controlair 2000 Manual

Contents
Section Description P ge
1.0 Introduction 2
2.0 Specifications 3
2.3 Approvals 4
3.0 Installation 4
4.0 Dimensions 9
5.0 Parts 10
6.0 Warranty 10
441-622-119 Type 2000 Page 1
8 Colum ia Drive
Amherst, NH 03031 USA
603-886-9400
Fax: [phone]
www.controlair.com
[e-mail]
Pne matic and Electropne matic
Valve Positioner
Installation, Operation and
Maintenance Instructions
Type 2000
Ordering Information
Use this coding system to order
Type of Positioner
00 P/P Pneumatic
10 E/P Electro-pneumatic;
FM/C A Intrinsically afe
11 E/P Electro-pneumatic;
ATEX Intrinsically afe
20 E/P Electro-pneumatic;
FM/C A Explosion-proof
21 E/P Electro-pneumatic;
ATEX Flame-proof
Type of
Motion
RRotary
LLinear
Model
CA20 -
• •
•
•
Indicator
NNone
( tandard Linear)
AArrow
( tandard Rotary)
DDome
(Option)
•
Spindle
0Namur (Rotary)
1tandard (Linear)
23/8" quare
31/2" quare
----
Accessories
Gauges 0-30 psi (0-2 bar), 1/8" NPT Back Mount P/N: 446-725-006
0-160 psi (0-11 bar), 1/8" NPT Back Mount P/N: 446-725-008
0-30 psi (0-2 bar), 1/8" NPT Bottom Mount P/N: 446-725-033
Cam
C1 90˚/180˚ ( tandard Rotary)
C2 45˚/90˚
C3 30˚/60˚ ( tandard Linear)

441-622-119 Type 2000 Page 2
DANGER, WARNING, CAUTION and NOTE statements
Refers to conditions or hazards which could result in serious personal in ury or death.
Refers to conditions or hazards which could result in personal in ury.
Refers to conditions or hazards which could result in equipment or property damage.
Alerts you to facts or special instructions.
ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL
1. INTRODUCTION
1.1 General
The ControlAir Type-2000 pneumatic and electro-pneumatic positioner provides stable and accurate positioning of rotary
and linear valves. The force balanced instrument is simple, reliable and user friendly for calibration, maintenance and field
upgrades. The electropneumatic unit is available with worldwide safety approvals in an Intrinsically Safe and Explosion-
proof version. The NEMA-4X (IP 66) housing provides rugged resistance to severe industrial environments. The modular
design of the Type-2000 allows multiple feature ordering options or easy field conversions.
1.2 Principles of Operation
The Type 2000 operates on a force balance principal of operation. Force is created by the input signal pressure acting on
the diaphragm (1) which transmits to the balance arm (2). An opposing force is created by the feedback spring (3) and
works in the opposite direction on the balance arm (2). The feedback spring, resting on the guide arm (4) is positioned by
the shape and response of the cam (5). The cam (5) is connected to the spindle and actuator shaft which provides feed-
back from the valve/actuator. The spool (6) in the pilot valve (7) is connected to the balance arm and follows the balance
arm’s movement.
The system is stable when these opposing forces that affect the balance arm are neutral. When there is a signal change
or a change in the position of the actuator occurs, the force balance is also changed and the spool moves. Supply air
immediately begins to flow through the pilot valve into the actuator (C+ or C-) which allows the feedback mechanism to
return the spool to the neutral position. At this point the two forces are equal and the unit is in balanced equilibrium.
NOTE
CAUTION
WARNING
DANGER
12
7345
1
2
345
6P
C-
C+
SUPPLY

