Installation and Operating Instructions

Power-Genex Pneumatic-Pneumatic Rotary Positioner

Description of Device

Power-Genex Pneumatic-Pneumatic Rotary Positioner (3~15psi) is the advanced control device for a rotary control
valve that provides unparalleled stability in difficult environments.

· Easy Maintenance
· Precise Calibration with simple SPAN and ZERO adjustments
· Simple Conversion to Direct Acting or Reverse Acting
· 1/2 Spilt Range Available by simple adjustments without changing parts
· Simple Structure for feedback connection
· Corrosion-Resistant Aluminum Die Casting Body
· Sensitive and Correct Response for high performance
· Economical Energy Saving
· Extremely Vibration Resistant Design
· Stainless Steel Gauges Standard
· A Restricted Pilot Valve Orifice Kit for small actuators included
· Optional Directly-Mountable Positioner guaranteeing more outstanding stability

Part Number System

Pressure
PP Actuator Feedback Pilot Mounting
Operation Gauge Valve
Lever (SUP.OUT) Orifice Bracket

Description Code Description Code

Actuator Operation: L : Linear Type Pilot Valve Orifice: S : Standard
R : Rotary Type (actuator volume over 180 )
M : Small Orifice ( 1.0 or 0.7)
(actuator volume 90~180 )
Feedback Lever :
- Linear Type A : Stroke (10~80mm)
B : Stroke (80~150mm)
Mounting Bracket: N: None
- Rotary Type A : Fork Lever M6 x 40L
1~3 : for Namur shaft type 1 : 80 x 30 x 20 (H)
B : Fork Lever M8 x 40L
4~5 : for Fork lever type 2 : 80 x 30 x 30 (H)
C : Fork Lever M6 x 60L
3 : 130 x 30 x 30 (H)
D : Fork Lever M8 x 60L
4 : DHCT Bracket 80 x 30
N : Namur Shaft
5 : Box Bracket 130 x 30
(direct mounting)
6 : DIN / IEC 534 (for PPL)

Pressure Gauge: 0 : 2 Bar (30psi)

1 : 6 Bar (90psi)
2 : 10 Bar (150psi)

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Power-Genex Installation and Operating Instructions
Pneumatic-Pneumatic Rotary Positioner

Specification

PPR
Rotary Type (Cam Feedback)
Single Double
Input Signal 0.2~1.0 kgf/cm2 (3~15psi) (Note. 1)
Air Supply Pressure Max. 7.0 kgf/cm2 (100psi)
Standard Stroke 60 º ~ 100º (Note. 2)
Air Piping Connection PT 1/4 (NPT 1/4)
Ambient Temperature -20 ~ 70oC
Pressure Gauge Stainless Steel
Output Characteristics Linear
Linearity Within ± 1.5 % F.S
Sensitivity Within 0.5 % F.S
Hysteresis Within 1.0% F.S
Repeatability Within ± 0.5 % F.S
Air Consumption 5 LPM (Sup. 1.4 kgf/cm2)
Flow Capacity 80 LPM (Sup. 1.4 kgf/cm2)
Material Aluminum Die Casting Body
Weight 2.1 kg
Note: 1) 1/2 spilt range can be adjusted
2) Stroke can be adjusted to 0 º ~ 60º or 0 º ~ 100º

Principle of Operation

As the input signal (3~15psi) from the controller Stopper screw Automatic

increases, the plate spring of the bellows works as a Do not move Manual

pivot. As the flapper receives the rotary torque in change-over screw

(Built-in bleed restriction)
the counter-clockwise direction, the clearance Air Sup.
Sensitivity adjusting screw
OUT2 OUT1
between the nozzle and the flapper will increase, (Adjusts GAIN)
Pilot valve
and the back pressure of the nozzle will decrease. Inlet valve A

As a result, the exhaust valve of the pilot valve Inlet valve B

moves to the right, and the output pressure of

OUT1 increases (as OUT 2 decreases) to move the Vent Diaphragm
Exhaust valve

cylinder actuator. Compensation spring

Zero adjusting spring

The movement of the actuator in turn rotates the Zero adjusting screw
feedback shaft, and the feedback spring lengthens
Feedback spring
or shortens by the movement of the feedback cam
Nozzle
connected to the feedback shaft. The actuator stays Flapper
Cylinder
in the position where the spring force is balanced Input signal

with the force generated by the input signal in the Plate spring Bellows

bellows. The compensation spring is for direct

feedback of the motion of the exhaust valve and is
connected to the flapper to enhance the stability of the loop. The zero point is adjusted by changing the zero adjustment spring
tension.

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Power-Genex Installation and Operating Instructions
Pneumatic-Pneumatic Rotary Positioner
positioner body
Mounting the Positioner and Attaching the Feedback Lever
- Standard Mounting (Fork Lever Type)
(1) Mount the bracket to the actuator. The brackets have been designed for actuators with
the 80 X 30mm NAMUR accessory pattern. For the 130 X 30mm pattern, the block A
type bracket is available.

