Flowserve APEX 4000 Pneumatic Positioner - Manual

© 2003, Flowserve Corporation, Printed in USA
3-Position Control/Dribble Control
SR Limit Switch Method
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
AXAIMO36-00 (AUTO-112) 07/03
Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr.
Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501
www.flowserve.com Phone: 801 489 8611 Phone: 931 432 4021
Page 1 of 8
Principles of Operation:
The Apex 4000 positioner causes rotation (or linear
movement) of valve actuator in proportion to an input
signal. This signal may take the form of pneumatic
pressure (Model 4000) or electric current (Models
4100, 4200, 4300 and 4400). Supply pressure is
directed to the actuator through a precision spool
valve. As input pressure is varied, the balance beam
shifts away from its neutral position. The spool also
shifts and a differential pressure is created across the
actuator causing rotation (or linear movement).
Actuator motion is fed back through the positioner
shaft and cam. Cam rotation causes movement of the
feedback arm, changing compression in the feedback
spring, forcing the balance beam and spool back to
their neutral positions. This shuts off the flow of air to
the actuator and rotation stops.
Installation:
The Apex 4000 positioner can be installed on rotary
and linear actuators. Actuators can be either double
acting or spring return. Positioners can be set up for
rotation in either direction (direct or reverse acting).
Supply Air Requirements: Air pressure must be
limited to 150 psi for supply and 30 psi for instrument
signal to avoid damage to the positioner. Supply air
must be clean, dry, and oil free instrument quality air in
accordance with ISA S7.3 specifications (dew point
>18 degrees below ambient temperature, particle size
<5 microns, oil content <1ppm).
Before making pneumatic connections to the
positioner, it is recommended that the supply air lines
are opened up and allowed to vent for 2-3 minutes to
clear any debris from the line. If excessive amounts of
oil and/or moisture are present, the plant air supply
should be evaluated to reduce possibility of premature
positioner failure.
Mounting: The following instructions apply to rotary actuators
only. Linear applications require special mounting and coupling
(consult factory).
1. Mount bracket to actuator. Tighten bolts finger tight only at
this time. A standard bracket is available for mounting to
NAMUR compliant actuators.
2. Install coupler (not required if installing to a NAMUR
compliant actuator) on actuator shaft making sure
it is centered.
3. Verify that orientation of actuator (and coupler) flats match
positioner shaft flats. If necessary, rotate the cam before
installing positioner (see “Cam Installation”).
Note:
Actuator should be in orientation corresponding
to zero input signal.
4. Install positioner onto bracket. Make sure positioner shaft
and coupler are engaged and centered. Tighten bolts finger
tight only at this time.
Pneumatic Connections: All pneumatic connections, the
supply, both output ports, and the instrument ports are
female 1/4" NPT. All connections require user-supplied
tubing fittings. Caution:
Do not use Teflon tape as a pipe
thread sealant. Use only a liquid or paste non-hardening
pipe sealant on the threads.
5. Connect positioner ports C1 and C2 to actuator. Port C2
is always connected to the actuator port used to drive
actuator away from its start or fail position (the factory
cam setting is full clockwise at minimum input). Port C1
is connected to the opposite port or may be plugged for
spring return actuators. Note:
For fail counterclockwise
applications, the cam must be flipped over so the “R”
side is facing upwards (see “Cam Installation”).
6. Connect supply air to the port marked “S”.
7. Connect instrument signal air to the port marked “I” for
model 4000. For models 4100, 4200, 4300 or 4400,
connect 4-20 mA and ground (-). For intrinsically-safe
applications (Model 4400 only), see separate intrinsically-
safe I-P IOM for barrier requirements and schematics.
The I-P is factory calibrated and cannot be adjusted.
8. 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 stroke.
Apex 4000 Positioner