Flowserve StarPac 3 User Manual

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

USER INSTRUCTIONS

StarPac 3 Intelligent Control System

FCD VLENIM0066-05 04/14

Installation

Operation

Maintenance

Experience In Motion

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Table of Contents

1 General Information .................................................................................... 5

1.1 Using ............................................................................................... 5

1.2 Applicability ..................................................................................... 5

1.3 Terms Concerning Safety ................................................................ 5

1.4 Personal Protective Equipment........................................................ 5

1.5 Qualiﬁed Personnel ......................................................................... 6

1.6 Spare Parts ...................................................................................... 6

1.7 Service / Repair ............................................................................... 6

1.8 Storage ............................................................................................ 6

2 Unpacking .................................................................................................. 8

3 Installation .................................................................................................. 8

4 Quick-Check ............................................................................................... 9

5 Valve Maintenance ...................................................................................... 9

6 Valve Disassembly and Inspection .............................................................. 10

7 StarPac 3 Operation .................................................................................... 11

7.1 Overview ......................................................................................... 11

7.2 Speciﬁcations .................................................................................. 11

7.3 Positioner Operation ........................................................................ 13

8 Mounting and Installation ........................................................................... 14

8.1 Mounting to Flowserve Valtek Linear Mark One Valves ................... 14

8.2 Mounting to Standard Flowserve Valtek Rotary Valves.................... 14

8.3 Optional Flowserve Valtek Rotary Mounting Procedure ................... 17

8.4 Tubing Positioner to Actuator .......................................................... 18

9 Wiring and Grounding Guidelines ............................................................... 19

9.1 Shielding Versus Grounding ............................................................ 20

9.2 Grounding Screw............................................................................. 20

9.3 24 VDC Power ................................................................................. 20

9.4 RS-485 Communications ................................................................ 20

9.5

9.6 Discrete Inputs and Outputs ............................................................ 20

9.7 RS-232 to RS-485 Converter Connection ........................................ 20

10 Wiring the StarPac 3 System ...................................................................... 21

10.1 General ............................................................................................ 21

10.2 Wiring Connections ......................................................................... 21

10.3 Setting the Jumpers ........................................................................ 23

4-20 mA Command Input, Auxiliary Input and Feedback Output

............... 20

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11 RS-485 Communication Conﬁgurations ..................................................... 24

11.1 System Communication Default Conﬁguration ................................ 24

11.2 Selecting Correct Address Setting ................................................... 24

11.3 Selecting Correct Baud Rate Setting ................................................ 24

11.4 Selecting Correct Modbus Transmission Mode ............................... 25

11.5 Selecting Proper RS-485 Termination Resistor Setting ................... 25

11.6 Communication Port B .................................................................... 25

12 StarPac 3 Calibration .................................................................................. 26

13 StarPac 3 Conﬁguration .............................................................................. 26

14 System Maintenance .................................................................................. 26

14.1 Overview ......................................................................................... 26

14.2 Mechanical Subsystem Maintenance ............................................... 26

14.3 Position Feedback System ............................................................... 27

14.4 Pressure Sensor Replacement ........................................................ 27

14.5 Pressure Sensor Cable Replacement ............................................... 29

14.6 Thermocouple Replacement ............................................................ 30

14.7 Keypad Assembly Replacement ....................................................... 31

14.8 Driver Module Assembly Replacement ............................................ 31

14.9 Regulator Replacement ................................................................... 35

14.10 Checking or Setting Internal Regulator Pressure .............................. 35

14.11 Checking or Setting the Driver Module Minimum Pressure ............. 37

14.12 Spool Valve Cover Replacement ....................................................... 39

14.13 Spool Valve Replacement ................................................................. 39

14.14 Stem Position Sensor Replacement ................................................. 40

14.15 Main PCB Assembly Replacement .................................................... 41

14.16 Customer Interface Board Replacement ........................................... 43

15 Optional Vented Design .............................................................................. 44

16 Parts List .................................................................................................... 46

17 StarPac 3 Spare Parts Kits .......................................................................... 48

18 StarPac 3 Mounting Kits ............................................................................. 49

19 Pressure Sensor Part Numbers .................................................................. 49

20 Pressure Sensor Spare Parts Kits ............................................................... 50

21 Temperature Sensor Spare Parts Kits ......................................................... 53

22 StarPac 3 Stainless Steel Tubing Kits ......................................................... 54

23 StarPac 3 System Troubleshooting ............................................................. 55

24 StarPac 3 Pressure Sensor Troubleshooting .............................................. 56

25 StarPac 3 Electronics Initialization Procedure ............................................ 57

26 How to Order .............................................................................................. 59

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StarPac Intelligent Control System FCD VLENIM0066-05 04/14