40(60)
B
actuator M6 x 1.25
shaft

DHCT Bracket (80 X 30) Block Type Bracket (130 X 30)

Standard Mounting
(2) Mount the fork lever “B” to the actuator and thread it into the actuator first before (Fork Lever Type)
positioner body
mounting the positioner and the bracket to the actuator.
(3) Once the bracket has been mounted to the actuator, mount the positioner to the bracket with the bolts (2-M8 or
3-M8). Be sure that the feedback lever (feedback lever shaft “A” + fork lever “B”) is in perfect alignment with a
rotary actuator output shaft. The spring pin of the feedback lever shaft “A” acts as a guide and should be placed
in the orifice of the fork lever “B”. Please note that linearity and hysteresis will suffer if these alignment and
placement are not correct.
- Direct Mounting (NAMUR Type, see the right picture)

33.5
5 4
3.95
4.8
10

3.95
NAMUR Type Bracket (80 X 30 X 20) NAMUR Type Bracket (130 X 30 X 30)
Direct Mounting
(NAMUR Type)

Cam and Indicator Adjustment

(1) Loosen the flange nut on the cam. Match the part of the cam with "0" marked on
it with the center of bearing as shown to the right. The span adjusting arm unit
should now be aligned.
(2) Tighten the flange nut of the cam after setting the cam.
(3) After cam installation, proceed to adjust zero and span. Once this is complete,
secure the indicator with the bolt (M6) to the feedback shaft according to the
actuator type (RA or DA) as shown below. The position for the indicator should
be arranged in the scale (0-90 degrees) shown on the cover.

Be sure that RA (reverse acting) is the standard factory

setting.

[RA] [DA]

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Power-Genex Insta llation and Operating Instructions
Pneumatic-Pneumatic Rotary Positioner
Span and Zero Adjustment

(1) Check all air connections. See the picture below on this page.

(2) Set input signal to 3psi while positioner is at the 0% or stroke starting point. Turn the zero adjustment knob clockwise or
counter clockwise to set the zero position.

(3) Check the stroke of actuator by setting the signal to 15psi. If the stroke does not meet 100%, turn the span adjustment
screw clockwise or counter clockwise until 100% is reached.

(4) Set input signal back to 3psi and adjust the zero adjustment screw until starting point is reached.

(5) Repeat the process until the desired set point is reached.

Air Connections

Direct Acting (DA) Reverse Acting (RA)

Main shaft Single Single
action actuator Main shaft action actuator

As the input signal increases, OUT2 As the input signal increases, OUT1
X X
Actuator stem rotates SUP
The cam Actuator stem rotates SUP The cam
should be should be
clockwise. set on the counter - clockwise. set on the
SIG DA surface SIG RA surface
OUT1 must be plugged
OUT2 must be plugged

Main shaft Double

action actuator Main shaft Double
action actuator

As the input signal increases, OUT1 OUT2 As the input signal increases, OUT2
OUT1
Actuator stem rotates SUP
The cam Actuator stem rotates The cam
should be SUP
clockwise. set on the counter - clockwise. should be
SIG DA surface set on the
SIG RA surface

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 Installation and Operating Instructions
Power-Genex Pneumatic-Pneumatic Rotary Positioner

Pilot Valve Seat Adjuster

The seat adjuster (sensitivity adjusting screw) located on the pilot valve is used to adjust the positioner for double-acting actuators.
Normally, no adjustment is required.

When the sensitivity is not optimal, rotate this screw clockwise. If there is hunting, rotate the screw counterclockwise. For smaller
actuators, it might be necessary to insert the small pilot valve orifice inserts if adjusting the seat does not improve performance.

Auto / Manual Operation

For manual operation using an external air regulator, set the Auto / Manual switch located on the pilot valve to M. This will
bypass the 3-15psi input signal.

Internal View of Power-Genex P/P Rotary Positioner

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 Power-Genex Installation and Operating Instructions
Pneumatic-Pneumatic Rotary Positioner
Optional Restricted Pilot Valve Orifice
WARNING: Before removing pilot valve, be sure to disconnect the
positioner from the signal and compressed air source.

For improved control using smaller actuators, a restricted pilot valve orifice kit is included
with the positioner. To install, the pilot valve must be removed from the positioner. Remove
the four screws holding the pilot to the positioner body. As you remove the valve, be sure to
hold the compensation spring (see page 2) in place. Flip the valve so the bottom faces you.
Remove the o-rings from the out 1 and out 2 ports (as shown in the diagram at right). Place
the orifice plates in their place with new o-rings above them, and re-install the pilot valve,
making sure the compensation spring is back in place. The positioner is now set up for
smaller actuators.

Troubleshooting Tips

Hunting * Check Zero and Span adjustments

* If your actuator is small, install orifice restrictions in ports 1 * Loose feedback lever – tighten feedback lever
and 2 of the pilot valve. Then the control valve moves slow.
* The nozzle might be clogged. Take the metal wire located in Poor Hysteresis
the positioner cover and clean the nozzle. * Loose mounting of the actuator to the positioner – tighten
the mounting bracket.
Poor Linearity * Adjust the seat, using the seat adjuster (double acting
* Air supply might be unstable- check or install a pressure actuators only)
regulator.

Dimensions
70 110

88

OUT2 (PT1/4)

168
21
17

3-M8
12

2-M8
42
44

OUT1 (PT1/4)
PPR
PNEUMATIC POSITIONER
PNEUMATIC-

POWER-GENEX

20

65
122
134

50
44

SUP (PT1/4)
30
34

36
SIG (PT1/4)
71 40 44 125 11

111 180 69.5 41.5