Flowserve XL90 User Manual

Page 1

GENERAL INFORMATION

This bulletin is designed to assist in installing, calibrating, troubleshooting and performing maintenance as required for the XL90 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.

T o avoid possible injury to personnel or damage to valve parts, WARNING and CAUTION notes must be strictly followed. Modifying this product, substituting nonfactory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment.

The XL90 high-performance positioner is a two-stage device and is designed for use in control loops where fast response is required. The XL90 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 XL90 high-performance positioner is designed as a fourway device, but can easily be converted to a three-way device by plugging one of the output ports.

NOTE: The XL90 high-performance positioner must use the I/P NT 3000 Transducer. The I/P 2000 Transducer is not acceptable for use with the XL90 Series Positioner.

The XL90 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 XL90 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.)

POSITIONER OPERATION

The positioner schematic (Figure 1) shows an XL90 Series positioner connected for double-acting service on a rotary rackand-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 feedback 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 forcebalance 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.

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.

VLAIM 048-00 (181157.000.000) Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-1

Flow Control

Installation, Operation, Maintenance Instructions

XL90 Series High-Performance Positioner

Page 2

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 causes a proportional inward movement of actuator pistons and a reversal in pinion direction.

Installation of XL90 Series Positioner on Actuators

The XL90 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 actuator 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 XL90 positioner. When retrofitting the XL90 positioner to an actuator equipped with another positioner, remove the existing positioner, tubing and associated bolting. See tubing instructions in Connecting XL90 Positioner Ports section.

48-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Figure 1: XL90 Positioner Schematic for Air-to-Open

Figure 2: Positioner Mounting with NAMUR shaft

Figure 3: Positioner Mounting with Double D Shaft

and Linkage

Supply Seat Upper Pilot

Poppet Exhaust Seat Port No. 1 Restriction Supply Pilot Valve

Capsule Exhaust Seat Port No. 2 Lower Pilot

Poppet Supply Seat

Piston Cylinder

Balance Adjustment Feedback Spring Zero Adjustment

Range Adjust Screws

Cam

Feedback (shaft)

Instrument Signal Upper Diaphragm Lower Diaphragm

Flapper

Detecting Nozzle

Input Capsule

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Mounting Instructions for XL90 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” instructions.)

4. Install the positioner onto the bracket. Make sure positioner shaft and coupler are engaged and centered. Finger tighten positioner bolts.

5. Proceed to “Connecting XL90 Positioner Ports.”

Mounting Instructions for XL90 Positioner on Sereg Rotary Actuators

1. Mount the positioner to the transfer case plate in the

proper orientation. Tighten the four bolts.

2. Loosen jam nut (see “Cam Installation” instructions).

3. Mount the follower arm, lockwasher and nut on the end of

the shaft and tighten nut. Carefully hold the shaft with wrench on shaft flats.

4. With valve in closed position, make sure follower pin lever

is mounted parallel to valve lever, flush with end of valve shaft and the nut is tight.

5. Place follower pin (mounted to the lever that is mounted to

the valve shaft) into follower arm slot and bolt the transfer case plate in place finger tight only. See Figure 3.

6. Orient the cam to align the “L” shaped line located on the

left side of the characteristic curve through the middle of the span arm roller. (See Figure 5.) The valve should be seated when this alignment is done. (See “Cam Installation” instructions.) For correct cam characteristics, see Table I.

7. Proceed to “Connecting XL90 Positioner Ports”

instructions.

Connecting XL90 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.

2. Connect supply air to the port marked “SUPPLY.”

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 adjustment. 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.)

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. A) For NAMUR shaft end connections make sure shaft is

properly aligned with coupler or actuator.

B) For Sereg actuators, make sure follower pin is in

follower arm groove.

2. Push span arm away from shaft to avoid pressure on the cam.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-3

Table I: Cam Characteristic Identification Sereg

Cam Guide

Sereg Actuator NR NX NL

Plug Characteristic MaxFlo Linear Linear Equal Percent Linear Equal Percent

Fail Position Close Open Close Open Close Open Close Open Close Open

Direct Acting

Linear A B N M A B

Positioner Equal % C E Q P N M C E A B

Equal % Mod B A

Reverse Acting

Linear B A M N B A

Positioner Equal % E C P Q M N E C B A

Equal % Mod A B

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3. Place cam over the shaft with the appropriate characteristic facing up and closest to the span arm roller. For Sereg cams, see Table I. For Accord cams, “D” represents directacting and “R” represents reverse acting.

4. A) For NAMUR shaft end connections, make sure the round mark on the left hand side of the characteristic curve is lined up with the span arm roller bearing. See Figure 4.

B) For Sereg actuators, make sure the line on the left hand side of the characteristic curve is lined up through the middle of the span arm roller bearing. See Figure 5.

5. Tighten jam nut making sure cam does not rotate. Use a flat screwdriver to prevent cam rotation and shaft flats to prevent shaft rotation (if necessary).

6. Connect supply pressure to port marked ‘Supply.’

7. 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.

