Flowserve 8000 User Manual
USER INSTRUCTIONS
Automax Valve Automation Systems
Apex 8000 High-Performance Positioner
AXENIM0130-06 11/10
Installation
Operation
Maintenance
Apex 8000 High-Performance Positioner AXENIM0130-06 11/10
Principles of Operation
This bulletin is designed to assist in installing, calibrating, troubleshooting and performing maintenance as required for the APEX 8000 Series
high-performance positioner.
Product users and maintenance personnel should thoroughly read and strictly follow the instructions contained in this bulletin
prior to operating the positioner. Any questions concerning this product should be directed to a Flowserve representative
To avoid possible injury to personnel or damage to valve parts, WARNING and CAUTION notes must be strictly followed.
Modifying this product, substituting non-factory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment.
The APEX 8000 high-performance positioner is a two-stage device and is designed for use in control loops where fast response
is required. The APEX 8000 positioner is designed to be modular and use the P/P module for 3-15 psi input signal or the NT
3000 Series Transducer Module for 4-20 mA input signal.
The APEX 8000 high-performance positioner is designed as a four-way device, but can easily be converted to a three-way device
by plugging one of the output ports.
NOTE: The APEX 8000 high-performance positioner must use the I/P NT 3000 Transducer. The I/P 2000 Transducer is not acceptable for use with the APEX 8000 Series Positioner.
The APEX 8000 positioner can handle supply pressures up to 150 psi; thus, a supply regulator is usually not required. However,
a five micron air filter is required for pneumatic positioners and a coalescing filter is required for I/P positioners.
NOTE: The air supply should conform to ISA Standard S7.3 (a dew point at least 18° F / -8° C below ambient temperature,
particle size below 5 microns, oil content not to exceed one part per million).
The APEX 8000 Series positioner features an adjustable gain of 400-1100:1. The medium gain setting is standard for smaller
actuators, while the high gain setting is used on larger actuators (refer to ‘Gain Adjustment Procedure’ section for further
details.)
Operation
The positioner schematic (Figure 1) shows an APEX 8000 Series positioner connected for double-acting service on a rotary
rack-and-pinion actuator. Tension on the feedback spring provides feedback to the positioner, which varies as the stem position
changes. The spring-loading force is applied through the feed-back linkage and cam to the positioner’s input capsule.
Instrument signal pressure is applied between the diaphragms in the input capsule. Therefore, the input capsule serves as a
force-balance member, matching the valve stem position (as measured by tension on the feedback spring) to the instrument
signal.
When the opposing forces balance exactly, the system will be in equilibrium and the stem will be in the exact position called for
by the instrument signal. If the opposing forces are not in balance, the input capsule will move up or down and, by means of
the pilot-valves, will change the output pressures, moving the stem until the tension on the feedback spring exactly opposes the
instrument signal pressure.
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Upper Pilot
Poppet
Exhaust Seat
Port No. 1
Restriction
Supply
Pilot Valve
Capsule
Exhaust Seat
Supply Seat
Balance Adjustment
Feedback Spring
Zero Adjustment
Apex 8000 High-Performance Positioner AXENIM0130-06 11/10
Range Adjustment
Screws
Piston Cylinder
Cam
Feedback
(Shaft)
Port No. 2
Lower Pilot
Poppet
Supply Seat
Flapper
Detecting
Nozzle
Input Capsule
Instrument Signal
Upper Diaphragm
Lower Diaphragm
Figure 1: Apex 8000 Positioner Schematic for Air-to-Open
The sequence of operation is as follows: An increase in instrument signal pressure forces the input capsule downward. Displacement of the
capsule in turn moves the flapper away from the detecting nozzle. This allows a larger flow rate through the nozzle, decreasing the pressure
exerted on the top of the pilot valve capsule.
Supply air biases the pilot-valve in an upward direction. As the capsule moves up, it will close the exhaust seat of the upper pilot poppet and
open the supply seat, which applies increased air pressure to the bottom cylinder port. At the same time, the pilot-valve capsule will open the
exhaust seat for the lower pilot poppet; thus, decreasing pressure to the top cylinder port.
This difference in pressure will drive the piston outward, rotate the pinion and stretch the feedback spring until the spring tension exactly
opposes the force resulting from the instrument signal pressure. At this point, the flapper will be moved toward the detecting nozzle to restore
the pressure above the pilot-valve capsule to its equilibrium value. As a force-balanced condition is approached, the pilot-valve capsule will be
forced back to a neutral position where the pilots are neither supplying air to, nor exhausting air from, their respective sides of the piston.
A decrease in instrument signal pressure reverses the described actions and cause a proportional inward movement of actuator
pistons and a reversal in pinion direction.