1 General Information

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 unpa-

cking, 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, and temperature). For this reason, they

should not be used in other applications without ﬁrst contacting the manufacturer. The product Installation, Operation,

and Maintenance Instructions provides important additional safety information.

1.2 Applicability

The following instructions are applicable to the maintenance and installation of Flowserve control valves with the StarPac

3 control system. These instructions cannot claim to cover all details of all possible product variations, nor can they pro-

vide information for every possible example of installation, operation or maintenance. This means that the instructions

normally include only the directions to be followed by qualiﬁed personal using the product for its 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. All Flowserve User Instruction Manuals are available at www.

ﬂowserve.com.

1.3 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 obvious, even to qualiﬁed

personnel. Compliance with other notes, which may not be particularly emphasized, with regard to transport,

assembly, operation and maintenance and with regard to technical documentation (e.g. in the operating instruc-

tions, product documentation, or on the product itself) is essential, in order to avoid faults, which can directly or

indirectly cause severe personal injury or property damage.

1.4 Personal Protective Equipment

Flowserve products are often used in problematic applications (e.g. under extremely high pressures with dangerous,

toxic or corrosive mediums). When performing service, an inspection or repair operation always ensure that the valve

and actuator are depressurized and that the valve has been cleaned and is free from harmful substances. In such cases,

pay particular attention to personal protection (e.g. protective clothing, gloves, glasses etc.).

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StarPac Intelligent Control System FCD VLENIM0066-05 04/14

1.5 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 authorized by

those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible

dangers.

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 long periods of time check them for corrosion or deterioration before putting them into use. See pages

46-54 for parts listings and numbers

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 those outlined in these Installation,

Operation, and Maintenance Instructions could drastically affect performance, be hazardous to personnel and equip-

ment, and may void existing warranties. Between the actuator and the valve there are moving parts. To avoid injury,

Flowserve provides pinch-point-protection 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 recognized 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 that 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 are well protected from corrosion.

Nevertheless, Flowserve products must be stored adequately in a clean, dry environment. Heating is not required. Con-

trol valve packages must be stored on suitable skids, not directly on the ﬂoor. Plastic caps are ﬁtted to protect the ﬂange

faces and prevent the ingress of foreign materials. These caps should not be removed until the valve is actually mounted

into the system.

Long Term Storage of StarPac 3 Positioner in Humid Locations

The StarPac 3 positioners are designed to operate in humid environments when connected to a proper instrument air

supply. There are some occasions when valves and positioners are stored at job sites or installed and commissioned

and then left without instrument air for months. To make startup easier for units that are left without instrument air and

insure that the positioners will be ready to operate, it is recommended that the vent assembly of the positioner be sealed

preferably with a desiccant pouch sealed with the vent assembly.

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

The vent assembly is located in the upper left side of the positioner. The gaps around the assembly as noted by the

arrows should be sealed for long storage.

A small desiccant package as shown can be included under the sealing tape to insure proper protection.

Joints to be sealed

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All of the edges around the vent assembly should be sealed similar to picture below.

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

Desiccant packet

The sealing tape and desiccant should be removed when instrument air is permanently applied to the positioner

2 Unpacking

1. While unpacking the StarPac 3 Intelligent Control System, check the packing list against the materials recei-

ved. Lists describing the system and accessories are included in each shipping container.

2. When lifting the control system from the shipping container, use straps through the yoke legs, or the lifting

lugs attached to the yoke bolting. Take care to position lifting straps to avoid damage to the tubing and moun-

ted accessories.

WARNING: When lifting a control system, be aware that the center of gravity may be above the lifting point.

Therefore, support must be given to prevent the valve from rotating. Failure to do so can cause serious injury to

personnel and damage to the valve and nearby equipment.