POSITIONER CALIBRATION Introduction

Valtek positioners are calibrated at the factory; however, due to shipping and handling, it may be necessary to check the calibration before operating the valve. The XL90 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 standard 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 6 and proceed as follows:

1. For 3-15 or 3-9 psi range, loosen by hand the zero adjustment 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.

3. With a phillips screwdriver adjust the span adjustment so valve is at full stroke with more than 15 psi for 3-15 or 915 psi range (adjust to 9 psi for 3-9 psi range).

4. Return to 3 psi (or 9 psi for 9-15 psi range) and check the zero. Repeat steps 1-4 if necessary.

5. Tighten the zero adjustment lock knob and span adjustment locking screw.

6. Use the same procedure for three-way split range.

7. Connect Cam return spring. See Figure 6.

Positioner Balance Adjustment

CAUTION: Balance pressure is 75 percent of the supply pressure and is the average pressure of output ports 1 and 2. Balance is preset at factory. However, if this adjustment becomes necessary, carefully make this adjustment slowly, allowing the positioner to stabilize. Check after a short while to make sure balance pressure is correct.

Balance adjustment is set at the factory and should not need adjustment. Balance adjustment (output pressure level) permits the equilibrium pressure in both sides of the actuator piston to be raised or lowered. The average actuator pressure level of output 1 or 2 is approximately 75 percent of supply pressure. For single-acting actuators, the balance pressure should be left at the factory setting. If it is necessary to adjust the output pressure level, follow the procedure outlined:

1. If output pressure level is low, before adjusting, check for

leaks in tubing connections between positioner and actuator and check supply pressure.

2. Make certain there is no process force or pressure in the

valve (The valve should be removed or isolated from the process.)

3. On positioners without gauges, connect gauges to ‘output

1’ and ‘output 2’ lines.

48-4 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Figure 5: Alignment for Sereg Cams

Figure 4: Alignment for Accord Cams

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4. Remove rubber cap over balance adjustment screw. (See Figure 6.)

5. Apply full actuator operating pressure to positioner supply port.

6. Set input signal to midscale (9 psi for 3-15 psi span). Output pressure level cannot be adjusted with actuator against valve seat or travel stops. Allow actuator pressure to stabilize.

7. Observe the pressure gauges. If reading is not correct, turn balance adjustment screw about 1/8 turn at a time and wait about 20-30 seconds for pressure to stabilize (counterclockwise to increase pressure). Continue until output pressure level of the higher pressure gauge is approximately 80 percent of supply.

8. Replace rubber cap over balance adjustment screw.

Gain Adjustment Procedure

The unique gain adjustment on the XL90 positioner provides a means to increase or decrease the responsiveness of the valve / actuator / positioner system. Increasing gain makes the valve more responsive and faster, while decreasing gain makes the system less sensitive and slower to respond (with increased damping).

The gain is infinitely adjustable between its highest and lowest settings. For convenience, three marks indicate (H) high, (M) medium and (L) low gain. Most sizes of actuators will respond well to a (M) setting. Unique actuator/valve configurations may require a gain adjustment at the factory or in the field.

1. Before adjusting the gain, place controller on manual and

isolate the valve from the process.

2. Turn off supply air to control valve actuator.

3. Using a 5/64-inch allen wrench, loosen both upper and lower lock screws about one half turn. Do not loosen the spacer nut. (See Figure 8.)

4. By grasping adjust lever , carefully rotate gain adjust assembly to desired position.

CAUTION: To avoid damaging gain adjust connecting spring mechanism, make sure both upper and lower gain adjust plates rotate together. When they are rotated to the new position, the connecting spring should be perpendicular to the plates.

5. When the gain is set to the desired position, firmly tighten both lock screws.

6. Turn on the supply pressure. Check actuator responsiveness by providing a step signal to positioner. When gain is set as desired, check valve zero and span calibration and re-calibrate if needed.

7. Return the valve to service.

Calibrating I/P Module Zero and Span Settings

NOTE: Although calibration can be accomplished using the output pressure gauge on the I/P module, its accuracy is ±3 percent. The standard gauge should be removed only for calibration and more accurate calibration equipment of ±0.1 percent of span should be used. The pressure gauge port is 1/8-inch NPT. Calibration manifolds are available from the factory (Part No. 97370).

1. Connect I/P module to a supply pressure between 30 to 150 psi.

2. Remove I/P module housing cover. (See Figure 9.)

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-5

Figure 6: Positioner Adjustments

Output 1 Zero Adjustment

Lock Knob Cam Follower Arm

(Range Arm) Output 2 (shown plugged) Balance

Adjusting Screw Feedback

Spring Pilot Relay

Assembly I/P Transducer

Zero Adjustment Knob

Span Adjustment

Feedback Spring Arm

Span Adjustment Locking Screw

Mounting Holes for Internal Electronics

Cam

Orifice Screw

Cam Spring

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WARNING: Be certain power to I/P module is disconnected before removing housing cover in explosive atmospheres; otherwise personal injury may occur.

3. Before adjusting the zero and span, be certain the MPC feature is disabled. Refer to Step 7 in the ‘Adjusting the Minimum Pressure Cutoff Feature’ section.