441-622-119 Type 2000 Page 3
1.3 Air Requirements
1.3.1 Supply air should be clean, dry, oil-free instrument air filtered to 40 micron. A filter regulator is recommended to
be installed as close to the Type-2000 as possible.
1.3.2 Maximum supply pressure is 150 psig (10 bar).
Water, Oil and Particulate in the air line will cause blockage and malfunction of the spool
valve and/or the I/P Transducer.
2. SPECIFICATIONS
2.1 Functional Specifications
Type-2000 Pneum tic (CA2000) Electro-Pneum tic Electro-Pneum tic
Intrinsic lly S fe Explosion-proof
(CA2010/CA2011) (CA2020/CA2011)
Input Sign l 3-15 PSI (0.2-1.0 Bar) 4-20 mA
Supply Pressure 145 PSI (10 Bar) maximum 21.8-145 PSI (1.5-10 Bar)
Line rity Error 0.7 % full span <1.0% full span
Hysteresis 0.4% full span <0.6% full span
Repe t bility 0.3% full span <0.5% full span
Pressure G in 750 P out/P in 750 P out/P in
Flow C p city SCFM Nl/min SCFM Nl/min
@29 PSI (2.0 Bar) 9.5 268.9 9.5 268.9
@87 PSI (6.0 Bar) 28.3 800.1 28.3 800.1
@145 PSI (10 Bar) 47.1 1333 47.1 1333
Air Consumption SCFM Nl/min SCFM Nl/min
@29 PSI (2.0 Bar) 0.18 5.09 0.2 5.7
@87 PSI (6.0 Bar) 0.53 424.5 0.6 17.0
@145 PSI (10 Bar) 0.88 707.5 1.0 28.3
Imped nce 260 Ohms at 70 degrees F
Loop Lo d 5.2 Volts at 70 degrees F
2.2 P ysical Specifications
Temper ture R nge -40˚ to 185˚ F (-40˚ to 85˚ C)
Port Sizes Pneumatic: 1/4" NPT; Gauge Ports - 1/8" NPT
Electric: 1/2" NPT; M20-1.5 (ATEX)
Medi Clean, dry, oil-free instrument air, filtered to 40 micron
Enclosure Nema 4X / IP66
Finish Polyester Epoxy
Weight 3.5 lbs (1.6 kg) 3.8 lbs (1.7 kg) 4.8 lbs (2.2 kg)
CAUTION

3. INSTALLATION
3.1 Safety Instructions
Beware of moving parts when positioner is operated!
Beware of parts with live voltage! A voltage, which is normally not dangerous, is supplied to the
positioner. Avoid touching live parts and bare wires as well as short circuting live parts and the
housing.
o not dismantle a pressurized positioner! ismantling a pressurized positioner will result in
uncontrolled pressure release. Always isolate the relevant part of the pipeline. Release the pres-
sure from the positioner and the piping. Failure to do this may result in damage or personal
injury.
o not exceed the positioner performance limitations! Exceeding the limitations marked on the
positioner may cause damage to the positioner, actuator and valve. amage or personal injury
may result.
WARNING
WARNING
WARNING
DANGER
441-622-119 Type 2000 Page 4
2.3 Hazardous Area Approvals
Model F ctory Mutu l (FM) & C n di n St nd rds (CSA) Approv ls
2010 Intrinsic lly S fe
Class I, ivision 1, Groups A, B, C,
Nonincendive
Class I, ivision 2, Groups A, B, C,
2020 Intrinsic lly S fe
Class I, II & III, ivision 1, Groups A, B, C, , E, F,G
Explosion-Proof
Class I, ivision 1, Goups B, C,
Dust Ignition-Proof
Class II, III, ivision 1, Groups E, F, G
Model ATEX Approv ls
2011 Intrinsic lly S fe
II 1 G Ex ia IIC T4/T5/T6
2021 Intrinsic lly S fe
II 1 G Ex ia IIC T4/T5/T6
Fl me-Proof – ATEX
II 2 G Ex d IIB + H2 T6
II 2 Ex t A21 T850C
Entity P r meters
Ui (Vmax) = 40 V C
Li (Imax) = 125 mA
Ci = 0
Li = 0
Pi = 0.7 watts max.
Entity P r meters
Ui (Vmax) = 40 V C
Li (Imax) = 125 mA
Ci = 0
Li = 0
Pi = 0.7 watts max.

3.2 Connections
S– Supply Air
CA2000: max 150 PSI / 10 BAR
CA2010, CA2011, CA2020, CA2021: min. 21 PSI / 1.5 BAR
IP– Input, pressure signal
CA2000: 3-15 PSI / 0.2-10 BAR
CA2010, CA2011, CA2020, CA2021, plugged
IEInput, Current signal
CA2010, CA2011, CA2020, CA2011 – 4-20mA
C+ - Actuator connection + stroke
C- - Actuator connection – stroke
EXHAUST – All air from the actuator, IP and positioner
is vented through this port. o not block!
Air connections for male 1/4" NPT
Gauge connections for male 1/8" NPT
Cable entry for conduit male 1/2" NPT
The appropriate threads are clearly indicated
by the markings on the housing.
Gauge ports I , C+ , C- and S are factory plugged.
Remove the plugs and replace with gauges.
Liquid sealant for threads, Loctite or similar, is recommended for all air connections.
The IPconnection must be plugged in CA2000. The IEconnection should be plugged in CA2000.
NOTE
NOTE
441-622-119 Type 2000 Page 5
Ip
C-
S
C+ EXHAUST
IE
Max. gauge
size Ø 1.7"
(Ø 43.5 mm)
Gauge Ports

