an Air-to-Close actuator with an Air-to-
Open actuator, do not forget to neutralize the limit stop by
screwing it down at the bottom of the piston.
- When replacing an Air-to-Open actuator with an Air-to-
Close actuator, set the limit stop to the opening position.
AIR-TO-CLOSE ACTUATOR AIR-TO-OPEN ACTUATOR
VariPak 28001
with single
lever
VariPak 28002
with adjustable
Cv(2 levers)
*Only with type 7700 positioner
Figure 6 - Identication of lever pivot pin holes

Masoneilan VariPak Control Valve Instruction Manual | 11© 2018 Baker Hughes, a GE company. All Rights Reserved.
3.1 Preliminary Steps
A. Before installing the valve in the line, remove all traces
of foreign material from the piping such as welding chips,
scale, oil, grease, etc.
B. Note down all the data given on the serial plate.
C. For valve inspection without interrupting process
operation, a hand-operated stop valve will be required on
either side of the VariPak, together with a hand-operated
throttling valve mounted on a bypass line.
3.2 Valve Installation (Figures 7, 8 and 9)
Connections: The body of the ANSI Class 1500* rated
VariPak valve can be:
- Bolted between 25 mm (1") pipe anges machined to
standards ISO-PN 10 to PN 250 (ANSI 150 - 300 - 600 - 900
and 1500 lb).
Use ASTM A 193 Gr B 7 (or equivalent) carbon steel bolting
for temperatures between -29° and +350 °C. For corrosive
or cryogenic service, use ASTM A 193 Gr B8 strain-
hardened stainless steel. All the line bolting required for
installation can be supplied by BHGE on request.
Figure 7 - VariPak anged connection
- Connected by 25 mm anges machined to standards ISO-
PN 20, 50 and 100 (ANSI 150, 300 and 600 lb).
Fit gaskets compatible with service conditions between the
valve body and the pipe anges.
Figure 8 - VariPak anged body
The VariPak valve body can be supplied on request with 1/2",
3/4", or 1" NPT threaded ends. Apply PTFE tape or a sealing
compound compatible with the process to the threaded pipe
ends.
Figure 9 - VariPak screwed connection (option)
Alignment: This valve is small and light, making it easy to
install on the piping. Support the valve body when tting
studs. Suitably shaped bosses are provided to center the
valve in the line and prevent rotation before the studs are
nally tightened.
The valve must always be installed with "ow tending to
open". The ow arrow on the valve body must be pointing in
the direction of ow. Fit the bolts and tighten in criss-cross
fashion.
3. Installation

12 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Insulation: If the valve is to be insulated, ensure that the
insulation does not exceed the shaded area shown in gure
10 below.
Figure 10 - Insulation limit for a VariPak valve
3.3 Pneumatic and Electrical Circuit
(Figures 3, 11 and 12)
- On-o valve: connect the air supply line directly to the 1/8"
NPT threaded connection in diaphragm cover (137).
- Control valve with 7700P positioner (air signal): connect
the supply and instrument signal lines to the appropriate
connections on the manifold block (144) (gure 11). Use 4 x
6 mm (1/4" O.D.) tubing.
- Control valve with 7700E positioner (electrical signal):
connect the manifold block (144) air supply line and make
the electrical connection for the I/P module (20) (gure 12).
Use 4 x 6 mm (1/4" O.D.) tubing for the air line.
Note: Check that the supply pressure is that indicated on the
serial plate.
7700P or 7700E positioners can be installed on both VariPak
28001 single-lever and VariPak 28002 adjustable-Cvvalves.
Figure 11 - Connections with 7700P positioner
Figure 12 - Connections with 7700E positioner
3.4 Limit Switches (Figure 13)
In some cases, limit switches can be provided for the VariPak
valve, on request. These are wired and adjusted in the
factory to customer order. The black wire is connected to
either the normally open or normally closed terminal of the
upper limit switch. The black and white wire is connected
to the common terminal of this switch. The red wire is
connected to either the normally open or normally closed
terminal of the lower limit switch.
The red and white wire is connected to the common terminal
of this switch. To adjust limit switches, loosen their fasteners
and move the valve to the required position. Adjust the
position of the switch until it trips. Tighten fasteners (160 -
161 - 162).