3. Contact your shipper immediately if there is shipping damage.

4. Should any problems arise, call your Flowserve representative.

3 Installation

DANGER: Before installation check the order number, serial number, and/or the tag number to ensure that the

Removable sealing tape

valve and actuator being installed are correct for the intended application.

CAUTION: Do not insulate extensions that are provided for hot or cold services. Do not insulate the StarPac 3

electronics housing or remote-mounted pressure or temperature sensors; otherwise excessive heat may build up

and affect operation.

CAUTION: If the StarPac 3 is being installed in an insulated process line, do not place more than four inches of

insulation around the pressure or temperature sensors.

CAUTION: On valves equipped with air ﬁlters, the air ﬁlter must point down to perform properly.

NOTE: In some rare cases, the air supply must be limited to less than 150 psi (10.3 bar). This is indicated on a

sticker found near the upper air port on the actuator cylinder. An air regulator should be installed to ensure the

supply pressure does not exceed the line pressure indicated on the sticker.

1. Pipelines must be correctly aligned to ensure that the valve is not ﬁtted under tension.

2. Fire protection must be provided by the user.

3. Before installing the valve, clean the line of dirt, welding chips, scale and other foreign material.

4. Whenever possible, the valve should be installed in an upright position. Vertical installation permits easier

valve maintenance.

5. Be sure to provide proper overhead clearance for the actuator to allow for disassembly of the plug from the

valve body. Refer to the appropriate actuator User Instructions for proper clearances. Actuator User Instructions

are available at www.ﬂowserve.com.

6. Double-check ﬂow direction to be sure the valve is installed correctly. Flow direction is indicated by the arrow

attached to the body.

7. If welding the valve into the line, use extreme care to avoid excess heat build up in the valve.

8. Connect the air supply and instrument signal lines.

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4 Quick-check

Prior to start-up, check the control valve by following these steps:

1. Stroke the valve and observe the plug position indicator on the stem clamp compared to the stroke indicator

plate. The plug should change position in a smooth, linear fashion.

NOTE: Due to excessive friction, graphite packing can cause the plug stem to move in a jerky fashion.

2. Check for full stroke by making appropriate instrument signal changes.

3. Check all air connections for leaks.

4. Check packing box bolting for the correct adjustment. Refer to the packing installation manual for speciﬁc

details on maintaining the style of packing supplied.

CAUTION: Do not over-tighten packing. This can cause excessive packing wear and high stem friction that may

impede plug movement.

5. Make sure the valve fails in the correct direction in case of air failure. This is done by turning off the air supply

and observing the failure direction.

6. After a temperature excursion has occurred, bonnet ﬂange bolting should be re-torqued to ensure bonnet

seals do not leak.

5 Valve Maintenance

At least once every six months, check for proper operation by following the preventative maintenance steps outlined

below. These steps can be performed while the valve is in-line and, in some cases, without interrupting service. If an

internal problem is suspected, refer to the Valve Disassembly and Inspection in the Installation, Operation and Mainte-

nance (IOM) instructions of the valve that the StarPac 3 system is mounted to.

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1. Look for signs of gasket leakage through the end ﬂanges and bonnet. Re-torque ﬂange and bonnet bolting (if

required).

2. Examine the valve for damage caused by corrosive fumes or process drippings.

3. Clean valve and repaint areas of severe oxidation.

4. Check packing box bolting for proper tightness. Refer to the Installation, Operation and Maintenance (IOM)

instructions for the valve for speciﬁc details on maintaining the style of packing supplied.

CAUTION: Do not over-tighten packing. This can cause excessive packing wear and high stem friction that may

impede stem movement.

5. If possible, stroke the valve and check for smooth, full-stroke operation. Unsteady stem movement could

indicate an internal valve problem.

NOTE: Due to excessive friction, graphite packing can cause the plug stem to move in a jerky fashion.

WARNING: Keep hands, hair and clothing away from all moving parts when operating the valve. Failure to do so

can cause serious injury.

6. Make sure positioner linkage and stem clamp are securely fastened. If the stem clamp is loose, check plug

thread engagement (refer to the “Reassembly and Installation” section for the correct procedure on aligning the

plug with the seat). Tighten stem clamp nut.

7. Ensure all accessories, bolting and brackets are securely fastened.

8. If possible, remove air supply and observe actuator for correct fail-safe action.

9. Check rubber actuator bellows for splits, cuts or wear.

10. Spray a soap solution around the actuator cylinder retaining ring and actuator stem guide to check for air leaks

through the O-rings.

