Dwyer Instruments W.E. Anderson 150N Series User manual

Series 150N Pneumatic Positioner
Installation and Operating Instructions
Bulletin F-56
W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC.
P.O. BOX 358 • MICHIGAN CITY, INDIANA 46361 U.S.A.
Phone: [phone] www.dwyer-inst.com
Fax: [phone] e-mail: [e-mail]
Bulletin F-56 6/27/05 9:37 AM Page 1

TABLE OF CONTENTS
SECTION TITLE PAGE
1.0 INTRODUCTION..................................................................................................3
1.1 MODEL DESIGNATION...........................................................................................3
1.2 SPECIFICATIONS...................................................................................................4
2.0 INSTALLATION.....................................................................................................5
2.1 SHIPPING AND STORAGE.....................................................................................5
2.2 MECHANICAL INSTALLATION................................................................................5
2.2.1 PROCEDURE..............................................................................................6
2.3 PNEUMATIC CONNECTIONS.................................................................................9
2.3.1 PIPING......................................................................................................10
2.3.2 INSTRUMENT AIR REQUIREMENTS.........................................................10
2.4 CAM INSTALLATION............................................................................................11
2.4.1 CAM IDENTIFICATION...............................................................................11
2.4.2 EQUIPMENT NEEDED...............................................................................11
2.4.3 PROCEDURE............................................................................................11
3.0 CALIBRATION....................................................................................................16
3.1 EQUIPMENT NEEDED..........................................................................................16
3.2 PROCEDURE.......................................................................................................16
4.0 PRINCIPLE OF OPERATION.............................................................................20
5.0 MAINTENANCE..................................................................................................22
5.1 RESTRICTION......................................................................................................22
5.2 FILTER SCREENS................................................................................................22
LIST OF ILLUSTRATIONS
SECTION TITLE PAGE
2-1 Cam and Associated Hardware..............................................................................7
2-2 Typical Positioner Mounting and Feedback Pin Connection....................................8
2-3 Standard Cam Characteristics..............................................................................13
2-4 Cam Installation, A Side Example.........................................................................14
2-5 Cam Installation, B Side Example.........................................................................15
3-1 Calibration............................................................................................................17
4-1 Schematic............................................................................................................21
9/94
PAGE 2 BULLETIN F-56
Bulletin F-56 6/27/05 9:37 AM Page 2

1.0 INTRODUCTION
The Model 150P Valve Positioner is a cam characterized, double-acting, pneumatic valve positioner
that accepts a 3-15 or 3-27 psig input signal and converts it to a pneumatic output to position a con-
trol valve actuator. The Positioner can be used with either rectilinear or rotary, single or double acting
actuators. A selection of cam profiles is available.
A high-gain, piloted spool valve is used to load the actuator for positioning in response to an input sig-
nal. Mechanical feedback is provided by a characterized cam.
No additional parts are necessary to change between single or double acting actuators or
direct/reverse action.
1.1 MODEL DESIGNATION
Each Positioner has a nameplate identifying the model number. The following decodes the model num-
ber on the nameplate. Before installing or servicing a Positioner, review the nameplate information.
TYPE
150N Pneumatic Valve Positioner
ACTION
L Rectilinear
R Rotary
CAM PROFILE
1 Standard Linear
2 Standard Rotary
INPUT
1 3 to 15 PSIG
2 3 to 27 PSIG
150N L 1 1 SAMPLE MODEL NUMBER
9/94
BULLETIN F-56 PAGE 3
Bulletin F-56 6/27/05 9:37 AM Page 3