Figure 13 - Limit switch installation

Masoneilan VariPak Control Valve Instruction Manual | 13© 2018 Baker Hughes, a GE company. All Rights Reserved.
VariPak valves are factory-calibrated according to the
components specied in the customer order. If for any
reason this calibration has been disturbed (e.g. after
changing from direct to reverse valve action, or replacing the
plug and seat ring), all or some of the adjustments below
must be carried out in the following order:
- Piston rod clevis (104b) adjustment.
- Plug stem adjustment.
- Limit stop adjustment.
- Cvadjustment.
- Positioner start-up pressure adjustment.
4.1 PISTON ROD CLEVIS ADJUSTMENT
4.1.1 Adjusting the piston rod clevis on the VariPak 28001
single-lever valve (Figures 14 and 26)
This adjustment is only required if the piston
(131) has been removed. In this case, it should
be carried out during reassembly, before
coupling the lever (113) to the clevises (chap.
MAINTENANCE - Reassembly. step H.).
With the piston resting against diaphragm cover (137), turn
clevis (104b) so that the top of actuator bracket (108) is 0.5
mm to 1 mm from the bottom of indicator (126). A shim
will simplify this operation. Admit enough air pressure to
disengage locknut (125) and tighten it against indicator.
Check that indicator (126) is correctly positioned. Release air
pressure.
4.1.2 Adjusting the piston rod clevis on the
Figure 14 - Piston rod clevis (104b) adjustment
VariPak 28002 adjustable-Cvvalve (Figures 14 and 27)
This adjustment is only required if the piston
(131) has been removed.
In this case, it should be carried out during
reassembly, before coupling the levers (21)
and (22) to the clevises (chap. MAINTENANCE -
Reassembly. step K.).
With the piston resting against diaphragm cover (137), turn
clevis (104b) so that the top of the actuator bracket (108) is
0.5 mm to 1 mm from the bottom of indicator (126). A shim
will simplify this operation.
Couple lever No. 2 (22) in this clevis position. Admit enough
air pressure to disengage locknut (125) and tighten it
against the indicator. Check that indicator (126) is correctly
positioned. Release air pressure.
4.2 PLUG STEM ADJUSTMENT
4.2.1 Adjusting the plug stem on the VariPak 28001 single-
lever valve (Figures 15, 16 and 26)
This adjustment should be carried out during
reassembly, before coupling the lever (113) to
the clevises.
A. Loosen nut (103) and turn the plug stem using a
screwdriver while blocking clevis (104a) until the clevis is in
the position shown in gure 15. Lock nut (103).
Figure 15 - Presetting the plug stem position
4. Calibration

14 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
B. Fit lever (113) with spring clamp (115) positioning hole
facing upwards, t pin (105) into hole A, then t pin (18)
into clevis (104a). Note: All pins should be greased slightly
before tting.
C. Press the lever on the actuator side to check for plug/seat
ring leaks at ΔP 3.5 barg (50 psig). If the valve is equipped
with a handwheel, lever (113) should not touch lever arm
stop (122). If the valve leaks, release the pressure at the
inlet and remove pin (18) of clevis (104a), then loosen nut
(103). Loosen the plug stem in order to move the clevis up
(104a). A complete turn moves the position up by 1 mm.
Then tighten the locknut (103) again.
D. Check that the distance between clevis (104b) pin and the
hole in lever (113) is approximately 2 mm. If necessary,
adjust the position of clevis (104a) to obtain this distance,
see gure 16. This value provides the initial compression
of actuator spring (134).
Figure 16 - Adjusting the lever (113)
E. Admit enough air pressure to the actuator to drive piston
clevis (104b) upwards. Couple the clevis to lever (113)
using pin (124).
F. Release the actuator pressure and repeat the plug/seat
ring leak test at ΔP 3.5 barg (50 psig). Dimension A should
be the same as in gure 16 . Release the valve pressure
once this step is completed.
4.2.2 Adjusting the plug stem on the VariPak 28002
adjustable-Cvvalve (Figures 27, 28 and 29)
Once all the coupling operations are completed, proceed as
follows:
A. Admit enough pressure to the actuator to drive out the
piston rod far enough to place a shim under the indicator
(126). Use a 1.5 mm shim for an Air-to-Open actuator, and
a 25 mm shim for an Air-to-Close actuator. Release the air
pressure after inserting the shim.
