Apex 5000 Positioner

Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800

Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

Installation, Operating and Maintenance Instructions

Principles of Operation:
The Apex 5000 positioner causes rotation (or linear Mounting: The following instructions apply to rotary actuators
movement) of valve actuator in proportion to an input only. Linear applications require special mounting and coupling.
signal. This signal may take the form of pneumatic
pressure (Model 5000) or electric current (Models 1. Mount bracket to actuator. Tighten bolts finger tight only at
5100, 5200, 5300, 5400 and 5600). Supply pressure is this time.
directed to the actuator through a precision spool
valve. As input pressure is varied, the balance beam 2. Install coupler (if required) on actuator shaft making sure
shifts away from its neutral position. The spool also it is centered.
shifts and a differential pressure is created across the
actuator causing rotation (of linear movement). 3. Verify that orientation of actuator and coupler flats matches
Rotation is fed back through the positioner shaft and positioner shaft flats. If necessary, rotate the cam before
cam. Cam rotation causes rotation of both follower arm installing positioner (see “Cam Installation”).
and feedback arm about their respective pivot pins.
Rotation of feedback arm changes compression in the 4. Install positioner onto bracket. Make sure positioner shaft
spring which forces the balance beam and spool back and coupler are engaged and centered. Tighten bolts finger
to their neutral positions. This shuts off the flow of air tight only at this time.
to the actuator and rotation stops. Pneumatic Connections: The supply and both output ports
are female 1/4” NPT. The instrument port is female 1/8”
Installation: NPT. All positioners are supplied with either gauges or pipe
plugs in the gauge ports. All connections require user-
The Apex 5000 positioner can be installed on rotary
supplied tubing fittings. Caution: Do not use Teflon tape as
and linear actuators. Actuators can be either double
a pipe thread sealant. Use only a liquid or paste non-
acting or spring return. Positioners can be set up for
hardening pipe sealant on the threads.
rotation in either direction (direct or reverse acting).
5. Connect positioner ports 1 and 2 to actuator. Port 2 is
Supply Air Requirements: Air pressure must be
always connected to the actuator port used to drive
limited to 120 psi for supply and 50 psi for instrument
actuator away from its start or fail position (the factory cam
signal to avoid damage to the positioner. Supply air
setting is full clockwise at minimum input). Port 1 is
must be clean, dry, and oil free instrument quality air in
connected to the opposite port or may be plugged for
accordance with ISA S7.3 specifications (dew point>
spring return actuators. Note: For fail counterclockwise
18 degrees below ambient temperature, particle size <5
applications, the cam must be flipped over so the “R” side
microns, oil content <1ppm).
is up (see “Cam Installation”).

6. Connect supply air to the port marked “S”.

7. Connect instrument signal air to the port marked “I” for

model 5000. For models 5100,5200 or 5400, connect 4-20
mA and(-). For intrinsically safe applications (Model 5400
only), See Figure 1 for barrier requirements and
schematics. The “I/P is factory calibrated and should not
require adjustment . See “I/P Module Calibration” if
adjustments are necessary.

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.

LMP0004-0 9/98 Page 1 of 8

© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

Cam Installation:
Introduction: The standard cam features linear, 90 degree 6. Turn span adjust pinion to rotate actuator/valve to
operation for full 3-15 psi input, 3-9 and 9-15 psi split desired end position. Counterclockwise rotation moves
ranges, and 3-15 psi 180 degree operation. The factory slide towards cam which moves actuator/valve
setting is 3-15 psi, 90 degrees, with “D” (direct) side up for towards start or fail position. Retighten lockscrew to
full clockwise position at 3 psi. lock setting.
Caution: Be sure supply air pressure is removed and no 7. Repeat steps 3 through 7 as necessary. Note: The
pressure exists in actuator before adjusting cam. Apex 5000 positioner is designed so that span
Cam Removal: With a wrench on the output shaft adjustment does not affect zero setting. However, zero
(if necessary), loosen and remove the jam nut. Remove setting may be affected slightly because of
pressure from feedback arm by pushing it away from cam. manufacturing tolerances and/or zero setting itself.
Remove cam.
Cam Installation: 8. While holding zero knob to prevent rotation, tighten
1. Be sure shaft is properly aligned with coupler jam nut to lock setting.
or actuator.
9. Replace cover.
2. Push feedback arm away from shaft to avoid pressure
on cam. Gain Adjustment:
3. Place cam over shaft. Make sure “D” is showing for Introduction: The Apex 5000 positioner features a patented
direct acting or “R” is showing for reverse acting. adjustable gain. This feature can be used to tune positioner
performance to specific applications. The adjustment
4. Align hole at start of desired range with bearing. primarily affects sensitivity, but also may affect overshoot
and speed (to a minor extent). for most applications,
5. Tighten jam nut making sure cam does not rotate. Use especially medium and large-sized actuators on valves with
a flat-bladed screwdriver to prevent cam rotation. resistive closure members (ball and plug valves), the
factory setting of maximum gain should be used for
maximum sensitivity and quick response. For smaller
Calibration: actuators or actuators on low resistance closure members
Caution: Cam pinch points may injure fingers. Be sure to (butterfly valves and dampers) lower gain may improve
avoid placing fingers and other objects in cam pinch points. performance by reducing overshoot. This also tends to
Also avoid touching balance beam and spool while making reduce sensitivity. On applications using the low flow spool
adjustments as unpredictable cam rotation may result. valve, the maximum gain setting is suggested.
Finally, maintain control of input signal while making
adjustments. 1. Remove cover and loosen gain adjust lockscrew.

