Electro-Pneumatic Positioner

Series 830/831-WP/EX
Operation & Maintenance Manual
Electro-Pneumatic Positioner Model 830/831- WP/EXP
This operation & maintenance manual corresponds to Forbes
Marshall Arca make Electro-Pneumatic Positioner model 830/831.

If you experience any difficulty with the installation or operation

of this equipment, please contact our Customer Support

Manufactured & Marketed by

Forbes Marshall Arca Pvt. Ltd.
A Forbes Marshall Company
A 34/35, H Block, MIDC Estate
Pimpri - 411018
Pune, India

TEL. : +912027442020
FAX. : +022027442040
 Table Of Contents

1.General

2.Nomenclature/ Model No.

3.Salient Features

4.Specifications

5.Principle Of Operation

6.Block Diagram

7.Installation & Calibration

8.Auto/Manual switch

9. Seat adjuster

10.Maintenance and check

11.Caution and Handling

12.Trouble shooting

13.Positioner With Feedback Transmitter

1. GENERAL

The electro -pneumatic positioner is used in Control Valves with pneumatically operated
actuators. The valve is operated by means of electrical controller or Control Systems With
an control signal of 4 to 20 mA or split ranges of 4~12/ 12~20 mA.

The 830/831 Electro-Pneumatic Positioner converts this control signal into a pneumatic
output in proportion to the lift of the control valve.

This manual contains the information required for the installation & usages of this
equipment. It is addressed to technically qualified & trained person or having relevant
knowledge of instrumentation & control technology.

It must be used in the way described in this manual. Successful safe operation of this
equipment is dependent upon the proper handling, installation, operation & maintenance.

2.Nomenclature/ Model No. –

8 3 0 - W P

83 SERIES POSITIONER

0 - NORMAL
1 - WITH FEEDBACK TRANSMITTER

ALWAYS "-"

WP - WEATHER PROOF IP66

EX - EXPLOSION PROOF IIB & IIC
3. SALIENT FEATURES

1. There is no change in performance in the range of 5-200Hz of Vibrations.

2. Can be Used for Split Range Application
3. Easy to adjust zero and span & calibrate to the required travel of the valve.
4. Easy to convert from ATO (Air to Open) to ATC (Air to Close) action or vice versa.
5. Easy Feedback connection.
6. Fast and accurate response.
7. Low air consumption.

4. SPECIFICATIONS

Input Signal 4~20 mA DC

Impedance 0-250 OHM

Supply Pressure 1.4~6 kg/cm2

Air Consumption 3 lpm at 1.4 bar

Air Flow capacity 80 lpm at 1.4 bar

Linearity ± 1% of FS

Hysteresis ± 0.2% of FS

Repeatability ± 0.5%

Air Connection ¼” NPT (F)

Gauge Connection 1/8” NPT (F)

Ambient Temp -20 0C to +80 0C

Protection IP 66

Weight 2.8 kg

Ex -Proof IIB & IIC

Elect. Connection G1/2 (PF1/2)

Electro Pneumatic Positioner
831-WP (With Feedback)

Electro Pneumatic Positioner

830-WP Positioner
5. PRINCIPLE OF OPERATION

This equipment works on the force balance principle and uses a flapper/ nozzle & set of springs
to bring the forces under equilibrium at the required valve position with respect to the
signal/command given to it.

When the input signal from the controller is applied to the torque motor, the armature receives a
torque in counter clock wise direction, due to this torque the counter weight/ flapper moves
towards left side and the clearance between the Nozzle & the Flapper increases, due to which,
the back pressure in the Nozzle decreases.

As a result of the above, the exhaust valve of the Pilot Valve moves towards right and the Inlet
Valve “A” opens, thereby the supply air goes to the actuator through port OUT1. The valve
Spindle will move up or down depending up on the actuator configuration (ATO/ATC) and the
Feedback Spring will lengthen or shortens by the movement of Feedback Lever.

When there is a force balance between Feedback Spring tension and the Torque generated by
the Torque Motor, the valve Spindle stays in it’s position.
6. BLOCK DIAGRAM

INPUT MAGNET & COIL FLAPPER & PILOT

4~20 mA ARRANGEMENT NOZZLE VALVE
SIGNAL MECHANISM

STABILIZER
/COMPENSATION ACTUATOR
SPRING

FEEDBACK FEED BACK (OUTPUT )

SPRING LEVER VALVE
STROKE

7. INSTALLATION & CALIBRATION

a. Check that the Pneumatic pipes/ tubing are properly flushed.

b. Connect the wires from the controller, at the terminal block of the positioner. “+” & “-“ signs are
printed at the terminal block of the positioner for the ease of connection. The grounding terminal
should also be connected.