At this closing point where the plug is not
tightened onto the seating, the slides of levers
No. 1 and 2 should be perfectly parallel. This
characteristic makes it possible to change the
adjustment knob (24) position later to obtain
the required real Cvvalue.
B. Loosen adjustment knob (24) and slide it along lever No.
1 to the maximum Cvposition on adjustment plate (25).
Fully tighten adjustment knob (24).
C. Loosen locknut (103) and, using a screwdriver, turn the
plug stem until the plug is just touching the seat ring. If
the valve has been removed from the pipe, a bubble test
can be performed on the calibration bench to obtain a
very accurate adjustment. Using the screwdriver to hold
the plug stem in position, tighten locknut (103) against
clevis (104a).
D. Admit air pressure again to remove the shim, then release
the pressure.
Note: On an Air-to-Open actuator, shim thickness may be
increased or decreased by one or two-tenths of a millimeter
to ensure that levers No. 1 and 2 are perfectly parallel and to
obtain the required tightness on closing, especially for very
low Cvvalues (Cv< 0.10).
4.3 LIMIT STOP ADJUSTMENT (Figure 5)
VariPak valves include a limit stop to prevent damage to the
plug and seat ring and/or plug stem in the event of actuator
or handwheel overstroke. This device consists of a nut (180)
acting as a stop, screwed onto the piston rod inside the
spring chamber, and a locknut (181).
If necessary, this device should be adjusted immediately
after plug stem adustment (see section 4.2).
A. Remove the shim (for VariPak 28002 adjustable- Cvvalve
only) and admit sucient supply pressure to close the
valve. Turn locknut (181) on the piston rod until it touches
locknut (125). Turn limit stop (180) until it just touches the
inside of actuator bracket (108).
B. Hold the limit stop with a 12 mm wrench and tighten
locknut (181). Release the air pressure.

Masoneilan VariPak Control Valve Instruction Manual | 15© 2018 Baker Hughes, a GE company. All Rights Reserved.
4.4 VARIPAK 28002 CvADJUSTMENT
This adjustment is carried out by moving adjustment knob
(24) along adjustment plate (25) fastened to the top of lever
No. 1 (21). See section “Adjusting the Cvof a Varipak 28002
valve for each plug and seat ring combination.”
4.5 POSITIONER START-UP PRESSURE ADJUSTMENT
(Figures 7, 25, 26 and 27)
A. Connect the air supply and signal lines to the 7700P or
7700E (with electrical signal) positioner.
B. Set the supply pressure according to the valve Cvvalue
(see the table in gure 3).
C. Set the signal to the minimum value for an Air-to- Open
actuator, and to the maximum value for an Air-to-Close
actuator. Turn take-up screw (116) until the piston rod just
begins to move. Tighten locknut (117).
5. Maintenance
CAUTION
CAUTION
WARNING
DANGER
Always ensure that there is no pressure in
the valve, actuator, or positioner before
maintenance or disassembly.
5.1 ACTUATOR DIAPHRAGM REMOVAL
(Figures 17, 24, 25, 26 and 27)
A. Unscrew the two pressure connection nuts (138a) and
pull tubing (140) out. Remove the four cap screws (139)
and diaphragm cover (137). Remove the worn diaphragm.
Form new diaphragm (136) and t it on the piston as
shown in gure 17. Fit the diaphragm roll into the bracket
groove. Take care not to twist or bend the diaphragm
during replacement. Ret diaphragm cover (137) with
the four screws (139) and reconnect the tubing with
the two pressure connection nuts (138a). Check that all
connections are leaktight.
Figure 17 - Diaphragm replacement
5.2 ADDING PACKING RING (Figures 18, 26 and 27)
A. Before adding packing ring, the valve must be isolated and
all pressure released. Remove packing ange nuts (8b), lift
the packing ange and follower, and insert a new packing
ring. Tighten nuts (8b) nger tight and then tighten one
full turn with the wrench.
Figure 18 - Adding a packing ring

16 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
5.3 DISASSEMBLY (Figures 5, 24, 25, 26, 27, 28 and 29)
In some cases, it may be necessary to disassemble the
VariPak valve, for example, to replace the plug/seat ring
assembly (tting new parts or changing the maximum Cv
value) or to change the packing rings when the maximum Cv
is less than 0.6.
