Flowserve 4000 User Manual

Automax Valve Automation Systems

3-Position Control/Dribble Control

Installation, Operation and Maintenance Instructions

Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr. Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501 www.flowserve.com Phone: 801 489 8611 Phone: 931 432 4021

SR Limit Switch Method

Apex 4000 Positioner

Principles of Operation:

The Apex 4000 positioner causes rotation (or linear movement) of valve actuator in proportion to an input signal. This signal may take the form of pneumatic pressure (Model 4000) or electric current (Models 4100, 4200, 4300 and 4400). Supply pressure is directed to the actuator through a precision spool valve. As input pressure is varied, the balance beam shifts away from its neutral position. The spool also shifts and a differential pressure is created across the actuator causing rotation (or linear movement). Actuator motion is fed back through the positioner shaft and cam. Cam rotation causes movement of the feedback arm, changing compression in the feedback spring, forcing the balance beam and spool back to their neutral positions. This shuts off the flow of air to the actuator and rotation stops.

Installation:

The Apex 4000 positioner can be installed on rotary and linear actuators. Actuators can be either double acting or spring return. Positioners can be set up for rotation in either direction (direct or reverse acting).

Supply Air Requirements: Air pressure must be limited to 150 psi for supply and 30 psi for instrument signal to avoid damage to the positioner. Supply air must be clean, dry, and oil free instrument quality air in accordance with ISA S7.3 specifications (dew point >18 degrees below ambient temperature, particle size <5 microns, oil content <1ppm).

Before making pneumatic connections to the positioner, it is recommended that the supply air lines are opened up and allowed to vent for 2-3 minutes to clear any debris from the line. If excessive amounts of oil and/or moisture are present, the plant air supply should be evaluated to reduce possibility of premature positioner failure.

Mounting: The following instructions apply to rotary actuators only. Linear applications require special mounting and coupling (consult factory).

1. Mount bracket to actuator. Tighten bolts finger tight only at this time. A standard bracket is available for mounting to NAMUR compliant actuators.

2. Install coupler (not required if installing to a NAMUR compliant actuator) on actuator shaft making sure it is centered.

3. Verify that orientation of actuator (and coupler) flats match positioner shaft flats. If necessary, rotate the cam before installing positioner (see “Cam Installation”).

Note:

Actuator should be in orientation corresponding

to zero input signal.

4. Install positioner onto bracket. Make sure positioner shaft and coupler are engaged and centered. Tighten bolts finger tight only at this time. Pneumatic Connections: All pneumatic connections, the supply, both output ports, and the instrument ports are female 1/4" NPT. All connections require user-supplied tubing fittings. Caution:

Do not use Teflon tape as a pipe thread sealant. Use only a liquid or paste non-hardening pipe sealant on the threads.

5. Connect positioner ports C1 and C2 to actuator. Port C2 is always connected to the actuator port used to drive actuator away from its start or fail position (the factory cam setting is full clockwise at minimum input). Port C1 is connected to the opposite port or may be plugged for spring return actuators. Note:

For fail counterclockwise applications, the cam must be flipped over so the “R” side is facing upwards (see “Cam Installation”).

6. Connect supply air to the port marked “S”.

7. Connect instrument signal air to the port marked “I” for model 4000. For models 4100, 4200, 4300 or 4400, connect 4-20 mA and ground (-). For intrinsically-safe applications (Model 4400 only), see separate intrinsicallysafe I-P IOM for barrier requirements and schematics. The I-P is factory calibrated and cannot be adjusted.

AXAIMO36-00 (AUTO-112) 07/03

8. Stroke actuator/valve two or three times to align positioner, coupler and actuator. With 50% input (actuator/valve at 45 degrees), tighten all mounting bolts. Stroke actuator/valve again to verify there is no misalignment throughout stroke.

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Automax Valve Automation Systems

3-Position Control/Dribble Control

Installation, Operation and Maintenance Instructions

SR Limit Switch Method

Calibration:

The unit is shipped from the factory pre-calibrated for 90 degree travel (±0.5 degrees rotation - can also be 30/45/ 60 degrees, see installed cam). For most applications, the valve closed position is much more critical than the valve open position. Most attention should be made to the valve closed position. Always start calibration procedure by applying 0% input signal, then adjusting zero position. The positioner is calibrated by turning thumbwheels (1) and (4). Arrows on arm (5) indicate turning direction of thumbwheels.

"+" = increase zero/span

▲ ▼

"-" = decrease zero/span

Caution:

Cam pinch points may injure fingers. Be sure to avoid placing fingers and other objects in cam pinch points. Also avoid touching balance beam and spool while making adjustments as unpredictable cam rotation may result. Finally, maintain control of input signal while making adjustments.

Calibration Procedure:

1. Apply O% input signal (0% = 20 kPa, 3 psi, or 4 mA).

2. Wait for steady state. It is important to wait for steady state. On very large actuators, it can take minutes to establish.

3. Adjust zero by turning the silver (lower) thumbwheel (4) with finger or with screwdriver (7) from the outside.

4. Apply 100% input signal (100% = 100 kPa, 15 psi, or 20 mA).

5. Wait for steady state; remember result.

6. Apply 0% input signal.

7. Adjust span per result in step (5) above. This is accomplished by first loosening screw (2), then turning the yellow (upper) thumbwheel (1) in appropriate direction with finger. Tighten screw 2. Spring top must not be in contact with spring guide (3).

8. Check and adjust zero.

9. Repeat steps 2 through 8 until desired calibration is achieved.

Span Adjustment

AXAIMO36-00 (AUTO-112) 7/03

SPAN

Zero Adjustment

ZERO

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Automax Valve Automation Systems

3-Position Control/Dribble Control

Installation, Operation and Maintenance Instructions

SR Limit Switch Method

Cam Installation:

Introduction: The standard cam (labeled "K1") features

linear, 90 degree operation for full 3-15 psi input, 3-9 and 9-15 psi split ranges, and 3-15 psi 180 degree operation. The factory setting is 3-15 psi, 90 degrees, with “D” (direct) side up for full clockwise position at 3 psi for 90° operation.

Caution:

pressure exists in actuator before adjusting cam.

Cam Adjustment:

1. Remove cover and indicator.

2. Loosen the camlock screw (1) and turn the cam

3. Adjust the cam (3) as desired, making sure that the

4. Secure the cam by finger tightening the cam locking

Be sure supply air pressure is removed and no

locking nut (2) counterclockwise until the cam is loose. It may be necessary to brace the output shaft while loosening the cam locking nut.

cam follower (4) always rides on an active lobe on the cam.

nut (2), and then tighten the camlock screw (1) (see below).

Correct

Incorrect

Figure below shows cam setting for reverse action, decreasing signal 100-0% (100-20 kPa, 15-3 psi) to open. Flip cam over, cam follower to ride on lobe R, 0-100%.

Split Range lobe is used to achieve high resolution in split range applications, where only a portion of the signal is used to obtain 90 degrees valve travel. For example, to operate 0 to 90 degrees rotation with 0-50% input signal (20-60 kPa, 3-9 psi), adjust cam follower to ride on Split Range 0-50% lobe D. Note:

cam over and use lobe R.

To obtain reverse action, flip

Figure below shows cam setting for Direct Action increasing signal 0-100% (20-100 kPa, 3-15 psi) to open. Cam follower to ride on lobe D, 0-100%.

ZERO

SPAN

AXAIMO36-00 (AUTO-112) 07/03

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