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Caution : The equipment has left the factory in a perfect The positioner may be used for either direct (air-to-
condition as regard safety. The notes and warnings close) or reverse (air-to-open) diaphragm actuators. The
in these "Instructions" must be observed by the user direction of actuator stem motion for an increase in
if this state is to be maintained and hazard-free diaphragm pressure determines the mounting of the
operation of the equipment assured. positioner on the actuator.
Figure 1 - Mounting
Caution: Do not place watches or delicate instruments the air supply contains large amounts of moisture, make
near the positioner since it employs a powerful Alnico provision to remove it before the air reaches the filter-
V Magnet. regulator in the supply piping. Adjust the regulator
to required reduced actuator supply pressure.\
Mounting (Fig. 1) Output Air: The 1/4" NPT output pressure connection
is located on the relay and is marked by an arrow. Use
The positioner is rigidly mounted on the actuator
1/4" OD tubing between this connection and the
mounting pad by means of a mounting plate. connection in the actuator diaphragm case.
**Warning :De-energise the electrical and pneumatic circuits, prior to any servicing or maintenance. Ensure all pneumatic
and 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 positioners
are normally dismantled, separately packed and bound to the actuator yoke as a precaution against transit
damages. This may be noted while opening the boxes.
2
Installation (Cont....)
Linkage Assembly (Fig. 2)
Turnbuckle (60)
When the positioner has been mounted Clevis (28)
on the actuator, the take-off clamp is Turnbuckle Screw (62)
Locknut (61)
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 Clamp Rod (63)
(Take-Off-Linkage)
the clevis. The lower end of the
turnbuckle has been machined round
to identify the right hand thread which Clamp Screw(64)
Take-off Clamp
50 39
16 46 8 12 41 6 52B 49 44 40 5B 5A 5C
59 74 11
3 -
Cover 12 - Force Balance Spring \ 31B - Pin (Lever stroke adj.) 49 -
Flexure
5A -
Upper pole piece Adjusting Nuts 31D - Pinion 50 -
Flexure
5B -
Lower pole piece 14 - Case 31G - Index lockscrew 52B -
Biasing spring
5C -
Magnet 15 - Terminal board (S/A) 32 - Stroke lever (S/A) 59 -
Metering tube (S/A)
6 -
Adjusting screw 16 - Nozzle 35 - Back lever adapter (S/A) 71 -
Bearing post
(Force balance spring) 20 - Relay (S/A) 39 - Spring bracket (Back lever adapter)
8 - Spring (Force balance) 22 - Mounting bracket 40 - Coil (S/A) 72 - Bearing post
11 - Biasing Spring 24 - Cover plate 41 - Beam (Lever stroke adjustment)
Adjusting (Stroke adjustment) 44 - Machine screw (Coil stop) 74 - Flame arrestor
Screw (Zero) 31A - Lever (Stroke adjustment) 46 - Flapper
nozzle back pressure decreases. The system then is in Actually, a small bleed is provided between supply and
equilibrium and positioner output is stabilized at an output to increase relay responsiveness.
amount necessary to maintain the desired control valve
plug position. Reverse Action
When the forces on beam are in equilibrium, there is, With reverse positioner action, an increase in the input
theoretically, no flow of air into or out from the relay. signal produces a decrease in output pressure.
Figure 4A
CIRCLIP
BACK LEVER
PINION
(31D)
LEVER (31A)
(STROKE
INDEX LOCK SCREW ADJUSTMENT)
(31G)
INDEX
STROKE
LEVER (S/A)
(32)
RELAY (S/A)
(20)
Figure 4B
TERMINAL BIASING BIASING SPRING ADJUSTING
BOARD (S/A) (15) BEAM SPRING SCREW (ZERO)
(41) (52B) (11)
4
Adjustments (Fig.2, 4, 4A, 4B)
Stroke: Matches the valve stem travel to a given Biasing Spring: Exerts a force on the beam to
range of positioner input signal. This adjustment is establish proper position of the stroke levers with respect
accomplished by loosening the index lockscrew (31 G) to the positioner Input signal range. The stroke lever
and rotating the pinion (31 D) with a screwdriver until (32) should be parallel to the slot in the stroke adjust-
the index is at the correct stroke value. ment lever (31 A) at midpoint of the positioner input
signal. This parallelism is obtained by adjusting of biasing
Force-Balance Spring: Primarily an adjustment for spring adjusment screw (11).
calibrating the stroke scale to compensate for variation
in coil strength. A full input signal change should fully Turnbuckle: Matches valve stem position with
stroke the valve stem when the index is at the correct input signal. This adjustment is made, with controller
stroke value. If valve stem travel is less than rated stroke, output signal at midrange, by rotating the turnbuckle
loosen locknut and turn adjusting screw (6) counter- (60) until the valve stem is at midstroke. After making
clockwise. Retighten locknut. adjustment, tighten the locknut (61)
Calibration
MIL 8013 Positioners, when furnished with MIL valves, stroke and stroke adjustment levers. If nece-
are factory mounted and calibrated for the rated stroke, ssary, repeat Steps 4 and 5 until the levers
the action and the DC input signal range specified. are parallel and the valve is at midstroke
with the controller at midpoint of output
Note: No further calibration is required in the field.
signal range.
