Dyna-Flo 4000 Parts list manual

Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
1
Dyna-Flo 4000
Operation, Parts and Instruction Manual
Table of Contents
Calibration 2
Adjustments 4
Maintenance 5
Changing Action 6
Relay Manifold 8
Output Signal 9
Start-Up & Tuning 11
Parts 12
Kits 12
Detailed 15

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
2
!NOTICE! These instructions are meant to be used with the Dyna-Flo 4000 Series Technical
Bulletin as they refer to Figures and Tables therein. If you do not have the
Technical Bulletin, contact Dyna-Flo immediately, or visit www.dynaflo.com
Each controller is factory checked. Check the calibration for the specific
application, before a controller is put into service.
Calibration Procedure Initial Set-up
The 4020 Differential Gap Instructions are at
the end of this section
1 It is recommended to calibrate the controller in
the position in which it will be operated.
2 Determine supply pressure requirement
by checking controller output signal range:
a) An output signal range of 6-30 psi (40-200
KPa) would require 35 psi (240 KPa)
supply pressure.
b) An output signal range of 3-15 psi (20-100
KPa) would require 20 psi (140 KPa)
supply pressure.
3 Connect a supply pressure line at the required
setting, to the SUPPLY connection at the back
of the case as shown in figure 12.
4 Install 1/4” NPT pipe plug at the OUTPUT
connection at the back of the case as shown in
figure 5. The controller output pressure change
is measured by the output pressure gauge.
5 Locate a pressure supply (of compressed air or
nitrogen) equivalent to the bourdon tube rating.
6 With the block valve closed, connect the
pressure supply through a block valve and
regulator to the CONTROL pressure block.
! NOTE !
There are 2 possible connections to the control
pressure block:
a) The CONTROL connection in the back of
the case
b) The connection at the left side of the case.
Plug the unused connection.
7 Verify that the calibration adjuster screws
(Figure 5, Key 44) are at mid-point in the
calibration adjuster (Figure 5, Key 8).
8 Inspect the following for leaks (using leak
detection solution or soapy water).
4000 / 4020 Controller
Relay Manifold
All tubing and connections (relay &
compensator)
Bellows, bellows frame and bellows screws
Proportional band and elbow fitting
4010 Controller
Relay Manifold
All tubing and connections (relay &
compensator)
Bellows, bellows frame and bellows screws
Proportional band and elbow fitting
Reset restrictor valve
Reset and compensator tubing
9 Set PRESSURE SETTING knob (Figure 4) at 0
(zero) seting.
10 Adjust the nozzle (Figure 5, Key 50), until the
output pressure is between 8 and 10 psi.
4000 Controller
A) Rotate proportional band knob and set at
zero (closed position).

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Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
3
Calibration Procedure Initial Set-up
(cont’d)
4000 Controller (cont’d)
The output pressure gauge should
indicate full supply pressure.
Check that for a direct acting unit the
bellows movement is downward, and
upward for a reverse acting controller.
B Rotate proportional band knob and set at 10
(open position).
The output pressure gauge should
indicate 0 - 5 psi pressure.
Check that for a direct acting unit the
bellows movement is downward, and
upward for a reverse acting controller.
C Rotate proportional band knob and set at 1.5
(15% proportional band).
The output pressure gauge should indicate
8-10 psi pressure.
4010 Controller
Refer to Figure 6.
Rotate Reset Restrictor Valve and set at MAX.
! Note !
If the 4010 is to be left at the maximum Reset
setting, the 4010 controller will perform as a
4000 (porportional band) controller. It is
recommended taht the reset bellows tubing be
removed and retubed as shown in Figure 7 for
a 4000 (proportional band) controller.
Range
4000 Controller
Verify that the proportional band is set at 1.5.
4010 Controller
Additionally, verify that the reset valve is set at
0.01 minutes per repeat.
A Apply input pressure equal to the bourdon tube
maximum rating.
B Rotate pressure setting knob (Figure 4) to the
maximum value which is equal to the bourdon
tube rating.
C Output gauge reading should be between 8 and
10 psi. If not, adjust controller span by
loosening one of the two calibration adjuster
screws (Figure 5, Key 44) and move the
calibration adjuster (Figure 5, Key 8) a small
distance as explained below and illustrated in
Figure 5.
For direct-acting controller
a) If output is below 8 to 10 psi, move
calibration adjuster to the left.
b) If output is above 8 to 10 psi, move
calibration adjuster to the right.
For reverse-acting controller
a) If output is below 8 to 10 psi, move
calibration adjuster to the right.
b) If output is above 8 to 10 psi, move
calibration adjuster to the left.
D Repeat calibration adjuster movements until
output guage reads between 8 and 10 psi on
both zero and maximum value. (Maximum
value is bourdon tube uper limit.)
E Isolate the controller from process, control, and
supply pressure.
F Vent any trapped pressure from the controller.
4020 Controller
A Temporarily set-up the 4020 (differential gap)
controller as a 4000 (proportional band)
controller, by changing the proportional band
tubing connection to the bellows frame. The
reversing block IS NOT inverted at this time.