4. Connect a current source to the terminal block on circuit board.

NOTE: The zero and span adjustments are multi-turn potentiometers (pots) that have no stops on the ends of their travel; however , they have a slip clutch to prevent damage from overadjustment. The pots also make a clicking noise when they have reached adjustment limits.

5. Apply a 4.0 mA signal to the input. Locate and adjust zero trim pot to achieve a 3.0 psi output. The output will increase with clockwise rotation of the zero trim pot. If calibrating an I/P module with a 10-50 mA input signal, apply a 10.0 mA signal to input.

6. Increase input signal to 20.0 mA (50 mA for 10-50 mA units). Locate and adjust span trim pot to achieve a 15.0 psi output. The output will increase with clockwise rotation of the span.

7. Recheck zero setting by repeating Step 5. The span adjustment may affect zero setting.

8. Repeat Steps 5, 6 and 7 until proper adjustments are obtained.

Adjusting the Minimum Pressure Cutoff Feature

The XL90 positioner with I/P Transducer has a “Minimum Pressure Cutoff” (MPC) feature, which allows the user to set

the positioner. When the input signal falls below a useradjustable current, the pressure output falls rapidly to approximately 1.7 psi, causing the valve to move to the failure position. This feature is generally used when the service requires a tight shut off or to prevent throttling near the valve seat. T o adjust this feature, refer to Figure 9 and perform the following :

NOTE: The following procedure applies only when the minimum pressure cutoff feature will be used.

NOTE: The zero and span settings of both the positioner and I/P transducer should be verified as accurate before the minimum pressure cutoff feature is enabled and adjusted.

1. Connect the I/P module to a 30 to 150 psi air supply pressure.

48-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Figure 7: Close-up of Gain Adjustment Figure 8: Gain Adjustment

Figure 9: NT 3000 Circuit Board Module

(housing cover removed)

Upper Lock Screw

Lower Lock Screw

Adjust Lever

Spacer Nut (Do not loosen)

RFI Can

Zero Adjustment Span Adjustment Minimum Pressure

Cutoff Adjustment

Circuit Board Mounting Screws

Grounding Screw

Terminal Block

Current Loop (-) Termination

Current Loop (+) Termination

FLOWSERVE

NO SERVICEABLE INTERNAL PARTS

SERIAL NUMBER

ZERO

SPAN

MPC

Page 7

2. Remove the I/P module housing cover.

WARNING: Be certain power to the I/P module is disconnected before removing the housing cover in explosive atmospheres; otherwise personal injury may occur.

3. Connect an adjustable current source to the terminal block on the circuit board. Apply the desired input signal to the positioner at which the output pressure is to fall to approximately 1.7 psi. This signal can range from factory setting of 3.7 to 8 mA.

4. Turn the minimum pressure cutoff pot clockwise until the output pressure drops off.

5. Fine-tune the pressure drop-off point by increasing the input signal and then decreasing it through the desired shut-off signal. Observe the signal value at which the pressure drops off. If the pressure drops off at a lower mA signal than desired, turn the MPC pot counterclockwise. If the pressure drops off at a higher signal than desired, turn the MPC pot clockwise.

6. Repeat Step 5 until the pressure drops off at the desired input signal.

7. T o disable the MPC feature turn the minimum pressure cutoff pot (marked “MPC”) 20 turns counterclockwise or until it makes a clicking noise.

Positioner Maintenance

NOTE: Refer to NT 3000 IOM for I/P module maintenance instructions.

For proper maintenance, proceed as follows:

1. Maintain a clean air supply, free of dust, oil and water. A coalescing air filter for I/P is required to ensure a clean air supply. Check and maintain filter regularly.

2. Make sure all arms and levers move freely.

3. Check for loose parts.

4. Be sure there are no leaks in the air supply tubing fittings or connections.

5. Refer to the troubleshooting chart on page 9 in case of problems.

Pilot Relay Disassembly and Reassembly

The pilot relay is available as a complete unit and can be easily replaced (See Steps 2 and 18.) Before attempting to correct any problem with the pilot relay assembly, obtain a positioner repair kit that contains the soft goods most commonly required.

NOTE: Numbers in parentheses correspond to the numbers in Figure 16.

1. Remove the feedback spring (47) and rotate the span and zero arms (40, 46) out of the way.

2. Remove four screws (33) holding the pilot relay to positioner base (1). Remove relay from positioner.

3. Remove the nut (25) connecting the flapper assembly (21) to the signal capsule.

4. Remove four screws (32) holding the two halves of the pilot relay assembly together. Carefully pull the relay assembly halves apart, making sure the flapper assembly (21) slides off the flapper adjustment screw (19) without damaging the signal diaphragm assembly (16). Pull the relay diaphragm assembly (13) out of the other half of the relay body (9).

5. With the relay assembly in two sections, remove two screws (22) holding flapper assembly (21) to the relay diaphragm assembly (13). Remove the flapper.