In the event a positioner is supplied for field mounting,
Step 6. Set controller for minimum of positioner input
or reversal of the positioner action in the field is
signal range (eg: 4 mA) and observe valve
required, the following steps should be taken after first
position as indicated on the valve travel plate.
making certain the valve is properly adjusted:
Step 7. Change controller setting for maximum of
Step 1. Mount positioner, connect input signal leads,
positioner input range (eg: 20 mA) and check
air piping and linkage assembly as directed
valve stem travel. If more than rated stroke,
under installation.
loosen lock-nut and turn force-balance spring
Step 2. Loosen index lockscrew (31 G) and rotate the adjusting screw (6) clockwise; If less than
pinion (31 D) with a screwdriver until the rated stroke, turn adjusting screw
stroke index is opposite the marking on the counterclockwise, until valve indicator disk
stroke scale corresponding to the rated indicates correct valve position. Tighten
stroke of the valve. locknut.
Step 3. With proper supply pressure to the positioner; Step 8. Set controller for midpoint of positioner input
set controller for midpoint of positioner input signal range and check to make certain that
signal range; e.g., 12 mA for a signal range stroke lever is still parallel to the slot in the
of 4-20 mA. stroke adjustment lever and valve is at mid-
Step 4. Adjust biasing spring (52 B) (See stroke. If incorrect, repeat Steps 4 to 8 until
"Adjustments") until the inside edge of the the positioner input signal range matches the
stroke lever (32) is parallel to the slot in the rated stroke of the valve and, with positioner
stroke adjustment lever (31 A). input signal at midrange, the levers are parallel
when the valve is at midstroke.
Step 5. Rotate the turnbuckle (60) until the valve
is at midstroke and recheck parallelism of
Maintenance
5
Maintenance (Cont ....)
Figure 5 - Relay
Step 5. Establish desired relay position and fasten Step 6. Remove four screws joining flexures, upper
relay to instrument case. pole piece and beam.
6
Maintenance (Cont....)
Step 7. Replace damaged flexures and reattach beam To Align Beam (Fig. 7)
to upper pole piece with flexures and screws. step 1. Insert 1/8" diameter rod into alignment hole
Do not tighten scews. and underneath the beam, as near as possible
to the the coil, a wedge which is 5/32" high
Step 8. Replace coil, if necessary, and/or realign beam and 1/32" in thickness (Fig. 7). Rod and
as described in following sections. wedge material should be nonmagnetic.
To Replace Coil (Fig. 6) Step 2. Tighten lower screws (two) of inner flexure
and lower screws (two) of outer flexure to
Step 1. Same as Steps 1 to 6 for replacing flexures. beam and upper pole piece, respectively.
Step 2. Unscrew coil and machine screws, freeing coil Step 3. Replace operating mechanism in case. Position
from beam. biasing spring bracket and tighten in position
with two mounting screws.
Step 3. Attach replacement coil loosely to the beam
with coil and machine screws. Step 4. Exerting downward pressure on beam
between 5/32" high wedge and nozzle,
Note: Machine screw (44) should not extend into the tighten four remaining flexure screws.
coil bobbin.
Step 5. Tighten the coil screw and remove alignment
Step 4. Reattach beam to upper pole piece with rod and wedge.
flexures and screws. Do not tighten screws.
Step 6. Adjust machine screw (44) so that flapper
Step 5. Align beam. travel is 1/32".
* Only in case of a positioner incorporated with intrinsic security circuit. This operation must be carried out outside of any hazardous location.
7
Maintenance (Cont....)
Terminal Board Replacement Step 3. Install new terminal board and fasten
securely to case.
If it becomes necessary to change the terminal board,
proceed as follows. Step 4. Insert operating mechanism in case and
tighten screws.
Step 1. Remove operating mechanism from case as
described in Steps 1 through 4 for replacing Step 5. Engage the force-balance spring with force
flexures. balance spring adjusting screw.