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
4
Calibration Procedure Initial Set-up
(cont’d)
4020 Controller (cont’d)
B Calibrate as a 4000 (proportional band)
controller.
C After calibration, restore the proportional band
tubing to it’s original connection on the bellows
frame.
D Due to physical differences in the bellows,
there may be a slight shift in the output
pressure. This will be adjusted out through
nozzle adjustments described below.
E Set the proportional band knob for the required
differential gap (See adjustment section for
differential gap details).
F Set the process pressure:
Direct Acting Controller
1 Move the pressure setting to the upper
switch point value at which the output pressure
will go from zero, to full supply pressure, with
rising process pressure.
2 Apply input pressure to the bourdon tube, as
you observe the output guage. When the upper
switch point value is reached, while increasing
input pressure, the controller output should
switch from zero pressure, to full supply
pressure.
3 Adjust the nozzle to correct any upper switch
point error, and retest until the switch point
and input pressure values agree.
Reverse Acting Controller
The controller output described above will be
reversed.
G Check controller operation by running the input
pressure from zero to above the upper switch
point, and observing the switching points. Set
a new differential gap, vary the input pressure,
and then repeat with the calibration settings.
Adjustments
Manual Set Point (4000 / 4010 / 4020)
Adjust the pressure setting by turning the pressure
setting knob (Figure 4) to the desired pressure. This
represents the upper switch point for a direct acting
4020.
Proportional Band (4000 and 4010)
To adjust the proportional band, rotate the
proportional band knob (Figure 4) to the desired
value (between 3 to 100%). This represents 3-100%
of the sensing element range, and controls the
percentage of sensed pressure change required to
cause full output of the controller.
Differential Gap (4020)
Adjust the proportional band knob (Figure 4) to set
the width of the differential gap about the switch
point. Use Table 1 as a guide. Calculate the
Differential Gap as follows:
(Upper Switch Point - Lower Switch Point) x 100
Boudon Tube Range
Table 1 - Differential Gap Setting Guide
Reset (4010 only)
To adjust the reset action, rotate the reset knob
(Figure 6) counter-clockwise to increase the spead.
The minutes per repeat indicate the time required
for the reset bellows pressure to equal the
proportional bellows pressure.
Proportional Band
Setting
Differential Gap
(% OF Element Range)
1.2 10
1.8 20
2.5 30
3.1 40
3.8 50
4.4 60
5.1 70
5.7 80
6.4 90
7 100

Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
5
Controller Maintenance
Regular Maintenance
A If the installation includes a supply regulator,
periodically open the drain on the filter
regulator to drain accumulated moisture.
B Push the cleaner wire on the relay orifice (key
83, Figure 3) to release moisture or particulate.
C Inspect, and if necessary, clean the opening of
the vent assembly (Key 71, Figure 4) or the
remote vent pipe, if one is used.
Replacing Gauges
Refer to Figure 4.
A Quantity 2 gauges (key 31) are used, one for
output and one for supply pressure.
B Always ensure to check the range of the
controller before ordering replacement gauges
(0-30 psi gauges WILL NOT work on a 6-30 psi
controller).
C Always use approved thread sealant on the
threaded connections.
Replacing Bourdon Tube
Refer to Figures 4 & 5.
! WARNING !
Isolate the process sensing line prior to
disconnecting the bourdon tube from the
control tubing (Key 14). Be aware of
potential hazards from disconnecting
process connections.
A Disconnect the control tubing (Figure 4, Key 14)
at the bourdon tube end.
B Remove the screw (Key 11) that connects the
link (Key 12) to the beam (Key 1).
C Unscrew two screws (Key 38) and washers (Key
35), and remove the bourdon tube (Key 7).
D Remove the screw (Key 11) that retains the link
(Key 12) and link bearing (Key 34) to the
bourdon tube (Key 7).
! NOTE ! Be careful! - Bearings are easy to loose.
E Attach the link and bearing to the replacement
bourdon tube.
F Attach the bourdon tube (Key 7) with two
machine screws (Key 38) and washers (Key35).
G Connect the link and bearing to the beam
(Key 1).
H Check to be sure that the beam is reasonably
parallel with the bottom of the case. The link
(Key 12) should be in tension. If the beam is
not parallel with the case, loosen the machine
screws (Key 38), reposition the bourdon tube
to get the beam parallel, and retighten the
screws.
! NOTE !
If a bourdon tube with a different range was
installed, install a dnew dial having an adjustment
range corresponding to the range of the bourdon
tube. Remove the machine screws and washer
(Key 19 and 72) and dial (Key 20).
! WARNING ! The following maintenace procedures require taking the controller out of service.
To avoid personnel injury, only qualified technicians should perform the following
procedures. Always ensure the controller is fully released of pressure or process
fluid before starting maintenance.

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
6
! WARNING ! The following maintenace procedures require taking the controller out of service.
To avoid personnel injury, only qualified technicians should perform the following
procedures. Always ensure the controller is fully released of pressure or process
fluid before starting maintenance.
Controller Maintenance
(cont’d)
I Check all tubing connections and the bourdon
tube machine screws for leaks, tighten as
necessary.
J Perform the calibration procedure.
Changing Proportional Valve
A Disconnect the tubing and remove the
proportional band valve assembly (Figure 4,
Key 55) from the elbow fitting (Key 11) by
turning it counter-clockwise.
B Install the desired replacement asssembly -
Do not over torque.
C Use a proper thread sealant when reinstalling
the tubing.
D Check for leaks.
Changing Reset Valve
A Disconnect the tubing and remove the reset
restriction valve assembly (Figure 6) by
removing a retaining screw (not shown) on the
back of the controller.
B Install the desired replacement assembly.
C Use a proper thread sealant when reinstalling
the tubing.
D Connect the tubing.
E Check all connections for leaks.
F Perform the calibration procedure.
Changing Action
Isolate the controller from process, control, and
supply pressure. Vent any trapped pressure from
the controller before proceeding.
Refer to Figure 2.
Direct to Reverse Action
Direct action
Increasing sensed pressure produces increasing
output pressure
Reverse action
Increasing sensed pressure produces
decreasing output pressure.
A Refer to Figure 2, and locate the new tubing and
reversing block positions for the action desired.
B Changing the action is accomplished by reversing
the position of 2 components:
1) the reversing block
2) the bellows tubing
C In the controller, locate the two bellows and the
reversing block (Key 63, Figure 2).
For a 4000 (proportional-only) controller
Disconnect the proportional tubing (Key 10) from the
bellows frame and reconnect it in the opposite hole.
For a 4010 (proportional-plus-reset) controller
Disconnect the proportional tubing (Key 10) and reset
tubing from the bellows frame, and reconnect them
in the opposite hole.
For both Models of Controllers
A Remove the reversing block screw (Key 66,
Figure 2) and reversing block assembly (Key 63).