11. Clean any dirt and other foreign material from the plug stem.

12. If an air ﬁlter is supplied, check and replace cartridge if necessary.

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6 Valve Disassembly and Inspection

The StarPac 3 Control Intelligent Control System can be mounted to a variety of different control valves. To disassemble

and inspect the control valve that the StarPac 3 is mounted to, refer to the Installation, Operation and Maintenance (IOM)

instructions for that particular valve (i.e. Mark One, Mark 100, ShearStream or MaxFlo 3). Refer to section 14 of this

manual for instructions on how to remove the pressure sensor cables and thermocouple prior to valve disassembly.

7 StarPac 3 Operation

7.1 Overview

The StarPac 3 is double-acting, capable of supplying air to either side of the actuator piston while exhausting

the other side to the atmosphere. Also, the positioner can be mounted on either Flowserve Valtek linear or rotary

actuators without modiﬁcation to the actuator.

Since the positioner is insensitive to supply pressure changes and can handle supply pressures from 30 to 150

psig, a supply regulator is usually not required; however, an air ﬁlter is required due to the close tolerances of the

spool assembly.

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7.2 Speciﬁcations

Table I: Flow Accuracy

The accuracy of the standard StarPac 3 model is +/- 2 percent of full scale ﬂow over the turndown of the control valve,

normally 30:1 for a globe valve. This can be improved by using characterized trim or reducing the turndown of the

high accuracy range.

Table II: Electrical Speciﬁcations

Power Supply Analog Inputs Isolation protection to 1000 V Analog Outputs Discrete Input Jumper selectable input voltages of 120 and 24 V accept either AC or DC signals,

Discrete Output: Pulse Relay

Discrete Output: Alarm Relay

Overload protection Minimum 500 volt isolation; 24 V power fuse protected Serial Interface Dual RS-485 ports; Modbus Protocol USB Interface 2.0 mini-B; Modbus Protocol Infrared PDA Keypad Emulation

Nominal 24 VDC (19 to 36 VDC allowable) providing 150 mA

Two (2) 4-20 mA that each drive up to 750 Ω

pulse width >1/16 sec. 24 VAC or VDC operation, max. output switching frequency of 166 Hz

Jumper selectable NO or NC contacts; maximum relay contact rating: 24 VDC resistive. Groups A & B - 230 mA, Group C - 590 mA, Group D - 800 mA

Table III: Software Speciﬁcations

Computer Minimum Pentium processor running Windows 95, 98, NT, 2000, XP, 32 MB total

memory (64 MB recommended), 30 MB available hard disk space, CD-ROM drive

Ports 1 minimum available with 8 maximum possible. (Can also communicate via USB

connection)

StarPacs per network Up to 31

Table IV: Environmental Speciﬁcations

Ambient -40° to 170° F (-40 to 75° C ) Process Media -320° to 1500° F (-195 to 815° C) Temperature Effect -40° to -10° F (-40 to 23° C): (0.07% °F)

-10° to 150° F (-23 to 66° C): (0.02% °F) 150° to 185° F (66 to 88° C): (0.07% °F)

Transport and Storage Tem-

-40° to 170° F (-40 to 76° C )

perature Range Operating Humidity 0 - 100% non-condensing Note: The air supply must conform to ISA standard ISA 7.0.01 ( a dew point at least 18 degrees Fahrenheit below

ambient temperature, particle size below ﬁve microns - one micron recommended - and oil content not to exceed one

part per million).

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StarPac Intelligent Control System FCD VLENIM0066-05 04/14

Table V: Physical Speciﬁcations

Housing Material powder painted aluminum stainless steel Soft Goods Buna-N Weight 10.3 pounds ( kg) aluminum 26.5 pounds ( kg) stain-

less steel Pressure Sensor 316 L stainless steel Pressure Sensor Over-range Two times maximum operating pressure with negligible change in output Pressure Sensor Seals Viton, Kalrez, EPDM O-rings PTFE, Spiral Wound Gaskets Tubing 316 stainless steel with Swagelok® ﬁttings

Table VI: Positioner Speciﬁcations

Deadband <0.1% full scale Repeatability <0.05% full scale Linearity <0.5% (rotary), <0.8 (sliding stem) full scale Air Consumption <0.3 SCFM (0.5 Nm3/hr) @ 60 psi (4 barg)

