OPERATION AND MAINTENANCE

MANUAL

MLI-A037

IBHCV Valve
2-1-2007
Valtek Mark One and
Mark Two Control Valves
GENERAL INFORMATION
The following instructions are designed to assist in
unpacking, installing and performing maintenance as
required on Valtek® Mark One and Mark Two control
valves. Product users and maintenance personnel
should thoroughly review this bulletin prior to installing,
operating or performing any maintenance on the valve.
Separate installation, operation, maintenance instruc-
tions cover additional features (such as special trim,
diaphragm actuator, handwheel and extension bonnets).
This publication does not contain information on Valtek
positioners. Refer to the appropriate Installation, Opera-
tion, Maintenance Instructions for installing, maintain-
ing, troubleshooting, calibrating and operating Valtek
positioners.
To avoid possible injury to personnel or dam-
age to valve parts, WARNING and CAUTION
notes must be strictly followed. Modifying this
product, substituting non-factory parts or us-
ing maintenance procedures other than out-
lined could drastically affect performance and
be hazardous to personnel and equipment and
may void existing warranties.
WARNING: Standard industry safety practices
must be adhered to when working on this or any
other process control product. Specifically, per-
sonal protective and lifting devices must be used
as warranted.
Valtek No.
Flowserve 49011 Valtek Control Products, Tel. USA 801 489 8611
Corporation,
NOTE: Selecting the proper fastener material is the
responsibility of the customer. Typically, the supplier
does not know what the valve service conditions or
environment may be. Flowserve's standard body bolt-
ing material is B7/2H. B8 (stainless steel) is optional for
applications more than 800° F / 425° C and with
stainless steel or alloy body valves. The customer
therefore must consider the material's resistance to
stress corrosion cracking in addition to general corro-
sion. As with any mechanical equipment, periodic
inspection and maintenance is required. For more
information about fastener materials, contact your
Flowserve representative.
Unpacking
1. While unpacking the valve, check the packing list
against materials received. Lists describing valve
and accessories are in each shipping container.
2. When lifting the valve from shipping container, posi-
tion the lifting straps through the yoke legs to avoid
damage to the tubing and mounted accessories.
WARNING: When lifting an actuator with lifting
straps through the yoke legs, be aware that the
center of gravity may be above the lifting point.
Therefore, support must be given to prevent the
actuator from rotating. Failure to do so can cause
serious injury to personnel, damage to the valve
or nearby equipment.
1-1
3. Contact your shipper immediately if there is shipping arrow attached to the body flange. Standard air-to-
damage. open valves close on air failure and should be
installed so the flow tends to close the valve, except
4. Should any problem arise, call your representative.
in rare circumstances that will be clearly indicated.
Standard air-to-close valves open on air failure and
Installation should be installed with the flow tending to open the
1. Before installing the valve, clean the line of dirt, valve.
welding chips, scale or other foreign material. 5. If welding the valve into the line, use extreme care to
2. Whenever possible, the valve should be installed in avoid excess heat buildup in the valve.
an upright position. Vertical installation permits 6. If the valve has separable end flanges, the half rings
easier valve maintenance. This is also important for must be installed on the valve body before bolting the
cryogenic applications to keep the packing isolated valve into the line to ensure a tight connection.
from the flowing medium, permitting the packing
temperature to remain close to ambient temperature. WARNING: Failure to install half rings on the
valve body can cause serious personal injury.
CAUTION: Do not insulate extension bonnets
that are provided for hot or cold services. 7. Connect air supply and instrument signal (air or mA)
lines. Throttling control valves are equipped with a
valve positioner. Two connections are marked: one
Table I: Overhead Clearance Requirement
for the air supply and the other for the instrument
Valve Size Clearance Valve Size Clearance signal. Both the actuator and the positioner are
(inches) (inches) (inches) (inches) suitable for 150 psi / 10.3 Bar air supply. An air
regulator is not required unless the supply pressure
1
/ 2 , 3/ 4 , 1 3 / 76 6 10 / 254 exceeds 150 psi / 10.3 Bar. An air filter should be
11/2, 2 5 / 127 8 13 / 330 installed before the positioner unless supply air is
3 6 / 152 10 14 / 356 clean and dry. All connections must be free of leaks.
4 8 / 203 12 15 / 381 CAUTION: On valves equipped with air filters, the
air filter must point down to perform properly.
3. Be sure to provide proper overhead clearance for the
NOTE: In some rare cases, the air supply must be
actuator to allow for disassembly of the plug from the
limited to less than 150 psi / 10.3 Bar. This is indi-
valve body. Refer to Table I for the necessary clear-
cated on a sticker found near the upper air port on the
ance needed for valve disassembly.
actuator cylinder. An air regulator should be installed
4. Double-check flow direction to be sure the valve is to ensure the supply pressure does not exceed the
installed correctly. Flow direction is shown by the line pressure indicated on the sticker.

Table II: Common Lubricants

Temperature
Lubricant Manufacturer Range Description Applications

Krytox 206 E.I. DuPont -5° to 550° F / Fluorinated general purpose grease; handles common
-20° to 285° C liquids and gases; good lubricity in harsh mediums;
nonflammable, chemically inert; will not harm plastic
or metal parts
GP 460 Graphite 32° to 1000° F / Graphite in petrolatum; high pressures; anti-galling,
Products Co. 0° to 540° C graphite remains above 600° F / 316° C
Aeroshell Shell Oil Co. -100° to 300° F / Synthetic oil based; low temperature applications
Grease 7 -75° to 150° C
Garlock Garlock Inc. 32° to 500° F / General purpose molybdenum disulfide lubricant
Luball 0° to 260° C economical; good in water, steam and common
chemicals; not good in harsh mediums where Krytox
206 is recommended

1-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Adjusting Screw
(Item No. 210)

Spring Adjusting Screw Gasket

(Item No. 229) (Item No. 248)

Piston Stem O-ring Spring Button

(Item No. 272) (Item No. 227)

Cylinder Actuator Stem Locknut

(Item No. 202) (Item No. 348)

Piston Actuator Stem Spacer

(Item No. 225) (Item No. 228)

Actuator Stem Bushing

Piston O-ring (Item Nos. 253/254)
(Item No. 271)
Actuator Stem O-ring
Yoke O-ring (Item No. 275)
(Item No. 274)
Actuator Stem
Stem Clamp (Item No. 211)
(Item No. 249)
Cylinder Retaining Ring
Gland Flange (Item No. 256)
(Item No. 80)
O
Stroke Plate
Upper Packing (item No. 213)
(Item No. 88)
Stem Bellows
Yoke Clamp S (Item No. 247)
(Item No. 76)
Yoke
Packing Spacer(s) (Item No. 201)
(Item Nos. 94-99)
Upper Stem Guide
Bonnet (Item No. 87)
(Item No. 40)
Upper Stem Guide Liner
Bonnet Flange (Item No. 86)
(Item No. 70)
Anti-Extrusion Spacer
Anti-Extrusion Spacer (Item No. 93)
(Item No. 93)
Bonnet Flange
Stud and Nut
Seat Retainer (Item Nos. 108/114)
(Item No. 30)
Bonnet Gasket
Seat Ring (Item No. 58)
(Item No. 20)
Lower Packing
Seat Ring (Item No. 88)
Gasket
Lower Stem
(Item No. 55)
Guide
Body (Item No. 83)
(Item No. 1)
Lower Stem
Half Ring Guide Liner
(Item No. 11) E0031
(Item No. 82)

End Flange Plug

(Item No. 10) (Item No. 50)
Figure 1: Mark One Control Valve
NOTE: Item numbers correspond directly to the valve's bill of material. Refer to it for specific part numbers.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 1-3
Quick-check
Prior to start-up, check the control valve by following
these steps:
1. Stroke the valve and observe the plug position
indicator on the stem clamp compared to the stroke
indicator plate. The plug should change position in
a smooth, linear fashion.
2. Check for full stroke by making appropriate instru-
ment signal change: 3-15, 3-9, 9-15 psi / 0-1, 0-0.6,
0.6-1 Bar or associated split ranges for pneumatic
positioners, 4-20 or 10-50 mA for electro-pneu-
matic positioners).
3. Check all air connections for leaks.
4. Adjust the packing nuts to slightly over finger-tight.
CAUTION: Do not overtighten packing. This can
cause excessive packing wear and high stem
friction that may impede plug movement.
5. Make sure the valve fails in the correct direction in
case of air failure. This is done by shutting off the air
supply and observing the failure direction.
6. After temperature excursion has occurred, bonnet
flange bolting should be retightened to ensure bon-
net gaskets do not leak. See Table III.
VALVE MAINTENANCE
At least once every six months, check for proper opera-
tion by following the preventative maintenance steps
outlined below. These steps can be performed while the
valve is in-line and, in some cases, without interrupting
service. If an internal problem is suspected, refer to the
“Valve Disassembly and Reassembly” section.
1. Look for signs of gasket leakage through the end
flanges and bonnet. Tighten flange and bonnet
bolting (if required). See Table III.
2. Check for fluid leakage to the atmosphere through
the pressure-balance sleeve, metal bellows seal
and body drain plug.
3. Examine the valve for damage caused by corrosive
fumes or process drippings.
4. Clean valve and repaint areas of severe oxidation.
5. Check packing box bolting for proper tightness.
Packing nuts should be slightly over finger-tight;
however, tighten only as necessary to prevent stem
leakage.
CAUTION: Do not overtighten packing. This can
cause excessive packing wear and high stem
friction that may impede stem movement.
6. If the valve is supplied with a lubricator fitting, check
lubricant supply and add lubricant if necessary. See
Table II for common lubricants.
1-4
7. If possible, stroke the valve and check for smooth,
full-stroke operation. Unsteady stem movement
could indicate an internal valve problem.
NOTE: Jerky stem motion is normal whenever
graphite packing is used.
WARNING: Keep hands, hair and clothing away
from all moving parts when operating the valve.
Failure to do so can cause serious injury.
8. Make sure positioner linkage and stem clamp are
securely fastened. If the stem clamp is loose, check
plug thread engagement (refer to the “Reassem-
bling the Actuator” section for the correct procedure
on aligning the plug with the seat.)
9. Ensure all accessories, brackets and bolting are
securely fastened.
10. If possible, remove air supply and observe actuator
for correct fail-safe action.
11. Check rubber bellows for wear.
12. Spray a soap solution around the cylinder actuator
retaining ring, adjusting screw and actuator stem
guide to check for air leaks through the O-rings.
13. Clean any dirt and other foreign material from the
plug stem.
14. If an air filter is supplied, check and replace car-
tridge if necessary.
VALVE DISASSEMBLY AND REASSEMBLY
Disassembling the Body
To disassemble the valve body, refer to Figures 1 and
4 then proceed as follows:
WARNING: Depressurize line to atmospheric pres-
sure and drain all fluids before working on the
valve. Failure to do so can cause serious injury.
1. If valve is air-to-open, apply air under the piston to
lift the plug off the seat before taking the valve apart.
If valve is air-to-close, proceed to step 2.
2. Remove the bonnet flange bolting and lift actuator,
bonnet and plug out of the valve.
CAUTION: Heavy actuators may require a hoist.
Lift the valve with the yoke legs using a lifting
strap and a hoist. Great care should be taken to
lift the actuator and plug straight out of the body
to avoid damage to the plug and seat.
3. Lift retainer, seat ring and gaskets free of the body.
4. Check to see the seating surfaces on both the seat
ring and plug are free of damage to ensure tight
shutoff. Make sure the gasket surfaces on the seat
ring, bonnet and body are clean and undamaged.
5. To inspect the plug, remove by loosening the stem
clamp and gland flange and by taking off the yoke
clamps.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Standard Twin Twin V-packing
V-packing V-packing w/ Lantern Ring

