MIL8013_instructionManual

Purchase Order No. :

The following instructions should be thoroughlyreviewed and understood prior to installing,operating or performing maintenance on thisequipment. Throughout the text, safety and/or

caution notes will appear and must be strictly adhered to,otherwise, serious injury or equipment malfunction could result.

Instruction Manual

INS/8013/REV-B/03-2006

ISO 9001 : 2000Certificate : 04100 2002 0157

MIL 8013

Electropneumatic Valve Positioner

MIL Controls Limited

2

the air supply contains large amounts of moisture, make

provision to remove it before the air reaches the filter-

regulator in the supply piping. Adjust the regulator

to required reduced actuator supply pressure.\

Output Air: The 1/4" NPT output pressure connectionis located on the relay and is marked by an arrow. Use1/4" OD tubing between this connection and theconnection in the actuator diaphragm case.

Installation**

**Warning :De-energise the electrical and pneumatic circuits, prior to any servicing or maintenance. Ensure all pneumaticand electrical connections are provided correctly, and the cover is in place, before energising the positioner

Note: Easily replaceable pressure gauges for air sets and externally mounted pressure gauges of positionersare normally dismantled, separately packed and bound to the actuator yoke as a precaution against transitdamages. This may be noted while opening the boxes.

Figure 1 - Mounting

Caution : The equipment has left the factory in a perfect

condition as regard safety. The notes and warnings

in these "Instructions" must be observed by the user

if this state is to be maintained and hazard-free

operation of the equipment assured.

Caution: For flame proof instruments, the positioner

cover should not be opened in the hazardous area,

when energised.

Location

Two factors should be considered for the location of

the positioner:

1. Temperature: Avoid locations which are subject

to wide ambient temperature variations. If control

valve is subject to subfreezing temperature, special

provision must be made for drying positioner air

supply.

2. Vibration: If possible, avoid locations where vibration

occurs.

The positioner may be used for either direct (air-to-

close) or reverse (air-to-open) diaphragm actuators. The

direction of actuator stem motion for an increase in

diaphragm pressure determines the mounting of the

positioner on the actuator.

On direct actuators, the positioner is mounted to the

left of the actuator stem and the positioner backlever

extends to the right of the positioner.

On reverse actuators, the mounting bracket is turned

over; the positioner is mounted to the right of the

actuator stem and the backlever is positioned to extend

to the left of the positioner.

Air Piping (Fig. 1)

Supply Air: The 1/4" NPT air supply connection is

located on the relay and is marked by an arrow. Use

1/4" OD tubing for piping supply air to the positioner.

On long runs, use larger diameter tubing or pipe. If

Caution: Do not place watches or delicate instruments

near the positioner since it employs a powerful Alnico

V Magnet.

Mounting (Fig. 1)

The positioner is rigidly mounted on the actuator

mounting pad by means of a mounting plate.

3

Linkage Assembly (Fig. 2)

When the positioner has been mounted

on the actuator, the take-off clamp is

attached to the actuator stem at a point

which permits full actuator stem travel.

The turnbuckle is installed in a vertical

position between the clamp rod and

the clevis. The lower end of the

turnbuckle has been machined round

to identify the right hand thread which

engages the turnbuckle screw.

Installation (Cont....)

Figure 2 - Take-Off Clamp S/A

General

The positioner is a force-balance

electropneumatic device which provides

an accurate means of obtaining a valve

stem position directly proportional to

a DC input signal. In addition, the

positioner provides a convenient means

of split-ranging controller output signal

for sequential operation of two control

valves by a single controller. It may

have either direct or reverse action on

either direct or reverse actuators.Figure 3

Diagrammatic of Operation

Direct Action

With direct positioner action, an increase

in the input signal produces a force on

the beam, moving the flapper to cover

the nozzle. The increase in nozzle back

pressure increases positioner output

pressure to the actuator. The resultant

valve stem motion is transmitted to the

force-balance spring, extending the

spring until the force exerted on the

beam balances the opposing force of

the coil. As these two forces equalize,

Operation (Fig. 3,4)

Take-off Clamp

Clevis (28)

Turnbuckle (60)

Turnbuckle Screw (62)Locknut (61)