PAGE 4 BULLETIN F-56
1.2 SPECIFICATIONS
Connections: 1/8˝ NPT
Input: 3-15 PSIG (.21-1.1 KG/CM2), 3-27 PSIG (.21-1.9 KG/CM2)
Supply: 30 PSIG (2.1 KG/CM2) minimum, 150 PSIG (10.5 KG/CM2) maximum
Supply Pressure Change Effect: output pressure changes less than 0.3% of span for a 5 PSIG (.35 KG/CM2)
change
Air Consumption: 0.7 SCFM (.33 L/S) at 60 PSIG (4.22 KG/CM2) supply
Air Pilot Capacity: 7.5 SCFM (3.5 L/S) at 60 PSIG (4.22 KG/CM2) supply
Adjustable Range: ±30% of input span or maximum rated travel
Stroke: Rectilinear, 1/2˝ to 2˝
Temperature Limits: -40°F to 180°F (-40°C to 82°C)
Weight: 2.5 lbs. (1.3 kgs)
Gauges............ Two: 0-160 PSIG (0-11.2 KG/CM2) gauges to monitor output
pressure;
One: 0-30 PSIG (0-2.1 KG/CM2) gauge to monitor input
pressure.
Position Indictor Indicator and tape scale to indicate valve position (rotary actuators only).
PERFORMANCE
Repeatability: 0.1% of span
Linearity: ±1% of span
Hysteresis: less than 0.75% of span
Dead Band: less than 0.1% of span
Response Level: less than 0.1% of span
9/94
Bulletin F-56 6/27/05 9:37 AM Page 4

BULLETIN F-56 PAGE 3
2.0 INSTALLATION
This section provides information pertaining to installation of a Series 150N Valve Positioner.
This entire section should be reviewed before proceeding with the installation.
Positioner installation is dependent upon the type of valve actuator and its characteristics, and the
effect of the valve on the process. Obtain this information before proceeding with the installation.
Operating temperature limits are stated in the Specifications section of this Instruction. The tempera-
ture in the selected location must not exceed the specified operating temperatures.
CAUTION
Exceeding the specified operating temperature limits can
adversely affect performance and may cause damage to the
Positioner.
The Positioner will need to be calibrated before being put into service.
2.1 SHIPPING AND STORAGE
If the Positioner is to be stocked, stored, or shipped to another location prior to piping, make sure that
the factory installed plastic plugs are in the pneumatic ports to prevent entry of moisture, dirt, or other
contaminant.
2.2 MECHANICAL INSTALLATION
Refer to Page 1 for dimensions and mounting hole locations.
Rigidly mount Positioner to actuator to prevent relative motion. The Positioner may be mounted in any
orientation. Feedback torque is 7 inch/lbs. maximum. The location must provide access for:
• Mechanical interconnecting of Positioner and actuator
• Routing of pneumatic piping
• Removing of access cover
• Servicing
Note that the extension spring and related parts mentioned in the following procedures, and shown in
Figure 2-1, are present only when a quick opening cam is used.
Bulletin F-56 6/27/05 9:37 AM Page 5

PAGE 6 BULLETIN F-56
2.2.1 Procedure
1. Loosen cover screws and rotate cover (and gasket) to provide access. See Page 1.
2. If present, remove extension spring from spring anchor (spring may be disconnected in a new
Positioner shipped from the factory). Then remove screw, washer, and anchor. See Figure 2-1.
3. Slightly loosen hex nut or standoff so input shaft is free to turn without turning cam (7/16˝ socket
needed).
4. If removed in step 2, loosely reinstall the spring anchor, washer, screw, and extension spring removed
in step 2.
5. For feedback connection between Positioner and actuator, refer to either A or B depending upon
type of actuator to be used.
A. RECTILINEAR ACTUATOR
Figure 2-2 shows Positioner and sample actuator. Fabricate and install a slotted bracket and feed
back pin based on following statements:
• Feedback level must be perpendicular to actuator stem with actuator at mid-stroke.
• Connection between actuator stem and feedback lever is typically made using a slotted brack
et attached to actuator stem and a feedback pin attached to the feedback lever. The slotted
bracket must be rigid and motion must be transferred without deflection.
• Figure 2-2, details A and B, show the feedback pin fixed to feedback lever, the preferred
method. The distance from the centerline of feedback pin to centerline of input shaft must equal
actuator stroke.
• Figure 2-2, detail C shows feedback pin fixed to slotted bracket, an alternate method that caus
es an increase in linearity error of approximately 2%. The distance from the centerline of free
end of feedback pin to centerline of Positioner input shaft must equal actuator stroke x 0.866.
B. ROTARY ACTUATOR
Fabricate and install a coupling based on the following statements:
• Couple the 0.5˝ square Positioner input shaft to actuator shaft.
• Shaft centerlines must be in-line to minimize friction and binding as shafts rotate.
6. Mount Positioner on actuator.
Bulletin F-56 6/27/05 9:37 AM Page 6