Twin Square Twin Square

Standard Twin Square Packing Packing
Square Packing Packing w/ Lubricator w/ Lantern
Fitting Ring

Graphite Graphite
Braided Rings (3) Rings (2)
Wiper
Rings (3)
Braided
Wiper
Rings (2)

Vacuum Seal
Standard Twin Graphite Vacuum Seal Twin V-packing
Graphite Packing Packing V-packing (w/ Lantern Ring)

Live Loading
(compressed) (not compressed)

Carbon-filled Carbon-filled
PEEK
Teflon Teflon
Backups
Backups Backups
Virgin Teflon Kalrez Kalrez
V-rings (2) V-rings (2) V-rings (2)

SafeGuard SureGuard SureGuard XT

Live-loaded Packing Packing
Packing Box
E0030

Figure 2: Typical Packing Configurations

NOTE: See step 1 in ”Reasembling the Body” section.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 1-5
 NOTE: With air-to-close, fail-open valves, it may be
necessary to apply a small amount of air to the top
of the actuator to move the plug away from the
bonnet. Otherwise, plug galling may occur.
Turn the actuator off the plug and bonnet without
allowing the plug to rotate within the bonnet. Pull the
plug carefully through the packing box.
CAUTION: To avoid scoring guides and plug
stem, follow the above procedure exactly.
6. If the seat surfaces need remachining, both sur-
faces on plug and seat ring must be reworked. The
seat angle on the plug is 30 degrees (36 degrees for
CavControl and Channel Stream valves); the seat
ring, 33 degrees. Lapping is not necessary if proper
assembly procedures are followed.
CAUTION: If remachining, protect the stem
while turning. Ensure concentricity of the seat
surface with the plug stem (or outside diameter
of the seat ring, if machining the seat).
7. To replace packing or change the packing box
configuration, from underneath the bonnet push out
packing, spacer and guides with a dowel of the
same approximate size as the plug stem.
WARNING: For valves equipped with separable
end flanges, do not machine body gasket sur-
faces. Machining could cause failure of the
separable flange lip causing end gasket leak-
age and valve failure.
8. If separable end flanges need to be removed, file off
tack welds or pull rivets behind the flanges.
CAUTION: When using separable end flanges
and spiral wound gaskets, use gaskets with
outer backup rings. Failure to do so could result
in excess stress in some applications.
NOTE: To prevent flanges from dropping off during
shipping, a tack weld or stainless steel rivet has
been installed behind the end flanges.
Reassembling the Body
To reassemble the valve body, refer to Figures 1, 2 and
4 then proceed as follows:
1. If the packing has been removed, refer to Figure 2
and reinstall new packing exactly as shown. Make
sure at least 1/8-inch is left at the top of packing box
for the top guide to enter. Different spacer lengths
permit a wide variety of packing configurations,
such as twin seal and vacuum-pressure packing.
WARNING: Valves with extended bonnets or
metal bellows seals must not have lower pack-
ing installed. Instead, lower packing rings
1-6
should be installed with the upper set. Lower
packing installed in extended bonnets or metal
bellows seal valves will diminish the integrity of
the packing assembly.
The graphite guide liners should be replaced each
time the valve packing is replaced. Do not rebuild
the valve without graphite liners in the guides.
2. Reinsert the plug stem into the packing box, being
careful not to score the stem or the guides.
3. Turn actuator back onto the plug, without turning
the plug inside the bonnet. Make sure the gland
flange and bonnet flange are in place before engag-
ing the plug stem and actuator stem threads.
NOTE: Do not allow the gland flange to contact and
gall the polished plug stem.
Leave approximately three to four plug stem
threads exposed. Attach yoke clamp and gland
flange bolting. For valves with a 2-inch spud, be
sure the half rings are in place between the yoke
and bonnet. Firmly tighten yoke clamp bolting. The
packing box nuts should be just over finger tight.
4. Install new bonnet and seat gaskets with the bev-
eled edge up for Teflon gaskets.
5. Insert the seat ring into the body with the step side
down. Place the seat retainer into the body with the
thin end of the cathedral window down.
NOTE: For ANSI Class 900 and above valves with
valve sizes 1/2- through 11/2-inch, the seat retainer
window should be placed in the body with the
window facing toward the valve ports. With valves
2-inches and larger, the retainer's bar should face
toward the valve ports.
6. Place air under the actuator piston on air-to-open
valves to retract the plug.
7. Lower the plug and bonnet squarely into the body.
Be careful not to scratch or gall the plug as it enters
the body.
8. To properly align the seat ring and plug, first bring
the bonnet bolting to finger-tightness.
a. With pneumatic actuators, apply air pressure
above the piston to seat the plug in the seat ring.
Proceed to step 9.
b. With electric or hydraulic actuators, move the
actuator stem down until it is completely ex-
tended. Next, retract the actuator stem 1/8 inch /
3.175 mm. Install the stem clamp onto the plug
stem / actuator stem and tighten the associated
bolting. Move the actuator stem completely
down. Adjust actuator limit switches according to
the actuator’s operating manual.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 NOTE: Step 9 applies only to valves with pneumatic
actuators. If an electric or hydraulic actuator is
used, return the plug to the midstroke position and
proceed to tighten.
CAUTION: Failure to return the plug to a
midstroke position (electric or hydraulic opera-
tors only) will cause damage to the actuator
and / or the valve during the bonnet tightening
sequence. This is due to the inability of most
electric / hydraulic actuators to accommodate
the 1/16 inch / 1.60 mm back-drive during the
tightening sequence.
9. For air-to-close valves, skip this step and go to step
10. For air-to-open valves, check for proper plug
seating as follows: When proper seating occurs,
the bonnet flange will be forced up against the
finger-tight body bolting with such force that it will be
impossible to move the flange. If proper seating
does not occur, the bonnet flange can be wiggled
with light hand force. Should this occur, place air
under the actuator piston and retract the actuator to
approximate midstroke position. Turn the plug out
of the actuator plug stem one additional thread and
O O
S S
Air-to-Open
Figure 3: Air-action Configurations
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
repeat above seating procedure. When the bonnet
flange becomes tight against the finger-tight body
bolting, the plug is properly seated. If necessary,
repeat above procedure until proper seating occurs.
10. Move the plug to the extended (or closed) position
for pneumatic actuators and to the midstroke posi-
tion for electric, hydraulic or mechanical actuators.
Begin tightening the bonnet flange bolting in a
manner that will keep the bonnet flange square /
parallel with the body. Tighten the first bolt 1/6 turn,
then tighten the bolt directly opposite 1/6 turn and so
on around the flange. Firmly tighten all bolts evenly
and completely to compress the bonnet gasket and
to seat the bonnet. Torque the bonnet bolts to the
suggested torque values in Table III.
11. Apply air over the piston to seat the plug. For all
throttling valves, adjust the stem clamp so that with
full instrument signal to the positioner the full signal
scribe line on the positioner cam points to the center
of the cam roller bearing.
NOTE: For on / off valves, the bottom of the stem
clamp should simply be lined up with the bottom of
actuator stem (plus or minus 1/16 inch / 1.60 mm).
E0032
Air-to-Close
1-7
 Tighten the stem clamp bolting. Proper tightness is 5. Disconnect tubing.
important since this adjustment secures the actua-
6. Remove the adjusting screw to relieve the spring
tor stem to the plug stem. Adjust the stroke plate so
compression.
the stem clamp points to the “closed” position.
WARNING: The spring compression must be
12. If the valve has been taken out of the line, make sure relieved before further disassembly; other-
the flow arrow indicates proper flow direction upon wise, serious personal injury can occur dur-
reinstallation. ing disassembly.

Table III: Suggested Bonnet Bolting 7. Remove the retaining ring from the groove at the
base of the cylinder by using two screwdrivers,
Torque Values (ft-lbs / Nm, ±10 percent) inserting them in the ring’s slot and prying the ring
from the groove.
Bolt Bolt/Stud Material
Size Carbon Stainless 8. Pull the cylinder off of yoke and piston. Some O-ring
(inches) Steel Steel resistance may be felt. Remove spring for cleaning
5
and inspection (air-to-open configuration only).
/8 80 / 108 50 / 68
3
/4 140 / 190 90 / 122 WARNING: Do not use air pressure to remove
7 cylinder. Serious personal injury can occur.
/8 230 / 312 150 / 203
1 350 / 475 220 / 298 9. To remove the spring on air-to-close configura-
1 1/ 8 510 / 690 330 / 447 tions, remove the piston retaining nut and slide
piston off of the actuator stem. The spring may now
1 1/ 4 730 / 990 460 / 624
be removed.
1 3/ 8 990 / 1342 630 / 854
1 1/ 2 1320 / 1790 840 / 1140 NOTE: Step 10 can only be performed if the actua-
tor has been removed from the valve.
1 5/ 8 1710 / 2318 1080 / 1484
1 3/ 4 2170 / 2942 1400 / 1898 10. To inspect the actuator stem O-ring, remove the
stem clamp and bellows. Push the actuator stem
1 7/ 8 2700 / 3660 1700 / 2305
through the yoke, being careful not to gall the stem.
2 3350 / 4542 2100 / 2847 The O-ring may now be removed for replacement.
NOTE: The actuator stem bushings are pressed
Disassembling the Actuator into the yoke; it is not necessary to remove the
bushing to replace the actuator stem O-ring.
With air-to-open valves, the actuator may be disas-
sembled while on the valve. With air-to-close valves,
the actuator must be removed from the valve prior to Reassembling the Actuator
disassembly. To disassemble the actuator, refer to
Figures 1, 3 and 5 then proceed as follows: To reassemble the actuator, refer to Figures 1, 3 and 5
then proceed as follows:
NOTE: Steps 1 through 4 apply to removing the actua-
tor from the valve. If disassembly is to take place with 1. All O-rings should be replaced and the new ones
the actuator still attached to the valve, go on to step 5. lubricated with a silicone lubricant (Dow Corning
55M or equivalent). Silicone O-rings must be lubri-
1. Make sure the plug is neither seated on the seat ring cated with Magnalube-G lubricant or equivalent. Do
nor back-seated against the bonnet by attaching an not use a silicone lubricant on silicone O-rings.
air hose on the appropriate side of the cylinder and
release the pressure on the opposite side. 2. Make sure all internal parts are thoroughly cleaned
and lubricated before beginning reassembly.
CAUTION: Galling of critical surfaces may re-
sult if the plug is not positioned correctly be- 3. If the actuator stem has been removed, replace the
tween the seat ring and bonnet. piston stem O-ring and reassemble the piston and
2. Loosen the stem clamp. actuator spacer on the actuator stem according to
the proper air-action (refer to Figures 3 and 5.) Air-
3. Remove packing box bolting and yoke clamps. to-close configurations require the spring button to
4. Completely turn the actuator off the plug and bon- be inserted under the actuator stem retaining nut.
net without rotating the plug inside the bonnet. Tighten the retaining nut firmly.
CAUTION: Do not allow the plug to drop and 4. For air-to-close configurations, place the spring
impact against the seat after turning the actua- under the piston and insert the actuator stem
tor off the plug threads. through the yoke, being careful to not gall the stem