1. Start with cover removed, supply air connected, and a 2. Move gain adjust assembly by holding the tab and
3 psi (4 mA) input signal. pushing towards balance beam (to decrease gain) or
away from balance beam (to increase gain). The
2. Loosen jam nut on zero adjust screw. triangle adjacent to adjustment assembly indicates
effective ends of adjustment travel when lined up with
3. Turn zero adjust screw to rotate actuator/valve to fillet closest to tab.
desired start or fail position. “Loosening” screw moves
actuator/valve away from start or fail position towards 3. Tighten lockscrew to lock setting and replace cover.
end position.
4. Important: Check positioner calibration after making
4. Change input signal to 15 psi (20 mA). gain adjustments.

5. Loosen span adjust lockscrew (larger screw on span

adjust assembly).

LMP0004-0 9/98 Page 2 of 8

© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

Maintenance:
The Apex 5000 positioner is designed for long life and 3. Check for smooth operation of the spool valve. If
trouble-free operation. The following steps should be followed it sticks or feels “gummy”, remove it and clean
every six months to assure proper operation. both spool and valve bore with solvent. Make
sure both parts are clean and dry before
1. Check air supply and associated filtration reinstalling. Do NOT apply grease to these parts.
equipment. See “Supply Air Requirements.”
4. Check for air leaks in air supply.
2. Make sure arms, bearings, and adjustment screws
move freely. Caution: Moving parts to check 5. Refer to “Troubleshooting” sections if
freedom with supply pressure connected will cause maintenance does not cure a problem.
rotation of cam. Be sure to keep fingers away from
cam pinch points. If parts do not move freely,
disassemble and lubricate with a light, instrument
grade grease (Lubriplate MAG 1 or equivalent).

Troubleshooting:
Problem Probable Cause/Solution
Actuator/Valve won’t stroke or 1. Positioner ports are connected to wrong sides of actuator.
goes full stroke with no control: 2. Cam on wrong side (see “Cam Installation”).
3. Stuck arm or spool valve (see “Maintenance”).
4. Input section problem (see “I/P Module Troubleshooting”).

Calibration Shifts: 1. Loose mounting hardware.

2. Loose cam nut.
3. Loose lock screws/nut.

Excessive air consumption (other 1. Spool valve gasket leaking or loose screws.
than normal exhaust of 10-30 scfh): 2. Air leak between positioner/actuator or within actuator.
3. If condition occurs at end of stroke only, calibration is incorrect.

Oscillation or hunting: 1. Air leak between positioner/actuator or within actuator.

2. Oversized spool valve (decrease size).
3. Gain setting too high (see “Gain Adjustment”).

Sluggish or slow response: 1. Undersized spool valve (increase size or add volume boosters).
2. Gain setting too low (see “Gain Adjustment”).
3. Tubing restriction (check supply between positioner/actuator).
4. Tubing too small (increase tubing size).

I/P Module:
General: All I/P Modules are factory calibrated and should not Ordering Information: The Apex 5000 Modular Positioning
require adjustment. However, long-term storage or storage in System (AMPS) allows easy field installation of four input
temperature extremes may affect calibration. The factory- options. Specify the following for changeover kits (Kits
installed pressure gauge may be used for calibration, but include modules, mounting hardware [if necessary],
accuracy is limited (+/- 3 percent). fasteners, and o-ring seals):

KM50 - Change I/P Module input to 3-15 psi pneumatic input.