BULLETIN F-56 PAGE 7
FIGURE 2-1 Cam and Associated Hardware
Bulletin F-56 6/27/05 9:37 AM Page 7

PAGE 8 BULLETIN F-56
FIGURE 2-2 Typical Positioner Mounting and Feedback Pin Connection
Bulletin F-56 6/27/05 9:37 AM Page 8

BULLETIN F-56 PAGE 9
2.3 PNEUMATIC CONNECTIONS
Pneumatic connections are shown on page 1 and listed below:
IN - Input (or instrument) connection
V1- No. 1 valve connection
V2 - No. 2 valve connection
S - Supply connection
Valve connections are used either independently or together to load the valve actuator. A user supplied
1/8˝ NPT pipe fitting is 12 foot-pounds. When only one valve connection is used, a user supplied 1/8˝
NPT pipe plug is required for the unused connection.
CAUTION
Pressure in excess of 150 psig to any connection may cause
damage to the Positioner.
Supply pressure to Positioner must not exceed actuator
maximum pressure rating.
Refer to the table to determine the required pneumatic connections between the Positioner and the
actuator.
ACTUATOR POSITIONER ACTION CONNECTIONS
TYPE
Single acting Direct acting (output increases Connect V2 and plug V1
with increasing input signal)
Single acting Reverse acting (output decreases Connect V1 and plug V2
with increasing input signal)
Double acting --- 1. Note actuator position desired for
minimum input signal to Positioner.
2. Connect V2 to actuator port that
causes actuator to move away from
position noted in above step.
3. Connect V1 to remaining port.
Bulletin F-56 6/27/05 9:37 AM Page 9

PAGE 10 BULLETIN F-56
2.3.1 Piping
All connections are 1/8˝ NPT.
User supplied materials:
• Scale free piping at least 3/16˝ OD
• 1/8˝ NPT pipe fitting is needed for each connection used; the maximum torque to be applied
when tightening a fitting is 12 foot-pounds
• 1/8˝ pipe plug to plug an unused port
Piping recommendations:
• Blow out all piping before connections are made to prevent dirt, chips, or debris from entering
the Positioner.
• Use pipe sealant sparingly and only on male threads. A non-hardening sealant is strongly
recommended.
• Connect the Positioner to a source of clean, oil-free instrument air. Instrument air requirements
are given in the following section. Failure to do so will increase the possibility of a malfunction
or deviation from specified performance.
2.3.2 Instrument Air Requirements
Instrument quality air must be supplied to the Positioner.
CAUTION
Synthetic compressor lubricants in the air stream at the Positioner
may cause it to fail.
There are many types of synthetic lubricants. Some may not be compatible with the materials used in
the construction of the Positioner. Wetting of these materials by such an oil mist of vapor may cause
them to deteriorate. This can result in failure of the Positioner. A list of materials used in the Positioner
is found in the SPECIFICATIONS section.
Requirements for a quality instrument air supply can be found in the Instrument Society of America’s
“Quality Standard for Instrument Air” (ISA-S7.3). Basically this standard calls for the following:
Particle Size - The maximum particle size in the air stream at the instrument should be no larger than 3
microns.
Bulletin F-56 6/27/05 9:37 AM Page 10