1-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 or the bushings. Make sure the spring is retained in
the groove provided in the top of the yoke. For air-
to-open configurations, insert the actuator stem
through the yoke and place the spring and spring
button above the piston.
5. Install the cylinder, making sure the yoke is pushed
deep enough into the cylinder to allow the retaining
ring to be installed.
6. Reinsert the retaining ring by feeding it into the
groove a little at a time until it snaps in place.
Replace the stem bellows and stem clamp.
7. Using a new adjusting screw gasket, reinstall the
gasket and adjusting screw. Tighten the adjusting
screw only enough to provide an air seal with the
gasket. Do not over tighten.
NOTE: On air-to-open configurations, make sure
the hole in the spring button is directly centered
under the adjusting screw hole.
8. Apply air over the piston and place the actuator
subassembly onto the valve, making sure the gland
flange and bonnet flange are in place. For valves
with a 2-inch spud, be sure the half rings are in place
between the yoke and bonnet. Engage the plug
stem and actuator stem threads. Carefully turn the
actuator clockwise until the plug stem is engaged
(three to four turns).
CAUTION: To avoid possible stem and / or seat
galling, do not allow the plug to turn on the seat.
9. Apply sufficient air under the piston (for air-to-open
valves) or over the piston (for air-to-close valves) to
prevent the plug head from touching either the seat
or the bonnet. Continue turning the plug stem into
the actuator stem until two to three plug stem
threads remain exposed.
CAUTION: Do not allow the gland flange to
contact or gall the polished plug stem.
CAUTION: To avoid possible stem and / or seat
galling, do not allow the plug to turn on the seat.
10. Apply air over the piston. This will drive the plug into
the seat and lift the yoke off the bonnet approxi-
mately 1/16 inch / 1.60 mm. If the space is not 1/16 inch
/ 1.60 mm, apply air under the piston to retract the
actuator stem and screw the plug in or out as
needed. Repeat this step until the 1/16 inch / 1.60
mm space is created.
11. Apply air under the piston and attach the yoke
clamps and packing box bolting. Tighten the yoke
clamp bolting firmly. The packing box nuts should
be just over finger-tight.
CAUTION: Do not overtighten packing. This can
cause excessive packing wear and high stem
friction that may impede plug movement.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
12. Apply air over the piston to seat the plug. For all
throttling valves, adjust the stem clamp so that with
full instrument signal to the positioner the full signal
scribe line on the positioner cam points to the center
of the cam roller bearing.
NOTE: For on / off valves, the bottom of the stem
clamp should simply be lined up with the bottom of
the actuator stem (± 1/16 inch / 1.60 mm).
Tighten the stem clamp bolting. Proper tightness is
important since this adjustment secures the actua-
tor stem to the plug stem. Adjust the stroke plate so
the stem clamp points to the “closed” position.
13. Reconnect the actuator / positioner tubing, supply
and signal lines.
REVERSING THE AIR-ACTION
Changing to Air-to-Open
To change the air-action from air-to-close to air-to-
open, refer to Figures 3 and 5 then proceed as follows:
1. Follow the instructions for disassembling the actua-
tor (see “Disassembling the Actuator” section).
2. Reassemble the actuator with the spring, actuator
stem spacer and spring button over the piston. For
proper alignment, the center hole in the spring
button should engage the end of the adjusting
screw.
3. The positioner must also be changed. To do this,
refer to the appropriate positioner Installation,
Operation, Maintenance Instructions.
Changing to Air-to-Close
To change the air action from air-to-open to air-to-close,
refer to Figures 3 and 5 then proceed as follows:
1. Follow the instructions for disassembling the actua-
tor (see “Disassembling the Actuator” section).
2. Reassemble the actuator with spring and actuator
stem spacer below the piston. The spring should sit
in the spring groove on top of the yoke. The spring
button is not used on air-to-extend configurations
and is stored above the piston (the actuator stem
retaining nut holds the spring button in place.)
3. The positioner must also be changed. To do this,
refer to the appropriate positioner Installation,
Operation, Maintenance Instructions.
1-9
 Packing Box Nut
(Item No. 117)

Gland Flange
(Item No. 80)

Upper Guide
(Item No. 87)

Stem Guide Liner

(Item No. 86)

Anti-Extrusion Spacer Clamp Nut Clamp Bolt

(Item No. 93) (Item No. 118) (Item No. 107)

Yoke Clamp
Female Ring (Item No. 76)
Upper Packing V-Ring
(Item No. 88)
Male Ring Bonnet
(Item No. 40)

Packing Spacer
(Item No. 94-99)
Packing Box Plug
Bolt (Item No. 50)
Female Ring (Item No. 109)
Lower Packing
(Item No. 88) Male Ring
Bonnet Gasket
(Item No. 58)

Anti-Extrusion Spacer Seat Retainer

(Item No. 93) (Item No. 30)

Stem Guide Liner

(Item No. 82) Seat Ring
(Item No. 83)
Lower Guide
(Item No. 83)
Seat Ring Gasket
Bonnet Flange Nut (Item No. 55)
(Item No. 114)

Bonnet Flange Stud Body

(Item No. 108) (Item No. 1)

Bonnet Flange
(Item No. 70)

End Flange
(Item No. 10)

Half Ring
(Item No. 11)

E0169

Figure 4: Exploded View – Body Assembly

NOTE: Item numbers correspond directly to the valve's bill of material. Refer to it for specific part numbers.

1-10 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Lifting Ring
(Item No. 209)

Adjusting Screw
(Item No. 210)

Adjusting Screw
Gasket
(Item No. 248)

Cylinder
(Item No. 202)

Spring Button Actuator Stem

(Item No. 227) Lock Nut
(Item No. 348)
Spring
(Item No. 229) Spring Button
(Item No. 227)
Actuator Stem
AIR-TO- Lock Nut Piston O-ring AIR-TO-
RETRACT (Item No. 348) (Item No. 271) EXTEND
Stem Spacer Piston
(Item No. 228) (Item No. 225)

Piston O-ring Piston Stem O-ring

(Item No. 271) (Item No. 272)

Piston Stem Spacer

(Item No. 225)
Spring
Piston Stem O-ring (Item No. 229)
(Item No. 272)

Actuator Stem
(Item No. 211)

Upper Stem Bushing

(Item No. 253)

Actuator Stem O-ring

(Item No. 275)

Lower Stem Bushing

(Item No. 254)

Yoke O-ring
(Item No. 274)

Yoke
(Item No. 201)

Stroke Plate Serial Plate

(Item No. 213) (Item No. 252)

Cylinder Retaining
Ring
(Item No. 256)

Stem Bellows Stem Clamp

(Item No. 247) (Item No. 249)

Stem Clamp Nut Stem Clamp Bolt

(Item No. 345) (Item No. 240)

E0170

Figure 5: Exploded View – Actuator Assembly

NOTE: Item numbers correspond directly to the valve's bill of material. Refer to it for specific part numbers.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 1-11
 Troubleshooting Chart
Problem Probable Cause Corrective Action
Stem motion 1. Overtightened packing 1. Adjust packing box nuts to slightly over finger-tight
impeded 2. Service temperature is beyond 2. Reconfirm service conditions and contact factory
operating limits of trim design
3. Inadequate air supply 3. Check for leaks in air supply or instrument signal
system; tighten loose connections and replace
leaky lines
4. Malfunctioning positioner 4. Refer to positioner maintenance instructions
Excessive 1. Improperly tightened bonnet 1. Refer to step 3 of “Reassembling the Body”
leakage flange bolting section for correct tightening procedure
2. Worn or damaged seat ring 2. Disassemble valve and replace or repair seat ring
3. Worn or damaged seat or 3. Disassemble and replace gaskets
bonnet gasket
4. Inadequate actuator thrust 4. Check for adequate air supply to actuator; if air
supply is adequate, reconfirm service conditions
and contact factory
5. Incorrectly adjusted plug 5. Refer to steps 8 - 10 of “Reassembling the Body”
section for correct plug adjustment
6. Improper flow direction 6. Refer to original specifications or contact factory
7. Improper handwheel adjustment 7. Adjust handwheel until plug seats properly
acting as a limit-stop
Inadequate 1. Improper plug adjustment, 1. Refer to steps 8 - 10 of “Reassembling the Body”
flow limiting stroke section for correct plug adjustment
2. Malfunctioning positioner 2. Refer to positioner maintenance instructions
3. Service conditions exceed trim 3. Verify service conditions and consult factory
design capacity
Plug slams 1. Incorrect plug adjustment 1. Refer to steps 8 - 10 of “Reassembling the Body”
allowing improper cushion of section for correct plug adjustment
air between actuator piston
and yoke
2. Inadequate air supply 2. Check air supply to actuator; repair leaks and
remove any restrictions in supply line
3. Trim sized too large for flow rate 3. Install reduced trim
Valve does 1. Incorrect flow direction 1. Reconfirm direction and, if necessary, correct flow
not fail in cor- direction through valve
rect position

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its
intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications
under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible
applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of Flowserve products.
The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe
use of Flowserve products in connection with the specific application.
While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or
as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect
to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change
without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any of its worldwide operations or offices.
For more information about Flowserve, contact www.flowserve.com or call USA 972 443 6500
Regional Headquarters Quick Response Centers
1350 N. Mt. Springs Prkwy. 12, av. du Québec, B.P. 645 5114 Railroad Street 1300 Parkway View Drive
Springville, UT 84663 91965, Courtaboeuf Cedex, Deer Park, TX 77536 USA Pittsburgh, PA 15205 USA
Phone 801 489 8611 France Phone 281 479 9500 Phone 412 787 8803
Facsimile 801 489 3719 Phone (33 1) 60 92 32 51 Facsimile 281 479 8511 Facsimile 412 787 1944
Facsimile (33 1) 60 92 32 99
12 Tuas Avenue 20 104 Chelsea Parkway
Republic of Signapore 638824 Boothwyn, PA 19061 USA
Phone (65) 862 3332 Phone 610 497 8600
Facsimile (65) 862 4940 Facsimile 610 497 6680

Flowserve and Valtek are registered trademarks of Flowserve Corporation.