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Model
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Operation, Parts and Instruction Manuals
Instruction Manual October 2005
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For both Models of Controllers (cont’d)
B Inspect the o-rings (Key 53) located in the
recessed area under the reversing block screw
head and between the reversing block
assembly and the calibration adjuster (Key 8,
Figure 5). Replace thesse o-rings, if necessary.
C Position the reversing block assembly, with
o-ring, on the calibration adjuster so that the
nozzle is on the opposite side of the beam
(Key 1, Figure 2) from which it was removed.
Properly position the reversing block assembly
so that the alignment pin engages the hole in
the calibration adjuster. Install the reversing
block screw (Key 66) with o-ring (Key 53).
D Install the sealing screw with o-ring in the
hole previously covered by the reversing
block assembly.
E Install the relay tubing (Key 58) in the
reversing block (Key 62).
F Check all the connections for leaks with leak
detector solution
G Perform the calibration procedure.
DIRECT
ACTING
POSITION
BEAM (KEY 44)
REVERSING
BLOCK (KEY 59)
RELAY TUBING
(KEY 103)
PROPORTIONAL
TUBING (KEY 104)
BELLOWS
(KEY 52)
P
X
PROPORTIONAL
TUBING (KEY 104)
REVERSE POSITION
REVERSE
ACTING
POSITION
REVERSING
BLOCK (KEY 59)
P
X
BELLOWS
(KEY 52)
RELAY TUBING
(KEY 103)
BEAM (KEY 44)
REVERSING
BLOCK (KEY 59)
DIRECT
ACTING
POSITION
R
P
PROPORTIONAL
TUBING (KEY 104)
RESET
TUBING (KEY 117)
NOTES:
P = PROPORTIONAL
BELLOWS
R = RESET BELLOWS
X = NO PRESSURE
REVERSING
BLOCK (KEY 59)
REVERSE
ACTING
POSITION
P
R
PROPORTIONAL
TUBING (KEY 104)
RESET
TUBING (KEY 117)
Direct Acting
Direct Acting
Reverse Acting
Reverse Acting
MODEL 4000 Proportional-Plus Reset Controller
MODEL 4000 Proportional-Only Controller
Figure 2 Tubing Connections

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
8
Relay Manifold
Replacement
Refer to Figure 4.
A Always shut down the supply, control and p
process pressure line to the controller.
B Disconnect the relay tubing (Key 58) from the
relay manifold (Key 56).
C Remove the relay manifold (Key 56) from the
case by unscrewing the 2 retaining screws
(Key 39 - not shown) on the back of the case.
D Remove the gauges, proportional band, and
elbow fitting from the manifold. Install the
gauges, proportional band, and elbow fitting
into the new replacement manifold.
E Replace the relay manifold o-rings (Key 57).
Place the o-rings on the inlet and outlet fittings
on the relay manifold. With the manifold in
place, insert and fasten the 2 screws (Key 39-
not shown) from the backside of the case.
F Connect the tubing, and check all connections
for leaks.
G Perform calibration procedure.
Relay Reconditioning
Refer to Figure 3.
Disassembly
A Complete steps A through D of relay manifold
replacement.
B Unscrew the orifice assembly (Key 83). Remove
the o-rings (Key 79) from the orifice assembly.
C Place the relay manifold on the work surface
with the casing screws facing up. Remove the
casing screws (Key 78), in a criss-cross
pattern.
D Remove and separate the lower casing (Key
76) bottom diaphragm (Key 86), spacer ring
(Key 84), diaphragm assembly (Key 75), relay
spring (Key 82), and valve plug spring (Key 88)
from the relay manifold (Key 81).
E Inspect the valve seats (under a good light) for
roughness due to corrosion. One seat is located
in the diaphragm assembly (Key 75), and the
other seat is located on the seat ring (Key 85),
which is found in the relay manifold (Key 81).
Replace the diaphragm assembly or seat ring
if seats are damaged or worn.
F To install a replacement seat ring (Key 85) in
the relay manifold, remove the 3 screws (Key
77) and washers (Key 80) retaining the seat
ring. Remove the seat ring (Key 85), and o-ring
(Key 74) from the seat pocket in the relay
manifold.
G Inspect diaphragms and gaskets, and replace
them if necessary.
H Replace the spring and valve plug if they show
signs of corrosion.
I The lower diaphragm is part of the diaphragm
assembly and must be replaced as an assembly.
J Clean all parts thoroughly before re-assembling.
Re-assembly
A With the opening in the relay manifold facing
up, place the valve plug spring in the bottom of
the manifold. Carefully place the valve plug on
top of the spring, such that the plug is pointing
up.
B Install the seat o-ring in the pocket of the relay
manifold. Carefully place the seat ring on top
of the o-ring, ensuring the plug is sticking
through the seat ring.
C With the seat ring in place, install the 3
screws and washers that retain the seat ring.

