LESLIE PILOT CONTROLLERS - Leslie Controls PILOT CONTROLLERS TABLE OF CONTENTS ... Volume booster...

12501 Telecom Drive, Tampa Florida 33637

A subsidiary of International, Inc.

20/1.5.2 Rev.3

INSTALLATION, OPERATING,AND MAINTENANCE INSTRUCTIONS

PARTS LIST

LESLIE PILOT CONTROLLERS

TABLE OF CONTENTS

ADJUSTABLE PROPORTIONAL BAND PILOT CONTROLLERS (PDAP and PRAP Types)SECTION I — INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2SECTION II —OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3SECTION III — MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5SECTION IV — SETTING OF ADJUSTING PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

STEM LENGTH AND SENSITIVITY ADJUSTMENT (PRA-1 and PRQ-1 Types)CONSTANT PRESSURE PILOT CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

CONSTANT, DIFFERENTIAL PRESSURE AND RATIO PILOT CONTROLLERSForce Balance, Fixed Band Types

SECTION I — INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8SECTION II — OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9SECTION III — MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-25

ILLUSTRATION INDEXDRAWING, DIMENSIONS, TYPICAL INSTALLATIONS AND MISCELLANEOUS DATA

Figure 1 - Pilot Controller Piping Details - Pressure Reduction Station . . . . . . . . . . . . . . . . . .2Figure 2 - Pilot Controller with 1:1 Volume Booster Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Figure 3 - Pilot Controller wit 1:1 Volume Booster and Reset Relay . . . . . . . . . . . . . . . . . . . . .3Figure 4 - Pilot Controller with Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Figure 5 - Pilot Controller with Inverse Derivative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Figure 6 - Type PRAP Pilot Controller (5-80 psig range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Figure 7 - Type PDAP Pilot Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Figure 8 - Position of sliders for nut/blade spring adjustment . . . . . . . . . . . . . . . . . . . . . . . . .5Figure 9 - Min./Max. Proportional Band Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Figure 10 - Adjustable Proportional Band Pilot Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . .6Figure 11 - PRA-1, PRW-1, PRQ, Pilot Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Figure 12 - Pilot Controller piping details — Typical Installation . . . . . . . . . . . . . . . . . . . . . . . .8Figure 13 - Drawing showing Direct Acting Type Pilot Controller (PDA-1, etc.) . . . . . . . . . . . .9Figure 14 - Partial Drawing showing lever and lever pin, etc. . . . . . . . . . . . . . . . . . . . . . . . . . .9Figure 15 - Diaphragm assembly for Pressure Ranges 13 PSIA - 20 PSIG to 50-125 . . . . . .11Figure 16 - Back Pressure or Pressure Relief Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Drawing - Pilot Controllers Types PDA-1, PDQ-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Drawing - Pilot Controller Types PRA-1, PRA-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Drawing - Pilot Controller Type PDAP-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Drawing - Pilot Controller Types PRAP-1, Range 5-70 & 50-800 . . . . . . . . . . . . . . . . . . . . .20Drawing - Differential Pilot Control Type UDDV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Drawing - Pilot Controller Type DDD, 15-75 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

SECTION I - INSTALLATION

Install pilot controller vertically, in an accessible location.Allow removal space for ease of maintenance.

Pilot controller may be located above or below line con-trolled.

IMPULSE LINE CONNECTION AND LENGTH

Connect impulse line from top of diaphragm cover to con-trolled pressure line. Make connection at least 3 feet from thevalve body opening or the end of any expander. Best resultsare obtained when the impulse line does not exceed 30 feet.Avoid connections near turbulent areas such as those creat-ed by orifices, elbows, sharp bends, or other flow directionchanging components.

PITCH OR SLOPE OF IMPULSE LINE

Steam and liquid impulse lines should slope toward the sens-ing head. This ensures that the lines stay full of liquid orcondensate. Pre-fill the sensing line before startup.

For noncondensing gases such as air, slope the lines awayfrom the pilot, so that any liquid contaminants drain back tothe process. Minimum slope is 1" per foot.

Accessary Equipment

Volume booster relays, positioners, reset relays, derivativeunits, etc. may be used with Leslie adjustable proportionalband pilot controllers where system characteristics requiretheir use.

HYDROSTATIC HEAD PRESSURE

When the pilot controller is installed under the line controlled,the total pressure resulting from hydrostatic head and con-trolled pressure must not exceed the maximum range of thepilot controller

SECTION II - OPERATION

The pilot is factory set and requires no adjustments other thanthose necessary to obtain the controlled pressure desired andthe width of proportional band required by the system.

1. Close inlet and outlet stop valves around the controlvalve.

2. Open air supply line and impulse line stop valves. Setproportional band adjustment at “Maximum Band.”

For Pressure Reducing Service Only (Refer toFigures 6 & 7)

3. Turn adjusting nut (22) of pilot controller counter-clock-wise until control valve is wide open.

4. Open outlet stop valve partially. Fully open inlet stopvalve slowly.

5. Make final adjustment for desired controlled pressurevalue. To increase controlled pressure screw adjustingnut (22) counter-clockwise. To decrease pressure screwadjusting nut clockwise.

6. Open outlet stop valve fully.

Figure 1. Pilot Controller Piping Details — Pressure Reduction Station

12"

1"

Slope as shown for condensible gas service 1" perfoot minimum.

Slope toward pilot for steam and liquids.

Impulse LIne-Use 1/2" schedule 40 pipe or tubingwith equivalent I.D.

Avoid loops or pockets in impulse line to insuretrue pressure signal to pilot diaphragm.

6" Vertical Section (Min.)

Union

Air Lines-Use 1.4" I.D. pipe or tubing.Use noncorrosive pipe and fittings.

Connect air supply to Pilot Controllerunder gauge marked Operating Supply.Connect outlet from Pilot Controllerunder gauge marked Control Valves toDiaphragm Control Valve.

LESLIE Class AF-2 Pressure ReducingValve. Set reducing valve to supply 20-22 psig air to pilot.

Stop Valve

Gage

For Back Pressure Service Only

3. Turn adjusting nut (22) of pilot controller counter-clock-wise until control valve is fully closed.

4. Open inlet stop valve fully. Partially open outlet stopvalve. Turn adjusting nut (22) of pilot controller clock-wise until control valve just begins to open. Open outletstop valve fully.

5. Make final adjustments for desired controlled pressurevalue. To increase controlled pressure screw adjustingnut (22) counter-clockwise. To decrease controlled pres-sure screw adjusting nut clockwise.

ADJUSTMENT FOR REQUIREDPROPORTIONAL BAND

Pilot controller is now ready for operation. Adjust for requiredwidth of proportional band as follows:

Turn adjusting know (76) counter-clockwise, moving pointertoward minimum band setting until the output air pressurebegins to cycle. Widen the proportional band until the cyclingstops.

N.O. Valve

Figure 2. Pilot Controller with 1:1 Volume Booster RelayFigure 4. Pilot Controller with Positioner. Split Rangingmay also be done.

Figure 3. Pilot Controller with 1:1 Volume Booster andReset Relay

Figure 5. Pilot Controller with Inverse Derivative

PDAP

Pressure Reduction

N.C. Valve

PRAP

Pressure Reduction

PDAP

N.O. Valve

Pressure Reduction

PRAP

N.O. Valve

Back Pressure

SECTION III - MAINTENANCEDISMANTLING

(Refer to Figures 6 and 7)

1. Bypass the control valve if system operation is neces-sary during maintenance work. Shut off air supply topilot controller.

2. Take out body screws (36). Slide pilot body assemblyoff base in a downward direction away from adjustingpin (64).

3. Remove bottom plug (47). Remove diaphragm plate (30)from pilot body by removing capscrews.

NOTE: Do not disturb position of proportional bandparts on diaphragm plate, unless work is required onthem.

Take out diaphragm nozzle disc (29) remove flange ring(37) and gasket (40). In PRAP types remove nozzle valve(79) and spring (80).

Cleaning and Reassembling Pilot Body Assembly

1. Wipe all parts clean. Check ports in pilot body, nozzleand orifice to be sure they are clear. DO NOT use sharpabrasives. Open air supply and blow out supply line.

2. Replace bottom plug (47) in pilot body. Place gasket(40) in pilot body. In PRAP types reinsert nozzle valve(79) and spring (80). Position flange ring (37) with nozzleupward on gasket (40). Insert flange ring screws andtighten.

3. Insert diaphragm nozzle disc (29) in pilot body with flatdisc end toward nozzle. Replace diaphragm plate (30)on pilot body, with knob (76) on the right hand side. Ifblade spring (66) was removed from the assembly, besure to reassemble it with the preformed end bendspointing upward.