1-12
FCD VLAIM001-21 Flowserve Corporation,
©1999 Flowserve Corporation. Flowserve Corporation, Valtek
Valtek Control Control
Products, Products,
Tel. USA 801Tel.
489 USA 801 489 8611
8611
Valtek MegaStream
Control Valves
GENERAL INSTRUCTIONS
The following instructions are designed to assist in the
disassembly, reassembly and troubleshooting of
MegaStreamTM attenuators in Valtek® valves. Product
users and maintenance personnel should thoroughly
review this bulletin in conjunction with Installation,
Operation, Maintenance Instructions 1 (Mark One and
Two Control Valves) before installing, operating or
performing any maintenance on the valve.
This publication does not contain information on install-
ing, maintaining, troubleshooting, calibrating, and oper-
ating Valtek positioners. Refer to the appropriate Main-
tenance Instructions when this information is required.
To avoid possible injury to personnel or damage
to valve parts, WARNING and CAUTION notes
must be strictly adhered to. Modifying this prod-
uct, substituting nonfactory parts, or inferior
parts, or using maintenance procedures other
than outlined could drastically affect perfor-
mance and be hazardous to personnel and
equipment.
MegaStream attenuators are designed to reduce gase-
ous noise in automatic control valves through staged
pressure reduction and turbulence control. Mega-
Stream valves have two basic designs: A one- or two-
stage attenuator for low to moderate pressure drop
services and a multi-stage attenuator for high pressure
drop applications. Pressure-balance designs are avail-
able in both types.
Installation
Standard unpacking and installation instructions are
outlined in Installation, Operation, Maintenance In-
structions 1. Regardless of the air-action, it is impera-
tive that valves equipped with MegaStream attenuators
be installed in the line with flow direction under the
Rev. 6/89 Valtek Part No. 10076401
plug. It is also strongly suggested that during start-
up, a strainer be placed in-line before valve to catch
debris prior to it reaching the MegaStream valve.
WARNING: Improper installation will result in ex-
cessive noise, causing possible damage to valve
parts or injury to personnel.
DISASSEMBLY AND REASSEMBLY
Disassembling Unbalanced MegaStream
Refer to Figure 1 and proceed as follows:
WARNING: Depressurize line to atmospheric pres-
sure and drain all fluids before working on the
valve. Failure to do so can cause serious injury.
1. Fully retract plug until stem clamp is pointing to the
open position on the actuator stroke plate.
2. Remove bonnet flange bolting and lift actuator, bon-
net and plug assembly out of the valve body. Re-
move the bonnet gasket.
WARNING: A hoist may be necessary for larger
actuators (size 50 and larger). Care must be
taken to lift the actuator and plug straight out of
the valve body. Any scraping of parts while
removing the actuator may damage valve parts.
When the actuator is not equipped with a lifting
ring, do not attach one; instead, lift the actuator
by using lifting straps through the yoke legs. In
this case, the center of gravity may be above the
lifting point. Therefore, support must be given to
prevent the actuator from rotating; otherwise,
serious injury may result.
3. With the actuator, bonnet and plug removed, the
attenuator can be lifted out of the valve body. In
larger sizes, the attenuator may be too heavy to lift
18-1
 Bonnet Bonnet Flange Bolting
(Item No. 40) (Item No. 108/114)

Bonnet Gasket Bonnet Flange

(Item No. 58) (Item No. 70)

Body Attenuator
(Item No. 1) (Item No. 30)

Seat Ring Plug

(Item No. 20) (Item No. 50)

Seat Ring Gasket

(Item No. 55)

Figure 1: Unblanced MegaStream Assembly

NOTE: Item numbers correspond directly to valve's bill of material. Refer to it for specific part numbers.

without a hoist; in this case, tapped holes are ma-
chined into the top of the attenuator for installation of
lifting rings.
4. Remove the seat ring and seat ring gasket.
5. The attenuator may now be cleaned according to
established industry methods. If uncertain as to
which methods to use with a particular attenuator
and application, contact factory.
Reassembling Unbalanced MegaStream
Refer to Figure 1 and proceed as follows:
1. Install a new seat ring gasket and reinstall seat ring.
NOTE: Bonnet and seat ring gaskets should be
replaced each time the valve is disassembled.
2. Install the cleaned attenuator, making sure the hole
pattern closest to the edge is situated at the bottom
(by the seat ring).
3. Replace bonnet gasket.
4. Fully retract the plug (stem clamp indicator pointing
to the open position) and lower the actuator, bonnet
and plug squarely into the body and attenuator.
CAUTION: The bonnet aligns closely to the
body. Damage could result from misalignment
of the plug and attenuator; therefore, extreme
caution should be exercised in this operation to
make sure it is installed squarely.
5. Once the actuator is resting on the body, tighten the
bonnet flange bolting fingertight.
6. Seat the plug two or three times to center the seat
ring. This can be done by applying air to the actuator.
7. Leaving the plug in the extended (or closed) position,
begin tightening the bonnet flange bolting in a criss-
cross pattern that will keep the bonnet square with
the body. Tighten the first bolt 1/6 turn, then tighten
the bolt directly opposite 1/6 turn.
8. Continue tightening all bolts until the bonnet is firmly

18-2
 Bonnet
(Item No. 40)
Bonnet Flange Bolting
Sleeve Gasket (Item No. 108/114)
(Item No. 56)

Bonnet Flange
Bonnet Gasket (Item No. 70)
(Item No. 58)

Sleeve
Body (Item No. 31)
(Item No. 1)

Attenuator
Seat Ring (Item No. 30)
(Item No. 20)

Plug Seals
(Item No. 65)

Plug
(Item No. 50)

Seat Ring Gasket

(Item No. 55)

Figure 2: Pressure-balanced MegaStream Assembly

NOTE: Item numbers correspond directly to valve's bill of material. Refer to it for specific part numbers.

seated, metal-to-metal, in the body. This can be
easily felt through the wrench.
9. Slowly stroke the plug up and down to check the
alignment of the plug with the attenuator.
Disassembling Pressure-balanced
MegaStream
Refer to Figure 2 and proceed as follows:
WARNING: Depressurize line to atmospheric pres-
sure and drain all fluids before working on the
valve. Failure to do so can cause serious injury.
1. Fully retract plug until indicator is pointing to the
open position.
2. Remove bonnet flange bolting and lift the actuator,
bonnet and plug out of the valve body. A hoist may
be necessary for larger valves.
WARNING: A hoist may be necessary for larger
actuators (size 50 and larger). Care must be
taken to lift the actuator and plug straight out of
the valve body. Any scraping of parts while
removing the actuator may damage valve parts.
When the actuator is not equipped with a lifting
ring, do not attach one; instead, lift the actuator
by using lifting straps through the yoke legs. In
this case, the center of gravity may be above the
lifting point. Therefore, support must be given to
prevent the actuator from rotating; otherwise,
serious injury may result.
WARNING: Danger exists in removing the actua-
tor, bonnet and plug– especially if Teflon pres-
sure-balanced seals are used. The attenuator
sleeve may stick to the plug and fall during
disassembly, causing possible serious injury
and/or damage to the valve or nearby equipment.
Steps 3 thru 6 must be followed before attempt-
ing to remove the plug from the sleeve.
3. If the sleeve is observed sticking to the plug during

