Automax Valve

3-Position Automation Systems

Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

Apex 4000 Positioner

Principles of Operation: Mounting: The following instructions apply to rotary actuators
The Apex 4000 positioner causes rotation (or linear only. Linear applications require special mounting and coupling
movement) of valve actuator in proportion to an input (consult factory).
signal. This signal may take the form of pneumatic
pressure (Model 4000) or electric current (Models 1. Mount bracket to actuator. Tighten bolts finger tight only at
4100, 4200, 4300 and 4400). Supply pressure is this time. A standard bracket is available for mounting to
directed to the actuator through a precision spool NAMUR compliant actuators.
valve. As input pressure is varied, the balance beam
shifts away from its neutral position. The spool also 2. Install coupler (not required if installing to a NAMUR
shifts and a differential pressure is created across the compliant actuator) on actuator shaft making sure
actuator causing rotation (or linear movement). it is centered.
Actuator motion is fed back through the positioner
shaft and cam. Cam rotation causes movement of the 3. Verify that orientation of actuator (and coupler) flats match
feedback arm, changing compression in the feedback positioner shaft flats. If necessary, rotate the cam before
spring, forcing the balance beam and spool back to installing positioner (see “Cam Installation”).
their neutral positions. This shuts off the flow of air to Note: Actuator should be in orientation corresponding
the actuator and rotation stops. to zero input signal.

Installation: 4. Install positioner onto bracket. Make sure positioner shaft

and coupler are engaged and centered. Tighten bolts finger
The Apex 4000 positioner can be installed on rotary
tight only at this time.
and linear actuators. Actuators can be either double
Pneumatic Connections: All pneumatic connections, the
acting or spring return. Positioners can be set up for
supply, both output ports, and the instrument ports are
rotation in either direction (direct or reverse acting).
female 1/4" NPT. All connections require user-supplied
tubing fittings. Caution: Do not use Teflon tape as a pipe
Supply Air Requirements: Air pressure must be
thread sealant. Use only a liquid or paste non-hardening
limited to 150 psi for supply and 30 psi for instrument
pipe sealant on the threads.
signal to avoid damage to the positioner. Supply air
must be clean, dry, and oil free instrument quality air in
5. Connect positioner ports C1 and C2 to actuator. Port C2
accordance with ISA S7.3 specifications (dew point
is always connected to the actuator port used to drive
>18 degrees below ambient temperature, particle size
actuator away from its start or fail position (the factory
<5 microns, oil content <1ppm).
cam setting is full clockwise at minimum input). Port C1
is connected to the opposite port or may be plugged for
Before making pneumatic connections to the
spring return actuators. Note: For fail counterclockwise
positioner, it is recommended that the supply air lines
applications, the cam must be flipped over so the “R”
are opened up and allowed to vent for 2-3 minutes to
side is facing upwards (see “Cam Installation”).
clear any debris from the line. If excessive amounts of
oil and/or moisture are present, the plant air supply
6. Connect supply air to the port marked “S”.
should be evaluated to reduce possibility of premature
positioner failure.
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.

FCD AXAIMO36-00 (AUTO-112) 10/04 Page 1 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

Calibration: Calibration Procedure:

The unit is shipped from the factory pre-calibrated for 90 1. Apply O% input signal (0% = 20 kPa, 3 psi, or 4 mA).
degree travel (±0.5 degrees rotation - can also be 30/45/
60 degrees, see installed cam). For most applications, 2. Wait for steady state. It is important to wait for steady
the valve closed position is much more critical than the state. On very large actuators, it can take minutes to
valve open position. Most attention should be made to establish.
the valve closed position. Always start calibration
procedure by applying 0% input signal, then adjusting 3. Adjust zero by turning the silver (lower) thumbwheel (4)
zero position. The positioner is calibrated by turning with finger or with screwdriver (7) from the outside.
thumbwheels (1) and (4). Arrows on arm (5) indicate
turning direction of thumbwheels. 4. Apply 100% input signal (100% = 100 kPa, 15 psi, or
▼▲

"+" = increase zero/span 20 mA).

"-" = decrease zero/span
5. Wait for steady state; remember result.
Caution: Cam pinch points may injure fingers. Be sure to
avoid placing fingers and other objects in cam pinch 6. Apply 0% input signal.
points. Also avoid touching balance beam and spool
while making adjustments as unpredictable cam rotation 7. Adjust span per result in step (5) above. This is
may result. Finally, maintain control of input signal while accomplished by first loosening screw (2), then turning
making adjustments. the yellow (upper) thumbwheel (1) in appropriate
direction with finger. Tighten screw 2. Spring top must
not be in contact with spring guide (3).

8. Check and adjust zero.

3 2
9. Repeat steps 2 through 8 until desired calibration is
achieved.