Clamp Rod (63)(Take-Off-Linkage)

Clamp Screw(64)

Figure 4 - Cross Sectional View

745916 46 8 12 41 6 52B 49

50

44

39

11

40 5B 5A 5C

3

31B3531A

31D

72 7131G1524

321420 22

3 - Cover5A - Upper pole piece5B - Lower pole piece5C - Magnet

6 - Adjusting screw(Force balance spring)

8 - Spring (Force balance)11 - Biasing Spring

AdjustingScrew (Zero)

12 - Force Balance Spring \Adjusting Nuts

14 - Case15 - Terminal board (S/A)16 - Nozzle20 - Relay (S/A)22 - Mounting bracket24 - Cover plate

(Stroke adjustment)31A - Lever (Stroke adjustment)

31B - Pin (Lever stroke adj.)31D - Pinion31G - Index lockscrew

32 - Stroke lever (S/A)35 - Back lever adapter (S/A)39 - Spring bracket40 - Coil (S/A)41 - Beam44 - Machine screw (Coil stop)46 - Flapper

49 - Flexure50 - Flexure

52B - Biasing spring59 - Metering tube (S/A)71 - Bearing post

(Back lever adapter)72 - Bearing post

(Lever stroke adjustment)74 - Flame arrestor

4

CIRCLIP

PINION

(31D)

INDEX LOCK SCREW

(31G)

RELAY (S/A)

(20)

BACK LEVER

LEVER (31A)

(STROKE

ADJUSTMENT)

INDEX

STROKE

LEVER (S/A)

(32)

Adjustments (Fig.2, 4, 4A, 4B)

nozzle back pressure decreases. The system then is in

equilibrium and positioner output is stabilized at an

amount necessary to maintain the desired control valve

plug position.

When the forces on beam are in equilibrium, there is,

theoretically, no flow of air into or out from the relay.

Actually, a small bleed is provided between supply and

output to increase relay responsiveness.

Reverse Action

With reverse positioner action, an increase in the input

signal produces a decrease in output pressure.

Operation (Fig. 3,4) (Cont....)

Figure 4A

Figure 4B

BIASING SPRING ADJUSTING

SCREW (ZERO)

(11)

BIASING

SPRING

(52B)

BEAM

(41)

TERMINAL

BOARD (S/A) (15)

FLAPPER(46)

(12)

FORCE BALANCE SPRING

ADJUSTING NUTS

(8)

SPRING

(FORCE BALANCE)

(16)

FORCE BALANCE SPRING

ADJUSTING SCREW

(5C)

MAGNET

(40) COIL S/A

5

Stroke: Matches the valve stem travel to a given

range of positioner input signal. This adjustment is

accomplished by loosening the index lockscrew (31 G)

and rotating the pinion (31 D) with a screwdriver until

the index is at the correct stroke value.

Force-Balance Spring: Primarily an adjustment for

calibrating the stroke scale to compensate for variation

in coil strength. A full input signal change should fully

stroke the valve stem when the index is at the correct

stroke value. If valve stem travel is less than rated stroke,

loosen locknut and turn adjusting screw (6) counter-

clockwise. Retighten locknut.

Biasing Spring: Exerts a force on the beam to

establish proper position of the stroke levers with respect

to the positioner Input signal range. The stroke lever

(32) should be parallel to the slot in the stroke adjust-

ment lever (31 A) at midpoint of the positioner input

signal. This parallelism is obtained by adjusting of biasing

spring adjusment screw (11).

Turnbuckle: Matches valve stem position with

input signal. This adjustment is made, with controller

output signal at midrange, by rotating the turnbuckle

(60) until the valve stem is at midstroke. After making

adjustment, tighten the locknut (61)

Adjustments (Fig.2, 4, 4A, 4B)

Calibration

MIL 8013 Positioners, when furnished with MIL valves,

are factory mounted and calibrated for the rated stroke,

the action and the DC input signal range specified.

Note: No further calibration is required in the field.

In the event a positioner is supplied for field mounting,

or reversal of the positioner action in the field is

required, the following steps should be taken after first

making certain the valve is properly adjusted:

Step 1. Mount positioner, connect input signal leads,

air piping and linkage assembly as directed

under installation.

