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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Website: www.dynaflo.com
Phone: 780 • 469 • 4000
Toll Free: 1 • 866 • 396 • 2356
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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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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
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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.

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
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
10
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.