Flowserve A9000 User Manual

ACCORD CONTROLS

Installation

Operation

Maintenance

APEX A9000 Digital Positioner

FCD ACENIM0132-01

1.1 Using

The following instructions are designed to assist in unpacking, installing and performing maintenance as required on FLOWSERVE products. Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating or performing any maintenance. In most cases FLOWSERVE valves, actuators and accessories are designed for specific applications (e.g. with regard to medium, pressure, temperature). For this reason they should not be used in other applications without first contacting the manufacturer.

1.2 Terms concerning safety

The safety terms DANGER, WARNING, CAUTION and NOTE are used in these instructions to highlight particular dangers and/ or to provide additional information on aspects that may not be readily apparent.

DANGER: indicates that death, severe personal injury and/or substantial property damage will occur if proper precautions are not taken.

WARNING: indicates that death, severe personal injury and/or substantial property damage can occur if proper precautions are not taken.

CAUTION: indicates that minor personal injury and/or property damage can occur if proper precautions are not taken.

NOTE: indicates and provides additional technical information, which may not be very obvious even to

qualified personnel.

Compliance with other, not particularly emphasised notes, with regard to trans- port, assembly, operation and maintenance and with regard to technical documentation (e.g. in the operating instruction, product documentation or on the product itself) is essential, in order to avoid faults, which in themselves might directly or indirectly cause severe personal injury or property damage.

1.3 Protective clothing

FLOWSERVE products are often used in problematic applications (e.g. extremely high pressures, dangerous, toxic or corrosive mediums). In particular valves with bellows seals point to such applications. When performing service, inspection or repair operations always ensure, that the valve and actuator are depressurised and that the valve has been cleaned and is free from harmful substances. In such cases pay particular attention to personal protection (protective clothing, gloves, glasses etc.).

1.4 Qualified personnel

Qualified personnel are people who, on account of their training, experience and instruction and their knowledge of relevant standards, specifications, accident prevention regulations and operating conditions, have been authorised by those responsible for the safety of the plant to perform the necessary work and who can recognise and avoid possible dangers.

1.5 Installation

DANGER: Before installation check the order-no, serial-no. and/ or the tag-no. to ensure that the valve/actuator

is correct for the intended application. Do not insulate extensions that are provided for hot or cold services.

Pipelines must be correctly aligned to ensure that the valve is not fitted under tension. Fire protection must be provided by the user.

1.6 Spare parts

Use only FLOWSERVE original spare parts. FLOWSERVE cannot accept responsibility for any damages that occur from using spare parts or fastening materials from other manufactures. If FLOWSERVE products (especially sealing materials) have been on store for longer periods check these for corrosion or deterioration before using these products. Fire protection for FLOWSERVE products must be provided by the end user.

1.7 Service / repair

To avoid possible injury to personnel or damage to products, safety terms must be strictly adhered to. Modifying this product, substituting non-factory parts, or using maintenance procedures other than outlined in this instruction could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties. Between actuator and valve there are moving parts. To avoid injury FLOWSERVE provides pinch-pointprotection in the form of cover plates, especially where side-mounted positioners are fitted. If these plates are removed for inspection, service or repair special attention is required. After completing work the cover plates must be refitted.

Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use, all recognised regulations for safety and good engineering practices must be followed.

WARNING:

Before products are returned to FLOWSERVE for repair or service FLOWSERVE must be provided with a certificate which confirms that the product has been decontaminated and is clean. FLOWSERVE will not accept deliveries if a certificate has not been provided (a form can be obtained from FLOWSERVE).

1.8 Storage

In most cases FLOWSERVE products are manufactured from stainless steel. Products not manufactured from stainless steel are provided with an epoxy resin coating. This means that FLOWSERVE products ar e well protected from corrosion. Nevertheless FLOWSERVE products must be stored adequately in a clean, dry environment. Plastic caps are fitted to protect the flange faces to prevent the ingress of fo- reign materials. If the positioner must be stored outdoors, it is important that all the cover screws are tightened and that all connections and ports are properly sea- led. Replace shipping plugs with proper plugs and do not leave ports open and facing upwards.