Step 2. Loosen index lockscrew (31 G) and rotate the

pinion (31 D) with a screwdriver until the

stroke index is opposite the marking on the

stroke scale corresponding to the rated

stroke of the valve.

Step 3. With proper supply pressure to the positioner;

set controller for midpoint of positioner input

signal range; e.g., 12 mA for a signal range

of 4-20 mA.

Step 4. Adjust biasing spring (52 B) (See

"Adjustments") until the inside edge of the

stroke lever (32) is parallel to the slot in the

stroke adjustment lever (31 A).

Step 5. Rotate the turnbuckle (60) until the valve

is at midstroke and recheck parallelism of

stroke and stroke adjustment levers. If nece-

ssary, repeat Steps 4 and 5 until the levers

are parallel and the valve is at midstroke

with the controller at midpoint of output

signal range.

Step 6. Set controller for minimum of positioner input

signal range (eg: 4 mA) and observe valve

position as indicated on the valve travel plate.

Step 7. Change controller setting for maximum of

positioner input range (eg: 20 mA) and check

valve stem travel. If more than rated stroke,

loosen lock-nut and turn force-balance spring

adjusting screw (6) clockwise; If less than

rated stroke, turn adjusting screw

counterclockwise, until valve indicator disk

indicates correct valve position. Tighten

locknut.

Step 8. Set controller for midpoint of positioner input

signal range and check to make certain that

stroke lever is still parallel to the slot in the

stroke adjustment lever and valve is at mid-

stroke. If incorrect, repeat Steps 4 to 8 until

the positioner input signal range matches the

rated stroke of the valve and, with positioner

input signal at midrange, the levers are parallel

when the valve is at midstroke.

Relay (Fig. 5)

Metering Tube

The metering tube for the nozzle air supply is furnished

with a clean-out plunger which forces a small wire

through the jewel orifice.

Disassembly

The metering tube body may be removed without remo-

ving the relay from the instrument case. If further

disassembly of the relay is required, proceed as follows:

Step 1. Disconnect air supply and output tubing.

Maintenance

6

Step 2. Unscrew the four mounting screws and

remove relay from instrument case.

Step 3. Remove holding screw and drop spring and

plug from relay body.

Step 4. Remove six screws holding relay cap, dia-

phragm S/A, bellofram plate S/A. gasket and

spring to relay body.

Step 5. Clean parts with soft cloth. Use solvent if

oil or grease is present. (Do not use solvent

on diaphragm or gasket). Blow out port with

clean air.

Reassembly

Step 1. Replace spring and position gasket on relay

body.

Step 2. Reassemble and align holes in relay cap,

diaphragm S/A and bellofram plate S/A. Insert

two screws, 1800 apart, through this assembly.

Step 3. Position assembly on spring and then, being

careful to align holes, exert sufficient down-

ward pressure on this assembly to engage

screws in relay body. Make certain that gasket

is properly seated before tightening screws.

Step 4. Insert remaining screws, replace relay plug,

spring and holding screw in relay body.

Step 5. Establish desired relay position and fasten

relay to instrument case.

Nozzle

To clean nozzle, shut off air supply; loosen screw

holding flapper to beam. Remove flapper and unscrew

nozzle from case. Clean nozzle with solvent and

blow out hole with clean air, Screw nozzle into case,

replace flapper on beam and tighten screw.

Beam alignment

The beam has been aligned at the factory and should

not require realignment unless the flexures are damaged

or it becomes necessary to replace the coil.

To Replace Flexures:

Step 1. Remove positioner from valve.

Step 2. Remove positioner cover and disconnect (or

unsolder *) coil leads from the terminal board.

Step 3. Disengage the end of the force balance spring

attached to the force balance spring

adjusting screw.

Step 4. Remove the two upper pole piece screws and

lift the entire operating mechanism from

the case.

Step 5. Remove biasing spring screw, releasing biasing

spring from the beam.

Step 6. Remove four screws joining flexures, upper

pole piece and beam.

Maintenance (Cont ....)

Figure 5 - Relay

7

Figure 6 - Coil Replacement

Step 7. Replace damaged flexures and reattach beam

to upper pole piece with flexures and screws.

Do not tighten scews.