3.3 General Mounting Instructions
The ControlAir Type-2000 has the ISO F05
hole pattern for mounting kits.
3.3.1 Rotary Actuator
The ControlAir Type-2000 has a very stable and properly sized drive shaft
bearing. However, the positioner drive (A) should be aligned properly to the
rotary actuator spindle (B).
A relatively small error combined with a rigid coupling can create very powerful
radial forces, which can in turn overload and in short time wear out even the
very best drive shaft bearing.
3.3.2 Linear Actuator
When mounting on linear actuators, the positioner should
be attached in such away that its drive is in the center of
the actuator’s stroke. Proper installation and alignment
will minimize linearity error.
441-622-119 Type 2000 Page 6
M6x1
11/32 [8.5] Deep
(4) Places
5/16-18
5/16 [7.9] Deep
(4) Places
A
B
=
=

441-622-119 Type 2000 Page 7
3.4 Cam Adjustment
The ControlAir Type-2000 is standard shipped with the C1-cam,
factory set for 90° ±1°, direct (CCW) turning.
3.4.1 Adjustments
Loosen and remove the front cover and indicator.
1 Loosen the screw (1) and the cam lock nut (2)
by turning counter clockwise.
2 Run the valve/actuator to the stop/endposition
at 0% input.
3 Turn the cam (3) so that the index mark (5) for
the selected curve aligns with and is riding on
the ball bearing (4).
4 To secure the cam, tighten the cam lock nut by hand (2).Check that
the screw (1) is still loose. (if not, loosen the screw slightly and tighten
the lock nut again)
5 Tighten the lock screw (1).
6. Install and adjust the indicator. Reinstall the front cover.
3.4.2 Cam Speci fications C1
Index mark Starting point of rotation
*5 90° Linear 0-100% CCW
6 180° Linear 0-100% CW
6 90° Linear 0-50% CW split range
7 90° Linear 50-100% CW split range
8 90° Linear 0-100% CW
9 180° Linear 0-100% CCW
9 90° Linear 0-50% CCW split range
10 90° Linear 50-100% CCW split range
*Increasing signal rotation.
Most valves rotate CW to close / CCW to open.
When field reversing action of positioner, tubing
must be reversed as well.
CAUTION
NOTE
NOTE

441-622-119 Type 2000 Page 8
3.5 4-20 mA Connection
3.5.1 Connecting the control signal
Loosen and remove the front cover and indicator. Loosen the screw (1)
enough so that the terminal connector board can be lifted. Terminal
block screws are now easily accessible. Connect the cables providing
the input signal from the controller to its respective pole. Max cable area
2.5mm2, ~AWG 13
The I/P transducer is factory-adjusted. No extra range or
zeroing adjustments are necessary.
3.6 Calibration
The ControlAir Type-2000 is delivered factory
calibrated 0 -100% for 90 + 1.0 degree rotation.
Calibration procedure
Zero
1 Set 0% input signal (3 psi/0.2 bar or 4 mA).
2 Wait until the valve has settled.
3 Adjust the zero position by turning the zeroing screw (1),
with a screw-driver from the outside or by using the slot (2a)
on the bottom wheel (2).
R nge
4 Increase to 100% input signal (15 psi/1.0 bar or 20 mA).
5 Wait until the valve has settled.
6 Adjust the range by using the slot (3a) on the top wheel (3).
Check the zero position. Make fine adjustments if necessary.*
*With Split Range, where zeroing can bedone by a signal other
than 0%, the steps 1-6 must be repeated until the desiredsetting has been
reached.
NOTE
NOTE
1
2a
+ %
- %
ZERO
>0<
2
1
+%
-%
RANGE
33a

441-622-119 Type 2000 Page 9
4. DIMENSIONS
2 3/4 [70]
1 7/8 [47]
M6x1
11/32 [8.5] Deep
(4) Places
1 13/32 [36]
2 1/4 [57]
1 13/32 [36]
2 1/4 [57]
9 23/32 [247]
1 1/32 [26]
15/32 [12]
1 11/32 [34]
5/16-18
5/16 [7.9] Deep
(4) Places
1 7/32 [31]
3 1/2 [89]*
7 1/2 [190]*
1 1/4 [32]* 1/2 NPT
CONDUIT
PORT
>0< ZERO
EXHAUST
3 3/4 [95]
OPTIONAL DOME INDICATOR
1/4 [7]
3 15/16 [100]
2 11/16 [68]
1 5/8 [42]
9/16 [14]
3/4 [19]
1 3/16 [30]
17/32 [14]
31/32 [17]
7/8 [22]
1/2 npt
1/4 NPT
4 Places
Ø 2 31/32 [75]
3 5/16 [84]
219/32 [66]
611/32 [161]
127/32 [47]*
6 5/8 [168]*
Ø1 9/16 [40]*
7/16 [13]* 5/16 [8] 4 11/32 [110]
INST.
SIGNAL
OUT-2
OUT-1
SUPPLY
1/2" NPT
423/32 [120] MAX.
1 13/16 [46]
41/2 [114]
411/32 [110]
17/8 [48]
1 29/32 [48] MIN.
1/2"NPT
L I N E A R ( L )
R O T A R Y ( R )
Optional Explosion-proof