Cleaning or Replacing Parts in Superstructure

NOTE: If maintenance work is necessary on superstructurealone, remove pilot body assembly from base as described inStep 2., Section III then proceed as shown below:

*NOTE: Spring (81) and spring seat (82) are not used in the 50-800 psig range PRAP Pilot Controller.

Figure 7. Type PDAP Pilot Body Assembly

Figure 6. Type PRAP Pilot Controller (5-80 psig range)

Dismantling Superstructure

1. Loosen setscrew (63) and disassemble adjusting pin(64) from stem (13).

2. Remove diaphragm cover (3), diaphragm spring (81)and diaphragm spring seat (82), diaphragm (6),diaphragm disc (7), diaphragm spacer (15) anddiaphragm guide (16). Lift out top spring seat (17) withstem (13), stem nut (19) and yielding spring (18).Remove adjusting spring (12), bottom spring seat (20),thrust bearing (21), adjusting nut (22) and locknut (23).

3. Clean all parts. Replace any worn or damaged part. Todisassemble stem (13) from top spring seat (17) holdtop spring seat rigidly on hex, press down on stem andremove stem nut from top spring seat.

REASSEMBLING SUPERSTRUCTURE

1. Reassemble locknut (23) (countersunk side downward),adjusting nut (22), thrust bearing (21), bottom springseat (20) and adjusting spring (12) to adjusting sleeve(14). Replace top spring seat (17) with assembled stemin yoke (10). Place diaphragm guide (16) in recess ofyoke (10).

2. Place diaphragm spacer (15) on yoke (10) with raisedface downward. Position diaphragm disc (7) on topspring seat (17). Place diaphragm (6), diaphragm springseat (82), diaphragm spring (81) and diaphragm cover(3) on diaphragm. Replace bolts (8) and nuts (2).Tighten firmly. Reassemble adjusting pin (64) to stem(13).

REASSEMBLING PILOT BODY ASSEMBLY TO BASE

1. Slide pilot body assembly upward on base so thatadjusting pin (64) passes smoothly through proportionalband blade spring. Replace pilot body screws (36) andtighten firmly. Reconnect impulse line to diaphragmcover. Open air supply line. Adjust pilot as described inSection IV.

SECTION IV - SETTING OF ADJUSTING PIN

Supply 20-22 psig operating pressure to controller. Turnadjusting nut to compress adjusting spring to set upperdiaphragm against its top limit stop. If possible, remove fluidpressure from top of diaphragm, if not, compress springsufficiently to overcome fluid pressure and move diaphragmto stop.

For PDAP Adjustable Proportional Band Type

Adjust sliders ZC\zn” apart as shown in sketch below. Moveproportional band nut upward on adjusting pin thread suffi-ciently to keep nut from touching blade spring during stemlength adjustment. Loosen adjusting pin set screw and turnadjusting pin either up or down until pilot air output is 0 psigthen turn adjusting pin downward toward pilot body until pilotair output increases from 0 to 21 psig. Lock set screw. Turn

proportional band nut down against blade spring until air out-put pressure decreases from 21 to 18 psig. With pin in stemhole to keep stem from turning, loosen set screw and turnadjusting pin upward away from pilot body approximately1Z\v turns. Lock set screw.

For PRAP Adjustable Proportional Band Type

Adjust slider ZC\zn” apart as shown in sketch below. Moveproportional band nut upward on adjusting pin thread suffi-ciently to keep nut from touching blade spring during stemlength adjustment. Loosen adjusting pin set screw and turnadjusting pin either up or down until pilot air output is 21 psig.Then turn adjusting pin downward toward pilot body untilpilot air output decreases from 21 to 0 psig. Lock set screw.Turn proportional band nut down against blade spring until airoutput pressure increases from 0 to 3 psig. With pin in stemhole to keep stem from turning, loosen set screw and turnadjusting pin upward away from pilot body approximately1Z\v turns. Lock set screw.

SLIDERPILOT TEST DISTANCERANGE PRESSURE BAND (PSIG)MIN. MAX.(PSIG) (PSIG) BAND BAND MIN. MAX.

5-70 50 23⁄4" 11⁄4" 2.0 - 4.5 7.0 - 11.0

50-800 80 23⁄4" 11⁄4" 5.5 - 8.5 15.0 - 21.

Figure 9. Min./Max. Proportional Band Table

NOTE: When the above adjustments have been properlymade, the proportional bands noted in Table - Figure 9 will beobtained when the sliders are set the approximate distancesapart as shown.

Figure 8. Position of sliders for nut/blade springadjustment

Nut (65)

Slider (70)13/16"

Slider 975)Knob(76)

Stem (13)

Blade Spring (66)

Figure 10. Adjustable Proportional Band PilotControllers

STEM LENGTH AND SENSITIVITY ADJUSTMENTTYPES PRA-1 AND PRQ-1

CONSTANT PRESSURE PILOT CONTROLLERS

FORCE BALANCE, FIXED BAND TYPES

ADJUSTMENT PROCEDURE

Supply 20-22 psig operating pressure to the pilot controller.Turn adjusting nut to compress adjusting spring to set upperdiaphragm against its top limit stop. If possible remove fluidpressure from top of diaphragm, if not compress springs suffi-ciently to overcome fluid pressure and move diaphragm tostop.

ADJUSTING RESPONSE SENSITIVITY

Remove nozzle disc pin, pilot cover and diaphragm nozzledisc.

For Normal Response Sensitivity adjust pilot controller forvery minor or no leak off. To do this relieve pressure of bladespring on nozzle stop by pressing lightly downward on it withfinger. Then screw nozzle stop downward until it is felt to bare-ly seat on nozzle nut.

For Supersensitive Response adjust pilot controller for con-tinuous leak off. To do this slowly screw nozzle stop furtherdownward until operating pressure flow is just detectablethrough nozzle bleed port. To check amount of leak off placefinger lightly over nozzle bleed port to seal air (do not pressdown on nozzle). Air pressure in output line to diaphragm con-trol valve should not build up any faster than 3-5 psig in 20-30seconds. Lock nozzle stop with blade spring.

To Test Pilot Controller Body and Diaphragm Control Valvefor response press downward on center of nozzle until 20-22psig air pressure registers on output gauge. Control valveshould move through full travel. Release nozzle. Air outputpressure should drop to 0 psig and control valve should returnto its original position.

After completing sensitivity adjustment replace diaphragmnozzle disc, nozzle disc pin and pilot cover.

LEVER SCREW ADJUSTMENT

Desired pilot controller performance will be obtained only if theupper (sensing) diaphragm is operating at or near its meanposition, i.e. half way between its top and bottom limit stops inbase and cover. Its position is determined by adjusting lengthof lever adjusting screw.

NOTE: THIS ADJUSTMENT IS FACTORY SET and shouldnot be disturbed unless it is obvious that the original settinghas been changed or major parts replacements were madewhich may cause need for readjustment.

These adjustments can be made when the pilot controller isset for either continuous or non-continuous leak off.

PRA-1 AND PRQ PILOT CONTROLLERS

1. Loosen locknut on lever setscrew. With 20 psig air pres-sure on out put gauge turn setscrew upward into leveruntil output air pressure just begins to fall away from 20psig.

2. Then turn lever screw downward (out of lever) 3/4 turnfor all low pressure pilots (up to and including the 50-125psig range) 1-1/4 turns for high pressure ranges (100-200) psig and over). Tighten locknut.

NOTE: With pilot air output at 20/22 psig, lever should beapproximately in the parallel position. If not parallel loosennozzle disc pin locknut and screw lower section of pin into orout of upper section of pin until lever is parallel. Tighten lock-nut.

Figure 11. PRA-1, PRW-1, PRQ, Pilot Controllers

Figure 12. — Pilot Controller piping details — Typical installation

STOP — LOOK — READ OBSOLETE

ADHERENCE TO THESE INSTRUCTIONSGUARANTEE OPTIMUM RESULTS

INSIST UPON THEIR BEING FOLLOWED.

SECTION I — INSTALLATION

Install Pilot Controller vertically in an accessible location.Allow removal¬ space for ease of maintenance. PilotController may be located above or below line controlled.NOTE: Whenever hydrostatic head exists on diaphragm effectmust be considered with relation to obtainable pressures.

Piping Details

Figure 1 shows control pilot piping details. Control valve pip-ing shown in figures is schematic only. Consult Control ValveInstructions for piping details.

Control Pipe Connection and Length

Connect Control Pipe from top of diaphragm cover to con-trolled pressure line. Make connection in controlled pressureline at least 3 feet from the valve body opening or the end ofthe expander, if one is in use. Best results are obtained whenlength of control pipe does not exceed 30 feet. Avoid con-nections near turbulent areas such as those created by ori-fices, elbows, sharp bends, or other flow direction changingcomponents.