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Website: www.dynaflo.com
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Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
9
Relay Manifold
(cont’d)
Re-assembly (cont’d)
D Place on the relay manifold, in order, the
relay spring, diaphragm assembly, spacer ring
and the top diaphragm. Ensure all the flow
passage holes are lined up.
E Once the assembly of all these compnents is
complete, the diaphragm casing can then be
installed. Place the diaphragm casing on top
of the relay manifold, taking care to maintain
the alignment of the flow passages. A second
check is to align the groves on the casing and
spacer ring, with the mark stamped on the
relay manifold.
F Install the casing screws, but do not tighten
them. Once they are all in, tighten in a criss-
cross pattern.
G Install the o-ring (Key 79) on the orifice
assembly (Key 83), and install the orifice
assembly into the diaphragm casing.
H Replace the relay manifold o-rings (Key 57).
Place the o-rings on the inlet & outlet fittings
on the relay manifold. With the manifold in
place, insert and fasten the 2 screws (Key 39
not shown) from the backside of the case.
I Install the elbow fitting (Key 11), proportional
band (Key 55), gauges (Key 31), and tubing
(Key 58). Check all connections for leaks.
J Perform the calibration procedure.
Changing Output Signal Range
From 3 to 15 psig (20 to 100 kpag) to a 6-30 psig
(40 to 200 psig) output signal range or vice
versa.
A Always shut down the supply, control and
process pressure line to the controller.
B Refer to the parts list to make sure you have
the bellows in appropriate range and
material. Quantity: 2 required.
C Disconnect the tubing (Key 58) from the
relay (Key 56) to the reversing block (Key
63, Figure 2), at the relay end.
Figure 3 Relay Manifold Cross-Section

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
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Changing Output Signal Range
(cont’d)
D Disconnect the tubing from the bellows frame
(Figure 5, Key 2) to the proportinal band
assembly, at the bellows frame end. (Bending
of the tubing will be reduced if you loosen the
fitting at the proportional valve end as well).
E Disconnect the tubing (Figure 4, Key 14) from
the CONTROL pressure block (Figure 4, Key 13)
to the bourdon tube (Key 7), at the CONTROL
pressure block end.
F Remove the 4 machine screws (Key 40, Figure
4), and lift the controller subassembly from the
case.
G Remove the screw (Key 11, Figure 5) that
connects the link (Key 12) to the beam (Key 1).
H Unscrew two screws (Key 38) and washers
(Key 35), and remove the bourdon tube (Key7).
I Remove the screw (Key 11) that retains the
link (Key 12) and bearing (Key 34) to the
bourdon tube.
! NOTE ! Be careful! - Bearings are easy to loose.
J Unscrew The bellows so that the end of the
bellows and beam can be removed from the
end of the bellows frame (Key 2).
K Compress the feedback bellows so that the
end of the bellows and beam can be removed
from the end of the bellows frame (Key 2).
L While firmly holding the bottom feedback
bellows (Key 22) in your hand, turn the upper
bellows counter clockwise with your other
hand to separate the bellows from the beam
assembly.
M Remove the bellows connecting stud (not
shown) for re-use with the new bellows.
N With the stud that connects the two bellows in
place in the spacer (Key 69), screw the new
bellows onto the stud. Install new gaskets (Key
3) on each bellows.
O Compress the feedback bellows, and install
them into the bellows frame (Key 2).
P With the beam parallel with the mounting base,
secure the feedback bellows with the bellows
screws (Key 23).
Q When tightening the bellows screws, make sure
that the nozzle (Key 50) is centered on the
flapper (Key 23).
R Install the bourdon tube if it was removed -
Refer to the Replacing Bourdon Tube section.
S Replace the subassembly in the case and
secure with the machine screws (Key 40,
Figure 4).
T Reconnect all tubing. Take care to get the
proportional tubing back in the right
connection on the proportional valve (Refer to
Figure 2).
U Unscrew tyhe supply and output gauges (Key
31, Figure 4) and install new gauges with
correct ranges.
V Check all tubing connections and teh bellows
screws (Key 4) for leaks. Tighten as necessary.
W Perform the calibration procedure.
! NOTE !
Use Proper Thread Sealant on all tubing
connections.