Note: If the maximum Cv ≥ 0.6, a quick change method can
be used to avoid disassembling the valve (see section 5.5).
CAUTION
CAUTION
WARNING
DANGER
The valve must be isolated and pressure
vented before disassembly.
A. Loosen cover screws (109) and remove cover (110). If the
valve is equipped with a handwheel, loosen cover screws
(109) and handwheel lock (121), then turn handwheel
(120) counterclockwise to release cover (110).
Disassembly procedure for the VariPak 28001 single-lever
valve:
B. Unlock nut (117) and completely loosen screw (116).
Remove spring clamp (115) from lever (113) and remove
spring (114) from the positioner.
C. Remove the two retainer clips (112c) from pin (124) and
disengage the pin to uncouple piston clevis (104b) from
lever (113).
Note: To simplify this operation, admit air pressure to the
actuator to drive the piston clevis (104b) upwards, then
release the air pressure.
D. Remove retainer clips (112b) from pin (18) and disengage
the pin from lever (113) and plug clevis (104a).
E. Remove two retainer clips (112a) from pin (105) and
disengage the pin to uncouple lever (113) from actuator
bracket (108). Now proceed in the same way as for the
VariPak 28002 adjustable- Cvvalve, as from step I.
Disassembly procedure for the VariPak 28002 adjustable-Cv
valve:
B. Adjust the signal to close the valve. Change the signal
slightly so that the plug just moves o the seat ring. Set
adjustment knob (24) to the minimum Cvposition.
C. Loosen locknut (103) and, using a screwdriver, turn the
plug stem one and three-quarter turns counter-clockwise.
Shut o signal and supply pressure. Slightly tighten
locknut (103) against the clevis.
D. Completely loosen locknut (117) and screw (116). Remove
spring clamp (115) from lever No. 2 and remove balance
spring (114) from the positioner.
E. Remove the retainer clip (112b) from each of the two pins
(184) and disengage the pins from lever No. 1 and clevis
(104a).
Note: This operation will be simplied by relieving the load
exerted on the plug clevis by the conical compression spring
(106). To do this push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112c) from pivot pin No.
4 (124) and disengage the pin to uncouple piston clevis
(104b) from lever No. 2 (22).
G. Remove the two retainer clips (112a) from pivot pin No. 1
(105) and disengage the pin to uncouple lever No. 1 from
the actuator bracket (108). Disengage the smooth end
of adjustment pin (23) from the groove in lever No. 2 and
remove adjustment knob (24) and adjustment pin (23)
from lever No. 1.
H. Drive out pivot pin No. 3 (18) and remove lever No. 2 (22).
I. Hold the plug stem in place using a screwdriver and unlock
nut (103). Loosen clevis (104a) and locknut (103). Remove
spring button (102), spring (106), and grommet plate (101).
J. Remove the two packing ange nuts (8b), packing ange
(10) and packing follower (9). Remove the two bracket
mounting nuts (8a) as well as the bracket (108).
K. Using a packing hook, remove as many packing rings (6) as
possible from the packing box. Remove safety pin (11) and
pull the plug stem to remove the packing spacer (5), the
plug and its stem and, if necessary, the rest of the packing.
L. Using a 9/16" or 14 mm piece of hex stock and a wrench,
unlock and pull out the seat-ring retainer (4).
M. Remove seat ring (3) and gasket (2) using a hook made
from steel wire, approx. diameter 3 mm. Carefully fettle
the hook end.
Note:
- The seat-ring of VariPak valves with Cvmax.< 0.10 consists
of two parts: the seat ring proper (3e), and a spacer (3f). These
parts have a small orice and so cannot be removed using a
hook. It is therefore necessary to remove the body from the
pipe and turn it over and, if necessary, hit the bottom with a
wooden mallet. If the seat ring (3a) is jammed in its housing,
it can be removed by inserting a screwdriver through the
outlet orice.

Masoneilan VariPak Control Valve Instruction Manual | 17© 2018 Baker Hughes, a GE company. All Rights Reserved.
- VariPak valves with Cvmax. 3.8 do not have seatring
gaskets (2).
5.4 REASSEMBLY (Figures 5, 15, 19, 20, 24, 25, 26, 27, 28
and 29)
Before reassembly, thoroughly clean the inside of the valve
body and parts, paying particular attention to gasket seating
surfaces and contact surfaces. Make sure to use a new seat-
ring gasket (2) and new packing (6) during reassembly.