+ -

SPAN 5
+ - 4 + -
ZERO
1 SPAN

Span Adjustment
Zero
Adjustment

FCD AXAIMO036-00 (AUTO-112) 10/04 Page 2 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

Cam Installation: Figure below shows cam setting for reverse action,
Introduction: The standard cam (labeled "K1") features decreasing signal 100-0% (100-20 kPa, 15-3 psi) to open.
linear, 90 degree operation for full 3-15 psi input, 3-9 Flip cam over, cam follower to ride on lobe R, 0-100%.
and 9-15 psi split ranges, and 3-15 psi 180 degree
operation. The factory setting is 3-15 psi, 90 degrees,
with “D” (direct) side up for full clockwise position at
3 psi for 90° operation.
Caution: Be sure supply air pressure is removed and no 0%
LIN
pressure exists in actuator before adjusting cam. 90
˚

0%
%
Cam Adjustment:

100
1. Remove cover and indicator.

K 1
2. Loosen the camlock screw (1) and turn the cam

SP
0%
locking nut (2) counterclockwise until the cam is

L
D

10
IT
loose. It may be necessary to brace the output shaft 50 RAN
GE 9
0˚
while loosening the cam locking nut.
%
18 0 ˚ L I N

3. Adjust the cam (3) as desired, making sure that the

cam follower (4) always rides on an active lobe on
the cam. Split Range lobe is used to achieve high resolution in split
range applications, where only a portion of the signal is
4. Secure the cam by finger tightening the cam locking used to obtain 90 degrees valve travel. For example, to
nut (2), and then tighten the camlock screw (1) operate 0 to 90 degrees rotation with 0-50% input signal
(see below). (20-60 kPa, 3-9 psi), adjust cam follower to ride on Split
2
Range 0-50% lobe D. Note: To obtain reverse action, flip
0% 1 cam over and use lobe R.
90˚
LI
N

0%
10
0%

Correct
K1
10
E

0%
NG
%

SP
50 L I T RA
18 0˚ L I N

Incorrect
3

Figure below shows cam setting for Direct Action

increasing signal 0-100% (20-100 kPa, 3-15 psi)
to open. Cam follower to ride on lobe D, 0-100%.
4

0% 90˚
L
IN

%
0

10
%0
K 1
90 ˚

10
E

0%
NG
%

SP
50 L I T RA
LI N
+
18 0˚
-

SPAN

+ -
ZERO

FCD AXAIMO36-00 (AUTO-112) 10/04 Page 3 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

3 6
Spool Valve Installation: 5
To change out or inspect spool valve, air supply to the
positioner must be removed.
4

To remove spool valve:

1. Remove screw (1). 3

2. Carefully lift out entire spool valve assembly (2),

disengaging spool (3) from balance arm (5). 2

To maintain highest performance, do not mix spool

and block. Do not lubricate spool valve. 1

To install new spool valve:

1. Check that O-rings are in place.

2. Insert spool valve assembly (2), making sure that

the leaf spring (4) and balance arm (5) engage the
slot in the spool (6).

3. Tighten screw (1).

4
5
4. Check for smooth operation of assembly.
5
5

I-P Installation:
All I-P modules are factory calibrated and cannot be NV
ER
TER mA a
kP
Ri< P
0
35 si

adjusted. Kits are available to allow easy field installa-

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I/P 29
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tion of various input options. Kits include modules,

˚C
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mounting hardware, fasteners, and O-rings.

1. Disconnect signal and supply air from positioner.

2. Remove screw (1) from positioner housing. 2

3. Make sure O-rings (2) are seated correctly in I-P 1

housing.

4. For weatherproof or intrinsically-safe I-P module,

remove cover (4) to allow access to third mount-
ing screw (5). "ZZ
"
1/4
I
"

C1
5. Attach I-P module (3) to positioner housing with
three mounting screws (5) provided. C2

EN
S IN
SW
ED

DE
MA

FCD AXAIMO036-00 (AUTO-112) 10/04 Page 4 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

Electrical Specifications:
Max. Voltage Min. Voltage Max. Current
Model Agency Approvals Hazardous Location Rating1
(VDC) (VDC) (mA)
4000 None None NA NA NA
4100 None None 30 VDC 6 VDC 150 mA
FM (EX) Cl. 1, Div. 1, Gr. B-D 30 VDC 6 VDC 150 mA
4200
CSA (EX) Cl. 1, Div. 1, Gr. B-D 30 VDC 6 VDC 150 mA
4300 DMT (EX) EEx d IIC T4-T63 30 VDC4 6 VDC 50 mA4
FM (IS) Cl. 1, Div. 1, Gr. A-D 28 VDC4 6 VDC 50 mA4
CSA (IS) Cl. 1, Div. 1, Gr. A-D 28 VDC 4 6 VDC 50 mA4
44002 3 4
SCS (IS) Ex I 1 G EEx ia IIC T6 30 VDC 6 VDC 110 mA4
TÜV (IS) Ex II 2 G EEx ia IIC T63 28 VDC4 6 VDC 60 mA4
Warning: These instruments must be installed in accordance with local and national electrical codes, especially for hazardous locations.
Consult unit label to determine specific unit certifications.
Notes:
1 See hazardous location certificate for detailed temperature ratings. All Apex 4000 units comply with ATEX directive for non-electric

equipment intended for use in hazardous locations to EX II 2 G.