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Website: www.dynaflo.com
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Fax: 780 • 469 • 3149
Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
11
Start-Up & Tuning Guidelines
4000
1 Check that controller is calibrated.
2 Check that supply regulator set point matches
the controller output range.
3 Set the pressure setting knob at the required
pressure.
4 Based on your process (fast, or slow) set the
proportional band:
a) for a fast (liquid) syster, use a setting of
10 (100 percent)
b) For slow (gas) system uses a calculated
proportional band setting, from the
expression:
20 X Allowable Error
Output Pressure Range
(X 10 for percent value)
Example:
- 3 psig Allowable Error
- 30 psig Output Range
20 X 3 / 30 = setting of 2 (20% PB)
5 Check the proportional action by either making a
small set point change, or bumping the flapper
lightly, and watching for the output to cycle. Lower
the proportional band setting if the system does
not cycle, and check again. Repeat this process
until the controller output does cycle, and then
double proprtional band setting for a reasonable
starting point.
6 Minimize proportinal band effect on set point by
turning the nozzle (Key 50) until the process
pressure matches the controller pressure setting.
7 Check the proportional band setting for stable
operation by making a change in the process and
watching for cycling.
4010
1 Check that controller is calibrated.
2 Check that supply regulator set point matches
the controller output range.
3 Set the pressure setting knob at the required
pressure.
4 Based on your process (fast, or slow) set the
reset:
a) for a fast (liquid) system use 0.05 minutes
per repeat
b) for a slow (gas) systerm use 0.5 minutes
per repeat
5 Based on your process (fast, or slow) set the
proportional band:
a) for a fast (liquid) system, use a setting of
10 (100 percent)
b) for slow (gas) system uses a calculated
proportional band setting, from the
expression:
20 X Allowable Error
Output Pressure Range
(X 10 for percent value)
Example:
- 3 psig Allowable Error
- 30 psig Output Range
20 X 3 / 30 = setting of 2 (20% PB)
6 Check the proportional action by either making
a small set point change, or bumping the
flapper lightly, and watching for the output to
cycle. Lower the proportional band setting if the
system does not cycle, and check again. Repeat
this process until the controller output does
cycle, and then double proportional band setting
for a reasonable starting point.
7 Check the reset action by either making a small
set point change, or bumping the flapper lightly,
and watching for the output to cycle. Increase
the reset setting if the system does not cycle,
and check again. Repeat this process until the
controller output does cycle, and then tripple
that reset setting for a reasonable starting point.
8 Check the reset setting for stable operation by
making a change in the process and watching
for cycling.

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
12
Parts Ordering
Whenever corresponding with Dyna-Flo about a
4000 series pressure controller, refer to the
nameplate (Key 48, Figure 4) for the serial
number of the unit. Please order by the complete
part number (as given in the following parts list)
of each part required.
Controller Repair Kit R4000X00L1D
Kit contains Keys 3, 12, 13a, 15,
23, 27, 28, 29, 34, 37, 49, 50, 51,
57, 62, 63, 66, and 68
Relay Repair Kit RRELAYX0L1D
Kit contains Keys 73, 74, 75, 76,
79, 82, 83, 86, 87, and 88
kit also includes part numbers:
1H2690301D - Gasket, Spring Plate, neoprene
(not shown)
1C89740301D - Gasket, Relay Mount, neoprene
(not shown)
Assemblies
Number
Proportional Band Valve Assembly 10A9122X03D
Reset Restriction Valve Assembly 19A4361X01D
Figure 4 Dyna-Flo Model 4000 General Detail

Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
13
Parts
Key Description Part Number
1 Beam, steel 1H26682507D
2 Bellows Frame, aluminum 2H26530801D
3* Bellows Gasket, neoprene 2D39700301D
(2req’d)
4 Bellows Screw (2 req’d) 1D39761402D
5 Bellows Stud, sst (not shown) 1H2658X001D
6 Bourdon Tube Bracket PC00000025D
7* Bourdon Tube, sst
0-30 psig 10B2892X01D
0-60 psig 10B2892X02D
0-100 psig 10B2892X03D
0-200 psig 10B2892X04D
0-300 psig 10B2892X05D
0-600 psig 10B2892X06D
0-1000 psig 10B2892X07D
0-1500 psig 10B2892X08D
0-3000 psig 10B2892X09D
0-5000 psig 10B2892X10D
0-8000 psig 10B2892X11D
0-10000 psig 10B2892X12D
8 Calibration Adjuster, steel pl 2H26624401D
9 Case, aluminum PC00000010D
10 Proportional Tubing Assembly, sst
4000 1H6864000AD
4010 1H6870000AD
11 Elbow Fitting, Prop. Band, PC00000043D
aluminum
12 Connecting Link, sst 1L37964101D
13 Control Pressure Block, steel pl PC00000024D
13a O-ring, Control Pressure
Block, neoprene (not shown)
14 Control Tubing Assembly PC00000023D
15 Cover Gasket, nitrile 1J40750643D
16 Cover Latch, steel pl 1H28862898D
17 Cover, aluminum PC00000011D
18 Cross Spring, sst (2 req’d) 1H26603703D
19 Dial Screw, steel pl 1J84152898D
20 Dial, sst
0-30 psig 16A7662X01D
0-60 psig 16A7662X02D
0-100 psig 16A7662X03D
0-200 psig 16A7662X04D
0-300 psig 16A7662X05D
0-600 psig 16A7662X06D
0-1000 psig 16A7662X07D
0-1500 psig 16A7662X08D
0-3000 psig 16A7662X09D
0-5000 psig 16A7662X10D
0-8000 psig 16A7662X11D
0-10000 psig 16A7662X12D
21 Door Latch Pin, steel pl (2 req’d) PC00000003D
22 Feedback Bellows
Brass
3-15 psig (20-100 kpag) (2 req’d) 14A5726X01D
6-30 psig (40-200 kpag( (2 req’d) 14A5726X03D
23 Flapper, sst 1H26694113D
24 Flexure Strip Base, steel 1C89772508D
25 Flexure Strip Washer, 16A7671X01D
steel pl (2 req’d)
26 Flexure Strip, sst 1C89783601D
27* Gasket, Bellows Frame 1H26540301D
(not shown), neoprene
28* Gasket, Gauge Glass, 0T01910408D
neoprene (2 req’d)
29* Gasket, Pressure Block, 1C32860301D
neoprene (not shown)
30 Gauge Glass (2 req’d) PC00000039D
31 Gauge, Supply and Output Pressure (2 req’d)
0-30 psig PC00000037D
0-60 psig PC00000038D
32 Latch Roll Pin, steel pl PC00000003D
33 Knob Spring, steel pl (not shown) 1C22152702D
34 Link Bearing Srew, sst (2 req’d) 1L37954620D
35 Lockwasher, Bourdon Tube, 1H26722898D
steel pl (2 req’d)
36 Lockwasher, steel pl (2 req’d) 1H26712898D
37 Machine Screw, Flapper, 1B27512899D
steel pl
38 Machine Screw, Bourdon Tube 1H26772898D
steel pl (2 req’d)
39 Socket Cap Screw, PC00000051D
sst (2 req’d)
40 Machine Screw, steel pl (4 req’d) 1A33212898D
41 Machine Screw, steel pl (4 req’d) 14B4995X01D
42 Machine Screw, steel pl (4 req’d) 1V74352898D
43 Machine Screw, steel pl, PC00000026D
pressure block (4 req’d) (not shown)
44 Machine Screw, steel pl (9 req’d) 1A5733X001D
45 Mounting Base, aluminum 2H26512501D
46 Mounting Screw for 1H52702898D
reset valve (not shown)
47 Nameplate Screw, steel pl 1C94192898D
(2 req’d)