A. Insert a new seat-ring gasket (2) into valve body (13), then
t seat ring (3), making sure that the gasket is correctly
centered on the seat-ring shoulder. Turn it so that one of
its ports is lined up with the valve body outlet orice.
Note: If the maximum Cv is less than 0.10, rst t the seat
ring (3e) on the new gasket (2), taking the same precautions
as above. Then t the spacer (3f), turning it so that one of its
ports is turned towards the body outlet orice.
VariPak valves with a maximum Cvof 3.8 do not include a
seat-ring gasket (2).
B. Carefully apply Never Seez grease or equivalent to the
threads and bottom of the seat-ring retainer (4). Using a
9/16" or 14 mm piece of hex stock and a wrench, torque
the retainer to 59 ftlb or 8 daN.m for stainless-steel
reinforced graphite gaskets or 40 ft-lb or 5.5 daN.m for
glass-lled PTFE gaskets (see gure 19).
Note: Torque the retainer to 30 ft-lb or 4 daN.m for valves
with a maximum Cvof 3.8.
C. Insert the plug and stem assembly into the seat ring. For
valves with a maximum Cv< 0.10, check that there are
no friction points in the plug stroke. If a friction point is
detected, loosen retainer (4) and reposition seat ring (3e)
until the stem slides smoothly. Fit spacer (5), turning it so
that one of its holes is aligned with safety pin (11) hole in
the valve body.
Note: For valves with a maximum Cvless than 0.10, check
that the retaining ring (182) is tted on the plug before tting
the plug in the spacer (3f). If the retaining ring is worn or
damaged, replace it.
Figure 19 - Tightening the seat-ring retainer (4)
D. Wind two layers of PTFE tape around the safety pin (11).
Screw the pin into the bonnet ve and a half to six turns
as from the thread engagement point.
Note: To determine the thread engagement point:
- Screw the safety pin about one turn.
- Pull the safety pin out while unscrewing it.
E. Fit the packing, making sure that the skive cut of each
packing ring is located 120° away from the that of the
adjacent ring. Push the rings down slightly using a 1/2"
sch., size 160 tube. Fit the packing follower (9) onto the
plug stem.
F. Fit actuator bracket (108) and secure it with two nuts (8a).
Slip packing ange (10) onto plug stem. Handtighten the
two packing ange nuts and add one full turn with the
wrench.
G. Fit, in the following order, grommet plate (101), conical
compression spring (106) and its spring button (102) (see
position in gure 26 and 27). Screw nut (103) and clevis
(104a) on the plug stem.
Adjust the nut and clevis without locking them together until
the clevis holes are positioned approximately:
- 2.3 mm below the alignment of the pin holes in the
actuator bracket (108) for the VariPak 28001 single-
lever valve (see gure 15).
- 1.5 mm above the alignment of the pin holes in
the actuator bracket (108) for the VariPak 28002
adjustable-Cv valve (see gure 20).
Note: Measuring this distance can be simplied by tting pins
(105), (184) and (18) into their holes.

18 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Figure 20 - Plug stem pre-adjustment for
VariPak 28002 adjustable-Cv
Reassembly procedure for the VariPak 28001 single-lever
valve (continued):
H. Couple lever (113) to actuator bracket (108) using pin
(105) and the 2 retainer clips (112a). Ensure that the holes
in lever (113) where spring clamp (115) is tted is located
above.
Note: Check that the clevis (104a) is correctly positioned
before tting the lever (113) on the actuator support (108).
To identify the position of the lever connecting holes and
the spring clamp (115) attachment hole, with respect to the
required action, see gure 6.
I. Couple clevis (104a) to lever (113). To do this, press the end
of the plug stem with a screwdriver until the holes in the
clevis and lever are aligned. Couple using the pin (18) and
retainer clips (112b).
Note: Slightly grease all pins before tting. Perform the
adjustment operation described in "Calibration", section 4.2.1.
J. If piston rod clevis (104b) has not been disturbed
during disassembly, couple it to the end of lever (113)
by admitting air pressure to the actuator to drive clevis
(104b) upwards. Couple the clevis to lever (113) using pin
(124) and two retainer clips (112c).