6. Remove diaphragm retaining plate (15) from relay diaphragm assembly (13) and relay plate (14).

7. Replace relay diaphragm assembly (13) with one from the positioner repair kit. Place the relay plate (14) between the new diaphragms making sure the 1/16-inch diameter holes between the relay plate (14) and the diaphragm line up. Position diaphragm retaining plate (15) on relay diaphragm assembly with rounded inner diameter edge against diaphragm.

8. Attach flapper assembly (21) onto relay diaphragm assembly (13) using two screws (22) with a locking adhesive on the threads. The flapper assembly should extend away from the 1/16-inch diameter hole through the relay plate. Make sure lettering on flapper assembly is facing away from diaphragm.

9. With relay halves still apart, remove relay tube O-rings (8) from upper and lower bodies (9, 7) and replace them with new O-rings (found in the positioner O-ring repair kit).

10.

Remove rubber cap (35) and balance adjust screw cap (36) from upper relay body (9). Remove O-ring (38) from balance adjust screw and install new O-ring.

11. To remove and clean poppets (28), remove the retaining rings (31), poppet covers (27), O-rings (30), and poppet springs (29) found at the end of each housing. After removing poppets, inspect them for dirt buildup or damage to seating surfaces.

12. The upper relay body (9) has a movable seat ring (34) which is adjusted with the balance adjust screw (36). This seat is removed by pushing it out with a soft instrument such as a wooden dowel. Be careful not to damage seating surface. Remove O-ring (37) from the seat ring (34).

13. Lubricate and replace the O-ring (37) on movable seat ring (34). Carefully reinstall the seat ring (34) into upper relay body (9), being careful not to damage seating surface or O-rings.

14. Reinstall poppets (28), poppet springs (29), Seat Spring (39), O-rings (30), and poppet covers (27) before installing retaining rings (31).

15. If signal diaphragm assembly (16) is damaged, proceed as follows: With relay halves still apart, remove four screws (32) holding signal diaphragm assembly (16) to the pilot relay assembly. Remove locking screw (23), washer (24),

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-7

Page 8

adjustable gain lower plate (26), and diaphragm plate. Remove signal diaphragm assembly (15) and remove relay plate (14) from between the diaphragms. Place relay plate (14) between the diaphragms on the new assembly taking

care to align the 1/16-inch diameter holes between the diaphragms and the relay plate (14). Replace diaphragm

plate (15), adjustable gain lower plate (26), washer (24), and locking screw, but do not tighten. Replace four screws (32) that hold signal diaphragm assembly together.

16. Pack O-ring grease into the O-ring groove and lightly lubricate the outside of the relay tube on diaphragm relay assembly (13). Make sure small holes on the side of the tube do not get plugged with grease. Insert the relay diaphragm assembly (13) as assembled in steps 7 and 8 into the lower relay half. Carefully align the flapper (21) over the adjustable gain screw (19) and replace and tighten the nut (25).

17. Fasten the two halves of the relay together using four long screws (32). Make sure the 1/16-inch diameter holes in the relay diaphragm assembly (13) and the upper relay body (9) line up. Set gain to desired setting and tighten locking screws (23, 25). See gain adjustment procedure.

18. Replace screen (110) and O-rings (8,12) found on the back of the pilot relay before reinstalling the pilot relay on the base of the positioner with four screws (33). Clean out any debris lodged in screen or replace with a new one.

19. Replace span arm and zero arm (40, 46) and feedback spring (47).

Installation, Operation and Maintenance of UltraSwitch Position Indicators

For detailed information, refer to the following Accord controls bulletins:

• PS0008, PS0009, PS0031, PS0032, PS0033, PS0034, PS0037 and PS0050

XL90 OPTIONS

Option F: 4-20 mA Transmitter

The XL 90 Feedback Option allows accurate and reliable monitoring of valve position when installed in the XL 90 positioner. The Feedback Option may be used in any non-hazardous location. For hazardous locations utilize the UltraSwitch L explosion proof limit switch enclosure.

Voltage Supply Required: 6-30 VDC Impedance: 300 Ohms at 20 mA Note: Impedance changes with current (see chart). To properly

design the current loop, use 300 Ohms and 20 mA current.

Option J and K: Mechanical Switches

Mechanical switch technology is the oldest yet most cost effective switching method used today. Tool-free cam adjustment is accomplished through a spring-loaded spline arrangement. Simply push or pull the cam, disengaging the splines, and rotate

to the desired switch trip point. After releasing, the spring causes automatic spline engagement, locking the setting.

2-SPDT

Load Capacity: 15 amp & 1/2 HP 125 VAC, 10 amp 250 VAC,

1/2 amp 125 VDC, 1/4 amp 250 VDC Operating Force: 4.8 ounces Differential Travel: 0.016 inches minimum Mechanical Life: 10,000,000 cycles

Option M and N: Proximity Switches

Proximity reed switches offer cost effective contacts for extended life in corrosive applications. These switches are tripped by magnets embedded in cams to indicate valve open and closed positions. Tool-free cam adjustment is accomplished through a spring-loaded spline arrangement. Simply push or pull the cam, disengaging the splines, and rotate to desired switch trip point. After releasing, the spring causes automatic spline engagement, locking the setting.