6 Positioner 1 2 3 4 5 6
Positioner
5 Mounting Bracket
Stroke Scanning
4
Lever

3 Threaded Pin

2 Link

1 Lift Indicator

Sr.
No. Part Name

c. Connect the Feedback lever to the Control Valve’s Link mounted on the Valve’s Lift Indicator.
Apply 50% signal ( i.e.12 mA DC) and position the Stroke Scanning Pin/ Positioner in such a way
that that the Feedback Lever is at 900.

d. For best performance the movement of the Feedback Lever should be between +15~200 to –15~200
from the 900 (horizontal position set at 50% signal). Pl. check that, while setting the full stroking
 angle, the Feedback Lever should not foul with the stoppers, provided near the Feedback Lever
Connection point on to the Positioner.

e. Position the SPAN le ver as per the actuator function i.e. ATO (Air to Open) or ATC (Air to close),
as explained under

ATC Actuator ATO Actuator

ATC ACTUATOR ATO ACTUATOR

SPAN Lever Fixing Screw

Lock Screw
Lock Screw

OUT2 OUT2
OUT1

OUT1
SPAN Lever Fixing Screw

SUP SUP
AIR
AIR

For changing the position of SPAN Lever, the Lock Screw, should be loosened slightly, to avoid
getting the Feedback Spring damaged. After re-orienting the SPAN Lever to the desired position, the
Lock Screw should be tightened carefully. While changing the position of SPAN Lever, pl. take care
not to stretch the Feedback Spring.

OUT2 port is not to be used, unless confirmed from works.

f. Apply, starting signal (4 mA) and turn the Zero setting adjuster, to set the zero setting. (Clockwise
rotation of the adjusting wheel will increase the pneumatic supply to the actuator, to decrease the
supply to actuator rotate the adjuster in CCW direction).

g. Then apply 100% signal (20 mA), if the valve is not taking 100% stroke then slightly loosen the
Lock Screw mounted on the SPAN Lever, rotate the knob on the SPAN lever to achieve the full
stroke position. After setting the SPAN, again check the Zero setting at 4 mA and set if found
disturbed. After setting, carefully tighten the Lock Screw of the SPAN Lever.

The positioner can be set in Split Range also (i.e. 4~12 mA or 12~20 mA), it can be done by doing
calibration as mentioned above.

8. By-Passing The Positioner/ ”A-M” Screw -

The Positioner can be by-passed, by the adjustment of “A-M” Screw. The factory setting is for
AUTO mode, however to by-pass the positioner, rotate the “A -M” screw in counterclockwise
direction slowly towards “M” marking on the Pilot Valve (Ref. fig. Under Point no.5

In by-pass mode, the full pr. of the supply air goes to the Actuator. Therefore, pl. be careful to check
the air supply recommended for the actuator. After using the Positioner in manual mode, again rotate
 the “A-M” Screw in Clockwise direction towards “A” to go into AUTO Mode. It should be fully
tightened for AUTO Operation.

9. SEAT ADJUSTOR – (Should Not be disturbed)

This is set at the factory at fully tight position and should not be disturbed. Disturbing this screw may
cause positioner malfunctioning.

10. MAINTENANCE AND CHECK

1. If the quality of the supply air is fouled, then the positioner may not operate normally. Moist air
may damage the Pilot Valve/ Torque Motor and cause Positioner to malfunction/ defunct.

The requirement for a quality air supply can be found in the instrument society of America’s
“Quality Standard for Instrument Air” (ISA-S7.3) or BS 5967:Part 2. 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.

Dew Point - The dew point -at line pressure- should be at least 10 0C below the minimum
temperature to which any part of the instrument air system is exposed at any
season of the year.

2. The compressed air cleaning/de -humidifying system should be checked periodically.

3. When the fixed orifice is clogged with carbon particle s or others, remove the pilot valve
Auto/Manual changeover screw (built-in fixed aperture) and clean it by inserting a 0.2 wire
(provided at the inside of the Positioner Cover) into the aperture. If it is required to be replaced
with new one, stop the supply pr. and remove the Stopper Screw of the pilot valve.

4. Check the positioner once a year. If any abnormality is observed, contact our works.

5. There should not be any air leakage from the tubing. Use pipe sealant sparingly, only on the
male thread of the tube fittings. A non-hardening sealant is strongly recommended.

11. CAUTION AND HANDLING

1. Do not apply large vibration or impact to the positioner. it causes trouble the positioner must be
handled very carefully during transportation and operation.