Step 2. Unscrew the two screws holding terminal Step 6. Connect (or soft-solder *) coil leads.
board to case.
Trouble Shooting
1. Proper supply pressure, i.e., 20 psi or 35 psi. After checking pneumatic circuit, the electrical circuit
should be checked with an ohmmeter as follows:
2. Proper electrical current for input signal.
3. Proper size nozzle and metering tube as indicated Step 1. Disconnect controller signal leads from
below and stamped on the component. positioner.
4. All components fastened firmly as required. Step 4. If coil resistance is approximately correct but
5. Machine screw (44) adjusted to allow approximately positioner circuit resistance is not, replace
1/32" flapper travel. terminal board. If coil resistance is not correct
replace coil.
Pneumatic Circuit
Step 5. Remove ohmmeter lead from negative
In the event of faulty operation of the positioner, where terminal and connect it to machine screw
the cause is not readily apparent, check air system as (44), check for short in coil. Replace coil if
follows: ohmmeter indicates a value other than infinite
Step 1. Exert sufficient force on the flapper to cover resistance.
the nozzle. Valve stem should travel its full
Caution : All Maintenance work to be carried out outside
stroke.
the hazardous area if instrument is Flame Proof /
Step 2. If response is other than indicated in the
Explosion proof certified.
above steps, push cleanout plunger of
metering tube. Inspect for plugged nozzle. * Only in case of a positioner incorporated with intrinsic
Check to see metering tube body is properly security circuit. This operation must be carried out outside
seated in the relay. If difficulty still persists, of any hazardous location
8
Split Range
In a SPLIT-RANGE assembly, the choice of the type of the coefficient to be applied to the actual stroke value
connection (in series or parallel) and the characteristics of the equipped valve in order to obtain the adjustment
of the positioners equipping each valve, depend on the value to be indicated on the stroke scale of each positioner.
controller output signal and impedance of the circuits.
In certain cases it is possible to have standard positio-
When the positioner is ordered specifically for split- ners operating in split-range.
range operation, a force balance spring with one-half
the standard rate is supplied. When this is so, our Engineering Department supplies
all the information necessary for the choice of the
The table below gives for each case (double or triple material or its eventual transformation.
split-range, connection of positioners in series or parallel),
Double
Split - Range
(2 Valves)
Triple
Split - Range
(3 Valves)
Note:The indicated maximum strokes taken into account the adjusting possibilities given with a standard 8013 positioner.
Protection Standards
Equipment for hazardous atmosphere to the fact that no spark, no thermal effect produced
according to the test conditions recommended by
These standards are divided into two groups ac- the standard regulation, can produce the ignition
cording to two types of protection of a given hazardous atmosphere.
1. Flameproof housing positoners : If because of a 3. Tight equipment for non-hazardous atmosphere :
failure, an internal part of the positioner causes 8013 positioner is also available as "Weather Proof"
a spark, this can ignite the hazardous mixture so as to protect the positioner against dust and
contained in the case. Thus the characteristics of stream of water. Devices manufactured under the
this case are calculated in order that it could resist reference "Weather Proof" (protection against dust
to the pressure developed during the internal and stream of water) meet specification requirements
explosion and prevent the transmission of the of IS 13947.
explosion to the environmental hazardous
atmosphere of the housing. Caution: Do not open loosen screws of the instruments,
2. Positioners for intrinsically safe circuit : This protection in flame proof atmosphere, for any repair or main-
system which applies to a complete circuit but not tenance work. The instrument has to be taken outside
to a single and isolated device, is particularly due the hazardous area.
9
Certifications for 8013 Positioners
a) Hazardous atmosphere 2. Intrinsically safe Gr. IIC as per IS 5780 (With Weather
proof IP65 Certification)
1. Flame proof to Gr. IIA, II B as per IS2148 (With
Weather proof IP55 Certification) b) Non-Hazardous atmosphere
The installation must be in accordance with the The positioner has been factory calibrated for the action
selected standard for the protection against required by the customer. If action is not specified, the
explosion. positioner is factory calibrated for direct action.
1. They are introduced in the case through the conduit 1. Reverse the positions of the coil leads to the terminal
connection located on the side. (¾" or ½" NPT) board (See diagram of figure 9)
2. Connections to the terminal board should be made 2. In case of intrinsically safe circuit replace the coil
respecting the polarities engraved on this terminal by another one corresponding to the new action.
board.
Caution: Incase of flame proof housing device, the
Connecting coil leads to the terminal board
positioner case should not be opened when the device
This connection determines the device action. is energized.