SPST Proximity Switches

Load Capacity: 0.35 amp 140 VAC, 1 amp 50 VDC, 50 Watt Max.

contact rating Contact Material: Rhodium plated Actuated by magnetic force

SPDT Proximity Switches

Load Capacity: 0.25 amp 120 VAC, 0.25 amp 28 VDC, 3 Watt

Max. contact rating Contact Material: Ruthenium plated Actuatore by magnetic force MOV and 0.25 amp fuse protected

Option Q: Intrinsically Safe Solid State Proximity Switches

With the same mounting as the mechanical switches the FM/CSA rated I.S. Solid State Proximity Switches can be used to obtain valve open and closed position. T ool-free cam adjustment is accomplished through a spring-loaded spline arrangement. Simply push or pull the cam, disengaging the splines, and rotate to the desired switch trip point. After releasing, the spring causes automatic spline engagement, locking the setting.

Load Capacity: ≤ (less than or equal to) 1 mA ≥ (greater than or

equal to) 3 mA Voltage Range: 5-25 VDC

48-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

1800 1600 1400 1200 1000

800 600 400

IMPEDANCE (OHMS)

200

4 8 12 16 20

CURRENT (mA)

Page 9

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-9

Failure Probable Cause Corrective Action

Valve won’t 1. Tubing to wrong ports 1. Re-tube to correct ports (see ‘Installation’ section) stroke, no 2. Cam action reversed 2. Refer to ‘Installation’ section and reverse cam excessive air is 3. Feedback lever arm is stuck 3. Work with lever arm until it turns freely exhausting 4. Low air supply 4. Increase air supply to recommended value from positioner 5. Relay tube stuck 5. Disassemble relay assembly and work relay tube free. Lightly lubricate

if necessary

6. Balance adjust screw not adjusted 6. Adjust balance pressure with adjusting screw correctly

7. I/P module filter plugged 7. Remove I/P module and replace filter

8. I/P module failure 8. Replace I/P module

9. I/P mounting bolts loose 9. Tighten mounting bolts

10. I/P pressure signal blocked 10. Remove I/P module and clear passageway; replace O-ring if necessary

Valve won’t 1. A diaphragm in relay assembly burst 1. Replace relay assembly or replace diaphragms stroke, 2. One of the poppets is stuck 2. Remove relay assembly/poppet cover; free stuck poppet excessive air 3. Internal control valve problem 3. Refer to instructions or check for actuator tubing leaks exhausting 4. Damaged relay O-rings on relay tube 4. Disassemble relay and replace O-rings from positioner 5. Blocked passageways in relay 5. Disassemble relay and check small holes under diaphragms; clean if

clogged

Actuator goes 1. Broken feedback spring 1. Replace feedback spring to full signal 2. Linkage is disconnected or stuck 2. Check and tighten bolts/nuts in linkage. Make sure linkage position does not hang up; grease pin that rides in follower arm slot regardless of 3. Orifice is clogged by water, oil or 3. Remove orifice screw and carefully clean orifice hole signal dust in air supply

4. Bent flapper, damaged nozzle 4. Straighten flapper or replace damaged parts

5. I/P module failure 5. Replace I/P module

6. Clogged orifice screen 6. Remove relay and clean or replace orifice screen

Calibration 1. Loose positioner mounting 1. Remove cover and check three screws holding positioner to

bracket; check two bolts holding bracket to yoke

2. Loose linkage 2. Tighten nuts and bolts on linkage and stem clamp

3. Loose zero adjustment locking knobs 3. Tighten zero adjustment locking knob; re-calibrate if necessary

4. Wear of arms or pins 4. Replace worn arms, pins; grease appropriately

5. I/P mounting bolts loose 5. Tighten I/P mounting bolts

6. Stroke has changed in valve 6. Refer to valve maintenance instructions

Excessive air 1. Air leakage from manifold rings 1. Tighten screws holding relay assembly together and/or replace O-rings consumption between relay and base (other than 2. Air leakage from tubing 2. Tighten or replace tubing fittings normal 3. Leaky cylinder piston O-rings 3. Replace O-rings in cylinder exhaust) 4. Air leakage from relay 4. Disassemble relay and check and replace dynamic O-rings next to tube

if necessary

Actuator 1. Connection between signal capsule 1. Adjust gain according to Figure 8 or until actuator strokes approxistrokes very and flapper misadjusted mately equal speed in both directions. Verify alignment of upper and slowly in one lower gain plates. Make sure spacer nut is tightened direction only 2. Tubing to cylinder is restricted 2. Inspect tubing/fittings for restrictions and replace if necessary

3. Balance pressure low 3. Adjust balance pressure according to page 5

Erratic 1. Dirt buildup on relay poppets or seats 1. Disassemble; clean poppets and seats; add air filter or change filter operation 2. Dirt buildup on relay tube 2. Disassemble; clean relay and lightly lubricate; replace O-rings if neces-

sary; add air filter or change filter

3. Clogged ports / passageways in relay 3. Disassemble, inspect and clean all ports and passageways

4. Faulty I/P module 4. Replace the I/P module

5. Clogged orifice screw 5. Remove orifice screw and carefully clean orifice

6. Mechanical binding in linkage or 6. Tighten linkage or refer to valve maintenance instructions internal galling in valve

7. Clogged orifice screen 7. Remove relay and clean or replace orifice screen

Excessive 1. Restricted air flow to positioner 1. Adjust air supply as needed overshoot 2. Balance pressure not set correctly 2. Adjust balance pressure according to page 5.