Pitch or Slope of Control Pipe

Pilot Above Line Controlled — Slope control pipe downward,away from the Pilot Controller. Provide at least 6" of verticalpipe at connection to pilot cover.

Pilot Below Line Controlled — Slope control pipe downwardtoward Pilot Controller.

Hydrostatic Head Pressure

Where the Pilot Controller is to be installed under the line con-trolled (and liquids or condensible gases are to be controlled)total pressure resulting from hydrostatic head and controlledpressure must not exceed the maximum range of the controlpilot.

AIR LINES — Use 5/16" (1/4"I.D.) pipe or tubing. Use non-corrosive pipe and fittings.

6" Vertical Section (Min.)

Connect outlet of air reducing valve toinlet of Pilot Controller (immediatelyunder gage marked “OperatingSupply”). Connect outlet of PilotController (immediately under gagemarked “Control Valve”) to diaphragmconnection of Control Valve.

Union

AVOID LOOPS OR POCKETS INCONTROL PIPES to insure truepressure signal to pilot diaphragm.

Control pipe — use 1/2" 40 sched-ule pipe or tubing with equivalentinternal diameter(For ranges up to and including50-125 psig: for ranges 100-200psig and over use 3/8" pipe).

Stop Valve

*See NOTE

Gage

Operating medium clean air** SetReducing Valve to supply 20-22 psigto pilot.

*NOTE: AIR CONNECTIONS — Pilot Controller is equippedwith stainless steel air supply and output fittings. DO NOTremove. Connect air lines directly to these fittings.

**NOTE: Operating medium for Classes PRA-1, PDA-1,UDRV, UDDV etc. (aluminum construction) must beclean air. (Win Class designation) are suitable for oil orwater as operating medium.

Strainer

*Use with Instruction 20/2.5.3 for replacing upper diaphragms — UDDV, UDRV Types.**Use instruction 20/3.5.1 for replacing upper diaphragms — DDD, UDDD Types.

Types Covered:

PDA-1 PDW-1 PDQ-1 UDDV* DDD**

PRA-1 PRW-1 PRQ-1 UDRV* UDDD***

CONSTANT, DIFFERENTIAL PRESSURE AND RATIOPILOT CONTROLLERS

Force Balance, Fixed Band Types

SECTION II — OPERATION

PROCEDURE: Follow Steps 1 and 2 then proceed withSteps 3 through 5 whichever applies to the particular service.

1. Close inlet and outlet stop valves around the controlvalve.

2. Open air supply line stop valve. Adjust 1/4" reducingvalve to supply 20-22 psig pressure to control pilot.

For Pressure Reduction Installation

3. Turn adjusting nut of Pilot Controller Until diaphragmcontrol valve is wide open.

4. Open outlet stop valve partially and control pipe stopvalve fully.

5. Open inlet stop valve slowly, until Pilot Controller takeshold and starts to close the diaphragm control valve.Screw adjusting nut upward to increase, downward todecrease the controlled pressure. After desired con-trolled pressure is obtained, open inlet stop and outletvalves fully.

For Overflow Relief Installation

3. Turn adjusting nut of Pilot Controller until diaphragmcontrol valve is closed.

4. Open inlet, outlet, and control pipe stop valves fully.

5. Turn adjusting nut of Pilot Controller so that diaphragmcontrol valve starts to open when desired inlet pressureis exceeded.

Differential Pressure Pilot Controllers

3. Turn adjusting nut of control pilot to adjust compressionon adjusting spring until control valve is wide open.

4. Open outlet stop valve partially and control pipe stopvalves fully.

5. Open inlet stop valve slowly, until controller takes holdand begins to close the control valve. Readjust theadjusting nut of the control pilot to obtain desired differ-ential. To increase differential, when highest pressure ison top of diaphragm, screw adjusting nut upward; todecrease differential, screw adjusting nut downward.When highest pressure is on underside of diaphragmscrew adjusting nut upward to decrease differential;downward to increase. After desired differential settingis obtained, open inlet and outlet stop valves fully.

NOTE: When systems are in full operation, use caution in cut-ting a controller in so that system differential will not be dis-turbed.

Figure 13. — Drawing showing Direct Acting Type PilotController (PDA-1, etc.).

Figure 14. — Partial Drawing showing lever and lever pin,etc., in lever action Types (PRA-1, etc.,).

DO NOT DISTURB SETTINGOF THIS PIN

SECTION III — MAINTENANCE(CONSULT FIGURES OF APPLICABLE DRAWINGS)

IMPORTANT: ALWAYS MAKE SURE THAT CONTROL PIPESAND AIR SUPPLY LINES ARE FREE AND CLEAR OF FOR-EIGN MATTER.

Dismantling Pilot Valve Bodies

1. By-pass diaphragm control valve if system operation isnecessary maintenance. Close air supply and controlpipe stop valves to pilot controller. Remove cover screwand cover from base.

2. In lever action types (PRA-1, etc.), lift right hand end oflever and remove lever pin assembly. (DO NOT disturbsetting of these parts as they are designed for initialfactory length adjustment only).

Loosen bottom plug (47.) Remove body screws (36)and take body assembly off base (25). Disassemblediaphragm plate capscrews (31), diaphragm plate (30)and nozzle disc diaphragm assembly (29) from body.

3. Take out flange ring screws (34), flange ring complete(37) and nozzle (42) with assembled parts. Disassemblenozzle stop (32) from flange ring. Remove bottom plug(47), pilot valve spring (45) and seat (43) from bodyunless it is damaged and must be replaced. (If removalis necessary, use piece of flat stock or wide screwdriverin lugs to loosen and unscrew).

Cleaning — Replacing Parts

1. Wipe all parts clean including pilot valve seat. Use anapproved, non-residue forming solvent, if necessary.

2. Inspect all parts. Replace any worn or damaged partsincluding neoprene nozzle diaphragm (40) and “O” ringbody gaskets (35) in back of body.

3. To change nozzle diaphragm insert pin in bottom port innozzle for grip, loosen diaphragm nut (39). Disassembleparts. Replace diaphragm. Reassemble parts. Tightendiaphragm nut.

NOTE: Do not use abrasive cloth on parts or grind in pilotvalve as parts may be damaged or important dimensionschanged. If necessary, crocus cloth may be used. All workingparts must be clean and free moving. Open air supply linevalve and blow out ports.

Reassembling Pilot Valve Bodies

1. Place pilot valve spring (45) and pilot valve (44) (withseating face upward) on bottom plug. Position parts inbody. Screw bottom plug all the way in. Tighten.

2. Insert nozzle (42) with assembled parts in upper end ofbody. Screw nozzle stop (32) part way into flange ring(37). Position flange ring complete on nozzle diaphragm(nozzle stop upward) with blade spring (33) on left handside facing gauges. Insert flange ring screws (34)through flange ring and into body threads. Start careful-ly into threads. Tighten evenly and sufficiently to makea good air seal.

3. Replace body assembly on base (25). Insert bodyscrews (36) through body and into base threads. Startcarefully into threads. Tighten securely to make a goodgasket seal between body and base.

4. Note: Adjust nozzle stop setting for leak off or non-leakoff setting at this point. Proceed as described for theparticular setting desired.

Adjusting Response Sensitivity

To adjust response sensitivity of a pilot controller supply 20-22 psig air to pilot controller then proceed as follows:

For Normal Response Sensitivity: Adjust pilot controller forvery minor or no leak off. To do this, relieve pressure of bladespring on nozzle stop by pressing lightly downward o it withfinger. Then screw nozzle stop downward until it is felt tobarely seat on nozzle nut (39).

For Supersensitive Response: Adjust pilot controller for con-tinuous leak off. To do this slowly screw nozzle stop furtherdownward until operating pressure flow is just detectablethrough nozzle bleed port. To check amount of leak off, placefinger lightly over nozzle bleed port to seal air (do not pressdown on nozzle). Air pressure in output line to diaphragmcontrol valve should not build up any faster than 3-5 psig in20-30 seconds. Lock nozzle stop with blade spring.

To Test Pilot Controller Body and Diaphragm Control Valve:For response press downward on center of nozzle until 20-22psig air pressure registers on output gauge. Control valveshould move through full travel. Release nozzle. Air outputpressure should drop to 0 psig and control valve should returnto its original position.

NOTE: Maintenance work can be performed on superstruc-ture, if necessary, as described under “Replacing UpperDiaphragm.” If unnecessary, proceed with Reassembly Step 5.

5. Place nozzle disc assembly in body recess with disctoward nozzle.

In PDA-1, etc. types, remove screw (27) from stemcomplete (13). Lift extension pin (86) upward into stemcomplete then replace diaphragm cover on body. Insertcapscrews (31) through cover into body. Tighten.Position end of adjusting pin (53) properly in recess innozzle disc then insert screw (27) through stem com-plete and extension pin and tighten.