Step 8. Replace coil, if necessary, and/or realign beam

as described in following sections.

To Replace Coil (Fig. 6)

Step 1. Same as Steps 1 to 6 for replacing flexures.

Step 2. Unscrew coil and machine screws, freeing coil

from beam.

Step 3. Attach replacement coil loosely to the beam

with coil and machine screws.

Note: Machine screw (44) should not extend into the

coil bobbin.

Step 4. Reattach beam to upper pole piece with

flexures and screws. Do not tighten screws.

Step 5. Align beam.

To Align Beam (Fig. 7)step 1. Insert 1/8" diameter rod into alignment hole

and underneath the beam, as near as possible

to the the coil, a wedge which is 5/32" high

and 1/32" in thickness (Fig. 7). Rod and

wedge material should be nonmagnetic.

Step 2. Tighten lower screws (two) of inner flexure

and lower screws (two) of outer flexure to

beam and upper pole piece, respectively.

Step 3. Replace operating mechanism in case. Position

biasing spring bracket and tighten in position

with two mounting screws.

Step 4. Exerting downward pressure on beam

between 5/32" high wedge and nozzle,

tighten four remaining flexure screws.

Step 5. Tighten the coil screw and remove alignment

rod and wedge.

Step 6. Adjust machine screw (44) so that flapper

travel is 1/32".

Step 7. Reattach biasing spring (52 B) to beam with

biasing spring nut.

Step 8. Engage force balance spring (8) with force

balance spring adjusting screw (6).

* Only in case of a positioner incorporated with intrinsic security circuit. This operation must be carried out outside of any hazardous location.

Maintenance (Cont....)

Figure 7 - Beam Alignment

8

Terminal Board Replacement

If it becomes necessary to change the terminal board,

proceed as follows.

Step 1. Remove operating mechanism from case as

described in Steps 1 through 4 for replacing

flexures.

Step 2. Unscrew the two screws holding terminal

board to case.

General

The following conditions are necessary for trouble free

operation:

1. Proper supply pressure, i.e., 20 psi or 35 psi.

2. Proper electrical current for input signal.

3. Proper size nozzle and metering tube as indicated

below and stamped on the component.

disassemble and clean relay (see “Main-

tenance”).

Electrical Circuits

After checking pneumatic circuit, the electrical circuit

should be checked with an ohmmeter as follows:

Step 1. Disconnect controller signal leads from

positioner.

Step 2. Connect ohmmeter leads to positioner

terminal posts and check positioner circuit

resistance with value indicated on serial plate.

Step 3. Disconnect (or unsolder *) coil lead from

positive terminal and connect it to one of

the ohmmeter leads. Connect other

ohmmeter lead to negative terminal. Coil

resistance value should approximate to 173

Ohms +_ 5%

Step 4. If coil resistance is approximately correct but

positioner circuit resistance is not, replace

terminal board. If coil resistance is not correct

replace coil.

Step 5. Remove ohmmeter lead from negative

terminal and connect it to machine screw

(44), check for short in coil. Replace coil if

ohmmeter indicates a value other than infinite

resistance.

Caution : All Maintenance work to be carried out outside

the hazardous area if instrument is Flame Proof /

Explosion proof certified.

* Only in case of a positioner incorporated with intrinsic

security circuit. This operation must be carried out outside

of any hazardous location

Maintenance (Cont....)

Trouble Shooting

NozzleNumber

20 psi Supply 35 psi Supply

11 11 11

13 12 11

15 13 12

18 13 12

24 13 13

MILActuator

Size

4. All components fastened firmly as required.

5. Machine screw (44) adjusted to allow approximately

1/32" flapper travel.

Pneumatic Circuit

In the event of faulty operation of the positioner, where

the cause is not readily apparent, check air system as

follows:

Step 1. Exert sufficient force on the flapper to cover

the nozzle. Valve stem should travel its full

stroke.

Step 2. If response is other than indicated in the

above steps, push cleanout plunger of

metering tube. Inspect for plugged nozzle.

Check to see metering tube body is properly

seated in the relay. If difficulty still persists,

Step 3. Install new terminal board and fasten

securely to case.

Step 4. Insert operating mechanism in case and

tighten screws.