KM51 - Change to Model 5100 I/P Module.
KM52 - Change to Model 5200 I/P Module.
KM53 - Change to Model 5300 I/P Module.
KM54 - Change to Model 5400 I/P Module.
KM56 - Change to Model 5600 I/P Module.
LMP0004-0 9/98 Page 3 of 8
© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

Electrical Specifications:
Parameter Model 5100 Model 5200 Model 5300 Model 5400 Model 5600
Max. Voltage VDC 30 30 28 30 28
Min. Voltage VDC 6 5.5 5.5 5.5 5.5
Max. Current (mA) 50 125 93.3 125 93.3
C (Micro Farad) 1 1 1 1 1
L (Mili Henry) 1 1 1 1 1
Hazardous Locations Exp. Proof Exp. Proof Intrinsically Safe Intrinsically Safe
CL l,ll, Div 1 EEx d llB+H2 CL l,ll Div 1 EEx ia llC T4
Non-incendive T6-40 to +40C Groups B-G
CL l, Div 2 T5-40 to +75C
Groups A-D T4-40 to 110C
Agency Approval FM/CSA SCS FM/CSA SCS

Class I, Division 2, Applications must be installed as specified in NEC Section 501-4 when barriers are not used.
(Refer to ANSI/ISA RP12.6 for guidance on installation).

Field Installation: All input options can be added/changed 4. Make electrical and pneumatic connections. Do not use
in the field without removing positioner cover. Figures 3 Teflon tape on supply connection fitting. Use only a
and 4 (5100 and 5200/5600 respectively) show mounting liquid or paste non-hardening pipe sealant on
information and location of terminal connections. the threads.
Caution: If I/P Module is installed in explosive atmosphere,
disconnect power prior to removing cover to avoid 5. For intrinsically safe applications (Model 5400 only)
personal injury. refer to Figure 1 for barrier information and schematics.
1. Remove supply pressure and input signal connection.
6. All I/P Modules are factory calibrated and should not
2. Remove old I/P Module or pneumatic manifold and require adjustment. However, it is recommended that
associated hardware. calibration be checked (see “I/P Module Calibration”).

3. Following applicable figure, install new I/P Module and 7. Install cover.
associated hardware. Be sure o-rings are in place.

LMP0004-0 9/98 Page 4 of 8

© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

I/P Module Calibration: Caution: If I/P Module is installed in 3. Change input to 20 mA and turn span pot until I/P
explosive atmosphere, disconnect power prior to removing Module gauge reads 15 psi.
cover to avoid personal injury. Figures 3 and 4 (5100, and 4. Zero and span adjustments are interactive, so repeat
5200-5600 respectively) show the locations of zero and steps 1 thru 3 as necessary.
span adjustments. 5. Replace cover.
1. Start with cover removed, supply pressure
connected, and a 4 mA input signal.
2. Turn zero potentiometer (pot) until I/P Module gauge
reads 3 psi.

I/P Module Troubleshooting (Model 5100 only - consult factory for 5200 & 5400):
Problem Probable Cause/Solution
I/P Module does not build up full output pressure 1. Improper zero/span setting.
regardless of input: 2. Low bias (see “Bias Adjustment”).
3. Air leakage (check o-rings & pneumatic diaphragm).
4. Low air supply.
5. Low regulator output (see “Regulator Adjustment”).

I/P Module does not build up any pressure (or does not
build up over bias pressure): Circuit Board LED not lit:
1. Loose, shorted, or reversed signal connection.
2. Coil connection reversed.
3. Controller board not responding (replace board).
Circuit Board LED lit:
1. Low bias pressure (see “Bias Adjustment”).
2. Air leakage (check o-rings & pneumatic diaphragm).
3. Bad coil connection or bad coil.
4. Dirty or plugged I/P Module filter (clean or replace).

I/P Module puts out excessive pressure at 4 mA: 1. Improper zero/span setting.
2. High bias (see “Bias Adjustment”).

I/P Module output fluctuates: 1. Air leakage (check o-rings & pneumatic diaphragm).
2. Zero or low bias pressure (see “Bias Adjustment”).

Bias Adjustment: With supply pressure connected and no the regulator setscrew (CW to increase, see figure 3). This
input signal, the I/P Module should put out between 2 and 2 adjustment may affect bias pressure, recheck bias pressure
1/2 psi. If necessary, turn the bias adjust setscrew after making adjustment.
(CW to increase, item 20 figure 3). Apex Modular Positioning System (AMPS) Options:
Regulator Adjustment: With supply pressure connected and The Apex 5000 positioner is also designed to accept modular
input adjusted to 24 mA or 125 percent, the I/P Module output accessories. These “bolt on” easily and require no
pressure should be between 18 and 20 psi. If necessary, turn housing modification. The following is a list of part numbers
to specify when ordering.

Electrical Output (Feedback) Options Pneumatic Output Options

Base No. Add Cam Option Suffix Options - Description Part Number Description
KMA A-Std. Linear Cam F - 4-20 mA Transmitter KMFC Flow Control Module
KMA B-30,45,60,90 G - 1K OHM Feedback Pot. KMBB Block/Bleed Module
KMA C-Characterized H - 10K OHM Feedback Pot. (Manual Override + lock-out)
KMS D-60° for butterfly valve K - 2-SPDT Mechanical Sw. KMBBFC Flow Control + Block/Bleed
KMS M - 2-SPST Proximity Sw. Modules
KMS N - 2-SPDT Proximity Sw.