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
14
Parts (cont’d)
Key Description Part Number
48 Nameplate, sst PC00000013D
49* Nozzle O-ring, nitrile 1E22260699D
50 Nozzle, Reversing Block, sst 1U63913513D
-under reversing block screw (Key 62)
-under reversing block (Key 63)
-under sealing screw (Key 66)
53 Pipe Plug, steel (not shown) 1A76752466D
54 Pressure Set Arm, steel pl PC00000012D
55 Proportional Band Valve 10A9122X03D
Assembly
56 Relay Manifold Assembly PC00000056D
57* O-ring, Relay Manifold, PC00000057D
nitrile (2 req’d)
58 Relay Tubing Assembly, sst 1H6861000AD
59 Reset Tubing Ass’y, sst 1H6866000AD
4010
60 Reset Valve Ass’y 10A9129X0AD
4010
61 Retaining Ring, Gauge Glass, PC00000006D
sst (2 req’d)
62 Reversing Block Screw, sst 24A5720X01D
63 Reversing Block, steel pl 26A0975X01D
64 Roll Pin, Door Hinge, 1H28882899D
sst (req’d)
65 Rotary Spring, sst 1J42343702D
66 Sealing Screw, sst 14A5721X01D
67 Set Point Adjustment Post, PC00000001D
aluminum (not shown)
68 Sleeve, Delrin 16A0976X01D
69 Spacer, aluminum 1H26594401D
70 Spring Washer, steel pl PC00000004D
71 Vent Assembly, plastic/sst Y602-12D
72 Washer, Dial, steel pl 1R98202507D
73 Washer, Cal. Adjuster, 1E87302899D
steel pl (2 req’d)
Relay (See Figure 3)
Key Description Part Number
74* O-ring, Relay Seat Ring, nitrile PC00000054D
75 Diaphragm Assembly 18A2451X01D
76 Diaphragm Casing Ass’y, 12B0460X04D
aluminum / steel
77 Machine Screw, sst (3 req’d) PC00000055D
78 Machine Screw, steel pl 1C89692898D
(6 req’d)
79 O-ring, nitrile (2 req’d) 1D68750699D
80 Washer, Relay Seat, PC00000053D
steel pl (3 req’d)
81 Relay Manifold, aluminum PC00000049D
82 Relay Spring, steel pl 1C89612701D
83 Reset Plug and Wire 12B0468X01D
Assembly
84 Spacer Ring, aluminum 38A3778X01D
85 Seat Ring, sst PC00000050D
86 Top Diaphragm 1L55560204D
87 Valve Plug, sst 0Y0617X002D
88 Valve Spring, sst 0X08363702D
Mounting (See Figure 7 & 8)
Key Description Part Number
89 Cap Screw, steel pl (4 req’d) 1B84802405D
for wall or Panel Mounting
90 Cap Screw, steel pl (specify qty req’d)
-5/16 UNC x 1 inch 1A35262405D
-5/16 UNC x 3/4 inch 1A38162405D
91 Cap Screw, steel pl (4 req’d) 1C33332898D
92 Hex Nut, steel pl (4 req’d) 1C33282898D
93 Lockwasher, steel pl (2 req’d) 1C22572898D
94 Machine Screw, steel pl 1C63922898D
(2 req’d)
95 Mounting Bracket, actuator 1F40122507D
casing, steel pl (not shown)
96 Mounting Bracket, actuator 1C22182502D
yoke, steel pl (not shown)
-Dyna-Flo Model DFC, DFR, and Others
97 Mounting Bracket, 1H2892000AD
Panel or Wall, steel pl (2 req’d)
98 Mounting Bracket, pipestand 3N97572509D
99 Mounting Spacer, steel pl 1F90672409D
(specify qty req’d)
100 Pipe Mounting Clamp, 1P42702898D
steel (2 req’d)
* Commonly Replaced Part

Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
15
Reset Valve Assembly Proportional Band Tubing
(To Reset Valve)
Proportional
Band Tubing
Reset Tubing
73
44
50
8
63
62
49
68
21
7
69
22
18
54
36
42
20
72
19
134 11
12
11
34
65
44 45
3
44
42
35
38
6
66
52
23
44
11
24
37
25
26
41
A
A
View A-A
Not Shown: Reset Valve Mounting Screw
Figure 5 Sub-Assembly Detail Figure 6 4010 Controller General Arrangement

Model
4000 Pressure Controller
Operation, Parts and Instruction Manuals
Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Instruction Manual October 2005
16
Figure 12 Model 4000 Mounting Details, Pipestand,
Surface Panel
99 98
93
100
92
94
92
92 94
94

Dyna-Flo Control Valve Services Ltd.
Edmonton, Alberta, CANADA
Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
Fax: 780 • 469 • 3149
Model
4000 Control Valve
Operation, Parts and Instruction Manuals
Instruction Manual October 2005
17
96
99
90
92
94
93
NOTE
When using yoke style
mounting, DON"T PUNCH
HOLES in back of case.
Use drill.
Our Commitment of Quality
Dyna-Flo is committed to continuous improvement. All efforts have been taken to maximize the accuracy of this
information.Without notification, product specifications and designs may be modified at any time. The issue of this
document is forinformation only, and does not imply suitability, a warranty, or guarantee for a specific service.
Figure 8 Model 4000
Mounting Details, Actuator Yoke