2 Additional information regarding entity parameters and instructions for wiring to intrinsically-safe I-P may be found in separate IOM, as

well as in the hazardous location certificate.

3 See hazardous location certificate for special conditions for safe use.
4 Maximum voltage and current considerations may be affected by application specifics, such as choice of barrier, ambient temperatures,

etc. See hazardous location certificate for additional information.

Filter Plug Replacement:
Caution: Do not operate the unit without filter and filter
plug installed. Do not attempt to unscrew filter plug while
positioner is pressurized.
Note: This filter is not designed to act as a permanent
source of clean, dry air.

1. Remove air supply pressure from positioner.

2. Unscrew filter plug (1) and O-ring.

3. Remove filter (3) and inspect filter and filter compart-

ment. If moisture is found, check upstream filters and
oil-water separators. Moisture can cause I-P failure.

4. Replace filter if necessary and reinstall.

3
2
1

FCD AXAIMO36-00 (AUTO-112) 10/04 Page 5 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

Maintenance:
The Apex 4000 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 signal problem.

Calibration Shifts: 1. Loose mounting hardware.

2. Loose cam locking nut.
3. Loose cam locking screw.

Excessive air consumption (other 1. Spool valve seals 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).

Sluggish or slow response: 1. Undersized spool valve (increase size or add volume boosters).
2. Tubing restriction (check supply between positioner/actuator).
3. Tubing too small (increase tubing size).

FCD AXAIMO036-00 (AUTO-112) 10/04 Page 6 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

18 3
19
18

18
5
4
18
16

4
19

I
NP
T 1/4
" 14
18
C1 18
10
C2

15

13
S 10
0%

10
17
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K1
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9

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18
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AN
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11
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18 18
12

19 8
7

APEX 4000 Spare Parts List 9

Item Spare
No. Part # Description Qty EN
ED
SW
IN
1 Housing 1 MA
DE

2 Front cover 1
3 Diaphragm cover incl. O-ring 1
4 Diaphragm 1
5 Diaphragm washer 2
6 Balance arm 1
7 Feedback spring assembly 1
8 Lower arm assembly 1
9 Rod 1
10 Tension spring 1
11 Lower arm guide 1
12 XK0213+ Spool valve incl. O-rings 1 +
Spool Valve Kits
13 Cam locking nut incl. screw 1
XK0213 Low flow spool valve assembly (includes O-rings)
14 Cam follower 1
XK0218 High flow spool valve assembly (includes O-rings)
15 X01162++ Cam 90°/180° Linear 0-100%,
split range 0-50-100% 1 ++
Cam Options
16 Output shaft 1
X01162 Standard linear 90˚/180˚/split range cam
17 Indicator 1
X01163 Linear 30˚/45˚/60˚ cam
18 XK0216* Screw set Set
X01166 Characterized cam, square, equal percentage
19 XK0217* Seal and O-ring set NBR, Nitrile rubber Set
X01167 Linear 60˚/120˚ butterfly valve cam
*Screw set and seal kit include components for I-P units also.

FCD AXAIMO36-00 (AUTO-112) 10/04 Page 7 of 8

© 2004, Flowserve Corporation, Printed in USA
 Automax Valve
3-Position Automation Systems
Control/Dribble Control
Installation, OperationSR Limit
and Switch Method
Maintenance Instructions
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 2233 Phone: 931 432 4021

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APEX 4000 I-P Spare Parts List

Item Spare
No. Part # Description Qty
1 KM41 General purpose I-P kit Kit
1a General purpose I-P module 1
1b I-P base block assembly (common) 1
1c I-P filter plug (common) 1
1d XK0219 I-P filter (common) 1
1e XK0216* Screw set (includes base 4000 components) Set
1f XK0217* Seal and O-ring set (includes base 4000 components) Set
2 KM42 Explosion-proof I-P kit Kit
2a Explosion-proof I-P module 1
3 KM44 Intrinsically-safe I-P kit Kit
3a Intrinsically-safe I-P module 1

* Note: KM kits do not include complete screw set and seal kit.
Complete screw sets and seal kits must be ordered separately.

FCD AXAIMO036-00 (AUTO-112) 10/04 Page 8 of 8

© 2004, Flowserve Corporation, Printed in USA