In PRA-1, etc. types, replace cover (30) on body. Insertcapscrews (29). Tighten. Then lift right hand end oflever and insert lever pin assembly in place betweenlever and nozzle disc making sure that pointed endscenter in recesses in disc and lever. Check oppositeend of lever to make sure that point of stem complete(13) has centered in recess in set-screw properly.

NOTE: If it was found necessary to disturb adjustment oflever screw of adjusting pin readjust as described under“STEM LENGTH ADJUSTMENT” shown on Page 4.

Replacing Upper DiaphragmsConstant Pressure Pilot Controllers(PDA-1, PRA-1, etc.)For Type UDDV, UDRV Consult Instruction 20/2.5.3For Type UDDD Consult Instruction 20/3.5.1

1. In all pilot controllers remove all adjusting spring com-pression by screwing locknut (23) downward as far as itwill go, then following with adjusting nut (22) until allcompression is removed from adjusting spring (12). Inthe case of lever action types (PRA-1, etc.) relieve leverspring compression also by removing spring cap (49).

2. Disassemble bolts and nuts (2/8), diaphragm cover (3)from diaphragm base (9). Remove spring (87) (13 psia -20 psig range only). Clean cover. In direct acting types(PDA-1, etc.) take screw (27) out of stem (13).

3. For all ranges from 13 psia - 20 psig to 50-125 psig Liftdiaphragm assembly out of diaphragm base (9). Holddiaphragm disc screw (1) rigidly on hex and loosendiaphragm disc nut (4). Disassemble parts. Clean parts,replace diaphragm. Place diaphragm disc (7),diaphragm (6), and diaphragm disc washer (5) ondiaphragm disc screw (1). Assemble diaphragm discnut (4) to diaphragm disc screw (1). Tighten snugly tomake a good pressure seal. Do not distort diaphragm.

For ranges 100-200 psig and over Diaphragm may bechanged by simply removing spring compression, dis-assembling bolts/nuts and cover, replacing diaphragmand closing unit up again.

NOTE: Balance of superstructure parts may be cleaned,examined, and replaced if necessary at this point. To examineyielding spring (18)(PDA-1, etc.) hold disc screw (1), rigidly onhex. Press down on stem (13). Remove stem nut (19).Disassemble parts. Reassemble. Tighten stem nut.

4. Replace diaphragm assembly in diaphragm base (9).Reassemble diaphragm cover (3), and bolts and nuts(2/8) to diaphragm base. Tighten bolts to make goodpressure seal.

Proceed with Step 5, “REASSEMBLY” insofar as itapplies to parts removed to permit rework of super-structure and stem length readjustment (if the latter isnecessary). Reassemble pilot cover and screw to base(25). Do not overtighten screw.

5. Reconnect control pipe to diaphragm cover and operat-ing medium lines to pilot controller and valve. Turn onoperating medium supply and adjust pilot controller fordesired controlled pressure as described under “OPER-ATION.”

Stem Length Adjustment (Pin/Lever)

Desired pilot controller performance will be obtained only ifthe upper (sensing) diaphragm is operating at or near its meanposition, i.e. half way between its top and bottom limit stopsin base and cover. Its position is determined by adjustinglength of adjusting pin (53) in PDA-1, etc. types and leverscrew (26) in PRA-1, etc. types.

NOTE: THIS ADJUSTMENT IS FACTORY SET and shouldnot be disturbed unless it is obvious that the original settinghas been changed or major parts replacements were madewhich may cause need for readjustment.

These adjustments can be made when the pilot controller isset for either continuous or non-continuous leak off.

Adjustment Procedure

In all cases: Supply 20-22 psig operating pressure to the pilotcontroller. Turn adjusting nut (22) to compress adjustingspring to set upper diaphragm against its top limit stop. Ifpossible, remove fluid pressure from top of diaphragm, if not,compress spring sufficiently to overcome fluid pressure andmove diaphragm to stop. Blank off output connection toD.C.V.

PDA-1, PDW-1, PDQ, UDDV, etc. Pilot Controllers

1. Loosen locknut (74) on adjusting pin (53). Turn adjustingpin (53) downward toward pilot until 0-3 psig air pres-sure shows on output gauge.

2. Then turn adjusting pin (53) back upward into extensionpin (86) (away from pilot body) 1 turn for all low pres-sure pilots (up to and including the 50-125 psig range);1-3/4 turns for high pressure pilots (ranges 100-200psig and over). Tighten locknut (74).

3. Reconnect output to D.C.V.

PRA-1, PRW-1, PRQ, UDRV, Etc. Pilot Controllers

1. Loosen locknut (27) on lever setscrew (87). With 20 psigair pressure on output gauge turn setscrew (87) upwardinto lever until output air pressure just begins to fallaway from 20 psig.

Figure 15. — FOR PRESSURE RANGES 13 PSIA - 20 PSIG TO50-125 THIS TYPE OF DIAPHRAGM ASSEMBLY IS USED

2. Then turn lever screw (26) downward (out of lever) 3/4turn for all low pressure pilots (up to and including the50-125 psig range; 1-1/4 turns for high pressureranges (100-200 psig and over). Tighten locknut (27).

3. Reconnect output to D.C.V.

NOTE: Differential and Ratio pilot controller (UDDV, UDRV orUDDD types) may require slight stem length readjustment toobtain complete balancing of the sensing diaphragm, ifchanges in static pressure on the diaphragm cause changesin pilot controller setpoint. To check this supply 20 psig oper-ating pressure to pilot. Adjust pilot for a constant differentialwithin its range. Apply a change in static pressure across theupper sensing diaphragms and observe output pressure onright hand gauge. If output pressure changes, readjust stemlength in small increments (by turning adjusting pin or leverscrew upward or downward as required) until changes in sta-tic pressure do not affect the air output pressure).

To Decrease Sensitivity of Pilot Controllers(Constant Pressure Types Only)

1. Readjust nozzle stop to non-leak off position (if leak offis in use).

2. Move diaphragm slightly away from its mean positionby readjusting stem length in small increments of about1/8 of a turn until desired operation is obtained.Caution: DO NOT turn excessively.

PDA-1, PRW-1 PDQ Pilot Controllers — In reducingservice move diaphragm upward by increasing the stemlength. In back pressure or relief service, movediaphragm downward by decreasing the stem length.

PRA-1, PRW-1, PRQ Pilot Controllers — In reducingservice move diaphragm downward by decreasing stemlength. In back pressure or relief service, movediaphragm upward by increasing the stem length.

After making readjustment retest pilot controller tomake sure that it will change the operating output pres-sure from 0 psig to 20 psig or vice versa with a reason-able change in controller pressure.

Figure 16. — Back Pressure or Pressure Relief Service

For Differential Pilot Installation Sketches,See Instructions 20/2.5.3

For Ratio Pilot Installation Sketch,See Instructions 20/3.5.1

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PARTS LIST

REFERENCE NUMBERS - EACH PRESSURE RANGEPART QTY. PER 15-75 50-125 100-200 175-300 275-450 400-600 550-800NO. PART NAME MATERIAL UNIT (NOTE 4) PSI PSI PSI PSI PSI PSI PSI

1 Disc Screw Aluminum 1 33930 33930 33930 - - - - - - - - - -3 Diaphragm Cast Aluminum 1 33949 33950 33951 33924 33925 33926 33927 339284 Diaphragm Disc Nut Aluminum 1 33932 33932 33932 - - - - - - - - - -5 Diaphragm Disc Washer Aluminum 1 33931 33931 33931 - - - - - - - - - -6 � Diaphragm, Upper Synthetic Rubber 1 12476 13257 13257 13226 13226 13226 13226 132267 Diaphragm,Disc Cast Aluminum 1 33915 33916 33917 33939 33940 33941 33942 339438 Bolt Steel, Cadmium Plated (NOTE 3) 12291 12291 12291 45749 45749 45749 45749 45749

10 Yoke Cast Aluminum 1 58408 58409 58410 33971 33971 33971 33971 3397112 Adjusting Spring Spring Steel, Plated 1 12475 12474 12474 13218 13218 13218 13218 1321813 Stem, Complete Aluminum 1 47133 47133 47133 47134 47134 47134 47134 4713414 Adjusting Sleeve Stainless Steel 1 33985 33985 33985 33986 33986 33986 33986 3398615 Diaphragm Spacer Cast Aluminum 1 - - - - - - 33934 33935 33936 33937 3393816 Diaphragm Guide Stainless Steel 1 - - - - - - 33933 33933 33933 33933 3393317 Top Spring Seat Cast Aluminum 1 - - - - - - 33944 33944 33944 33944 3394487 Upper Diaphragm Spring Stainless Steel 1 53566 - - - - - - - - - - - - - -