Direct action : A signal increase produces an output
Note 1 : The standards concerning electrical equip-
pressure increase.
ment utilized in hazardous atmospheres can
Reverse action : A signal increase produces and be identified with serial plate fastened to
output pressure decrease. the side.
The diagram of figure-9 shows the position of the coil Note 2 : Besides the mark corresponding to the
leads and the connecting terminals used for the terminal positioner action, coils always have a color
board for each action of the device. code permitting the identification of the
nominal resistance. In the event of coil removal
DIRECT ACTION REVERSE ACTION
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.
10
MIL Controls Ltd. Branch Offices Overseas Sales Offices
A KSB Company
NEW DELHI CHINA
MIL Controls Limited KSB-Shanghai Office
KSB House, A-96, Sector 04, Rm. D-E1. 26/F., Zao-Feng Universe Building,
Gautam Budh Nagar, No. 1800 West Zhongshan Road, Shanghai,
Noida 201 301, India P.R. China. Post Code: 200235.
Tel: 91 (0)120 2541091 to 93, 2541501 to 03 Tel: (86)-21-6440 1668 Ext. 832
Fax: 91 (0)120 2550567, 2525626 Fax: (86)-21-6440 0228
Email: milnoida@ksb.co.in
REGD. OFFICE & WORKS / FINLAND
SPARE PARTS & AFTERSALES DEPARTMENTS MUMBAI KSB Finland Oy
MIL Controls Limited MIL Controls Limited Savirunninkatu 4, FI-04260
Meladoor , Mala 126, Maker Chamber III, Nariman Point, Kerava, Finland
PIN 680 741, Thrissur Dist., Kerala, India Mumbai - 400 021, India. Tel: 358 10 288 5427
T: 91 (0)480 2890272, 2890772, 2891773 Tel: 91 (0)22 56588787, Fax: 358 10 288 5685
F: 91 (0)480 2890952 56588757 to 59, 56588761
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W: www.milcontrols.com Email: milmumbai@vsnl.com, KSB Limited
mum-mil@ksb.co.in 17/F, Chuang’s City Tower,
MARKETING HEAD OFFICE 39 Morrison Hill Road,
MIL Controls Limited KOLKATA Causeway Bay, Hong Kong
N.H. 47, Thaikkattukara P.O., Aluva MIL Controls Limited Tel: 852 2147 1220
PIN 683 106, Ernakulam Dist, Kerala, India 2nd Floor, 30 Circus Avenue, Fax: 852 2147 1230
T: 91 (0)484-2624955, 2624876, 2628041 Kolkata 700 017, India Email: ksb_hk@pacific.net.hk
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E: ksbmil@sancharnet.in, mail@milcontrols.com Fax: 91 (0) 33 22470588 MALAYSIA
Email: milcal@vsnl.net, cal-mil@ksb.co.in KSB Malaysia Pumps & Valves SDN BHD
11A, Jalan PJU 3 / 47, Sunway Damansara
CHENNAI 47810 Petaling Jaya,
MIL Controls Limited Selangor Darul Ehsan, Malaysia.
Guindy House, 2nd Floor, Tel: 60-03 7781 3026
95, Annai Salai, Fax: 60-03 7781 3020
Chennai 600 032, India Email: ksbamri@po.jaring.my
Tel: 91 (0)44 22352571 to 72, 22300629
Fax: 91 (0)44 22352749 MIDDLE EAST
Email: che-mil@ksb.co.in KSB Middle East FZE,
PO Box 18315
VADODARA Jebel Ali, Dubai, UAE.
MIL Controls Limited Tel: 9714-8830455
4-B, Ramakrishna Chambers, Fax: 9714-8830456
Productivity Road,
Vadodara 390 005, India SINGAPORE
Tel: 91 (0)265 2330532, 2333226 KSB Singapore (Asia Pacific) PTE Ltd
Fax: 91 (0)265 2314693 25 Tagore Lane, 02-08/09
Email: ksbad1@sancharnet.in Singapore Godown, Singapore 787602
Tel: 65 6555 0366
PUNE Fax: 65 6553 3500
MIL Controls Limited Email: sales@ksb-amri.com.sg
KSB Pumps Limited
D-II Block, MIDC TAIWAN
Chinchwad KSB Taiwan Co Ltd
Pune - 411 019 Virtuoso Enterprise Building, 12F-1, No.380,
Tel: 91 (0)20 2740 9100 Fushing South Road, Sec. 1, Taipei 106,
Fax: 91 (0)20 2747 0890 Taiwan, ROC
Tel: 886-2 2755 5858
Fax: 886-2 2703 3366
Email: ksbtwn@gmail.gcn.net.tw