Step 5. Engage the force-balance spring with force

balance spring adjusting screw.

Step 6. Connect (or soft-solder *) coil leads.

9

Split Range

In a SPLIT-RANGE assembly, the choice of the type of

connection (in series or parallel) and the characteristics

of the positioners equipping each valve, depend on the

controller output signal and impedance of the circuits.

When the positioner is ordered specifically for split-

range operation, a force balance spring with one-half

the standard rate is supplied.

The table below gives for each case (double or triple

split-range, connection of positioners in series or parallel),

the coefficient to be applied to the actual stroke value

of the equipped valve in order to obtain the adjustment

value to be indicated on the stroke scale of each positioner.

In certain cases it is possible to have standard positio-

ners operating in split-range.

When this is so, our Engineering Department supplies

all the information necessary for the choice of the

material or its eventual transformation.

Note:The indicated maximum strokes taken into account the adjusting possibilities given with a standard 8013 positioner.

Stroke AdjustmentValve

TripleSplit - Range

(3 Valves)

Actual Stroke x 1.3max. stroke: 2" (50.8 mm)

Actual Stroke x 2.6max. stroke: 1" (25.4 mm)

DoubleSplit - Range

(2 Valves)

Stroke AdjustmentValve

Actual Strokemax. stroke: 3" (76.2 mm)

Actual Stroke x 2max. stroke: 11/2" (38.1 mm)

Figure 8 - Split Range Options

Equipment for hazardous atmosphere

These standards are divided into two groups ac-

cording to two types of protection

1. Flameproof housing positoners : If because of a

failure, an internal part of the positioner causes

a spark, this can ignite the hazardous mixture

contained in the case. Thus the characteristics of

this case are calculated in order that it could resist

to the pressure developed during the internal

explosion and prevent the transmission of the

explosion to the environmental hazardous

atmosphere of the housing.

2. Positioners for intrinsically safe circuit : This protection

system which applies to a complete circuit but not

to a single and isolated device, is particularly due

Protection Standards

to the fact that no spark, no thermal effect produced

according to the test conditions recommended by

the standard regulation, can produce the ignition

of a given hazardous atmosphere.

3. Tight equipment for non-hazardous atmosphere :

8013 positioner is also available as "Weather Proof"

so as to protect the positioner against dust and

stream of water. Devices manufactured under the

reference "Weather Proof" (protection against dust

and stream of water) meet specification requirements

of IS 13947.

Caution: Do not open loosen screws of the instruments,

in flame proof atmosphere, for any repair or main-

tenance work. The instrument has to be taken outside

the hazardous area.

10

a) Hazardous atmosphere

1. Flame proof to Gr. IIA, II B as per IS2148 (With

Weather proof IP55 Certification)

Certifications for 8013 Positioners

2. Intrinsically safe Gr. IIC as per IS 5780 (With Weather

proof IP65 Certification)

b) Non-Hazardous atmosphere

1. Weather proof IP65 as per IS 2147

Electrical circuit

The installation must be in accordance with the

selected standard for the protection against

explosion.

CONNECTING SIGNAL LEADS

1. They are introduced in the case through the conduit

connection located on the side. (¾" or ½" NPT)

2. Connections to the terminal board should be made

respecting the polarities engraved on this terminal

board.

Connecting coil leads to the terminal board

This connection determines the device action.

Direct action : A signal increase produces an output

pressure increase.

Reverse action : A signal increase produces and

output pressure decrease.

The diagram of figure-9 shows the position of the coil

leads and the connecting terminals used for the terminal

board for each action of the device.

Electrical Circuits

The positioner has been factory calibrated for the action

required by the customer. If action is not specified, the

positioner is factory calibrated for direct action.

Changing of action :

1. Reverse the positions of the coil leads to the terminal

board (See diagram of figure 9)

2. In case of intrinsically safe circuit replace the coil

by another one corresponding to the new action.

Caution: Incase of flame proof housing device, the

positioner case should not be opened when the device

is energized.

Note 1 : The standards concerning electrical equip-

ment utilized in hazardous atmospheres can

be identified with serial plate fastened to

the side.