ALL PARTS BELOW ARE INTERCHANGEABLE IN ALL PRESSURE RANGESPART QTY. PERPART NAME MATERIAL REFERENCE NUMBERS - ALL RANGESNO. UNIT

2 Nut Steel, Cadmium Plated (NOTE 3) 4284318 Yielding Spring Steel, Nickel Plated 1 1247119 Stem Nut Aluminum 1 3183920 Bottom Spring Seat Stainless Steel 1 1168321 Thrust Bearing Stainless Steel & Brass 1 1168422 Adjusting Nut Cast Bronze 1 1239523 Lock Nut Brass 1 1283324 Washer Stainless Steel 2 3067325 Base Aluminum 1 4332026 Nut Steel, Cadmium Plated 1 1374427 Screw Stainless Steel 1 4806329 � Diaph. Nozzle Disc, Comp. (NOTE 2) Stainless Steel 1 1508630 Diaphragm Plate Cast Aluminum 1 3803031 Cap Screw Aluminum 2 3367932 Nozzle Stop Aluminum 1 33673

34 Screw Aluminum 4 3367835 � O-Ring Synthetic Rubber 2 4221336 Screw Steel, Cadmium Plated 4 3395937 Flange Ring, Complete Aluminum 1 3367238 Body Aluminum 1 4044539 Diaphragm Nut Stainless Steel 1 3331640 � Diaphragm Synthetic Rubber 1 1236841 Diaphragm Washer Stainless Steel 1 3367642 � Nozzle Aluminum 1 3834743 � Pilot Valve Seat Celcon 1 1235344 � Pilot Valve, Complete Stainless Steel 1 3367545 � Pilot Valve Spring Stainless Steel 1 3366647 Bottom Plug Aluminum 1 33667

49 Cover Aluminum 1 4044750 Cover Screw Steel, Plated 1 3396051 � Pressure Gage. Steel Case, Clearlok Crystal 2 52354

53 � Adjusting Pin Brass 1 1240154 Connector Piece Cold Rolled Steel 2 4163774 Lock Nut Stainless Steel 1 4713886 � Extension Pin Stainless Steel 1 4709789 Washer Stainless Steel 1 1168588 Cover Screw Washer Rubber 2 57685

Adjusting Rod Steel, Plated 1 11808

� RECOMMENDED SPARE PARTS� THESE PARTS SHOULD BE ON HAND, PLUS RECOMMENDED SPARE PARTS WHEN OVERHAULING THIS EQUIPMENT.

TYPES PDA-1, PDQ-1 PILOT CONTROLLERSWHEN ORDERING PARTS, PLEASE GIVE PAT NAME AND PART REFERENCE NUMBER FROM TABLE BELOW

USE PART NUMBER ONLY TO LOCATE PART ON DRAWING

PDQ-1ALL PARTS ARE SAME AS PDA-1 SHOWN IN TABLE ABOVE, EXCEPT FOR PARTS SHOWN BELOW

PART NO. PART NAME MATERIAL QTY. PER REFERNCE NO.UNIT

42 Nozzle Aluminum 1 3898143 Pilot Valve Seat Stainless Steel 1 1235844 Pilot Valve Complete Stainless Steel 1 12350

NOTE 1 - Consists of Stem and Stem Head.NOTE 2 - Consist of Nozzle Disc; Retaining Ring, and DiaphragmNOTE 3 - Quantities are: Eight (8) for 13 psia - 20 psig to 50 - 125 Pressure Ranges and Size (6) for 100 - 200 to 550 - 800 Pressure Ranges.NOTE 4 - Range 13 psia to 20 psig (3.5 Hg. Vacuum).

FOR ALL TYPES NOT LISTED, PLEASE ORDER PARTS BY NAME AND INCLUDE RANGE, TYPE AND SERIAL NUMBER

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PART QTY. PER REFERENCE NUMBERS - EACH RANGENO. PART NAME MATERIAL UNIT NOTE 5 15-75 50-125 100-200 175-300 275-450 400-600 550-800

1 Disc Screw Aluminum 1 33929 33929 33929 - - - - - - - - - -2 Nut Steel, Cad. Plated (NOTE 6) 42843 42843 42843 42843 42843 42843 42843 428433 Diaphragm Cover Cast Aluminum 1 33949 33950 33951 33924 33925 33926 33927 339284 Diaphragm Disc Nut Aluminum 1 33932 33932 33932 - - - - - - - - - -5 Diaphragm Disc Washer Aluminum 1 33931 33931 33931 - - - - - - - - - -

� 6 Diaphragm, Upper Synthetic Rubber 1 12476 N1325794 13257 13226 13226 13226 13226 132267 Diaphragm Disc Cast Aluminum 1 33915 33916 33917 33939 33940 33941 33942 339438 Bolt Steel, Cad. Plated (NOTE 6) 12291 12291 12291 45749 45749 45749 45749 45749

10 Yoke Cast Aluminum 1 58408 58409 58410 33971

12 Adjusting Spring Spring Steel, Plated 1 12475 12474 12474 13218 13218 13218 13218 1321813 Stem, Complete (NOTE 1) Stainless Steel 1 12382 12382 12382 13218 13218 13218 13218 1321814 Adjusting Sleeve Stainless Steel 1 33985 33985 33985 33986 33986 33986 33986 3398615 Diaphragm Spacer Cast Aluminum 1 - - - - - - 33934 33935 33936 33937 3393816 Diaphragm Guide Stainless Steel 1 - - - - - - 33933 33933 33933 33933 3393317 Top Spring Seat Cast Aluminum 1 - - - - - - 33968 33968 33968 33968 33968

� 87 Upper Diaphragm Spring Stainless Steel 1 53566 - - - - - - - - - - - - - -

PILOT CONTROLLER TYPES PRA-1, PRQ-1 AIR ACTUATEDWHEN ORDERING PARTS, PLEASE GIVE RANGE TYPE, PART NAME AND PART REFERENCE NUMBER FROM TABLE BELOW


ALL PARTS LISTED BELOW ARE INTERCHANGEABLEIN ALL RANGES

13 PSIA - 20 PSIG TO 550 - 800

REFERENCE NUMBERS13 PSIA - 20 PSIG TO 550 - 800

18 Bottom Spring Seat Stainless Steel 1 1168319 Thrust Bearing Stainless Steel & Brass 1 1168420 Adjusting Nut Cast Bronze 1 1239521 Lock Nut Brass 1 1283322 Washer Stainless Steel 2 3067323 Base Die Cast Aluminum 1 4332124 Nut Steel, Cad. Plated 1 1374425 Lever, Complete (NOTE 2) Brass 1 2015927 Set Screw Stainless Steel 1 56775

� 28 Diaphragm Nozzle Disc, Stainless Steel 1 15831Comp. (NOTE 3)

29 Cap Screw Aluminum 2 3367930 Diaphragm Plate Die Cast Aluminum 1 3803031 Nozzle Stop Aluminum 1 3367332 Washer Stainless Steel 1 1168533 Screw Aluminum 4 33678

� 34 O-Ring Synthetic Rubber 2 4221335 Screw Steel, Cad. Plated 4 3395936 Flange Ring, Complete Die Cast Aluminum 1 3367237 Body Die Cast Aluminum 1 4044538 Diaphragm Nut Stainless Steel 1 33316

� 39 Diaphragm Synthetic Rubber 1 1236840 Diaphragm Washer Stainless Steel 1 33676

� 41 Nozzle Aluminum 1 38347� 42 Pilot Valve Seat Celcon 1 12353� 43 Pilot Valve, Complete Stainless Steel 1 33675� 44 Pilot Valve Spring Stainless Steel 1 33666

46 Bottom Plug Aluminum 1 3366748 Nut Brass 1 1282749 Lever Spring Cap Aluminum 1 33923

� 50 Lever Spring Spring Steel, Plated 1 1596051 Lever Stud Stainless Steel 1 1237353 Cover Die Cast Aluminum 1 4044754 Cover Screw Steel, Plated 1 3396055 Gauge Steel Case, Clearlok 2 52354

Crystal57 Connector Piece Cold Rolled Steel 2 41637

� 59 Adjusting Pin, Male Brass 1 47265(NOTE 4)

� 60 Adjusting Pin, Female Brass 1 47266(NOTE 4)

61 Lock Nut Stainless Steel 1 4713863 Jam Nut Stainless Steel 1 56776

� 64 Cover Screw Washer Rubber 2 57685Adjusting Rod Cold Rolled Steel 1 11808

� RECOMMENDED SPARE PARTS.� THESE PARTS SHOULD BE ON HAND. PLUS RECOMMENDED SPARE PARTS, WHEN OVERHAULING THIS EQUIPMENT.NOTE 1 - Consists of Stem and Retainer.NOTE 2 - Consists of Lever; Set Screw, Part No. 27 and Jam Nut, Part No. 63.NOTE 3 - Consists of Nozzle Disc, Retaining Ring and Diaphragm.NOTE 4 - May be furnished as individual parts or as Nozzle Disc Pin Complete, Ref. No. 12377.NOTE 5 - Range: 13 PSIA - 20 PSIG (3.5 Hg Vacuum).NOTE 6 - Quantities are: Eight (8) for Ranges 13 PSIA - 20 PSIA - 20 PSIG to 50 -125 and Six (6) for 100 - 200 to 500 - 800 Ranges.