18-3
 6. Lift the actuator bonnet and plug assembly from
body, taking care not to damage the sleeve bore or
plug head.
7. Remove the sleeve attenuator, seat ring and gaskets
from the body.
8. The attenuator may now be cleaned according to
established industry methods. If uncertain as to
which methods to use with a particular attentuator
and application, refer to factory.
Reassembling Pressure-balanced
MegaStream
Refer to Figure 2 and proceed as follows:
1. Install new seat gasket and reinstall seat ring.
NOTE: All gaskets should be replaced whenever
the valve is disassembled.
2. Install attenuator and sleeve. Replace bonnet and
sleeve gaskets, and plug seals.
3. Lower the actuator, bonnet and plug assembly
squarely into the sleeve bore. If Teflon seals are
used, the plug may remain retracted. With metal
piston ring seals, the plug must be extended a few
Troubleshooting MegaStream Control Valves
Problem Probable Cause
Jerky 1. Galling or scoring between
stem travel plug and pressure-balanced
sleeve
2. Overtightened packing
3. Service temperature exceeds
operating parameter of trim design
4. Inadequate air supply
5. Malfunctioning positioner
Excessive 1. Insufficiently tightened
leakage bonnet flange bolting
2. Worn or damaged seat ring
3. Worn or damaged plug seals
4. Worn or damaged gaskets
5. Inadequate actuator thrust
6. Incorrectly adjusted plug
Restricted 1. Dirty attenuator
flow
2. Incorrectly adjusted limit-
stop or handwheel
Excessive 1. Improper flow direction
noise 2. Excessive pressure drop
3. Jerky or improper stemtravel
4. Throttling too close to the seat
5. Loose parts
18-4 © 1997, Valtek Incorporated, a unit of Flow Control Division, Flowserve Corporation. Valtek is a registered trademark of Valtek Incorporated.
inches to allow the use of a ring compressor on the
metal rings. A suitable sized screw-type hose clamp
will also serve to compress the rings for reassembly.
Care should be taken to avoid damaging the sealing
surfaces while fitting the plug into the sleeve bore.
4. Once the bonnet is resting on the body, reinstall and
tighten the bonnet flange bolting fingertight.
5. Using the actuator, seat the plug two or three times
to center the seat ring.
6. Leaving the plug in the extended (or closed) posi-
tion, begin tightening the bonnet flange bolting in a
crisscross pattern that will keep the bonnet square
with the valve. Tighten the first bolt 1/6 turn, then
tighten the bolt directly opposite 1/6 turn.
7. Continue tightening all bolting until the bonnet is
firmly seated, metal to metal, in the body. This can
be easily felt through the wrench.
8. Slowly stroke the plug up and down to check the
alignment of the plug with the attenuator. If binding,
sticking or scraping noises are heard, stop stroking
valve immediately. Disassemble the valve to deter-
mine noise and to detect possible damage.
Corrective Action
1. Superficial scoring or galling may be removed with a light application
of emery cloth; if more serious damage exists, contact factory
CAUTION: Trim parts are machined to close tolerances which are essential
for correct functioning of the valve; attempting to remove deep scratches
could result in high leakage rates or improper functioning of valve.
2. Adjust the packing box nuts to slightly over finger-tight (over-tightening
will cause excessive packing wear and high stem friction)
3. Reconfirm service conditions and contact factory
4. Check for leaks in air supply or instrument signal system; tighten any
loose connections and replace any leaky lines
5. Refer to positioner maintenance instructions
1. Refer to “Reassembly” section for correct tightening procedure
2. Disassemble and replace or repair seat ring (for correct procedure on
remachining seat, see Maintenance Instructions 1)
3. Disassemble and replace plug seals
4. Disassemble and replace gaskets
5. Check for adequate air supply to the actuator; if supply is okay, reconfirm
service conditions and contact factory.
6. Refer to Maintenance Instructions 1 for correct plug adjustment
1. Disassemble and clean attenuator, using established industry
cleaning methods
2. Check stroke limiting device and correct, if necessary
1. Check installation for flow direction under the seat; reinstall, if necessary
2. Check design service conditions
3. See corrective action under “Jerky stem travel”
4. Recommended throttling should be 5 percent or more open
5. Check all external bolts and nuts for tightness; if noise is internal,
disassemble, check for damaged, scored parts or missing seat gasket
Valtek Spring Cylinder
Linear Actuators
GENERAL INFORMATION
The following instructions are designed to assist in
installing, troubleshooting and servicing Valtek spring
cylinder actuators. Product users and maintenance
personnel should thoroughly review this bulletin prior
to installing, operating or disassembling the actuator.
Separate installation, operation and maintenance
instructions cover additional features (such as hand-
wheels, limit stops, fail-safe systems or limit
switches).
This publication does not contain information on
Flowserve positioners. Refer to the appropriate instal-
lation operation and maintenance instructions for
installing, maintaining, troubleshooting, calibrating and
operating Flowserve positioners.
To avoid possible injury to personnel or dam-
age to valve parts, WARNING and CAUTION
notes must be strictly followed. Modifying this
product, substituting non-factory or inferior
parts or using maintenance procedures other
than outlined could drastically affect perfor-
mance, void product warranties and be hazard-
ous to personnel and equipment.
WARNING: Standard industry safety practices
must be followed when working on this or any
process control product. Specifically, personal
protection and lifting devices must be used as
warranted.
Valtek No.
Flowserve 49012 Valtek Control Products, Tel. USA 801 489 8611
Corporation,
Unpacking
While unpacking the actuator, check packing list against
materials received. Lists describing the actuator and
accessories are included in each shipping container.
1. Position the lifting straps and hoist to avoid damage
to the tubing and mounted accessories when lifting
the actuator from the shipping container.
WARNING: When lifting an actuator with lifting
straps through the yoke legs, be aware the
center of gravity may be above the lifting
point. Therefore, support must be given to
prevent the actuator from rotating or causing
serious injury to personnel or damage to
nearby equipment.
2. Contact your shipper immediately in the event of
shipping damage.
3. Contact your Flowserve representative for any
problems.
Installation
Prior to installation, make sure adequate overhead
clearance for the actuator is provided to allow for proper
removal from the valve body and for proper mainte-
nance. Refer to Table 1.
NOTE: If the actuator is attached to a valve body
assembly, see Installation, Operation, Maintenance In-
structions 1 for overhead clearances.
2-1
 Table 1:
Overhead Clearance for Disassembly
Actuator Size Minimum Clearance
25 6 inches
50 8 inches
100,200,300
9 inches
400,500,600
1. Connect the air supply and instrument signal air
lines to the two appropriately marked connections
on the positioner. Since both the cylinder and
positioner are suitable for 150 psi air supply, an air
regulator should not be used unless the supply
exceeds 150 psi.
NOTE: In some cases, air supply must be limited to
100 psi rather than 150 psi; this will be indicated by
a sticker found near the upper air port on the cylinder.
WARNING: To avoid personal injury or equip-
ment damage, do not exceed recommended
supply pressure.
2. Installation of an air filter on the supply line is
recommended.
3. Use a soap solution to make sure all air connections
are leak free.
MAINTENANCE
At least once every six months, check for proper opera-
tion by following the preventative maintenance steps
outlined below. These steps can be performed while
the actuator is in service and, in some cases, without
interrupting service. If an internal problem is suspected
with the actuator, refer to the “Disassembly and Reas-
sembly” section.
1. Examine the actuator for damage caused by corro-
sive fumes and process drippings.
2. Clean the actuator and repaint any areas of severe
oxidation.
3. If possible, stroke the actuator and check for
smooth, full-stroke operation.
WARNING: To avoid serious injury, keep hands,
hair and clothing away from all moving parts
while operating the actuator.
4. Make sure positioner mounting bolts, linkage and
stem clamp are securely fastened.
5. Ensure all accessories, brackets and associated
bolting are securely fastened.
6. If possible, remove air supply and observe actuator
for correct fail-safe action.
7. Check rubber bellows for wear.
8. Spray soap solution around the cylinder retaining
ring, the adjusting screw and the lower actuator
stem bushing to check for air leaks through the
O-rings and gasket.
2-2
9. Clean any dirt or foreign material from the actuator
stem.
10. If an air filter is supplied, check and replace
cartridge as necessary.
DISASSEMBLY AND REASSEMBLY
Disassembling the Actuator
Refer to Figures 1 through 5 to disassemble the cylinder
actuator.
1. Shut off air supply. If actuator is installed on a
Flowserve valve, remove the valve per Installation
Operation, Maintenance Instructions 1.
WARNING: To avoid serious injury, depressur-
ize the line to atmospheric pressure and drain
all fluids before working on the actuator.
2. Disconnect all tubing. Remove stem clamp and
stem bellows from the actuator stem.
3. Relieve spring compression completely by remov-
ing the adjusting screw. Remove adjusting screw
gasket from adjusting screw.
CAUTION: Do not use a screwdriver or bar to
turn the adjusting screw; instead, use a
wrench on the flats of the screw.
WARNING: To avoid serious personal injury,
relieve the spring compression before further
disassembly. The cylinder could possibly fly
off the yoke when removing the cylinder
retaining ring.
4. Remove the cylinder retaining ring from the groove
at the base of the cylinder by using two screw-
drivers. Insert one screwdriver in slot found in the
ring and pry the ring from the groove. Use the other
screwdriver to help work the ring out of the cylinder
groove.
5. Pull the cylinder off the yoke and piston; some
O-ring resistance may be felt.
WARNING: To avoid serious personal injury,
do not use air pressure to remove the cylinder.
The cylinder could possibly fly off the yoke.
6. For heavy-duty spring designs using a spring cap
(see Figure 4), remove the spring cap and cap
O-ring from the cylinder.
7. For air-to-retract configurations, remove the
spring(s) and spring button for cleaning and inspec-
tion (see Figures 1, 3 and 5). Remove the actuator
stem locknut and slide the piston and stem spacer
off the actuator stem. The spring guide should be
removed when using heavy-duty spring designs.
NOTE: The dual, heavy-duty spring configuration
(Figure 3) has two springs, one inside the other.
Remove both springs during this step.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Adjusting Screw
Adjusting Screw Gasket (Item No. 210)
(Item No. 248)

Cylinder
Spring Button (Item No. 202)
(Item No. 227)

Spring
Actuator Stem Locknut (Item No. 229)
(Item No. 348)

Stem Spacer
Piston Stem O-ring (Item No. 223)
(Item No. 272)

Piston O-ring
Piston (Item No. 271)
(Item No. 225)

Yoke O-ring
Upper Stem Bushing (Item No. 274)
(Item No. 253)

O Cylinder Retaining
Actuator Stem O-ring Ring
(Item No. 275) (Item No. 256)

Lower Stem Bushing Actuator Stem

(Item No. 254) (Item No. 211)
S

Stem Clamp Bolting Stem Bellows

(Item No. 240/345) (Item No. 247)

Stem Clamp Stroke Plate

(Item No. 249) (Item No. 213)

Yoke
(Item No. 201)

Figure 1: Air-to-retract Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

For air-to-extend configurations, slowly loosen and
remove the actuator stem locknut. Be certain the
piston follows the stem locknut up the actuator stem
and does not bind on the actuator stem. Remove
the actuator stem locknut, spring button, piston,
spring and stem spacer.
WARNING: To avoid personal injury, be certain
the spring force is completely relieved before
removing actuator stem locknut.
8. Remove the piston O-ring, piston stem O-ring and
yoke O-ring.
9. Remove the actuator stem O-ring.
NOTE: The upper and lower stem bushings are
pressed into the yoke. Removal of the bushings to
replace the actuator stem O-ring is unnecessary.
10. Use appropriately sized press to push worn or
damaged bushings out of yoke.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 2-3
 Adjusting Screw
Adjusting Screw Gasket (Item No. 210)
(Item No. 248)

Actuator Stem Locknut

(Item No. 348)
Cylinder
(Item No. 202)
Piston
(Item No. 225)
Spring Button
(Item No. 227)
Stem Spacer
(Item No. 228)

Piston O-ring
(Item No. 271) Actuator Stem O-ring
(Item No. 275)

Piston Stem O-ring Yoke O-ring

(Item No. 272) (Item No. 274)

Spring Cylinder Retaining Ring

(Item No. 229) (Item No. 256)
O

Upper Stem Bushing Actuator Stem

(Item No. 253) (Item No. 211)

Lower Stem Bushing Stem Bellows

(Item No. 254)
S (Item No. 247)

Stem Clamp Bolting Stroke Plate

(Item No. 240/345) (Item No. 213)

Stem Clamp Yoke

(Item No. 249) (Item No. 201)

Figure 2: Air-to-extend Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

Reassembling the Actuator
To reassemble the cylinder actuator, refer to Figures 1
through 5:
1. All O-rings should be replaced. New O-rings should
be lubricated with a silicone lubricant (Dow Corning
55M or equivalent). Silicone O-rings must be lubri-
cated with Magnalube-G lubricant or equivalent. Do
not use silicone lubricant on silicone O-rings.
2. Thoroughly clean all internal parts before beginning
assembly. Lubricate cylinder wall with silicone
lubricant.
3. Lubricate the outside of the replacement bushings
if the stem bushings have been removed. Press a
new lower stem bushing into the actuator stem bore
in the yoke until it bottoms out. Press the upper
stem bushing into the bore until it is flush with the
top of the yoke (refer to Figures 1 or 2).
4. Replace the actuator stem O-ring and yoke O-ring.
5. Reassemble the piston, piston stem O-ring and
stem spacer on the actuator stem according to the
proper air-action (refer to either Figure 1 or 2).
Replace the piston O-ring. Air-to-extend configura-
tions require the spring button to be stored under
actuator stem locknut. Tighten the locknut firmly.
NOTE: When reassembling heavy-duty, spring-
design actuators, the spring guide must be first
inserted under the actuator stem locknut (see
Figures 3 and 4).