Note: If the clevis (104b) has been disturbed, proceed with
adjustment and coupling as described in "Calibration", section
4.1.1.
K. Release the pressure from the actuator and check
tightness again (see "Calibration", section 4.2.1). Then
continue from step M. of the VariPak 28002 procedure.
Reassembly procedure for the VariPak 28002 adjustable-Cv
valve (continued):
H. Couple lever No. 2 (22) to the actuator bracket (108) using
pin (18). Ensure that the hole in lever No. 2 where spring
clamp (115) is tted is located above and in line with
balance spring (114).
I. Fit adjustment pin (23) in the slide of lever No. 1 and screw
adjustment knob (24) on its threaded end. Insert the
smooth end of pin (23) into the groove in lever No. 2 and
place lever No. 1 on support bracket (108). Couple lever No.
1 to actuator bracket (108) using pin (105) and two retainer
clips (112a).
Note: Check that the clevis (104a) is correctly positioned
before tting lever No. 1 on the actuator support (108)
To identify the position of the connecting holes of levers No. 1
and 2 with respect to the required action, see gure 6.
J. Set adjustment knob (24) to the minimum Cvposition.
K. If piston rod clevis (104b) has not been disturbed during
disassembly, couple it to the end of lever No. 2 using pin
(124) and two retainer clips (112c).
Note: This operation will be simplied by applying air
pressure to the diaphragm (136) to set the piston rod to an
intermediate position, and by setting the adjustment knob to
a position where lever No. 2 is most accessible. If the clevis
(104b) has been disturbed, proceed with adjustment and
coupling as described in "Calibration", section 4.1.1.
L. Couple clevis (104a) to lever No. 1. To do this, press the
end of the plug stem with a screwdriver until the holes in
the clevis and lever No. 1 are aligned. Couple using the two
pins (184) and retainer clips (112b).
Note: The clips are inserted on the pins between the sides of
the clevis and lever No. 1.
M. Fully unscrew take-up screw (116) from spring clamp
(115), then t clamp, after hooking balance spring (114)
rst to the positioner spring bracket of the diaphragm S/A
(152), and then to spring clamp (115).
Note: The spring clamp (115) has two holes. If an Air-to-Open
actuator is used, the spring must be hooked to the top hole. If
an Air-to-Close actuator is used, the spring must be hooked to
the bottom hole (see gure 6).

Masoneilan VariPak Control Valve Instruction Manual | 19© 2018 Baker Hughes, a GE company. All Rights Reserved.
N. Admit the signal and supply pressure and complete
calibration. Ret cover (110) using the two screws (109).
If the valve is equipped with a handwheel, ret the cover,
then turn the handwheel clockwise until it is engaged in
lever arm stop (122). Tighten cover screws (109).
O. If the valve body has been removed, reinstall it taking the
precautions given under "Valve Installation" in section 3.2.
Put the valve back into service.
5.5 PACKING QUICK CHANGE METHOD (ONLY FOR
VALVES WITH MAX. CvOF 0.6 TO 3.8)
(Figures 21, 26 and 27)
The quickest and easiest way to replace packing is to
remove the entire actuator from the valve body, taking
care not to modify the actuator setting. This method is not
recommended, however, for valves with a maximum Cvless
than 0.6 because of their extremely ne plugs. For these
valves, disassemble the valve to replace the packing (see
"DISASSEMBLY", section 5.3).
Figure 21 - Packing replacement (for Cv maxi ≥ 0.6)
Vent the valve pressure and proceed as follows:
A. Check that the plug is not resting on the seat ring. For
valves equipped with an Air-to-Open actuator, admit air
pressure under the diaphragm and turn the handwheel to
move the plug o its seat ring.
B Remove safety pin (11) from the valve body. The safety
pin stub engages with the hole in packing spacer (5). The
function of the safety pin and spacer is to prevent the
plug from being pushed out if the actuator is accidentally
removed while the valve is still pressurized. The internal
parts of the valve cannot be removed unless the safety pin
is removed rst. Remove the two packing ange nuts (8b)
and back o the two actuator bracket mounting nuts (8a)
as far as possible.
C. Remove the actuator-plug assembly from the valve body,
tapping it o with a block of wood and mallet if necessary.
