Flowserve XL Series High-Performance Positioner - Manual (Page 8)

45-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
damage the seating surface or O-rings.
14. Reinstall the poppets (28), poppet springs (29),
Seat Spring O-rings (30), and poppet covers (27)
before installing retaining rings (31).
15. If the signal diaphragm assembly (16) is damaged,
proceed as follows: With the relay halves still apart,
remove the four screws (32) holding the signal
diaphragm assembly (16) to the pilot relay assem-
bly. Remove the locking screw (23), washer (24),
adjustable gain lower plate (26), and diaphragm
plate. Remove the signal diaphragm assembly (15)
and remove the relay plate (14) from between the
diaphragms. Place the relay plate (14) between the
diaphragms on the new assembly
taking care to
align the 1 /
16
-inch diameter holes between the dia-
phragms and the relay plate (14). Replace the
diaphragm plate (15), the adjustable gain lower
plate (26), the washer (24), and the locking screw,
but do not tighten. Replace the four screws (32) that
hold the signal diaphragm assembly together.
16. With O-ring grease, pack grease into the O-ring
groove and lightly lubricate the outside of the relay
tube on the diaphragm relay assembly (13) making
sure the small holes in the side of the tube on the
ends do not get plugged with grease. Insert the
relay diaphragm assembly (13) as assembled in
steps 7 and 8 into the lower relay half. Carefully
align the flapper over the adjustable gain screw (19)
and replace and tighten the nut (25).
17. Fasten the two halves of the relay together using
the four long screws (32). Make sure the 1 /
16
-inch
diameter holes in the relay diaphragm assembly
(13)
and the upper relay body (9) line up. Set the
gain to the desired setting and tighten the locking
screws (23, 25). See gain adjustment procedure.
18. Replace the screen (110) and the O-rings (8,12)
found on the back of the pilot relay before reinstall-
ing the pilot relay on the base of the positioner with
four screws (33). Clean out any debris lodged in the
screen or replace with a new one.
19. Replace the span arm and zero arm (40, 46) and
the feedback spring (47).
1. Remove the feedback spring (47) and rotate the
span and zero arms (40, 46) out of the way.
2. Remove four screws (33) holding the pilot relay to
positioner base (1). Remove relay from positioner.
3. Remove the nut (25) connecting the flapper assem-
bly (21) to the signal capsule.
4. Remove four screws (32) holding the two halves of
the pilot relay assembly together. Carefully pull the
relay assembly halves apart, making sure the flap-
per assembly (21) slides off the flapper adjustment
screw (19) without damaging the signal diaphragm
assembly (16). Pull the relay diaphragm assembly
(13) out of the other half of the relay body (9).
5. With relay assembly in two sections, remove two
screws (22) holding flapper assembly (21) to the relay
diaphragm assembly (13). Remove the flapper.
6. Remove diaphragm retaining plate (15) from the
relay diaphragm assembly (13) and relay plate (14).
7. Replace relay diaphragm assembly (13) with one
from positioner repair kit. Place relay plate (14)
between the new diaphragms making sure the
1 /
16
-
inch diameter holes between the relay plate (14)
and diaphragm line up. Position diaphragm retain-
ing plate (15) on the relay diaphragm assembly with
rounded inner diameter edge against the diaphragm.
8. Attach the flapper assembly (21) onto the relay
diaphragm assembly (13) using two screws (22)
with a locking adhesive on the threads. The flapper
assembly should extend away from the
1 /
16
-inch
diameter hole through the relay plate. Make sure
the lettering on the flapper assembly is facing away
from the diaphragm.
9. With the relay halves still apart, remove relay tube
O-rings (8) from the upper and lower bodies (9, 7)
and replace them with new O-rings (found in the
positioner O-ring repair kit).
10. Remove the rubber cap (35) and the balance adjust
screw cap (36) from the upper relay body (9).
Remove the O-ring (38) from the balance adjust
screw and install new O-ring.
11. To remove and clean the poppets (28), remove the
retaining rings (31), poppet covers (27), O-rings (30),
and poppet springs (29) found at the end of each
housing. After removing the poppets, inspect them for
dirt buildup or damage to seating surfaces.
12. The upper relay body (9) has a movable seat ring
(34) which is adjusted with the balance adjust screw
(36). This seat is removed by pushing it out with a
soft instrument such as a wooden dowel. Be careful
not to damage the seating surface. Remove the O-
ring (37) from the seat ring.
13. Lubricate and replace the O-ring (37) on the mov-
able seat ring (34). Carefully reinstall the seat ring
into the upper relay body (9), being careful not to
Orifice Screw
The orifice screw enhances positioner stability. If the
positioner overshoots excessively or remains in the full-
signal position regardless of the signal, the orifice may
be partially or full plugged.
When checking the orifice screw, care should be taken
to retain the O-ring and orifice filtering screen located on
the end of the screw. The screen is secured by the O-
ring. Do not overtighten when replacing the orifice
screw.