2-4 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Adjusting Screw Gasket Adjusting Screw
(Item No. 248) (Item No. 210)

Outer Spring Cylinder

(Item No. 229) (Item No. 202)

Inner Spring Spring Button

(Item No. 230) (Item No. 227)

Actuator Stem Locknut Spring Guide

(Item No. 348) (Item No. 326)

Piston Stem O-ring Piston O-ring

(Item No. 272) (Item No. 271)

Piston Yoke O-ring

(Item No. 225) (Item No. 274)

Upper Stem Bushing Cylinder Retaining Ring

(Item No. 253) O (Item No. 256)

Actuator Stem O-ring Actuator Stem

(Item No. 275) (Item No. 211)

S Stem Bellows
Lower Stem Bushing
(Item No. 254) (Item No. 247)

Stem Clamp Bolting Stroke Plate

(Item No. 240/345) (Item No. 213)

Stem Clamp Yoke

(Item No. 249) (Item No. 201)

Figure 3: Dual-spring Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

6. For air-to-extend configurations, place the spring
under the piston and insert the actuator stem
through the yoke, being careful not to pinch the
actuator stem O-ring or gall the stem and stem
bushings. For air-to-retract configurations, insert
the actuator stem through the yoke and place the
spring(s) and spring button above the piston.
7. Replace the cap O-ring and install the spring cap in
the cylinder when using heavy-duty spring designs
using spring caps (see Figure 4).
8. Install the cylinder, making sure the yoke is pushed
deeply enough into the cylinder to allow the cylinder
retaining ring to be installed. Care should be taken
not to scar or cut the piston and yoke O-rings.
9. Reinsert the cylinder retaining ring by until it snaps
in place. Use a hammer and drift punch to lightly tap
the retaining ring in the groove.
WARNING: To avoid personal injury, the cylin-
der retaining ring must be solidly in place. The
cylinder could possibly fly off when pressur-
ized. Be careful not to pinch or cut fingers on
the square edges of the retaining ring during
installation.
10. Reinstall the adjusting screw using a new adjusting
screw gasket.
NOTE: Be certain the hole in the spring button is
directly centered under the adjusting screw hole in
the cylinder on air-to-retract configurations.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 2-5
 Adjusting Screw
Adjusting Screw Gasket (Item No. 210)
(Item No. 248)
Spring Cap
Spring Button (Item No. 325)
(Item No. 227)
Spring
Cap O-ring (Item No. 229)
(Item No. 270)

Cylinder
Actuator Stem Locknut (Item No. 202)
(Item No. 348)

Spring Guide
Piston Stem O-ring (Item No. 326)
(Item No. 272)
Piston O-ring
Piston (Item No. 271)
(Item No. 225)
Yoke O-ring
Upper Stem Bushing (Item No. 274)
(Item No. 253)
Cylinder Retaining Ring
Actuator Stem O-ring (Item No. 256)
(Item No. 275) O
Actuator Stem
Lower Stem Bushing (Item No. 211)
(Item No. 254)
S Stem Bellows
Stem Clamp Bolting (Item No. 247)
(Item No. 240/345)
Stroke Plate
Stem Clamp (Item No. 213)
(Item No. 249)
Yoke
(Item No. 201)

Figure 4: Cap-spring Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

11. Tighten the adjusting screw enough to provide an
air seal with the gasket. Do not overtighten.
12. Reinstall the stem bellows and stem clamp.
NOTE: To ensure maximum clamping strength
when installing the stem clamp, make sure the stem
clamp bolting is perpendicular to one of the slots
machined into the actuator stem.
13. Apply air over the piston. Tighten the stem clamp
bolting with the stem clamp adjusted to point at the
closed position of the stroke indicator plate.
NOTE: If the actuator is installed on a Flowserve
valve, refer to Installation, Operaton, Mainte-
nance Instructions 1 for correct plug stem thread
engagement.
14. Reconnect tubing, supply and signal lines.
Reversing the Air-action
To change the air action from air-to-retract to air-to
extend, or vice versa, refer to Figures 1, 2 or 5:
NOTE: Heavy-duty spring actuators are not reversible.
1. Disassemble the actuator according to the “Disas-
sembling the Actuator” section.
2. For air-to-retract action, reassemble the actuator
with stem spacer and spring button over the piston.
3. For air-to-extend action, reassemble with spring
and stem spacer below the piston and with the
spring button stored above the piston.
4. Reassemble the actuator according to the “Reas-
sembling the Actuator” section.
5. The positioner must also be reversed. See the
appropriate positioner maintenance instructions.

2-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Lifting Ring
(Item No. 209)

Adjusting Screw
(Item No. 210)

Adjusting Screw Gasket

(Item No. 248)

Cylinder
V
(Item No. 202)
A
L
T
E Actuator Stem Lock Nut
K (Item No. 348)
Spring Button
(Item No. 227)

Spring
(Item No. 229) Spring Button
(Item No. 227)
Actuator Stem Lock Nut
AIR-TO- Piston O-ring
(Item No. 348)
(Item No. 271)
AIR-TO-
RETRACT Stem Spacer EXTEND
Piston
(Item No. 228)
(Item No. 225)

Piston O-ring Piston Stem O-ring

(Item No. 271) (Item No. 272)

Stem Spacer
Piston
(Item No. 225)
Spring
(Item No. 229)
Piston Stem O-ring
(Item No. 272)

Actuator Stem
(Item No. 211)

Upper Stem Bushing

(Item No. 253)

Actuator Stem O-ring

(Item No. 275)

Lower Stem Bushing

(Item No. 254)

Yoke O-ring
(Item No. 274)

Yoke
Serial Plate
(Item No. 201)
(Item No. 252)

Stroke Plate
(Item No. 213)

Cylinder Retaining Ring

(Item No. 256) Stem Clamp
(Item No. 249)

Stem Bellows Stem Clamp Bolt

(Item No. 247) (Item No. 240)

Stem Clamp Nut E0170

(Item No. 345)

Figure 5: Exploded View, Spring Cylinder Actuator

NOTE: Item numbers correspond directly to actuator's bill of material. Refer to it for specific part numbers.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 2-7
 Troubleshooting
Problem Probable Cause
High air consumption or 1. Leaks in the air supply or instru-
leakage ment signal system
2. Malfunctioning positioner
3. Leaks through O-rings or adjusting
screw gasket
Actuator does not move to 1. Air pressure in cylinder not venting
fail position upon loss because of faulty positioner
of air supply pressure 2. Spring failure
3. Internal valve problem
Jerky or sticking 1. Insufficient air supply pressure
stem travel
2. Unlubricated cylinder wall
3. Worn or damaged stem bushings
4. Improperly assembled spring
5. Internal valve problem
Corrective Action
1. Tighten connections and replace any
leaking lines
2. Refer to appropriate positioner
maintenance bulletin
3. Replace O-rings or gasket
1. Refer to appropriate positioner
maintenance bulletin
2. Replace spring
3. Refer to valve’s maintenance bulletin
1. Check air supply and any filters or
regulators; check for leaking O-rings
2. Lubricate cylinder wall with silicone
lubricant
3. Check actuator stem for damage;
replace actuator stem, O-ring, and
stem bushings, if necessary
4. Disassemble actuator and check
cylinder and piston for damage;
reassemble actuator correctly
5. Refer to valve’s maintenance
instructions

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this
Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve
products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service
conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all
possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installa-
tion, operation and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation
Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in
connection with the specific application.
While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes
only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be
construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is
continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to
change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation
at any of its worldwide operations or offices.

For more information about Flowserve and its products,

For more information, contact: contact www.flowserve.com or call USA 972 443 6500

Regional Headquarters Quick Response Centers

1350 N. Mt. Springs Prkwy. 5114 Railroad Street

Springville, UT 84663 Deer Park, TX 77536 USA
Phone 801 489 8611 Phone 281 479 9500
Facsimile 801 489 3719 Facsimile 281 479 8511

12 Tuas Avenue 20 104 Chelsea Parkway

Republic of Signapore 638824 Boothwyn, PA 19061 USA
Phone (65) 862 3332 Phone 610 497 8600
Facsimile (65) 862 4940 Facsimile 610 497 6680

12, av. du Québec, B.P. 645 1300 Parkway View Drive

91965, Courtaboeuf Cedex, France Pittsburgh, PA 15205 USA
Phone (33 1) 60 92 32 51 Phone 412 787 8803
Facsimile (33 1) 60 92 32 99 Facsimile 412 787 1944
Flowserve and Valtek are registered trademarks of Flowserve Corporation.

2-8
FCD VLAIM002-15 ©1999 Flowserve Corporation. Flowserve Corporation, Valtek Control
Flowserve Corporation, Products,
Valtek ControlTel. USA 801
Products, 489
Tel. 8611
USA 801 489 8611

Installation, Operation, Maintenance Instructions
XL90 Series
High-Performance
Positioner
GENERAL INFORMATION
This bulletin is designed to assist in installing, calibrating,
troubleshooting and performing maintenance as required for the
XL90 Series high-performance positioner.
Product users and maintenance personnel should thoroughly
read and strictly follow the instructions contained in this bulletin
prior to operating the positioner. Any questions concerning this
product should be directed to a Flowserve representative.
To avoid possible injury to personnel or damage to valve
parts, WARNING and CAUTION notes must be strictly
followed. Modifying this product, substituting non-
factory parts or using maintenance procedures other
than outlined could drastically affect performance and be
hazardous to personnel and equipment.
The XL90 high-performance positioner is a two-stage device
and is designed for use in control loops where fast response is
required. The XL90 positioner is designed to be modular and use
the P/P module for 3-15 psi input signal or the NT 3000 Series
Transducer Module for 4-20 mA input signal.
The XL90 high-performance positioner is designed as a four-
way device, but can easily be converted to a three-way device by
plugging one of the output ports.
NOTE: The XL90 high-performance positioner must use the
I/P NT 3000 Transducer. The I/P 2000 Transducer is not
acceptable for use with the XL90 Series Positioner.
The XL90 positioner can handle supply pressures up to 150 psi;
thus, a supply regulator is usually not required. However, a five
micron air filter is required for pneumatic positioners and a
coalescing filter is required for I/P positioners.
NOTE: The air supply should conform to ISA Standard S7.3 (a
dew point at least 18° F / -8° C below ambient temperature,
VLAIM 048-00 (181157.000.000) Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Flow Control
particle size below 5 microns, oil content not to exceed one
part per million).
The XL90 Series positioner features an adjustable gain of
400-1100:1. The medium gain setting is standard for smaller
actuators, while the high gain setting is used on larger actuators
(refer to ‘Gain Adjustment Procedure’ section for further details.)
POSITIONER OPERATION
The positioner schematic (Figure 1) shows an XL90 Series
positioner connected for double-acting service on a rotary rack-
and-pinion actuator. Tension on the feedback spring provides
feedback to the positioner, which varies as the stem position
changes. The spring-loading force is applied through the feed-
back linkage and cam to the positioner’s input capsule.
Instrument signal pressure is applied between the diaphragms in
the input capsule. Therefore, the input capsule serves as a force-
balance member, matching the valve stem position (as measured
by tension on the feedback spring) to the instrument signal.
When the opposing forces balance exactly, the system will be
in equilibrium and the stem will be in the exact position called
for by the instrument signal. If the opposing forces are not in
balance, the input capsule will move up or down and, by means
of the pilot-valves, will change the output pressures, moving the
stem until the tension on the feedback spring exactly opposes
the instrument signal pressure.
The sequence of operation is as follows: An increase in instru-
ment signal pressure forces the input capsule downward.
Displacement of the capsule in turn moves the flapper away
from the detecting nozzle. This allows a larger flow rate through
the nozzle, decreasing the pressure exerted on the top of the
pilot valve capsule.
48-1
 Balance Adjustment Feedback Spring Zero Adjustment