1.9 Valve and actuator variations

These instructions cannot claim to cover all details of all possible product variations, nor in particular can they prov- ide information for every possible example of installation, operation or maintenance. This means that the instructions normally include onl y the directions to be followed by qualified personal where the product is being used for is defined purpose. If there are any uncertainties in this respect particularly in the event of missing product-related information, clarification must be obtained via the appropriate FLOWSERVE sales office.

2. Unpacking

Each delivery includes a packing slip. When unpacking, check all delivered valves and accessories using this packing slip. Report transport damage to the carrier immediately. In case of discrepancies, contact your nearest FLOWSERVE location.

3. Certificates

Please note that a full copy of certificates and approvals for Intrinsically safe and Explosion proof applications can be downloaded in pdf format from our web page:

http://www.flowserve.com

APEX A9000 Overview

The Apex A9000 is a two-wire loop powered, 4-20 mA input digital valve positioner. The Apex A9000 positioner controls actuators with rotary mountings. The Apex A9000 is completely powered by the 4-20 mA input signal. The minimum input signal required to function is

3,6 mA. As an option the D20 can be equipped with HART protocol to allow bidirectional communication.

Since the positioner is insensitive to supply pressure changes and can handle supply pressures from 1,5 to 6 barg (22 to 105 psig), a supply regulator is usually not required; however, in applications where the supply pressure is higher than the maximum actuator pressure rating a supply regulator is required to lower the pressure to the actuator’s maximum ra- ting (not to be confused with operating range). A coalescing air filter is recommended for all applications due to the close tolerances in the positioner.

Apex A9000 positioner accessories: Optional analog feedback system as well as limit switch unit and a directly attachable double acting module.

NOTE: The air supply must conform to ISA 7.0.01 or IEC 770 (a dew point at least 10°C/18°F below ambient temperature, particle size below five microns – one micron recommended – and oil content not to exceed one part per million).

5. Specifications

5.1 Technical data

Input signal 4-20 mA Current supply min. 3,6 mA Current supply Max. 150 mA Load Standard 400 ohm at 20mA Load HART 470 ohm at 20mA Voltage dropStandard 8 VDC at 20mA Voltage drop HART 9.4 VDC at 20mA Angle of rotation min 0-40° Angle of rotation Max 0-90° Air supply range 1.5 – 6 bar Out put 0-100% of air supply pressure Air supply quality Free from oil, dust and moisture IEC 770,

ISA 7.0.01 Air supply effect <0.1%FS for10% pressure change at 6 Bar Ingress protection IP66 / Nema 4X Operating humidity 0-100% rh non-condensing Air connections 1/4” NPT Cable entry 2 x 1/2” NPT or 2 x M20x 1,5 Terminals Screw terminals 2,5 mm2 (AWG 14) Operating Temperature -20 to +85°C-40 to +85°C (optional) Storage temperature -40 to +85°C Air delivery capacity 7 Nm3/h @ 6 bar (3 bar diff pressure) Air delivery capacity Double acting 7 Nm3/h @ 6 bar (3 bar diff pressure) Air consumption Single acting 0,120 Nm3/h @ 6 bar Air consumption Double acting 0,120 Nm3/h @ 6 bar Cv air delivery Single acting 0,12 Cv air delivery Double acting 0,12 Cut off function Close 0.5% Open 99.5% Linearity <1% Sensitivity <0.05% Resolution <0,1% Repeatability <0.2% Hysteresis + dead band <0.5% Temp effect <0.1%/10K Mounting position effect <0,2% CE 93/68/EEC, 2004/108/EEC, 2006/95/EEC Approvals Ex II G Ex ia IIC T4 Ta: 85°C Class I Division 2 Groups A,B,C,D T4 non-incendive with fieldwiring Class I Division 2 IIC T4 non-incendive with fieldwiring I.S. Class I Division 1 Groups A,B,C,D T4 I.S. Aex ia IIC T4 Certificate nr Nemko 08ATEX1362X Housing material Die cast Aluminium Surface treatment Powder coating Soft goods Nitrile Weight 1,5 kg (3.0 kg Explosion proof version)

5.2 Limit switches

Type SPDT Size Sub Sub miniature Rating 3A, 125 VAC / 2A, 30VDC Mechanical life >1 x 106 operations