Note 2 : Besides the mark corresponding to the

positioner action, coils always have a color

code permitting the identification of the

nominal resistance. In the event of coil removal

be sure that the colour code of the new coil

is identical with the old one eg : 4-20 mA

coil with colour code blue.

Note3 : Be sure that leads connecting the coil to the

terminal-board do not block the beam

motion.Figure 9 - Coil Leads Position

Cross the leads over the beam

REVERSE ACTIONDIRECT ACTION

Branch Offices

NEW DELHI


KSB House, A-96, Sector 04,

Gautam Budh Nagar,

Noida 201 301, India

Tel: 91 (0)120 2541091 to 93, 2541501 to 03

Fax: 91 (0)120 2550567, 2525626

Email: [email protected]

MUMBAI


126, Maker Chamber III, Nariman Point,

Mumbai - 400 021, India.

Tel: 91 (0)22 56588787,

56588757 to 59, 56588761

Fax: 91 (0)22 56588788

Email: [email protected],

[email protected]

KOLKATA


2nd Floor, 30 Circus Avenue,

Kolkata 700 017, India

Tel: 91 (0)33 22470473, 22400117, 22400418

Fax: 91 (0) 33 22470588

Email: [email protected], [email protected]

CHENNAI


Guindy House, 2nd Floor,

95, Annai Salai,

Chennai 600 032, India

Tel: 91 (0)44 22352571 to 72, 22300629

Fax: 91 (0)44 22352749


VADODARA


4-B, Ramakrishna Chambers,

Productivity Road,

Vadodara 390 005, India

Tel: 91 (0)265 2330532, 2333226

Fax: 91 (0)265 2314693


PUNE


KSB Pumps Limited

D-II Block, MIDC

Chinchwad

Pune - 411 019

Tel: 91 (0)20 2740 9100

Fax: 91 (0)20 2747 0890

Overseas Sales Offices

CHINA

KSB-Shanghai Office

Rm. D-E1. 26/F., Zao-Feng Universe Building,

No. 1800 West Zhongshan Road, Shanghai,

P.R. China. Post Code: 200235.

Tel: (86)-21-6440 1668 Ext. 832

Fax: (86)-21-6440 0228

FINLAND

KSB Finland Oy

Savirunninkatu 4, FI-04260

Kerava, Finland

Tel: 358 10 288 5427

Fax: 358 10 288 5685

HONG KONG

KSB Limited

17/F, Chuang’s City Tower,

39 Morrison Hill Road,

Causeway Bay, Hong Kong

Tel: 852 2147 1220

Fax: 852 2147 1230


MALAYSIA

KSB Malaysia Pumps & Valves SDN BHD

11A, Jalan PJU 3 / 47, Sunway Damansara

47810 Petaling Jaya,

Selangor Darul Ehsan, Malaysia.

Tel: 60-03 7781 3026

Fax: 60-03 7781 3020


MIDDLE EAST

KSB Middle East FZE,

PO Box 18315

Jebel Ali, Dubai, UAE.

Tel: 9714-8830455

Fax: 9714-8830456

SINGAPORE

KSB Singapore (Asia Pacific) PTE Ltd

25 Tagore Lane, 02-08/09

Singapore Godown, Singapore 787602

Tel: 65 6555 0366

Fax: 65 6553 3500


TAIWAN

KSB Taiwan Co Ltd

Virtuoso Enterprise Building, 12F-1, No.380,

Fushing South Road, Sec. 1, Taipei 106,

Taiwan, ROC

Tel: 886-2 2755 5858

Fax: 886-2 2703 3366


REGD. OFFICE & WORKS /

SPARE PARTS & AFTERSALES DEPARTMENTS


Meladoor , Mala

PIN 680 741, Thrissur Dist., Kerala, India

T: 91 (0)480 2890272, 2890772, 2891773

F: 91 (0)480 2890952

E: [email protected], [email protected],

W: www.milcontrols.com

MARKETING HEAD OFFICE


N.H. 47, Thaikkattukara P.O., Aluva

PIN 683 106, Ernakulam Dist, Kerala, India

T: 91 (0)484-2624955, 2624876, 2628041

F: 91 (0)484-2623331

E: [email protected], [email protected]

MIL Controls Ltd.

A KSB Company

MIL8013_instructionManual

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