Supply Seat Range Adjust

Screws
Upper Pilot
Poppet Piston
Exhaust Seat Cylinder
Cam
Port No. 1

Restriction

Supply

Pilot Valve Feedback

Capsule (shaft)

Exhaust Seat Instrument Signal

Port No. 2 Upper Diaphragm
Detecting
Lower Pilot Nozzle Lower Diaphragm
Poppet Flapper Input Capsule
Supply Seat

Figure 1: XL90 Positioner Schematic for Air-to-Open

Supply air biases the pilot-valve in an upward direction. As

the capsule moves up, it will close the exhaust seat of the upper
pilot poppet and open the supply seat, which applies increased
air pressure to the bottom cylinder port. At the same time, the
pilot-valve capsule will open the exhaust seat for the lower pilot
poppet; thus, decreasing pressure to the top cylinder port.
This difference in pressure will drive the piston outward, rotate
the pinion and stretch the feedback spring until the spring ten-
sion exactly opposes the force resulting from the instrument sig-
nal pressure. At this point, the flapper will be moved toward the
detecting nozzle to restore the pressure above the pilot-valve
capsule to its equilibrium value. As a force-balanced condition
is approached, the pilot-valve capsule will be forced back to a
neutral position where the pilots are neither supplying air to, nor
exhausting air from, their respective sides of the piston. Figure 2: Positioner Mounting with NAMUR shaft
A decrease in instrument signal pressure reverses the described
actions and causes a proportional inward movement of actuator
pistons and a reversal in pinion direction.

Installation of XL90 Series Positioner on Actuators

The XL90 can be installed on most sizes of rotary and linear
actuators. Actuators can be either double acting or spring return.
Cams can be used for direct acting or reverse acting directions.
These instructions apply to rotary actuators only. For linear actu-
ator mounting instructions, consult the factory.
NOTE: For retrofitting to an actuator equipped with an Apex
positioner, the same bracket and bolting may be used.
NOTE: NAMUR mounting is available with the XL90 position-
er. When retrofitting the XL90 positioner to an actuator
Figure 3: Positioner Mounting with Double D Shaft
equipped with another positioner, remove the existing posi-
and Linkage
tioner, tubing and associated bolting. See tubing instructions
in Connecting XL90 Positioner Ports section.

48-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Mounting Instructions for XL90 with NAMUR Shaft
Connection
1. Mount the bracket to the actuator. Finger tighten the
bracket bolting.
2. If required, install a coupler on the actuator shaft. Make
sure the shaft and coupler are centered. See Figure 2.
3. Verify the orientation of the actuator and coupler flats
match the positioner flats on the end of the shaft. Loosen
the cam if necessary. (See “Cam Installations”
instructions.)
4. Install the positioner onto the bracket. Make sure positioner
shaft and coupler are engaged and centered. Finger tighten
positioner bolts.
5. Proceed to “Connecting XL90 Positioner Ports.”
Mounting Instructions for XL90 Positioner on
Sereg Rotary Actuators
1. Mount the positioner to the transfer case plate in the
proper orientation. Tighten the four bolts.
2. Loosen jam nut (see “Cam Installation” instructions).
3. Mount the follower arm, lockwasher and nut on the end of
the shaft and tighten nut. Carefully hold the shaft with
wrench on shaft flats.
4. With valve in closed position, make sure follower pin lever
is mounted parallel to valve lever, flush with end of valve
shaft and the nut is tight.
5. Place follower pin (mounted to the lever that is mounted to
the valve shaft) into follower arm slot and bolt the transfer
case plate in place finger tight only. See Figure 3.
6. Orient the cam to align the “L” shaped line located on the
left side of the characteristic curve through the middle of
the span arm roller. (See Figure 5.) The valve should be
seated when this alignment is done. (See “Cam Installation”
instructions.) For correct cam characteristics, see Table I.
7. Proceed to “Connecting XL90 Positioner Ports”
instructions.
Connecting XL90 Positioner Ports
1. For double acting actuators, connect positioner ports 1
and 2 to the actuator. Port 1 is always connected to the
actuator port used to drive the actuator away from its start
or fail position (the factory cam setting is full clockwise at
minimum input signal).
NOTE: For single acting, spring return actuators, plug
output port 2.
2. Connect supply air to the port marked “SUPPLY.”
3. Connect air (for pressure inputs) or instrument tubing
or wiring (for 4-20 mA inputs). For current inputs, the
terminal is marked (+) and (-) inside the I/P module. The
I/P is factory calibrated and should not require adjust-
ment. If adjustments are necessary, see “Calibrating I/P
Module Zero and Span Settings” section.
CAUTION: Signal air pressure higher than 30 psi may
damage the module gauge and instrument signal cap-
sule; a 3-15 psi instrument signal is recommended on
the pneumatic module.
4. 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 the
stroke.
5. Calibrate valve and adjust cam if necessary. (See “Cam
Installation” and “Positioner Calibration” instructions.)
Cam Removal: Disconnect cam return spring. With a wrench
carefully placed on the output shaft (if necessary), loosen and
remove the jam nut. Remove pressure from the span arm by
pushing it away from the cam. Remove the cam.
Cam Installation:
1. A) For NAMUR shaft end connections make sure shaft is
properly aligned with coupler or actuator.
B) For Sereg actuators, make sure follower pin is in
follower arm groove.
2. Push span arm away from shaft to avoid pressure on the
cam.

Table I: Cam Characteristic Identification Sereg

Cam Guide
Sereg Actuator NR NX NL
Plug Characteristic MaxFlo Linear Linear Equal Percent Linear Equal Percent
Fail Position Close Open Close Open Close Open Close Open Close Open
Direct Acting Linear A B N M A B
Positioner Equal % C E Q P N M C E A B
Equal % Mod B A
Reverse Acting Linear B A M N B A
Positioner Equal % E C P Q M N E C B A
Equal % Mod A B

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-3
 Figure 4: Alignment for Accord Cams
3. Place cam over the shaft with the appropriate characteristic
facing up and closest to the span arm roller. For Sereg
cams, see Table I. For Accord cams, “D” represents direct-
acting and “R” represents reverse acting.
4. A) For NAMUR shaft end connections, make sure the round
mark on the left hand side of the characteristic curve is
lined up with the span arm roller bearing. See Figure 4.
B) For Sereg actuators, make sure the line on the left hand
side of the characteristic curve is lined up through the
middle of the span arm roller bearing. See Figure 5.
5. Tighten jam nut making sure cam does not rotate. Use a flat
screwdriver to prevent cam rotation and shaft flats to pre-
vent shaft rotation (if necessary).
6. Connect supply pressure to port marked ‘Supply.’
7. Stroke actuator/valve two or three times to align position
with actuator. With a 50 percent input signal, tighten all
mounting bolts. Stroke actuator to verify proper alignment.
POSITIONER CALIBRATION
Introduction
Valtek positioners are calibrated at the factory; however, due to
shipping and handling, it may be necessary to check the cali-
bration before operating the valve. The XL90 positioner can be
calibrated to a range of 3-15; two-way split range, 3-9, or 9-15;
and three-way split ranging, 3-7, 7-11, 11-15 psi using the stan-
dard feedback spring.
WARNING: When stroking the actuator during calibration,
keep hands, hair and clothing away from moving parts.
Failure to do so may cause serious personal injury.
Note: Positioners and I/Ps are calibrated at the factory. Use
mechanical adjustments in positioner for calibration. Zero and
span on the I/P should not be used to calibrate the valve.
For calibration, refer to Figure 6 and proceed as follows:
1. For 3-15 or 3-9 psi range, loosen by hand the zero adjust-
ment locking knob and adjust the zero adjustment knob
until the valve begins to stroke with more than 3 psi signal
(for 9-15 psi range adjust to 9 psi).
48-4
Figure 5: Alignment for Sereg Cams
2. Loosen the span adjustment locking screw no more than
1/8 turn.
3. With a phillips screwdriver adjust the span adjustment so
valve is at full stroke with more than 15 psi for 3-15 or 9-
15 psi range (adjust to 9 psi for 3-9 psi range).
4. Return to 3 psi (or 9 psi for 9-15 psi range) and check the
zero. Repeat steps 1-4 if necessary.
5. Tighten the zero adjustment lock knob and span adjustment
locking screw.
6. Use the same procedure for three-way split range.
7. Connect Cam return spring. See Figure 6.
Positioner Balance Adjustment
CAUTION: Balance pressure is 75 percent of the supply pres-
sure and is the average pressure of output ports 1 and 2.
Balance is preset at factory. However, if this adjustment
becomes necessary, carefully make this adjustment slowly,
allowing the positioner to stabilize. Check after a short while
to make sure balance pressure is correct.
Balance adjustment is set at the factory and should not need
adjustment. Balance adjustment (output pressure level) permits
the equilibrium pressure in both sides of the actuator piston to
be raised or lowered. The average actuator pressure level of out-
put 1 or 2 is approximately 75 percent of supply pressure. For
single-acting actuators, the balance pressure should be left
at the factory setting. If it is necessary to adjust the output pres-
sure level, follow the procedure outlined:
1. If output pressure level is low, before adjusting, check for
leaks in tubing connections between positioner and actua-
tor and check supply pressure.
2. Make certain there is no process force or pressure in the
valve (The valve should be removed or isolated from the
process.)
3. On positioners without gauges, connect gauges to ‘output
1’ and ‘output 2’ lines.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Zero Adjustment
Knob
Output 1

Zero Adjustment Span Adjustment

Lock Knob
Feedback Spring
Cam Follower Arm Arm
(Range Arm)
Span Adjustment
Output 2 (shown plugged) Locking Screw
Balance Mounting Holes
Adjusting Screw
for Internal
Feedback Electronics
Spring
Cam
Pilot Relay
Assembly Orifice Screw