Figure 2: Positioner Mounting with NAMUR Shaft
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Apex 8000 High-Performance Positioner AXENIM0130-06 11/10
Installation of APEX 8000 Series Positioner on Actuators
The APEX 8000 can be installed on most sizes of rotary and linear actuators. Actuators can be either double acting or spring return. Cams can
be used for direct acting or reverse acting directions. These instructions apply to rotary actuators only. For linear actu ator mounting instructions, consult the factory.
NOTE: For retrofitting to an actuator equipped with an Apex positioner, the same bracket and bolting may be used.
NOTE: NAMUR mounting is available with the APEX 8000 positioner. When retrofitting the APEX 8000 positioner to an actuator equipped with
another positioner, remove the existing positioner, tubing and associated bolting. See tubing instructions in Connecting APEX 8000 Positioner
Ports section.
Mounting Instructions for APEX 8000 with NAMUR Shaft Connection
1. Mount the bracket to the actuator. Finger tighten the bracket bolting.
2. If required, install a coupler on the actuator shaft. Make sure the shaft and coupler are centered. See Figure 2.
3. Verify the orientation of the actuator and coupler flats match the positioner flats on the end of the shaft. Loosen the cam if necessary.
(See “Cam Installations” instruc tions.)
4. Install the positioner onto the bracket. Make sure positioner shaft and coupler are engaged and centered. Finger tighten positioner bolts.
5. WARNING: Once the positioner is mounted on the bracket, make certain that the vent on the bottom of the positioner is not covered by
the bracket. If it is, remove the positioner from bracket and drill a ½” hole in the bracket to allow venting of the positioner. Blocking the
vent can cause pressurization of the housing and cause positioner failure.
6. Proceed to “Connecting APEX 8000 Positioner Ports.”
Connecting APEX 8000 Positioner Ports:
1. For double acting actuators, connect positioner ports 1 and 2 to the actuator. Port 1 is always connected to the actuator port used to drive
the actuator away from its start or fail position (the factory cam setting is full clockwise at minimum input signal).
NOTE: For single acting, spring return actuators, plug output port
2. Connect supply air to the port marked “SUPPLY.”
3. Connect air (for pressure inputs) or instrument tubing or wiring (for 4-20 mA inputs). For current inputs, the terminal is marked (+) and
(-) inside the I/P module. The I/P is factory calibrated and should not require adjust ment. If adjustments are necessary, see “Calibrating
I/P Module Zero and Span Settings” section. Caution: Signal air pressure higher than 30 psi may damage the module gauge and
instrument signal capsule; a 3-15 psi instrument signal is recommended on the pneumatic module.
4. 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 the stroke.
5. Calibrate valve and adjust cam if necessary. (See “Cam Installation” and “Positioner Calibration” instructions.)
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Apex 8000 High-Performance Positioner AXENIM0130-06 11/10
Figure 6: Alignment for Cams
Cam Removal
Disconnect cam return spring. With a wrench carefully placed on the output shaft (if necessary), loosen and remove the jam nut. Remove
pressure from the span arm by pushing it away from the cam. Remove the cam.
Cam Installation
1. Make sure shaft is properly aligned with coupler or actua tor.
2. Push span arm away from shaft to avoid pressure on the cam.
3. Place cam over the shaft with the appropriate characteristic facing up and closest to the span arm roller. “D” represents direct-acting and
“R” represents reverse acting.
4. Make sure the round mark on the left hand side of the char acteristic curve is lined up with the span arm roller bearing. See Figure 3.
5. Tighten jam nut making sure cam does not rotate. Use a flat screwdriver to prevent cam rotation and shaft flats to pre vent shaft rotation
(if necessary).
6. Connect supply pressure to port marked ‘Supply ‘stroke actuator/valve two or three times to align position with actuator. With a 50
percent input signal, tighten all mounting bolts. Stroke actuator to verify proper alignment.
Position Calibration
Introduction
APEX 8000 positioners are calibrated at the factory; however, due to shipping and handling, it may be necessary to check the cali bration before
operating the valve. The APEX 8000 positioner can be calibrated to a range of 3-15; two-way split range, 3-9, or 9-15; and three-way split
ranging, 3-7, 7-11, 11-15 psi using the stan dard feedback spring.
WARNING: When stroking the actuator during calibration, keep hands, hair and clothing away from moving parts. Failure to do so may
cause serious personal injury.
Note: Positioners and I/Ps are calibrated at the factory. Use mechanical adjustments in positioner for calibration. Zero and span on the
I/P should not be used to calibrate the valve.
For calibration, refer to Figure 4 and proceed as follows:
1. For 3-15 or 3-9 psi range, loosen by hand the zero adjust ment locking knob and adjust the zero adjustment knob until the valve begins to
stroke with more than 3 psi signal (for 9-15 psi range adjust to 9 psi).
2. Loosen the span adjustment locking screw no more than 1/8 turn.
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