Table VII: Measurement Repeatability

Flow 0.25% full scale Pressure (max.) 0.1% full scale Temperature 1° C body temperature measured by Type K thermocouple Drift 1% full scale / 6 months Calibration Independent zero and span adjustment for all sensors

Table VIII: Hazardous Area Certiﬁcations

Explosionproof / Flameproof Nonincendive/Div 2

APPROVED

Class I, Div 1, Groups B,C,D Class II, Div 1, Groups E,F,G Class III With Non-Incendive Outputs T6 Max ambient 75

Class I, Div 2, Groups A,B,C,D Zone 2, Ex nIIC

Electromagnetic Coil

Nozzle

Flapper

Digital Position

Algorithm

Spool Valve

Flame Arrestors

Pressure Sensor

Air Supply

Orifice

Exhaust

OUTPUT 1

OUTPUT 2

Exhaust

Flame Arrestor

Air-to-Open

Configuration

Flame Arrestor

Filter

Regulator

Hall Effect Sensor

Stem Position Sensor

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

7.3 Positioner Operation

Figure 1: StarPac 3 Positioner Schematic (air-to-open conﬁguration)

The StarPac 3 Positioner is an electric feedback instrument. Figure 1 shows a StarPac 3 installed on a double-acting

actuator for air-to-open action. Positioning is based on a balance of two signals: one proportional to the modulator input

signal and the other proportional to the stem position.

The supply pressure for the positioner modulator is tapped off the main supply and is ﬁltered as it passes through a ﬁeld-

replaceable, coalescing ﬁlter element in the module. Next it passes through an internal pressure regulator that regulates

it to approximately 21.5 psig. The air then goes through an oriﬁce that restricts the ﬂow and air consumption (refer to

Figure 1).

The air is further controlled to 6-12 psig using a spring-diaphragm ﬂapper that is attracted by an electromagnet to a noz-

zle. A temperature compensated Hall Effect sensor mounted on a circuit board senses the spool valve position. The Hall

Effect sensor and circuitry create a feedback loop, which determines how much current to send to the electromagnet for

a desired spool valve position. The electromagnet in the feedback loop varies the nozzle-ﬂapper spacing, which regulates

the output pressure to 6-12 psig proportional to the command input signal.

When these opposing signals are equal, the system will be in equilibrium and the stem will be in the position called for

by the command signal. If these opposing signals are not equal, the spool valve will move up (or down) and, by means

of the modulator, will change the output pressures and ﬂow rate. This will cause the piston to move until the signal of the

feedback sensor equalizes with the command signal.

The detailed sequence of positioner operations are as follows: An increase in the command signal forces the modulator

signal capsule and spool valve upward. This motion of the modulator also pushes the pilot valve spool upward from its

equilibrium position. This opens the pilot valve ports, supplying air to port one and exhausting air from port two. This

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StarPac 3

Locknut Washer

Follower Arm

Bracket Bolts

Bracket

Positioner Bolts

Stem Clamp

Metal Washers

Bolts

Take-off Arm

Follower Pin

Nut

Lock Washer

Nut

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

causes the actuator piston to move upward.

This upward motion of the piston is transmitted back to the positioner through the feedback linkage and position feed-

back potentiometer signal changing proportionally to the valve position. The piston continues to stroke upward until the

signal of the feedback sensor increases sufﬁciently to counter the signal being sent to the modulator. At this point, the

spool is at its equilibrium position as the pressures in the cylinder stabilize and the air ﬂow to the actuator decreases.

After the piston has reached the required position, the feedback signal will equal the spool position generated in the mo-

dulator capsule. The computer will then make small null adjustments to ﬁne-tune the desired position and compensate

for changes in dynamic loading.

A decrease in the command signal reverses the described actions causing a proportional downward movement of the

actuator piston and stem.

