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
diaphragm.
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 positioner O-ring repair kit).
10 Remove rubber cap (35) and balance adjust acrew cap (36) from upper relay body (9). Remove O-ring (38) from
balnce 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 the seat ring (34).
13 Lubricate and replace the O-ring (37) on movable seat ring (34). Carefully reinstall the seat ring (34) into upper relay
body (9), being careful not to damage seating surface or O-rings.
14 Reinstall poppets (28), poppet springs (29), Seat Spring (39), O-rings (30), and poppet covers (27) before installing
retaining rings (31).
15 If signal diaphragm assembly (16) is damaged, proceed 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) between 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 diaphragm 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 holes on the side of the tube 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 (21) 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 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 feedback spring (47).