LMP0004-0 9/98 Page 5 of 8

© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

30
30B
31F 30C
24B
30A
24A

24
31E
29

23
31D 28
21
27

31 25 22
26 21A
19
26A 21B
4
2B
3 9

6
34
2A
20

2
32 8

7
5 1
18

33
15
10
12
11 N0.
Item Part # Description Req’d
13 18 X00461 8-32 x 1/4 PHS 1
14 19 XA0093 Gain Adjustment Asmbly. 1
20 XM0122 Gain Adjstmt. Slide Pin 1
16 21 XA0100 Zero Arm Assembly 1
21A Zero Adjustment Screw
Bill of Material 17 21B Jam nut (1/4 - 28)
No. 22 X00474 Washer 2
Item Part # Description Req’d 23 X00471 E-Clip 2
1 Housing 1 24 XA0090 Span Arm Assembly 1
2 XA0092 Balance Beam Assembly 1 24A Pinion
2A Hinge Spring 24B Lockscrew
2B Feedback Spring 25 XM0106 Shaft (Standard) 1
3 XM0121 Hinge Spring Block 1 26 X00455 Snap Ring 1
4 XM0112 Hinge Spring Nut 1 26A X00625 Snap Ring 1
5 X00462 6-32 x 7/8 FHS 2 27 XM0077 Cam (Linear) 1
6 XA0089 Spool Valve Assembly (HF) 1 28 102476 Jam Nut (3/8 x 16) 1
(LF - XA0091; MF - XA0103) 29 X00359 Flat Rotor OPT
7 X00452 Spool Valve Gasket 1 30 SPCF Flat Cover Assembly OPT
8 X00449 Spool Clip 1 30A X00457 O-Ring 1
9 101920 8-32 x 3/4 RHS 2 30B X00456 Cover Screw 4
10 X00444 Signal Diaphragm 1 30C X00454 Washer 4
11 X00245 Diaphragm Washer 2 31 SPCP Pharos Cover Assembly OPT
12 X00465 Seal Screw 1 31D 102258 O-Ring 1
13 X00428 Diaphragm Cover 1 31E SXLROTOP Pharos Rotor 1
14 105330 6-32 x 1/2 PHS 4 31F 104010 Pharos Dome 1
15 103603 O-Ring 2 32 X00121 Pharos Adapter OPT
16 XM0105 Manifold 1 33 X00464 Vent Screen 1
17 X00257 8-32 x 5/8 PHS 4 34 X00463 Conduit Plug 1

LMP0004-0 9/98 Page 6 of 8

© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

11
10 Regulator Set
9
Screw
26

1 8
7
TERMINAL
BLOCK
19 22 23
25
21

SPAN
ADJ.
ZERO
ADJ. 2

3
12
27 13 24
14 4
19 15
5
29 16
6
28 17
18
FIG. 3
(Bias Adjustment)
20

Model 5100 I/P Transducer

Bill of Material
No. No.
Item Part # Description Req’d Item Part # Description Req’d
1 Housing 1 16 X00108 Washer 4
2 X00486 O-Ring 1 17 X00351 Bias Spring 1
3 XM0092 Filter/Regulator Spool 1 18 XM0115 Coil Retainer 1
4 X00435 Filter 1 19 X00466 6-32 x 1/4 PHS 6
5 X00487 O-Ring 1 20 X00358 1/4-28 Set Screw 1
6 XM0093 Filter Cover 1 21 101263 O-Ring 1
7 X00133 O-Ring 1 22 XA0094 PCB Assembly 1
8 X00488 Spacer 1 23 X00216 8-32 x 1/2 PHS 1
9 X00120 Regulator 1 24 102304 8-32 x 1 1/4 PHS 4
10 XM0114 Regulator Cover 1 25 103603 O-Ring 2
11 101921 6-32 x 3/8 PHS 2 26 X00096 Gauge 1
12 X00489 Coil Spacer 1 27 X00491 O-Ring 1
13 X00214 O-Ring 1 28 XM0083 Cover 1
14 XA0016 Coil Assembly 1 29 X00360 Cover Screw 4
15 X00054 Spider Diaphragm 1

LMP0004-0 9/98 Page 7 of 8

© 1998, Flowserve Corporation, Cincinnati, OH
 Apex 5000 Positioner
Flowserve Corporation 11444 Deerfield Road Phone: 513 489 7800
Flow Control Division Cincinnati, Ohio 45242 Facsimile: 513 489 5243
Automax Valve Automation Systems www.flowserve.com Email: [email protected]

Model 5200 - 5600

I/P Transducer

SPAN TERMINAL
ADJ. BLOCK

ZERO
ADJ.

OUTPUT
GAUGE

FIG. 4

LMP0004-0 9/98 Page 8 of 8

© 1998, Flowserve Corporation, Cincinnati, OH