48-8
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
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 the relay assembly in two sections, remove
two screws (22) holding flapper assembly (21) to the
relay diaphragm assembly (13). Remove flapper.
6. Remove diaphragm retaining plate (15) from relay
diaphragm assembly (13) and relay plate (14).
7. Replace relay diaphragm assembly (13) with one
from the positioner repair kit. Place the relay plate
(14) between the new diaphragms, making sure the
1
/
16
-inch diameter holes between the relay plate (14)
and the diaphragm line up. Position diaphragm
retaining plate (15) on relay diaphragm assembly
with rounded inner diameter edge against dia-
phragm.
8. Attach flapper assembly (21) onto 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 lettering on
flapper assembly is facing away from diaphragm.
9. With relay halves still apart, remove relay tube O-
rings (8) from upper and lower bodies (9, 7) and
replace them with new O-rings (found in the posi-
tioner O-ring repair kit).
10. Remove rubber cap (35) and balance adjust screw
cap (36) from upper relay body (9). Remove O-ring
(38) from balance adjust screw and install new O-
ring.
11. To remove and clean 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 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 seating surface. Remove O-ring (37) from
seat ring.
13. Lubricate and replace O-ring (37) on movable seat
ring (34). Carefully reinstall seat ring into upper relay
body (9), being careful not to damage seating surface
or O-rings.
14. Reinstall poppets (28), poppet springs (29), Seat
Spring O-rings (30), and poppet covers (27) before
installing retaining rings (31).
15. If signal diaphragm assembly (16) is damaged, pro-
ceed as follows: With relay halves still apart, remove
four screws (32) holding signal diaphragm assembly
(16) to the pilot relay assembly. Remove locking
screw (23), washer (24), adjustable gain lower plate
(26), and diaphragm plate. Remove signal diaphragm
assembly (15) and remove relay plate (14) from
between the diaphragms. Place relay plate (14) be-
tween the diaphragms on the new assembly,
taking
care to align the
1
/
16
-inch diameter holes between the
diaphragms and the relay plate (14). Replace dia-
phragm plate (15), adjustable gain lower plate (26),
washer (24), and locking screw, but do not tighten.
Replace four screws (32) that hold signal diaphragm
assembly together.
16. Pack O-ring grease into the O-ring groove and lightly
lubricate the outside of the relay tube on diaphragm
relay assembly. (13) Make sure small end holes on
the side of the tube do not get plugged with grease.
Insert the relay diaphragm assembly (13) as as-
sembled 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 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 gain to desired setting
and tighten locking screws (23, 25). See gain adjust-
ment procedure.
18.
Replace screen (110) and O-rings (8,12) found on the
back of the pilot relay before reinstalling the pilot relay
on the base of the positioner with four screws (33).
Clean out any debris lodged in screen or replace with
a new one.
19. Replace span arm and zero arm (40, 46) and feed-
back spring (47).
Installation, Operation and Maintence of
UltraSwitch position indicators
For detailed information, refer to the following Accord
controls bulletins:
•
PS0008, PS0009, PS0031, PS0032, PS0033,
PS0034, PS0037 and PS0050