Namur sensors

Type P+F NJ2 V3 N Inductive DIN 19234 Load current <1mA>3mA Voltage range 5-25 VDC Hysteresis 3-15% (5% typical) Temp range -25° to +100° C (-248° to 373° F)

Namur sensors

Type P+F SJ2-N Normal Voltage 8 VDC Load current 1mA<I<3mA Voltage range (5-25 VDC) Hysteresis (max) 0.2% Temp range -25° to +100° C (-248° to 373° F)

Namur sensors

Type P+F SJ2-SN Normal Voltage 8 VDC Load current 1mA<I<3mA Voltage range 5-25 VDC Hysteresis (max) (0.2%) Temp range -40° to +100° C (-233° to 373° F)

Namur sensors

Type P+F SJ2-S1N Normal Voltage 8 VDC Load current 1mA<I<3mA Voltage range 5-25 VDC Hysteresis (max) 0.2% Temp range -25° to +100° C (-248° to 373° F)

Proximity switches

Type SPDT Rating 10W Voltage max 200VDC Current max 500mA Contact resistance max 0.2 ohm Operating time 1.0 ms

Transmitter

Power supply 12-28 VDC Output 1-22 mA Resolution 0.1% Linearity ±0.5% Load impedance 600 ohm at (12 VDC and 20mA)

Alarm Output

Supply 3-28 VDC Output 20mA @ 24 VDC

5.3 Type sign

5.4 APEX A9000 Model Code

□ BRAND

AC – ACCORD Black Polyester Paint

□ MODEL

90 – Digital Positioner, Single Button Interface, LED Status 92 – Digital Positioner, Full LCD Menu, LED Status

□ APPROVAL, CERTIFICATIONS

G – General Purpose I – Intrinsically Safe, ATEX/FM N – Class I Division 2, Non-incendive, with Fieldwiring E – Explosionproof, ATEX/FM

□ CONNECTIONS, AIR/ELECTRICAL M – ¼” NPT Air, M20 x 1.5 Electrical N – ¼” NPT Air, ½” NPT Electrical

□ HOUSING / SURFACE TREATMENT U – Aluminum, Powder Epoxy, Black R – Remote Mount Feedback Sensor S – Explosionproof, Stainless Steel Enclosure ( N Connections Only

□ FUNCTION

S – Single Acting D – Double Acting, (Note Available on Explosionproof Enclosures) See Note 1

□ SHAFT

23 – NAMUR, VDI/VDE 3845, Rotary

□ COVER

1 – Flat Top, All Options ( See Note 2) ** Only option for Explosionproof 2 – Dome Indicator, Red/Green, (General Purpose/IS Only) See Note 2 3 – Flat Top, Green/Black Flat Indicator, (General Purpose/IS Only) See Note 2

□ TEMPERATURE / SEALS Z – Standard Temperature -20°C to 85°C ( -4°F to 185°F ) Q – Low Temperature -40°C to 85°C (-40°F to 185°F )

□ INPUT SIGNAL / PROTOCOL

N – 4-20mA / None

H – 4-20mA / HART

□ FEEDBACK OPTIONS

X – No Feedback Options

T – 4-20mA Feedback Transmitter Only S – Switches, Mechanical, SPDT + 4-20mA Transmitter, (See Note 3) N – NAMUR, V3 Type Sensor, P&F NJ2-V3-N + 4-20mA Transmitter, (See Note 3) N – Limit Switches, Proximity, SPDT + 4-20mA Transmitter, (See Note 3)

□ OPTIONS / ADDITIONAL ELECTRONICS

0 – Standard Diagnostics

1 – Advanced Diagnostics, ( Available in Model 92 Only )

□ ACCESSORIES

X – No Accessories

M – Gauge Block, 1/8” G, ( 2 Gauges Included) See Note 4 N – Gauge Block, 1/8” NPT, (2 Gauges Included) See Note 4

NOTES:

1) If you order double acting, you do not need to order a gauge block. Comes with 2 gauges, Stainless Steel with Brass internals.

2) Cover options are valid only for General Purpose, Intrinsically Safe, and Class I Division 2, Nonincendive, ( G, I, and N Approvals options ).

3) Switches are not available in explosionproof enclosure.

4) Gauge blocks are only needed for the General Purpose, Intrinsically Safe, and Class I Division 2, Non-incendive options ( Approvals G, I and N).