Clean the packing box in the valve body. Remove the worn
packing, then clean the plug stem thoroughly. Carefully t
new packing rings around the stem, positioning the skive
cut of each ring 120° from that of the adjacent ring.
D. Ret the actuator-plug assembly on the valve body, taking
care to: - align hole in packing spacer (5) with safety pin
(11) hole,
- and ret the two mounting nuts (8a).
- Take extra care when guiding each packing ring into the
packing box.
E. Wind two layers of PTFE tape around the safety pin. Screw
the pin into the bonnet ve and a half to six turns as from
the thread engagement point.
Note: To determine the thread engagement point:
- Screw the safety pin about one turn,
- Pull the safety pin out while unscrewing it.
F. Ret the packing follower, packing ange, and ange nuts
(8b). Tighten the packing assembly correctly. If the valve
is equipped with an Air-to- Open actuator, release the air
pressure or turn the handwheel to bring the plug back into
contact with the seat ring. Put back into service.
5.6 7700P OR 7700E POSITIONER MAINTENANCE
(Figures 22, 23, 24, 25, 26 and 27)
CAUTION
CAUTION
WARNING
DANGER
Shut o the signal and supply pressure. Isolate
and depressurize the valve body.
A. Disconnect the two pressure connection nuts (138a) and
pull tubing (140) out.

20 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
B. Loosen the two cap screws (141a) and remove manifold
block (144), spring (158), gasket (146) and its three
O-rings, pilot valve assembly (155 to 157), shims (145),
and O-ring (153).
CAUTION
CAUTION
WARNING
DANGER
Caution: Handle the shims carefully (145).
C. Loosen locknut (117) and take-up screw (116), unhook
the spring clamp from lever (22) or (113).
D. Unscrew cap screws (141b) from positioner block (147)
and remove the positioner block from the actuator
bracket.
Remove screws (148) to separate positioner diaphragm
assembly (152) and spring (154) from the positioner block.
Examine all the parts and replace if worn or damaged.
E. Ret positioner diaphragm assembly (152) and spring
(154) to positioner block and tighten screws (148).
Check that the small signal port Oring is in its recess in
the diaphragm assembly.
F. Reinstall the block assembly on the actuator bracket.
Note: When installing the positioner block (147), turn it so
that when the manifold block (144) is installed, the gauge(s)
is(are) facing in the right direction (gure 22).
Figure 22 - Positioner assembly
Note how the positioner (147) and gasket (146) are oriented
G. Check that gasket (146), three O-rings, and seats are
not worn or damaged and replace if necessary.
H. Fit O-ring (153), shims (145), pilot valve assembly, gasket
(146) and its three O-rings, spring (158) and manifold
block (144). Tighten the screws (141a), ret tubing (140)
and tighten pressure connection nuts (138a).
Note: The ports in gasket (146) must be aligned with those
in the positioner block (147).
To ensure correct positioner performance, check that all
gaskets are perfectly leaktight.
I. Hook spring clamp (115) to lever (22) or (113). In the
case of VariPack 28001 valve, see gure 6 to position the
spring clamp (115) according to the actuator required
action. Admit the supply pressure and the signal. Set the
start-up pressure following the instructions given in the
"Calibration" chapter. Put back into service.
Positioner Signal (Psi) Spring ref.
No.
Spring color
code
7700P
3-15
or
6-30
or
3-27
114
154
Yellow
Red
3-9 114
154
White
Blue
9-15 114
154
White
Green
7700E 4-20 mA 114
154
Yellow
Red
Figure 23 - Color code for positioner springs
(114 and 154)
5.7 MAINTENANCE OPERATIONS SPECIFIC TO THE
7700E POSITIONER
REFER TO ATEX INSTRUCTION MANUAL
No. 185977 FOR ALL MAINTENANCE ON
THE ELECTRICAL PARTS OF THE 7700E
POSITIONER.
A. Loosen screws (27) and remove I/P module (20).
Note: If damaged, the I/P module must be replaced.
B. Check that O-rings (28, 29 and 30) and their seats are
not worn or damaged.
Note: All worn or damaged parts must be replaced.
C. Fit O-rings (28, 29 and 30) in their recesses on the I/P
module (20). Ret I/P module (20) on manifold block
(144). Tighten screws (27).
Note: To ensure correct positioner performance, check that
all gaskets are perfectly leaktight.