ALL PARTS ARE SAME AS PRA-1 SHOWN IN TABLE ON PAGE 3, EXCEPT FOR PARTS SHOWN BELOW.

FOR ALL TYPES NOT LISTED, PLEASE ORDER PARTS BY NAME AND INCLUDE RANGE, TYPE AND SERIAL NUMBER.

PRQ-1

PART QTY. PER REF.NO. PART NAME MATERIAL UNIT NO.41 Nozzle Aluminum 1 3898142 Pilot Valve Seat Stainless Steel 1 1235843 Pilot Valve Complete Stainless Steel 1 12350

PILOT CONTROLLER TYPES PRA-1, PRQ-1 AIR ACTUATED

PILOTCONTR

OLL

ERS,AIR

ACTU

ATED

TYPESPDAP-1,RANGE5-70

&50

-800

WITH

ADJU

STA

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PROPORTIONALBAND

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ALL

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AB

LES

TAT

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SI

APPROX.NETWT.

WITH

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PIL

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2 3 6 7

15 16 17 108 12 13 14 20 21 22 23 24 25 24 26 63 64 65 66 30 29 77 34 35 37 40 38 78 36 47

1/4in.(6mm)

PIPETH

READ

3-3/4in.

(95.3m

m)

6-1/8in.

(155

.6mm)

15/16in.

(23.8m

m)

1-7/16

in.

(36.5m

m)

4-1/4 in.(108.0mm)

6-1/2 in.(165.1mm)

16-7/8 in.(428.6mm)

22

80 90 18 19 73

9/16

in.ho

le(14.3m

m)

1/4in.

(31.8m

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1in.

(31.8m

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4-1/2in.

(114

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FORPRESSURERANGE5-70

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67 68 69 70 71 72 74

76 75

54

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WHEN ORDERING PARTS, PLEASE GIVE TYPE, PART NAME AND PART REFERENCE NUMBER FROM TABLE BELOW.USE PART NUMBER ONLY TO LOCATE PART ON DRAWING

QTY REF. NO. - EACH RANGEPART PART NAME MATERIAL MATERIAL SPEC. PERNO. UNIT 5-70 50-800

2 Nut Steel, Cadmium Plated ASTM A-194 Gr. 2H 6 42843 428433 Diaphragm Cover Cast Aluminum ASME B-26 Alloy 356. OT6 1 33927 33928

� 6 Diaphragm Synthetic Rubber Neoprene 1 13226 132267 Diaphragm Disc Aluminum ASTM B-211 2017/2024 1 33942 339438 Bolt Steel, Cadmium Plated ASTM A-193 Gr. B7 6 45749 4574910 Yoke Cast Aluminum` ASTM B-26 Alloy B443.0 1 33971 3397112 Adjusting Spring Spring Steel, Plated Commercial 1 51483 1321813 Stem, Compl. (Note 2) Aluminum ASTM B-211 2017/2024 1 45085 4508514 Adjusting Sleeve Stainless Steel AISI Type 410 1 33986 3398615 Diaphragm Spacer Aluminum ASTM B-211 2017/2024 1 33937 3393816 Diaphragm Guide Stainless Steel AISI Type 302 1 33933 3393317 Tope Spring Seat Cast Aluminum ASTM B-26 Alloy B443.0 1 33944 33944

� 18 Yielding Spring Steel, Nickel Plated Commercial 1 12471 1247119 Stem Nut Aluminum ASTM B-211 2017/2024 1 31839 3183920 Bottom Spring Seat Stainless Steel AISI Type 410 1 11683 1168321 Thrust Bearing Stainless Steel & Brass AISI Type 320 & ASTM B16 1 11684 1168422 Adjusting Nut Cast Bronze ASTM B-61 1 12395 1239523 Lock Nut Brass ASTM B-16 1 12833 1283324 Washer Stainless Steel AISI Type 410 1 30673 3067325 Base Die Cast Aluminum ASTM B-85 Alloy A360 1 43320 4332026 Nut For Frame Steel, Cadmium Plated Commercial 1 13744 13744

� 29 Diaph. Nozz. Disc, Compl. (Note 1) Stainless Steel AISI Type 302 1 15086 1508630 Diaph. Plate Die Cast Aluminum ASTM B-85 Alloy A360.0 1 38030 3803034 Screw Aluminum ASTM B-211 2017/2024 4 33678 33678

� 35 O-Ring Synthetic Rubber Neoprene 2 42213 4221336 Screw Aluminum ASTM B-211 2017/2024 4 33959 3395937 Flange Ring Die Cast Aluminum ASTM B-85 Alloy A360.0 1 47910 4791038 Body Die Cast Aluminum ASTM B-85 Alloy A360.0 1 40445 40445

� 40 Gasket Synthetic Rubber Neoprene 1 47916 4791647 Bottom Plug Aluminum ASTM B-211 2017/2024 1 33991 3399149 Cover Die Cast Aluminum ASTM B-85 Alloy A360.0 1 40447 4044750 Cover Screw Steel, Cadmium Plated Commercial 1 33960 33960

� 51 Gage Steel Case, Clearlok Crystal Commercial 2 52354 5235454 Connector Piece Cold Roll;ed Steel AISI 1117 2 41637 4163763 Allen Set Screw Steel, Cadmium Plated Commercial 1 12390 12390

� 64 Adjusting Pin Aluminum ASTM B-211 2017/2024 1 38032 3803265 Nut Steel, Cadmium Plated ASTM A-194 Gr. 2H 1 38060 38060

� 66 Blade Spring Stainless Steel AISI Type 301-2B 1 38036 3803667 Screw Stainless Steel Commercial 2 38123 3812368 Bearing Stainless Steel AISI Type 302 1 38034 3803469 Adjusting Screw Stainless Steel AISI Type 302 1 38033 3803370 Proportioning Slider, Rt. Hand Stainless Steel AISI Type 302 1 38028 3802871 Drive Screw Steel, Cadmium Plated ASTM A-228 1 58376 5837672 Indicator Stainless Steel AISI Type 302 1 38027 3802773 Washer Stainless Steel AISI Type 302 1 11685 1168574 Cap Screw Aluminum Commercial 2 33679 3367975 Proportioning Slider, Left Hand Stainless Steel AISI Type 302 1 38029 3802976 Knob Plastic Commercial 1 38126 38126

� 77 Nozzle Aluminum AISI Type 316 1 22339 2233978 Orifice Plug Aluminum ASTM B-211 2017/2024 1 33990 33990

� 88 Cover Screw Washer Rubber Commercial 2 57685 5768589 Diaphragm Spring Inconel Commercial 1 10980 - -90 Diaphragm Spring Seat Aluminum ASTM B-211 2017/2024 1 58128 - -

Adjusting Rod Cold Rolled Steel Commercial 1 11808 11808

� RECOMMENDED SPARE PARTS.� THESE PARTS SHOULD BE ON HAD, PLUS RECOMMENDED SPARE PARTS, WHEN OVERHAULING THIS EQUIPMENT.

NOTE 1 - CONSISTS OF NOZZLE DISC, RETAINING RING AND DIAPHRAGMNOTE 2 - CONSISTS OF STEM AND STEM HEAD

FOR ALL TYPES NOT LISTED, PLEASE ORDER PATS BY NAME AND INCLUDE RANGE, TYPE AND SERIAL NUMBER

PILOT CONTROLLERS, AIR ACTUATED, TYPES PDAP-1, RANGE 5-70 & 50-800WITH ADJUSTABLE PROPORTIONAL BAND

MA

XIM

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ALL

OW

AB

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TAT

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ACTU

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TYPESPRAP-1,RANGE5-70

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WITH

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STA

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PROPORTIONALBAND

89 90 2 3 6 715 16 17 10

8 19 12 13 14 20 21 22 23 24 25 24 26 63 64 65 66 30 29 77 79 34 35 37 40 38 80 78 36 47

15/16in.

(23.8m

m)

1/4in.NPT

3-3/4in.

(95.3m

m)

6-1/8in.

(155

.6mm)

1-7/16

in.

(36.5m

m)

4-1/4 in.(108.0mm)

6-1/2 in.(165.1mm)

16-7/8 in.(428.6mm)

18 73 9/16

in.ho

le(14.3m

m)

1in.