3. Gain is set too high 3. Lower gain mechanism until overshoot is minimized

Troubleshooting XL90 Positioners

Page 10

1 Base assembly 2 Cover 3 Screw 6 Pressure gauge 0-160 psi 7 Bottom relay assembly 8 O-ring

9 Upper relay assembly 10 Orifice screw 11 O-ring 12 O-ring 13 Relay diaphragm assembly 14 Relay plate 15 Diaphragm retaining plate 16 Signal diaphragm assembly 17 Set screw 18 Spring 19 Set screw 20 Nut 21 Adjustable gain upper plate/flapper assembly 22 Pan head screw 23 Socket screw 24 Washer 25 Spacer nut

26 Adjustable gain lower plate 27 Poppet cover 28 Poppet 29 Poppet spring 30 O-ring 31 Retaining ring 32 Screw 33 Screw 34 Adjustable seat 35 Rubber cap 36 Balance adjust screw 37 O-ring 38 O-ring 39 Adjustable seat spring 40 Span arm 43 Pivot bushing 44 Pivot screw 45 Snap ring 46 Zero arm 47 Feedback spring 48 Pivot block 49 Adjust zero knob 50 Zero locking knob

48-10 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

119

Figure 16: XL90 Positioner – Exploded View – Accord Cam

52 Cam shaft 53 Cam 55 Nut 56 Screw 57 O-ring 66 Pneumatic adapter 67 Screw 69 O-ring 72 I/P module

73 Screws 106 Washer 107 Signal gauge 110 Orifice screen 112 Snap ring 116 Rotor or indicator 117 O-ring 118 O-ring 119 Dome 120 Adapter shaft 121 Screw 128 Jam nut 130 Spring 200 Relay assembly

All of the above parts are in stock and can be purchased in a spare parts kit. For selecting and ordering the appropriate kit or a new positioner, contact your Flowserve representative or the factory.

121 119 116

118

120

117

107

116 128

112

117

44 43 45

106

112

118

31 27

130

22 32

200

35 38

10 57

110

31 27

Page 11

1 Base assembly 2 Cover 3 Screw 6 Pressure gauge 0-160 psi 7 Bottom relay assembly 8 O-ring

27 Poppet cover 28 Poppet 29 Poppet spring 30 O-ring 31 Retaining ring 32 Screw 33 Screw 34 Adjustable seat 35 Rubber cap 36 Balance adjust screw 37 O-ring 38 O-ring 39 Adjustable seat spring 40 Span arm 43 Pivot bushing 44 Pivot screw 45 Snap ring 46 Zero arm 47 Feedback spring 48 Pivot block 49 Adjust zero knob 50 Zero locking knob 52 Cam shaft 53 Cam

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-11

55 Nut 56 Screw 57 O-ring 66 Pneumatic adapter 67 Screw 69 O-ring 72 I/P module

73 Screws 106 Washer 107 Signal gauge 110 Orifice screen 112 Snap ring 116 Rotor or indicator 117 O-ring 118 O-ring 119 Dome 120 Adapter shaft 121 Screw 125 Cam 126 Cam clip 127 Screw 128 Jam nut 130 Spring 200 Relay assembly

119

Figure 17: XL90 Positioner – Exploded View – Sereg Cam

121 119 116

118

120

117

107

116 128

112

117

44 43 45

106

112

118

125

126

127

31 27

130

200

35 38

10 57

110

31 27

Page 12

XL90 Part Numbering System

PREFIX

Selection Code

Automax Manufacture - Black Epoxy MB Automax Manufacture - White Food Grade Epoxy MW Accord Manufacture - Black Epoxy AB Accord Manufacture - White Food Grade Epoxy AW Sereg Manufacture - White Epoxy SW Valtek Manufacture - White Epoxy VW

INPUT MODEL

Selection Code

Pneumatic Input 3-15 psi 90 Electro-Pneumatic Input 4-20mA 91

General Purpose NT3000

Electro-Pneumatic Input 4-20mA 92

FM/CSA Explosion Proof and Intrins. Safe NT3000

Electro-Pneumatic Input 4-20mA 93

CENELEC EExd (Explosion Proof) NT3000

Electro-Pneumatic Input 4-20mA 94

CENELEC EExia & EExib (Intrinsically Safe) NT3000

INDICATION

Selection Code

Flat Lens with Green Indicator 1

(Standard)

Ultradome with Green Indicator U Cover for top-mounted Namur UltraSwitch T

(includes UltraSwitch mounting kit)

GAGES

Selection Code

3 Stainless Steel Gages with Brass Fittings 2

(Standard)

2 Stainless Steel Gage with Brass Fitting 3

(Standard)

