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.

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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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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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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