(25.4m

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FORPRESSURERANGE5-70

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.TH

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FORPRESSURERANGE50

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TYPE PRAP-1, RANGE 5-70 AND 50-800WHEN ORDERING PARTS, PLEASE GIVE TYPE, PART NAME AND PART REFERENCE NUMBER FROM TABLE BELOW.


QTY REF. NO. - EACH RANGEPART PART NAME MATERIAL MATERIAL SPEC. PERNO. UNIT 5-70 50-800

2 Nut Steel, Cadmium Plated ASTM A-194 Gr. 2H 6 42843 428433 Diaphragm Cover Aluminum Alloy ASME SB-211 Alloy 6061-T6 1 33927 33928

� 6 Diaphragm Synthetic Rubber Neoprene 1 13226-94 13226-947 Diaphragm Disc Aluminum ASTM B-211 2017/2024 1 33942 339438 Bolt Steel, Cadmium Plated ASTM A-193 Gr. B7 6 45749 45749

10 Yoke Cast Aluminum` ASTM B-26 Alloy B443.0 1 33971 3397112 Adjusting Spring Spring Steel, Plated Commercial 1 51483 1321813 Stem, Compl. (Note 2) Aluminum ASTM B-211 2017/2024 1 45085 4508514 Adjusting Sleeve Stainless Steel AISI Type 410 1 33986 3398615 Diaphragm Spacer Aluminum ASTM B-211 2017/2024 1 33937 3393816 Diaphragm Guide Stainless Steel AISI Type 302 1 33933 3393317 Tope Spring Seat Cast Aluminum ASTM B-26 Alloy B443.0 1 33944 33944

� 18 Yielding Spring Steel, Nickel Plated Commercial 1 12471 1247119 Stem Nut Aluminum ASTM B-211 2017/2024 1 31839 3183920 Bottom Spring Seat Stainless Steel AISI Type 410 1 11683 1168321 Thrust Bearing Stainless Steel & Brass AISI Type 320 & ASTM B16 1 11684 1168422 Adjusting Nut Cast Bronze ASTM B-61 1 12395 1239523 Lock Nut Brass ASTM B-16 1 12833 1283324 Washer Stainless Steel AISI Type 410 1 30673 3067325 Base Die Cast Aluminum ASTM B-85 Alloy A360 1 43320 4332026 Nut For Frame Steel, Cadmium Plated Commercial 1 13744 13744

� 29 Diaph. Nozz. Disc, Compl. (Note 1) Stainless Steel AISI Type 302 1 15086 1508630 Diaph. Plate Die Cast Aluminum ASTM B-85 Alloy A360.0 1 38030 3803034 Screw Aluminum ASTM B-211 2017/2024 4 33678 33678

� 35 O-Ring Synthetic Rubber Neoprene 2 42213-94 42213-9436 Screw Aluminum ASTM B-211 2017/2024 4 33959 3395937 Flange Ring Die Cast Aluminum ASTM B-85 Alloy A360.0 1 47910 4791038 Body Die Cast Aluminum ASTM B-85 Alloy A360.0 1 40445 40445

� 40 Gasket Synthetic Rubber Neoprene 1 47916-95 47916-9547 Bottom Plug Aluminum ASTM B-211 2017/2024 1 33992 3399249 Cover Die Cast Aluminum ASTM B-85 Alloy A360.0 1 40447 4044750 Cover Screw Steel, Cadmium Plated Commercial 1 33960 33960

� 51 Gage Steel Case, Clearlok Crystal Commercial 2 52354 5235454 Connector Piece Cold Roll;ed Steel AISI 1117 2 41637 4163763 Allen Set Screw Steel, Cadmium Plated Commercial 1 12390 12390

� 64 Adjusting Pin Aluminum ASTM B-211 2017/2024 1 38032 3803265 Nut Steel, Cadmium Plated ASTM A-194 Gr. 2H 1 38060 38060

� 66 Blade Spring Stainless Steel AISI Type 301-2B 1 38036 3803667 Screw Stainless Steel Commercial 2 38123 3812368 Bearing Stainless Steel AISI Type 302 1 38034 3803469 Adjusting Screw Stainless Steel AISI Type 302 1 38033 3803370 Proportioning Slider, Rt. Hand Stainless Steel AISI Type 302 1 38028 3802871 Drive Screw Steel, Cadmium Plated ASTM A-228 1 58376 5837672 Indicator Stainless Steel AISI Type 302 1 38027 3802773 Washer Stainless Steel AISI Type 302 1 11685 1168574 Cap Screw Aluminum Commercial 2 33679 3367975 Proportioning Slider, Left Hand Stainless Steel AISI Type 302 1 38029 3802976 Knob Plastic Commercial 1 38126 38126

� 77 Nozzle Stainless Steel AISI Type 316 1 47909 4790978 Orifice Plug Aluminum ASTM B-211 2017/2024 1 33990 33990

� 79 Nozzle Valve Stainless Steel AISI Type 302/304 1 47903 4790380 Spring Stainless Steel AISI Type 302 1 23922 23822

� 88 Cover Screw Washer Rubber Commercial 2 57685 57685� 89 Diaphragm Spring Inconel Commercial 1 10980 - -

90 Diaphragm Spring Seat Aluminum ASTM B-211 2017/2024 1 58128 - -Adjusting Rod Cold Rolled Steel Commercial 1 11808 11808

� RECOMMENDED SPARE PARTS.� THESE PARTS SHOULD BE ON HAD, PLUS RECOMMENDED SPARE PARTS, WHEN OVERHAULING THIS EQUIPMENT.

NOTE 1 - CONSISTS OF NOZZLE DISC, RETAINING RING AND DIAPHRAGMNOTE 2 - CONSISTS OF STEM AND STEM HEAD

FOR ALL TYPES NOT LISTED, PLEASE ORDER PATS BY NAME AND INCLUDE RANGE, TYPE AND SERIAL NUMBER

PILOT CONTROLLERS, AIR ACTUATED, TYPES PRAP-1, RANGE 5-70 & 50-800WITH ADJUSTABLE PROPORTIONAL BAND

TYPE UDDV, DIFFERENTIAL PILOT CONTROL(BI-DIRECTIONAL - DIFFERENTIAL)

HIGH PRESSURE AT CONN. “A” ADJ. DIFF. 0 - 100 P.S.I.HIGH PRESSURE AT CONN. “B” ADJ. DIFF. 0 - 35 P.S.I.

MAXIMUM STATIC PRESSURE ON EITHER CONN. “A” OR “B” 600 P.S.I.RATIO 1:1

APPROX. NET WT. 25 lb. (11.3 kg)