3 Stainless Steel Gages 4 2 Stainless Steel Gages 5 No Gages 6

TEMPERATURE

Selection Code

Standard Temperature (Buna-N soft goods) 7 Extended Temperature (Fluorosilicone soft goods) 8

CAM

Selection Code

Accord Linear Cam A Accord 30, 45, 60 & 90 Degree Linear Cam B Accord Linear, Square, Square Root (Damper) Cam C Accord 0-60 Degree Cam (Butterfly Valves) D Sereg Linear and =% Cam - Diaphragm Actuator E Valtek Linear Cam - Piston Actuator F Valtek =% Cam-Piston Actuator-Rotary Valve G

CONDUIT THREAD CONNECTION

Selection Code

1/2" NPT (Standard) P M20 Threads R

OPTIONS - As Needed (See notes 1-4 below)

ANALOG OUTPUTS

Selection Code

4-20mA Transmitter F

INTERNAL LIMIT SWITCHES

2-SPDT Mechanical Switches with High Resolution Cams J 2-SPDT Mechanical Switches K 2-SPST Proximity Switches M 2-SPDT Proximity Switches N 2-Intrinsically Safe Solid State Proximity Switches Q

Conduit

Input Temp- Thread

Prefix Model Indication Gages erature Cam Connection Option

■■■■ ■■■■ ■■ ■■ ■■ ■■ ■■ ■■

48-12 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Notes: 1. Internal limit switches and an internal transmitter cannot be used simultaneously.

2. When options F, J, K, M, or N are used with an I/P transducer, input model number 91 must be used.

3. When option Q is used with an I/P transducer, input model numbers 90 or 92 must be used.

4. Internal limit switches or an internal transmitter cannot be used in an explosion proof environment. As an alternative, the explosion proof UltraSwitch may be mounted on top of the positioner. (Use option T.)

5. Namur shaft end connections are standard for Automax and Accord positioners, Double “D” shaft end connections are standard for Sereg and Valtek positioners. Contact factory for exceptions to this standard.

Page 13

General Spare Parts Kits

Standard O-ring Kit – Part No. 10094526

Item No. Description Quantity

8 Relay/base O-ring and relay tube O-ring 6 11 Orifice screw O-ring 1 12 Relay/base O-ring 2 30 Relay retainer O-ring 2 37 Adjustable seat O-ring 1 38 Adjustable screw O-ring 1 57 Orifice face O-ring 1 69 Input signal O-ring 2

117 Cover O-ring 1

Standard Diaphragm Kit – Part No. 10094528

Item No. Description Quantity

13 Relay diaphragm assembly (Includes 1

item No. 78, 79, 80, 81, 82, 83)

16 Signal diaphragm assembly (Includes 1

item No. 78, 79, 80, 83, 85, 86)

Standard Relay Kit – Part No. 10094530

Item No. Description Quantity

200 Relay assembly (Includes item Nos. 1

7-39, 56, 57, 110)

Shaft Kit, Double D End Connection – Part No. 10118747

Item No. Description Quantity

52 Cam Shaft 1

112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1 55 Nut 1

Ext. Temp. Relay Kit – Part No. 10094531

Item No. Description Quantity

200 Relay assembly (Includes item Nos. 1

7-39, 56, 57, 110)

Ext. Temp. O-ring Kit – Part No. 10094527

Item No. Description Quantity

117 Cover O-ring 1

Ext. Temp. Diaphragm Kit – Part No. 10094529

Item No. Description Quantity

13 Relay diaphragm assembly (Includes 1

item No. 78, 79, 80, 81, 82, 83)

16 Signal diaphragm assembly (Includes 1

item No. 78, 79, 80, 83, 85, 86)

Cover Kit, Ultradome, White – Part No. 10118702

Item No. Description Quantity

2 Cover 1

3 Screw 4

117 O-ring 1 119 Dome 1 122 Sticker, Rotor 1 120 Adapter Shaft 1 121 Screw 4 118 O-ring 1 116 Rotor 1

Cover Kit, Ultradome, Black – Part No. 10118719

Item No. Description Quantity

2 Cover 1

3 Screw 4

117 O-ring 1 119 Dome 1 122 Sticker, Rotor 1 120 Adapter Shaft 1 121 Screw 4 118 O-ring 1 116 Rotor 1

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-13

Page 14

48-14 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Shaft Kit, NAMUR End Connection – Part No. 10118753

