Emerson Q Series Einrichtungshandbuch

Q-Series

Switch Adjustment and Feedback Mechanism replacement

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

March 2018

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

Table of Contents

March 2018

3Table of Contents

Contents

1 Before you start ....................................................................................................4

Scope...................................................................................................................................................... 4

General safety messages ......................................................................................................................... 4

Required tools......................................................................................................................................... 5

2 Disassembly procedure.........................................................................................6

3 Reassembly procedure..........................................................................................9

4 Adjusting the switch points.................................................................................11

March 2018

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

1 Before you start

1.1 Scope

This repair manual is intended to give instructions to replace the switch adjustment screws and/or the

feedback mechanism of the Q-Seires Control modules.

1. Repair of the switch adjustment screws may be neccesary in case too much force was applied on the screw

heads and the screw heads were damaged as such.

2. Repair of the feedback mechanism may be neccesary in case too much force was applied on the threads of

the mechanism and threads were damaged as such.

Figure 1 Scope of the manual

1.2 General safety messages

WARNING

Avoid personal injury or property damage from sudden release of process pressure or bursting of parts.

Before performing any maintenance procedures on the QC range of Control Modules:

- Always wear protective clothing, gloves, and eye wear when performing any maintenance procedures to

avoid personal injury or property damage.

- Do not remove the actuator from the valve while the valve is still pressurized.

- Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator.

Be sure the actuator cannot suddenly open or close the valve.

- Use bypass valves or completely shut off the process to isolate the control valve from process pressure.

Relieve process pressure from both sides of the valve.

- Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.

- Check with your process or safety engineer for any additional measures that must be taken to protect

against process media.

- Vent the pneumatic actuator loading pressure and relieve any actuator spring pre-compression so the

actuator is not applying force to the valve stem; this will allow for the safe removal of the stem connector.

- Donotremoveorreplacewhilecircuitislivewhenaammableorcombustibleatmosphereispresent.

- Substitution of electronics cartridge, switch cartridge, pilot valve cartridge, pneumatic cartridge, enclosure

and seals must be with parts from Emerson else the suitability for Division 1 or 2 will be impaired. Always use

proper component replacement techniques, as presented in this manual. Improper techniques or component

selectionmayinvalidatetheapprovalsandtheproductspecications,asindicatedinapplicableControl

module Installation Guides and may also impair operations and the intended function of the device.

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

March 2018

IMPORTANT

When replacing any of the components of the Control Module, the maintenance should be performed in an

instrument shop whenever possible. Make sure that the electrical wiring and pneumatic tubing is

disconnected prior to disassembling the instrument.

1.3 Required tools

In order to replace the switch adjustment screws and/or feedback mechanism below tool are required.

Figure 2 Required tools

Plastic mallet

Punch drive

Set of metric

allen keys

Slot screw

driver or

equivalent

E-clips tool

for size

2.5mm

March 2018

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

2 Disassembly procedure

IMPORTANT

Inordertoreplacetheadjustmentscrews,rstthefeedbackmechanismneedstobedisassembled.

1. Remove the cover screws on the back side of the control module. Check if the O-ring seals are in good shape.

Replace if neccesary.

Figure 3 Remove the cover screws

3 mm Allen keyPay attention to the

two bound seal washers

2. Remove the cover and guide bushing. Check if the O-ring seals are in good shape. Replace if neccesary.

Figure 4 Remove cover and guide bushing

Pay attention

to the

two bound

seal washers

Guide

bushing

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

March 2018

WARNING - WEAR SAFETY GLASSES

Watch out for the spring when release the screw driver after remove the e-clip.

3. Remove the E-clips from groove using the slot screw driver.

Figure 5 Remove E-Clips

4. Take out the feed back mechanism. The plastic adjustment screws are under the feed back mechanism.

Figure 6 Remove feedback mechanism

Adjustment

screws

March 2018

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

5. Punch the plastic screws from bottom untill they are free to be removed from the top.

Figure 7 Remove the adjustment screws

Adjustment

screws

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

March 2018

3 Reassembly procedure

IMPORTANT

Check before replacing that both plastic adjustment screws have two O-rings in the top and bottom groove.

1. Mountthenewadjustmentscrewsandpressthemdownuntiltheyareushwiththebody.

Figure 8 Mount the new adjustment screws

O-ring seals

2. Adjust the orientation of the heads of setting screws of the feedback mechanism to match the direction of

new adjustment screws.

Figure 9 Adjust the orientation of the heads of setting screws

Heads of setting screws

of the feedback

mechanism

3. Place the feedback mechanism back into housing. The mechanism can be pressed down to the same level

of the machined surface if the rotation of the screw and plastic are matched in step 2.

4. Place the spring back and put the washer on, make sure the direction of washer is correct so that the E-clip

can sit in.

Figure 10 Place the feedback mechanism back

Press down to the same levelPlace the spring back and put the

washer on top

March 2018

Repair Instruction Manual

DOC.SAFM.Q4.E Rev. 0

WARNING - WEAR SAFETY GLASSES

Wear safety glasses when compressing the spring.

Releaseyourngersslowlyaftermountingthee-clip.

Try a different angle if you fail to compress the spring and washer.

5. Press the spring with spring washer down untill the groove and the switch operating rod is visible.

6. Use the e-clip tool to mount the e-clip in the groove.

Figure 11 Mount the E-clip

Groove on switch operating rod.

7. Place back the bushing and mount the cover back in place. Tighten the screws with 8.85 lbf.in (0.73 lbf.ft or

1 Nm) of torque.

IMPORTANT

Make sure that the bound seals are in place when mounting the cover screws.

Figure 12 Place back the bushing and mount the cover

Guide bushing Make sure that the bound seals

are in place when mounting the

cover screws

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