2. If the positioner is used under temperature outside of the specifications, the sealing materials
may deteriorate quickly and also the positioner may not operate properly.

3. Do not open the terminal cover at a dangerous position (hazardous area) during operation or
during power conduction.

4. Be sure that the terminal cover and body cover are put on during the operation.

5. If you leave the positioner at the operation site for a long time without using it, put a polythene
cover on it so that the rainwater does not harm it in any way.
 6. If the atmosphere is of high temp. Or high humidity, take measures to avoid condensation during
shipment.

7. For proper functioning of the positioner, use only factory authorized replacement parts.
Substitutions of components can impair the performance of the equipment.

8. When the positioner is installed without safety barriers, switch off electrical power supply at its’
source before connecting or disconnecting signal/feedback wiring.

12. TROUBLE SHOOTING

PROBLEM CAUSE WHAT TO DO

Too Low or None Supply Pr. Check Supply Pr.
Wrong Wiring of (+ve) & (-ve)
Correct (+ve) & (-ve)
Terminals
Short or Open Circuit of Torque
Replace Motor Unit
No Res ponse when Motor
Input Signal is Applied Clean The Nozzle with the
help of wire provided in the
Clogged Nozzle
Positioner Cover OR Replace
the Motor Unit
Loose or Wrong Setting of
Correct Setting/ Tighten
Feedback Lever
Correct to the Required
Wrong Orientation of SPAN Switch
Position (Refer Point 8e)
Valve Operates Only
for 0% & 100% Signal Fully tighten the “A -M”
“A-M” Screw is Disturbed
i.e. No Response for in Screw (It has two ‘O- Rings)
between Signals and
Correct the Pneumatic
Actuator Operates Only
Wrong Connection of OUT1 & Connection w.r.t. the Position
to ON or OFF Position
of SPAN adjustment Switch
OUT2 Ports
(Refer Point 8e).

Tighten or Replace ‘O’ Rings

Leakage of A/M Switch
of A/M Switch

Correct to the Required

OUT PUT Pressure
Wrong Orientation of SPAN Switch Position (Refer Point 8e)
Raised and Stays, Does
Not Come Down
Clean the Orifice with the
help of Wire, provided in the
Clogged Fixed Orifice
Positioner Cover

Clean The Nozzle with the

OUT PUT Pressure is help of wire provided in the
Operated by A/M Clogged Nozzle Positioner Cover OR Replace
Switch Only the Motor Unit
 PROBLEM CAUSE WHAT TO DO
Correct the Positioning of
Disturbed Compensation/ Stabilizer
Stabilizer Spring
Spring
Clean The Nozzle with the
Hunting is Occurring
help of wire provided in the
Clogged Fixed Nozzle Positioner Cover OR Replace
the Motor Unit

Readjust the setting of the

Wrong Setting of Feed Back Lever
Wrong ZERO, SPAN adjustment
Linearity is not Good
Supply Pressure is unstable
Loose Pneumatic connections in the
Actuator or Positioner
Feed Back Lever
(Refer Point 8a & 8b)
Readjust the ZERO & SPAN
Check the Air Leakage from
the Pneumatic supply OR
Replace the Air Filter
Regulator
Check & correct

13. POSITION TRANSMITTER (Model No.831-WP/EXP)

Electronic position transmitter is designed for sensing mechanical position change of Valve Spindle
vis-à-vis signal given to the Positioner. The output is in DC current 4~20 mA. The split range
feedback can also be set with the help of ZERO & SPAN setting.

13.1 Technical Data

Connection Type 2 Wire

Input Signal Up to 0~450 Angular Travel
Output Signal 4-20mA DC
Supply Voltage 12-36 VDC
Load resistance 0-600 Ohm
Noise Range 50mV pp
Ambient Temp. -20 o C – 60o C (-40 to –1400 F)
Linearity ± 1% of FS
Hysteresis ± 0.5% of FS
Sensitivity ± 0.5% of FS
13.2 Wiring Diagram

SPAN
ACTUATOR SELECTION
ZERO SWITCH

ATC ATO

+ - + - ATC - Air to Close Actuator

ATO - Air to Open Actuator

OUTPUT 4 ~20 mA
INPUT (4 ~20 mA) (AT 24 VDC)

[ Note : Position of Actuator Selection Switch is for ATO Actuator ]

13.3 Adjustment Instruction

1) ZERO Adjustment –

Clockwise adjustment shall increase the output current.

2) SPAN Adjustment –

Clockwise adjustment shall increase the output current.

After adjusting the SPAN, again check the ZERO setting, if required, adjust it.

Note : Adjustment should be done carefully as excessive rotation of the adjustment screw
may damage the adjustment POTs.