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

Feedback Spring Kit – Part No. 10094524

Item No. Description Quantity

47 Feedback spring assembly (Includes 1

item Nos. 103, 104) 48 Pivot block 1 49 Adjustment knob 1 50 Lock knob 1

Manufacturer-Specific Spare Parts Kits

Sereg Cam Kit – Part No. 10116036

Item No. Description Quantity

53 Direct Acting Cam 1

125 Reverse Acting Cam 1 126 Cam Cover Clip 1 127 Screw 1 130 Cam Spring 1 131 Screw 1 132 Sticker, Cam 1

Cover Kit, Lens, White, Sereg – Part No. 10118691

Item No. Description Quantity

2 Cover 1

3 Screw 4 117 O-ring 1 119 Sereg Lens 1 116 Indicator 1 118 O-ring 1

Cover Kit, Lens, Black, Accord – Part No. 10118697

Item No. Description Quantity

2 Cover 1

3 Screw 4 117 O-ring 1 119 Accord Lens 1 116 Indicator 1 118 O-ring 1

Cover Kit, Lens, White, Valtek – Part No. 10118690

Item No. Description Quantity

2 Cover 1

3 Screw 4 117 O-ring 1 119 Valtek Lens 1 116 Indicator 1 118 O-ring 1

Cover Kit, Lens, Black, Automax – Part No. 10118698

Item No. Description Quantity

2 Cover 1

3 Screw 4 117 O-ring 1 119 Dome 1 116 Indicator 1 118 O-ring 1

Electronic Spare Parts Kits

WARNING: Internal electronic kits cannot be used in applications requiring explosion-proof components.

As an alternative, the explosion-proof UltraSwitch position indicator may be mounted to the top of the positioner. Consult your local Flowserve representative for ordering information.

Transmitter Kit, 4-20mA Output, Double D Shaft End Connection – Part No. 10118423

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1

55 Nut 1 130 Electronics Kit (Includes shaft gear, 1

circuit board and mounting screws)

Page 15

Transmitter Kit, 4-20mA Output, NAMUR Shaft End Connection – Part No. 10118427

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1 130 Electronics Kit (Includes shaft gear, 1

circuit board and mounting screws)

High Resolution Mechanical Limit Switch Kit, Double D Shaft End Connection – Part No. 10118432

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1

55 Nut 1 130 Electronics Kit (Includes shaft cams, 1

spring, circuit board and mounting spacers and screws)

High Resolution Mechanical Limit Switch Kit, NAMUR Shaft End Connection – Part No. 10118451

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1 130 Electronics Kit (Includes shaft cams, 1

spring, circuit board and mounting spacers and screws)

Mechanical Limit Switch Kit, Double D Shaft End Connection – Part No. 10118439

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1

55 Nut 1 130 Electronics Kit (Includes shaft cams, 1

spring, circuit board and mounting spacers and screws)

Mechanical Limit Switch Kit, NAMUR Shaft End Connection – Part No. 10118454

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1 130 Electronics Kit (Includes shaft cams, 1

spring, circuit board and mounting spacers and screws)

Proximity Limit Switch Kit, SPST, Double D Shaft End Connection – Part No. 10118444

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1

55 Nut 1 130 Electronics Kit (Includes shaft cams, 1

magnets, spring, circuit board and mounting spacers and screws)

Proximity Limit Switch Kit, SPST, NAMUR Shaft End Connection – Part No. 10118455

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1 130 Electronics Kit (Includes shaft cams, 1

magnets, spring, circuit board and mounting spacers and screws)

Proximity Limit Switch Kit, SPDT, Double D Shaft End Connection – Part No. 10118446

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1

55 Nut 1 130 Electronics Kit (Includes shaft cams, 1

magnets, spring, circuit board and mounting spacers and screws)

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-15

Page 16

48-16 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Intrinsically Safe Proximity Limit Switch Kit, NAMUR Shaft End Connection – Part No. 10118458

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1 130 Electronics Kit (Includes shaft cams, 1

magnets, spring, circuit board and mounting spacers and screws)

Proximity Limit Switch Kit, SPDT, NAMUR Shaft End Connection – Part No. 10118457

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1 130 Electronics Kit (Includes shaft cams, 1

magnets, spring, circuit board and mounting spacers and screws)

Intrinsically Safe Proximity Limit Switch Kit, Double D Shaft End Connection – Part No. 10118450

Item No. Description Quantity

52 Cam Shaft 1 112 Retaining Ring 2 128 Jam Nut 1

54 Lock Washer 1

55 Nut 1 130 Electronics Kit (Includes shaft cams, 1

magnets, spring, circuit board and mounting spacers and screws)

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of Flowserve products. The purchaser/user should read and understand the Installation, Operation, Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.

While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any of its worldwide operations or offices.

For more information about Flowserve and its products, contact www.flowserve.com or call USA 972 443 6500.

Regional Headquarters

1350 N. Mt. Springs Prkwy. Springville, UT 84663 Phone 801 489 8611 Facsimile 801 489 3719

12 Tuas Avenue 20 Republic of Singapore 638824 Phone (65) 862 3332 Facsimile (65) 862 4940

12, av. du Québec, B.P. 645 91965, Courtaboeuf Cedex, France Phone (33 1) 60 92 32 51 Facsimile (33 1) 60 92 32 99

Quick Response Centers

5114 Railroad Street Deer Park, TX 77536 USA Phone 281 479 9500 Facsimile 281 479 8511

104 Chelsea Parkway Boothwyn, PA 19061 USA Phone 610 497 8600 Facsimile 610 497 6680

1300 Parkway View Drive Pittsburgh, PA 15205 USA Phone 412 787 8803 Facsimile 412 787 1944

For more information, contact:

Flowserve and Valtek are registered trademarks of Flowserve Corporation.