8 Mounting and Installation

8.1 Mounting to Flowserve Valtek Linear Mark One Valves

Figure 2: Linear Mark One Control Valve Mounting (Sensor Mounting not shown)

To mount the StarPac 3 positioner to a Flowserve Valtek linear Mark One valve, refer to Figure 2 and proceed as out-

lined below. The following tools are required:

• 9/16” open-end wrench (or 1/2” for spud sizes 2.88 and smaller)

• 7/16” box wrench

• 3/8” open-end wrench

1. Remove washer and nut from follower pin assembly. Insert pin into the appropriate hole in follower arm,

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

based on stroke length. The stroke lengths are stamped next to their corresponding holes in the follower

arms. Make sure the unthreaded end of the pin is on the stamped side of the arm. Re-install lock washer and

tighten nut to complete follower arm assembly.

2. Slide double-D slot in the follower arm assembly over the ﬂats on the position feedback shaft in the back of

the positioner. Make sure the arm is pointing toward the customer interface side of the positioner. Slide lock

washer over the threads on the shaft and tighten down the nut.

3. Line up the mounting bracket with the mounting holes on the actuator yoke. Bolt the mounting bracket on to

actuator yoke.

4. Align the three outer mounting holes on the positioner with the three positioner mounting holes on the bra-

cket. Fasten with 1/4-20 x1/2” bolts.

5. Position the take-off arm mounting slot against the stem clamp mounting pad. Apply Loctite 222 to the take-

off arm bolting and in and insert through washers into the stem clamp. Leave bolts loose.

6. Slide the appropriate pin slot of the take-off arm, based on stroke length, over the follower arm pin. The

appropriate stroke lengths are stamped by each pin slot.

7. Center the take-off arm on the rolling sleeve of the follower pin.

8. Align the take-off arm with the top plane of the stem clamp and tighten bolting. Torque to 120 in-lb.

NOTE: If mounted properly, the follower arm should be horizontal when the valve is at 50% stroke and should

move approximately ±30° from horizontal over the full stroke of the valve. If mounted incorrectly, a stroke ca-

libration error will occur. Reposition the feedback linkage or rotate the position sensor to correct the error.

8.2 Mounting to Standard Flowserve Valtek Rotary Valves

The standard rotary mounting applies to Flowserve Valtek valve/actuator assemblies that do not have mounted volume

tanks or handwheels. The standard mounting uses a linkage directly coupled to the valve shaft. This linkage has been

designed to allow for minimal misalignment between the positioner and the actuator. The tools required for the following

procedure are:

• 5/32” Allen wrench

• 1/2” open-end wrench

• 3/8” socket with extension

• 3/16” nutdriver

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StarPac 3

Follower Arm

*Located in appropriate hole pattern as indicated on bracket. (25, 50, 100/200)

Positioner Bolts 5/16-18 (4)*

Bracket Bolts 5/16-18 (2, not shown)

Take-off Arm, Rotary Lock Washer (2) 10-32 Bolt 10-32 Nut

Self-tapping Screws (2)

Spline Lever Adapter

10-32 Nut Lock Washer

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Figure 3: Standard Rotary Mounting (Sensor Mounting not shown)

1. Fasten the splined lever adapter to the splined lever using two #4-40 x 1/2” self-tapping screws.

2. Slide the take-off arm assembly onto the splined lever adapter shaft. Insert the screw with star washer

through the take off arm and add the second star washer and nut. Tighten nut with socket so arm is lightly

snug on the shaft but still able to rotate. This will be tightened after linkage is correctly oriented.

3. Attach follower arm to positioner feedback shaft using the star washer and 10-32 nut.

NOTE: The arm will point up when feedback shaft is in the free position.

4. Using four 5/16”-18 x 5/8” bolts, fasten positioner to universal bracket using appropriate hole pattern (stam-

ped on bracket).

5. Using a 1/2” end wrench and two 5/16”-18 x 1/2” bolts, attach bracket to actuator transfer case pad. Leave

these bolts slightly loose until ﬁnal adjustments are made.

6. Rotate take-off arm so the follower pin will slide into the slot on the take-off arm. Adjust the bracket position

as needed noting the engagement of the follower pin and the take-off arm slot. The pin should extend appro-

ximately 1/16” past the take-off arm. When properly adjusted, securely tighten the bracketing bolts.

7. Tube the StarPac 3 positioner to the actuator according to the instructions given in Section 8.4, “Tubing Posi-

tioner to Actuator.”

8. With supply pressure off, rotate the follower arm in the same direction the shaft would rotate upon a loss of

STOP!

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supply pressure. When the mechanical stop of the follower arm (positioner) is reached, rotate back approxi-

mately 15 degrees.