TYPE UDDV CONTROL PILOTWHEN ORDERING PARTS, PLEASE GIVE PART NAME AND PART REFERENCE NUMBER FROM TABLE BELOW


PART MATERIAL QTY. PER REF.NO. PART NAME MATERIAL SPEC UNIT NO.1 Diaphragm Cover Cast Aluminum ASTM B-26 Alloy 319.0 1 490582 Connector Bolt Stainless Steel AISI Type 416 1 490303 Lock Nut Steel, Cadmium Plated Commercial 1 403484 Bolt Steel, Cadmium Plated Commercial 6 490875 Nut Steel, Cadmium Plated ASTM A-194 GR. 2H 8 428426 Diaphragm Disc, Upper Aluminum ASTM B211, 2011/2024 1 490297 � Diaphragm Synthetic Rubber Fairprene 2 1325710 Vent Chamber Cast Aluminum ASTM B-26 Allow 139.0 1 4902811 Diaphragm Disc Aluminum ASTM B211 2017/2024 1 4900213 Diaphragm Seal Spacer Aluminum ASTM B211 2017/2024 1 4118714 Diaphragm Base Cast Aluminum ASTM B-26 Alloy 319.0 1 4118415 � Diaphragm, Small Synthetic Rubber Fairprene 1 1944616 Diaphragm Washer, Complete Aluminum Commercial 1 3308917 Diaphragm Ring Aluminum ASTM B211 2017/2024 1 4118818 Set Screw Steel, Cadmium Plated Commercial 1 4119719 Connector Bolt Nut Aluminum ASTM B211 2017/2024 1 3183620 Screw Stainless Steel Commercial 6 3063821 Spring Seat Stainless Steel AISI Type 301/302 2 1168322 Yielding Spring Steel, Nickel Plated Commercial 1 1247123 Stem Nut Aluminum ASTM B211 2017/2024 1 3183924 Stem, Complete (Note 4) Aluminum ASTM B211 2017/2024 1 4713525 Adjusting Spring Steel, Cadmium Plated Commercial 1 1247426 Adjusting Sleeve Stainless Steel AISI Type 416 1 4725927 Yoke Cast Aluminum ASTM B26 Alloy B443.0 1 3400628 Thrust Bearing Stainless Steel & Brass AISI 316 & B-16 1 1168429 Adjusting Nut Cast Bronze ASTM B-61 1 1239530 Lock Nut Brass ASTM B-16 1 1283331 Washer Stainless Steel AISI Type 302 2 3067332 Base Die Cast Aluminum ASTM B-85 Alloy A360.0 1 4332033 Nut Steel, Cadium Plated Commercial 1 1374436 � Adjusting Pin Brass ASTM B-16 1 1240137 � Diaphragm Nozzle Disc, Compl. (Note 1) Stainless Steel AISI Type 303 1 1508638 Diaphragm Plate Die Cast Aluminum ASTM B-85 Alloy A360.0 1 3803039 Cap Screw Aluminum Commercial 2 3367942 Screw Aluminum Commercial 4 3367843 � O-Ring Synthetic Rubber Commercial 2 4221344 Screw Steel, Cadium Plated Commercial 4 3395945 Flange Ring, Complete (Note 2) Die Cast Aluminum ASTM B-85 Alloy A360.0 1 3367246 Body Die Cast Aluminum ASTM B-85 Alloy A360.0 1 4044550 � Nozzle Aluminum Commercial 1 3834753 � Pilot Valve Spring Stainless Steel Commercial 1 3366655 Bottom Plug Aluminum Commercial 1 3366763 Cover Die Cast Aluminum ASTM B-85 Alloy A360.0 4 4044764 Cover Screw Steel, Plated Commercial 1 3396065 � Pressure Gage Steel Case, Clearlok Crystal Commercial 2 5235467 Diaphragm Disc, Lower Aluminum ASTM B211 2017/2024 1 4900368 Connector Piece Cold Rolled Steel Commercial 2 4163769 Spring Cap, Complete Stainless Steel AISI Type 302 1 4642770 � Gasket Aluminum Annealed Commercial 1 4642071 Upper Spring Steel AISI 1095 1 4638772 � O-Ring Synthetic Rubber Commercial 1 2365673 Screw Stainless Steel AISI Type 302/304 1 4806374 Lock Nut Stainless Steel Commercial 1 4713886 � Extension Pin Stainless Steel Commercial 1 4709787 Pilot Valve Seat Celcon Commercial 1 1235388 Nozzle Stop Aluminum ASTM 211 2017/2024 1 3367389 � Pilot Valve, Complete Stainless Steel AISI Type 302/304 1 3367590 Diaphragm Nut Stainless Steel Commercial 1 3331691 Diaphragm Washer Stainless Steel AISI Type 302/304 1 3367692 � Diaphragm Synthetic Rubber Neoprene 1 1236893 Blade Spring (Note 3) Stainless Steel AISI Type 302 1 33677103 Bolt Steel, Cadium Plated Commercial 2 49422104 � Cover Screw Washer Rubber Commercial 2 57685

Adjusting Rod Cold Rolled Steel Commercial 1 11808

NOTE 1: Requires four (4) R/N 45840 and two (2) R/N 59478.NOTE 2: Furnished with Heater Coil but may be ordered separately.NOTE 3: Includes seal plate (#21), screws (#17) and lock washers (#18)NOTE 4: Consists of Stem and Stem Head.

FOR ALL TYPES NOT LISTED. PLEASE ORDER PARTS BY NAME AND INCLUDE RANGE. TYPE AND SERIAL NUMBER.� Recommended spare parts.� These parts should be on hand, plus recommended spare parts, when overhauling equipment.

REF PRESSUREPIPE CONNECTION1/4” PIPE THREAD

REF PRESSUREPIPE CONNECTION3/8” PIPE THREAD

1/4” LESLIE SELF-CLEANING STRAINER

1/4” APPLICABLE LESLIEPRESSURE REDUCING VALVE

MAXIMUM STATIC PRESSURE 300 PSIG.

RATIOSSPECIFY WHEN ORDERING

1.1:11.2:11.3:11.4:11.5:11.6:1

2:13:1

SUPERSEDES DRAWING NO. CP-14620 F, ALT. 3

RPIP1/4

REPIPE3/8”

1/4” LESLIE SELF-CLEANING STRAINER

1/4” APPLICABLE LESLIEPRESSURE REDUCING VAVAV LVLVL E

PILOT CONTROLLER — TYPE DDD, 15-75 RANGE

PILOT CONTROLLER — TYPE DDD, 15-75 RANGEWHEN ORDERING PARTS, PLEASE GIVE RANGE, TYPE, PART NAME AND PART REFERENCE NUMBER FROM

BELOW. USE PART NUMBER ONLY TO LOCATE PART ON DRAWING

123456789

10111111111111131415161718192021222324252627282930313233343637383940

42434445464748495051525355

575859606162636465666768748688

PART QTY PERNO. PART NAME MATERIAL UNIT REF. NO.

Diaphragm CoverConnector BoltLock NutBoltNutDiaphragm Disc, UpperDiaphragmDiaphragm SpacerSignal ChamberVent ChamberDiaphragm Disc, Ratio 2:1 & 3:1Diaphragm Disc, Ratio 1.1:1Diaphragm Disc, Ratio 1.2:1 & 1.4:1Diaphragm Disc, Ratio 1.3:1Diaphragm Disc, Ratio 1.5:1Diaphragm Disc, Ratio 1.6:1Diaphragm, Seal SpacerDiaphragm BaseDiaphragm, SmallDiaphragm Washer, CompleteDiaphragm RingSet ScrewConnector Bolt NutScrewSpring SeatYielding SpringStem NutStemAdjusting SpringAdjusting SleeveYokeThrust BearingAdjusting NutLock NutWasherBaseNut, FrameScrewAdjusting PinDia. Nozzle Disc, Compl. (NOTE 1)Diaphragm PlateCap ScrewNozzle Stop

ScrewO-ringScrewFlange Ring, CompleteBodyDiaphragm NutDiaphragmDiaphragm WasherNozzlePilot Valve SeatPilot Valve, CompletePilot Valve SpringBottom Plug

KnobNeedle Valve StemO-ringNeedle Valve BonnetO-ringO-ringCoverCover ScrewPressure Gage, Control ValvePressure Gage, Operating SupplyDiaphragm Disc, LowerConnector PieceLock NutExtension PinCover Screw WasherAdjusting Rod

Cast AluminumStainless SteelSteel, Cadmium PlatedSteel, Cadmium PlatedSteel, Cadmium PlatedAluminumSynthetic RubberCast AluminumCast AluminumCast AluminumAluminumAluminumAluminumAluminumAluminumAluminumCast AluminumCast AluminumSynthetic RubberAluminumAluminumSteel, Cadmium PlatedAluminumStainless SteelStainless SteelSteel, Nickel PlatedAluminumAluminumSteel, Cadmium PlatedStainless SteelCast AluminumStainless Steel & BrassCast BronzeBrassStainless SteelAluminumSteel,Cadmium PlatedStainless SteelBrassStainless SteelAluminumAluminumAluminum

AluminumSynthetic RubberSteel, Cadmium PlatedAluminumAluminumStainless SteelSynthetic RubberStainless SteelAluminumCelconStainless SteelStainless SteelAluminum

PhenolicStainless SteelSynthetic RubberStainless SteelSynthetic RubberSynthetic RubberAluminumSteel, Cadmium PlatedPlasticPlasticAluminumCold Rolled SteelStainless SteelStainless SteelRed RubberSteel, Plated

1118813111111111111111162111111111211111121

4241111111111

1111121111121121

411814118540348411944284246405132574118641182

(NOTE 2)411904943846439464404644141189411874118419446330894118841197318363063811683124713183947135124744725934006116841239512833306734332013744480631240115086380303367933673

33678422133395933672404453331612368336763834712353336753366633667

38126430722386943070284212365640447339601239319815

(NOTE 3)4163747138470975768511808

NOTE 1 - Consists of Nozzle Disc, Retaining Ring and Diaphragm.NOTE 2 - Ref. No. 41183 for Ratios 1.3:1, 1.4:1. 1.5:1, 1.6:1. and 2:1. Ref. No. 46396 for Ratios 1.2:1 & 1.1:1 and Ref. No. 55835 for Ratio 3:1.NOTE 3 - Ref. No. 49002 for 3:1 Ratio and Ref. No. 41189 for all other Ratios.

FOR ALL TYPES NOT LISTED, PLEASE ORDER PARTS BY NAME AND INCLUDE RANGE, TYPE AND SERIAL NUMBER

NOTES:

PRINTED IN USA20/1.5.2Rev.3/0012

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LESLIE PILOT CONTROLLERS - Leslie Controls PILOT CONTROLLERS TABLE OF CONTENTS ... Volume booster...

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