Figure 1

6. Principle of operation

The APEX A9000 positioner is a digital positioner with various options. The positioner consists of three main modules:

1. The microprocessor-based electronic control module includes direct local user interface switches

2. The piezo valve-based electro- pneumatic converter module

3. The infinite resolution valve position sensor.

The basic positioner operation is best understood by referring to figure 1. The complete control circuit is powered by the two-wire, 4-20 mA command signal. The analog 4-20 mA command is passed to the microprocessor, where it is compared to the measured valve stem position. The control algorithm in the processor performs control calculations an d produces an output command to the piezo valve, which drives the pneumatic amplifier. The position of the pilot valve in the pneumatic amplifier is measured and relayed to the inner loop control circuit. This two-stage control provides for more responsive and tighter control than is possible with a single stage control algorithm. The pneumatic amplifier controls the airflow to the actuator. The change of pressure and volume of the air in the actuator causes the valve to stroke. As the valve approaches the desired position, the difference between the commanded position and the measured position becomes smaller and the output to the piezo is decreased. This, in turn, causes the pilot valve to close and the resulting flow to decrease, which slows the actuator movement as it approaches, the new commanded position. When the valve actuator is at the desired position. the pneumatic amplifier output is held at zero, which holds the valve in a constant position.

7. Mounting and installation

7.1 General

Before starting installation, inspect the digital positioner for any transit damages.

I/P cover APEX A9000

0,65 Nm

+/- 15%

APEX A9000

1,20 Nm

+/- 15%

F5EX and XCL / XML / XV

M6 / M8

7 Nm

After installation, ensure all screw connections are tightened correctly and all moving parts are free from excessive friction.

NOTE!

All products that are covered by an ATEX Certification number ending with an

“X”, special care must be taken when cleaning the surface of the product. “The enclosure must be cleaned with a damp cloth due to static electricity for plastic windows/surfaces” For securing covers and lids, it’s important to use the correct torque:

Product Size (screw) Torque Nm

Covers (thread on) for APEX A9000 EX, D3EX, Tighten fully and secure

Exhaust ports

Apex A9000 exhaust actuator through a hole in the backside, covered by a plate.

Apex A9000 Explosion proof has 2 x exhaust ports, located on the flat areas. Make sure that both these ports are not left open, facing up or side wards.

Protected by a proper bleeder cap or a fitting with short tube (≥ Ø 4 mm inner dia, max 80 mm long) facing downwards

Bleeder cap

7.2 Dimensional drawings

7.3 Mounting

NOTE. If the positioner is installed in a hazardous environment, it must be of a type approved for this purpose.

The Apex A9000 positioner, all versions, has an ISO F05 footprint, A. The holes are used to attach the Apex A9000 to the mounting bracket B. Please contact Flowserve or your local distributor representative with actuator specifics for the proper mounting bracket and hardware.

It is important that the positioner’s spindle, that transfer the actuator movements, are correctly mounted. Any tension between these parts can cause incorrect operation and abnormal wear.

Assembly Example:

Rotary actuators Mounting the Apex A9000 positioner on a quarter-turn actuator (closed or open by spring)

The mounting of a pneumatic double-piston part-turn valve actuator (in accordance with VDI/VDE 3845) is described as an example by using the following equipment:

Quarter-turn valve actuator: Rack & pinion or scotch yoke, closed or open by spring.

Rotary actutaors VDI/VDE 3485 (Namur)

Mount bracket 1 to positioner. Secure with 4 x M6 screws 2. Fit positioner on actuator and secure with 4 x screws 3.

Install tubing 4 between actuator and po-

sitioner.

2 3

Mounting the positioner

Place the positioner (1) onto the mounting block (2) of the actuator using four screws (3) Ensure the coupler fits

on to the shaft of the quarter-turn connection on the part-turn valve actuator.

(Figure 6)

8. Tubing positioner to actuator

After mounting has been completed, tube the positioner to the actuator using the appropriate compression fitting connectors:

Air connections: 1/4” NPT (standard air connection).

Auxiliary power: Pressurized air or permissible gases, free of moisture and dust in according with IEC 770 or ISA

7.0.01. Pressure range: 1,5 – 6 bar (30 – 90 psi). For connecting the air piping, the

following notes should be observed:

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