441-622-119 Type 2000 Page 10
5. SPARE PARTS
5.1 PARTS LIST
6. WARRANTY & DISCLAIMER
ControlAir, Inc. products are warranted to e free from defects in materials and workmanship for a period of eighteen months from the
date of sale, provided said products are used according to ControlAir, Inc. recommended usages. ControlAir, Inc.’s lia ility is limited to the
repair, purchase price refund, or replacement in kind, at ControlAir, Inc.’s sole option, of any products proved defective. ControlAir, Inc.
reserves the right to discontinue manufacture of any products or change products materials, designs or specifications without notice.
These products are intended for use in industrial compressed-air systems only.
Do not use these products where pressures and temperatures can exceed those
listed under Specifications.
Before using these products with fluids other than air, for non-industrial application, life-support systems, or other applications not
within pu lished specifications, consult ControlAir, Inc.
WARNING
Item Description . . . . . . . . . . . . . . .Qty
1 iaphragm Cover (includes) . . . .1
-Screw . . . . . . . . . . . . . . . . . . . .4
-O-ring . . . . . . . . . . . . . . . . . . .1
2 Cover Plate . . . . . . . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .2
3 I/P Transducer Plate . . . . . . . . .1
-590-AC Transducer . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . . .2
4 XP I/P Transducer Plate . . . . . .1
-595-AC Transducer . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .2
5 Screw, iaphragm . . . . . . . . . .1
6 Washer, iaphragm . . . . . . . . . .1
Item Description . . . . . . . . . . . . . . .Qty
7 iaphragm . . . . . . . . . . . . . . . . .1
8 Piston, iaphragm . . . . . . . . . . .1
9 O-ring Seal . . . . . . . . . . . . . . . .1
10 Filter Cap . . . . . . . . . . . . . . . . . .2
-Rubber Channel . . . . . . . . . . .1
-Filter . . . . . . . . . . . . . . . . . . . . . .1
11 Housing . . . . . . . . . . . . . . . . . . . .1
12 rive Shaft . . . . . . . . . . . . . . . . .1
-O-ring . . . . . . . . . . . . . . . . . . .1
-O-ring . . . . . . . . . . . . . . . . . . .1
13 Screw, Back Plate . . . . . . . . . .4
14 Back Plate . . . . . . . . . . . . . . . . .1
Item Description . . . . . . . . . . . . . . .Qty
15 Nitrile Gasket . . . . . . . . . . . . . .1
16 Spring, Safety Valve . . . . . . . . . .1
17 Safety Valve . . . . . . . . . . . . . . . .1
18 Pipe Plug ¼ NPT . . . . . . . . . . .1
19 O-ring Seal . . . . . . . . . . . . . . . . .1
20 Pilot Valve . . . . . . . . . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .1
- Gasket . . . . . . . . . . . . . . . . . . .1
21 Pipe Plug, 1/8 NPT . . . . . . . . . . .4
22 Exhaust Filter . . . . . . . . . . . . . . .1
23 Zero Plug . . . . . . . . . . . . . . . . .1
24 Balance Arm . . . . . . . . . . . . . . . .1
25 Spring, Guide Arm . . . . . . . . . . .1
26 Guide Pin . . . . . . . . . . . . . . . . . .1
27 Guide Arm . . . . . . . . . . . . . . . .1
-Roller Bearing . . . . . . . . . . . . . .1
-Zero Screw . . . . . . . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .1
-Bearing . . . . . . . . . . . . . . . . . .1
28 Holding Washer . . . . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .1
29 Feedback Spring Assembly . . . .1
30 E-clip . . . . . . . . . . . . . . . . . . . . . .1
31 Cam (C1 Shown) . . . . . . . . . . . .1
32 Cam Nut . . . . . . . . . . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .1
33 Indicator with Label . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .1
34 Front Cover Seal . . . . . . . . . . . . .1
35 Front Cover . . . . . . . . . . . . . . . .1
- Label . . . . . . . . . . . . . . . . . . . . .1
-Screw . . . . . . . . . . . . . . . . . . .4
36 Screw, Pin Retain . . . . . . . . . . .2
37 Screw, Balance Arm . . . . . . . . .2
38 Screw, Terminal Block . . . . . . . .1
39 Screw, Ground . . . . . . . . . . . . .2
40 Lock Washer, Ground . . . . . . . .2
1
2
3
4
5
6
7
8
10
9
11
12
13
141516 17
18
19
20
21
23
24
25
26
27
28
29 30
31
32
33
34
35
36
37
38
39
39
40
22