9. Hold the take-off arm in place; tighten the take-off arm screw.

NOTE: The take-off arm should be snug enough to hold the follower arm in place

but allow movement when pushed.

10. Connect regulated air supply to appropriate port in manifold.

11. Remove main cover and perform a stroke calibration using the key pad (refer to the StarPac 3 User Interface

Manual. Make sure the StarPac 3 has been conﬁgured with the proper air action.

12. If the calibration was successful, continue with step 9. If the calibration failed, the A/D feedback values were

exceeded and the arm must be adjusted away from the positioners limits. Return to step 2 and rotate the arm

back approximately 10 degrees.

NOTE: Remember to remove the air supply before re-adjusting take-off arm.

13. Tighten the nut on the take-off arm. The socket head screw of the take-off arm must be tight, about 40 in-

lb.

NOTE: If the take-off arm slips, the positioner must be recalibrated.

WARNING: Failure to follow the procedure will result in positioner and/or linkage damage. Check air-action and

stroke carefully before lockdown of take-off arm to splined lever adapter.

8.3 Optional Flowserve Valtek Rotary Mounting Procedure

Figure 4: Optional Rotary Mounting (Sensor Mounting not shown)

Locknuts (2)

Tripper

Tripper Clamp

Bracket Bolts 5/16-18 (2)

Ball Joint Ends

* Tie Rod must be cut to desired length

Bolts (2)

Tie Rod*

10-32 Nut Lock Washer

Follower Arm

Rotate Positioner 90 Degrees

Mounting Bolts 1/4-20 (4)

ﬂowserve.com

STOP!

StarPac Intelligent Control System FCD VLENIM0066-05 04/14

The optional rotary mounting applies to Flowserve Valtek valve/actuator assemblies that are equipped with moun-

ted volume tanks or handwheels. The optional mounting uses a four-bar linkage coupled to the valve shaft. The follow tools are required:

• 3/8” open-end wrench

• 1/2” open-end wrench

1. Using a 1/2” open-end wrench and two 5/16-18 x 1/2” bolts, attach bracket to actuator transfer case pads.

Leave bracket loose to allow for adjustment.

2. Using four 5/16”-18 x 5/8” bolts and a 1/2” open-end wrench, fasten positioner to universal bracket, using the

four-hole pattern that locates the positioner the farthest from the valve. Rotate positioner 90 degrees from normal so gauges are facing upward.

3. Attach follower arm to positioner feedback shaft, using the star washer and 10-32 nut.

4. Attach tripper and tripper clamp to valve shaft using two 1/4-20 bolts and two 1/4-20 locknuts. Leave tripper

loose on shaft until ﬁnal adjustment.

5. Thread ball joint linkage end to tripper and tighten (thread locking compound such as Loctite is recommended

to prevent back threading). Adjust the length of tie rod so follower arm and tripper rotate parallel to each other (the rod must be cut to the desired length). Connect the other ball joint end to follower arm using a star washer and 10-32 nut.

6. Tighten bracket and tripper bolting.

7. Check for proper operation, not direction of rotation.

WARNING: If rotating in wrong direction, serious damage will occur to the positioner and/ or linkage. Check

air action and stroke direction carefully before initiating operation.

8.4 Tubing Positioner to Actuator

The StarPac 3 positioner is insensitive to supply pressure changes and can handle supply pressures from 30 to 150 psig. A supply regulator is recommended if the customer will be using the diagnostic features of the StarPac 3 but is not required. 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 rating ( not to be confused with operating range). An air ﬁlter is highly recommended for all applications where dirty air is a possibility.

NOTE: The air supply must conform to ISA Standard ISA 7.0.01 (a dew point at least 18°F below ambient

temperature, particle size below ﬁve microns – one

micron recommended – and oil content not to exceed one part per million).

Air-to-open and air-to-close are determined by the actuator tubing, not the software. When air action selection is made during conﬁguration, that selection tells the control which way the actuator has been tubed. The top output is labeled Output 1. Output 1 should be tubed to the side of the actuator that must receive air to begin the correct action on increasing signal. Verify that tubing is correct prior to a stroke calibration. Proper tubing orientation is critical for the positioner to function correctly and have the proper failure mode. Refer to Figure 1 and follow the instructions:

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