I/P Transducer Cam Spring

Figure 6: Positioner Adjustments

4. Remove rubber cap over balance adjustment screw. (See
Figure 6.)
5. Apply full actuator operating pressure to positioner supply
port.
6. Set input signal to midscale (9 psi for 3-15 psi span).
Output pressure level cannot be adjusted with actuator
against valve seat or travel stops. Allow actuator pressure
to stabilize.
7. Observe the pressure gauges. If reading is not correct, turn
balance adjustment screw about 1/8 turn at a time and wait
about 20-30 seconds for pressure to stabilize (counter-
clockwise to increase pressure). Continue until output
pressure level of the higher pressure gauge is approxi-
mately 80 percent of supply.
8. Replace rubber cap over balance adjustment screw.
Gain Adjustment Procedure
The unique gain adjustment on the XL90 positioner provides a
means to increase or decrease the responsiveness of the valve /
actuator / positioner system. Increasing gain makes the valve
more responsive and faster, while decreasing gain makes the
system less sensitive and slower to respond (with increased
damping).
The gain is infinitely adjustable between its highest and lowest
settings. For convenience, three marks indicate (H) high, (M)
medium and (L) low gain. Most sizes of actuators will respond
well to a (M) setting. Unique actuator/valve configurations may
require a gain adjustment at the factory or in the field.
1. Before adjusting the gain, place controller on manual and
isolate the valve from the process.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
2. Turn off supply air to control valve actuator.
3. Using a 5/64-inch allen wrench, loosen both upper and
lower lock screws about one half turn. Do not loosen the
spacer nut. (See Figure 8.)
4. By grasping adjust lever, carefully rotate gain adjust assem-
bly to desired position.
CAUTION: To avoid damaging gain adjust connecting
spring mechanism, make sure both upper and lower gain
adjust plates rotate together. When they are rotated to
the new position, the connecting spring should be per-
pendicular to the plates.
5. When the gain is set to the desired position, firmly tighten
both lock screws.
6. Turn on the supply pressure. Check actuator responsive-
ness by providing a step signal to positioner. When gain is
set as desired, check valve zero and span calibration and
re-calibrate if needed.
7. Return the valve to service.
Calibrating I/P Module Zero and Span Settings
NOTE: Although calibration can be accomplished using the
output pressure gauge on the I/P module, its accuracy is
±3 percent. The standard gauge should be removed only for
calibration and more accurate calibration equipment of ±0.1
percent of span should be used. The pressure gauge port is
1/8-inch NPT. Calibration manifolds are available from the
factory (Part No. 97370).
1. Connect I/P module to a supply pressure between 30 to
150 psi.
2. Remove I/P module housing cover. (See Figure 9.)
48-5
 Upper
Lock Screw

Lower
Lock Screw Spacer Nut
(Do not loosen)

Adjust Lever

Figure 7: Close-up of Gain Adjustment Figure 8: Gain Adjustment

WARNING: Be certain power to I/P module is disconnected
before removing housing cover in explosive atmospheres;
otherwise personal injury may occur.
3. Before adjusting the zero and span, be certain the MPC fea-
ture is disabled. Refer to Step 7 in the ‘Adjusting the
Minimum Pressure Cutoff Feature’ section.
the positioner. When the input signal falls below a user-
adjustable current, the pressure output falls rapidly to approxi-
mately 1.7 psi, causing the valve to move to the failure position.
This feature is generally used when the service requires a tight
shut off or to prevent throttling near the valve seat. To adjust this
feature, refer to Figure 9 and perform the following :

4. Connect a current source to the terminal block on circuit NOTE: The following procedure applies only when the mini-
board. mum pressure cutoff feature will be used.

NOTE: The zero and span adjustments are multi-turn potentio- NOTE: The zero and span settings of both the positioner and
meters (pots) that have no stops on the ends of their travel; I/P transducer should be verified as accurate before the min-
however, they have a slip clutch to prevent damage from over- imum pressure cutoff feature is enabled and adjusted.
adjustment. The pots also make a clicking noise when they 1. Connect the I/P module to a 30 to 150 psi air supply
have reached adjustment limits. pressure.
5. Apply a 4.0 mA signal to the input. Locate and adjust zero
Circuit Board
trim pot to achieve a 3.0 psi output. The output will increase Mounting
with clockwise rotation of the zero trim pot. If calibrating an Screws
I/P module with a 10-50 mA input signal, apply a 10.0 mA
Grounding
signal to input. Screw
6. Increase input signal to 20.0 mA (50 mA for 10-50 mA FLOWSERVE
NO SERVICEABLE Terminal
units). Locate and adjust span trim pot to achieve a 15.0 psi INTERNAL PARTS
SERIAL NUMBER Block
output. The output will increase with clockwise rotation of
the span. ZERO

RFI Can
7. Recheck zero setting by repeating Step 5. The span adjust- SPAN
Current
ment may affect zero setting. MPC
Loop (-)
Zero Adjustment Termination
8. Repeat Steps 5, 6 and 7 until proper adjustments are
obtained. Span Adjustment Current
Loop (+)
Minimum Pressure Termination
Cutoff Adjustment
Adjusting the Minimum Pressure Cutoff Feature
The XL90 positioner with I/P Transducer has a “Minimum Figure 9: NT 3000 Circuit Board Module
Pressure Cutoff” (MPC) feature, which allows the user to set (housing cover removed)

48-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 2. Remove the I/P module housing cover.
WARNING: Be certain power to the I/P module is discon-
nected before removing the housing cover in explosive
atmospheres; otherwise personal injury may occur.
3. Connect an adjustable current source to the terminal block
on the circuit board. Apply the desired input signal to the
positioner at which the output pressure is to fall to approx-
imately 1.7 psi. This signal can range from factory setting
of 3.7 to 8 mA.
4. Turn the minimum pressure cutoff pot clockwise until the
output pressure drops off.
5. Fine-tune the pressure drop-off point by increasing the
input signal and then decreasing it through the desired
shut-off signal. Observe the signal value at which the
pressure drops off. If the pressure drops off at a lower mA
signal than desired, turn the MPC pot counterclockwise. If
the pressure drops off at a higher signal than desired, turn
the MPC pot clockwise.
6. Repeat Step 5 until the pressure drops off at the desired
input signal.
7. To disable the MPC feature turn the minimum pressure cut-
off pot (marked “MPC”) 20 turns counterclockwise or until
it makes a clicking noise.
Positioner Maintenance
NOTE: Refer to NT 3000 IOM for I/P module maintenance
instructions.
For proper maintenance, proceed as follows:
1. Maintain a clean air supply, free of dust, oil and water. A
coalescing air filter for I/P is required to ensure a clean air
supply. Check and maintain filter regularly.
2. Make sure all arms and levers move freely.
3. Check for loose parts.
4. Be sure there are no leaks in the air supply tubing fittings or
connections.
5. Refer to the troubleshooting chart on page 9 in case of
problems.
Pilot Relay Disassembly and Reassembly
The pilot relay is available as a complete unit and can be easily
replaced (See Steps 2 and 18.) Before attempting to correct any
problem with the pilot relay assembly, obtain a positioner repair
kit that contains the soft goods most commonly required.
NOTE: Numbers in parentheses correspond to the numbers in
Figure 16.
1. Remove the feedback spring (47) and rotate the span and
zero arms (40, 46) out of the way.
2. Remove four screws (33) holding the pilot relay to posi-
tioner base (1). Remove relay from positioner.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
3. Remove the nut (25) connecting the flapper assembly (21)
to the signal capsule.
4. Remove four screws (32) holding the two halves of the
pilot relay assembly together. Carefully pull the relay
assembly halves apart, making sure the flapper assembly
(21) slides off the flapper adjustment screw (19) without
damaging the signal diaphragm assembly (16). Pull the
relay diaphragm assembly (13) out of the other half of the
relay body (9).
5. With the relay assembly in two sections, remove two
screws (22) holding flapper assembly (21) to the relay
diaphragm assembly (13). Remove the flapper.
6. Remove diaphragm retaining plate (15) from relay
diaphragm assembly (13) and relay plate (14).
7. Replace relay diaphragm assembly (13) with one from the
positioner repair kit. Place the relay plate (14) between the
new diaphragms making sure the 1/16-inch diameter holes
between the relay plate (14) and the diaphragm line up.
Position diaphragm retaining plate (15) on relay diaphragm
assembly with rounded inner diameter edge against
diaphragm.
8. Attach flapper assembly (21) onto relay diaphragm assem-
bly (13) using two screws (22) with a locking adhesive on
the threads. The flapper assembly should extend away from
the 1/16-inch diameter hole through the relay plate. Make
sure lettering on flapper assembly is facing away from
diaphragm.
9. With relay halves still apart, remove relay tube O-rings (8)
from upper and lower bodies (9, 7) and replace them with
new O-rings (found in the positioner O-ring repair kit).
10. Remove rubber cap (35) and balance adjust screw cap
(36) from upper relay body (9). Remove O-ring (38)
from balance adjust screw and install new O-ring.
11. To remove and clean poppets (28), remove the retaining
rings (31), poppet covers (27), O-rings (30), and poppet
springs (29) found at the end of each housing. After remov-
ing poppets, inspect them for dirt buildup or damage to
seating surfaces.
12. The upper relay body (9) has a movable seat ring (34)
which is adjusted with the balance adjust screw (36). This
seat is removed by pushing it out with a soft instrument
such as a wooden dowel. Be careful not to damage seating
surface. Remove O-ring (37) from the seat ring (34).
13. Lubricate and replace the O-ring (37) on movable seat ring
(34). Carefully reinstall the seat ring (34) into upper relay
body (9), being careful not to damage seating surface or
O-rings.
14. Reinstall poppets (28), poppet springs (29), Seat Spring
(39), O-rings (30), and poppet covers (27) before installing
retaining rings (31).
15. If signal diaphragm assembly (16) is damaged, proceed as
follows: With relay halves still apart, remove four screws
(32) holding signal diaphragm assembly (16) to the pilot
relay assembly. Remove locking screw (23), washer (24),
48-7
 adjustable gain lower plate (26), and diaphragm plate.
Remove signal diaphragm assembly (15) and remove relay
plate (14) from between the diaphragms. Place relay plate
(14) between the diaphragms on the new assembly taking
care to align the 1/16-inch diameter holes between the
diaphragms and the relay plate (14). Replace diaphragm
plate (15), adjustable gain lower plate (26), washer (24),
and locking screw, but do not tighten. Replace four screws
(32) that hold signal diaphragm assembly together.
16. Pack O-ring grease into the O-ring groove and lightly lubri-
cate the outside of the relay tube on diaphragm relay
assembly (13). Make sure small holes on the side of the
tube do not get plugged with grease. Insert the relay
diaphragm assembly (13) as assembled in steps 7 and 8
into the lower relay half. Carefully align the flapper (21) over
the adjustable gain screw (19) and replace and tighten the
nut (25).
17. Fasten the two halves of the relay together using four long
screws (32). Make sure the 1/16-inch diameter holes in the
relay diaphragm assembly (13) and the upper relay body
(9) line up. Set gain to desired setting and tighten locking
screws (23, 25). See gain adjustment procedure.
18. Replace screen (110) and O-rings (8,12) found on the back
of the pilot relay before reinstalling the pilot relay on the
base of the positioner with four screws (33). Clean out any
debris lodged in screen or replace with a new one.
19. Replace span arm and zero arm (40, 46) and feedback
spring (47).
Installation, Operation and Maintenance of
UltraSwitch Position Indicators
For detailed information, refer to the following Accord controls
bulletins:
• PS0008, PS0009, PS0031, PS0032, PS0033, PS0034,
PS0037 and PS0050
XL90 OPTIONS
Option F: 4-20 mA Transmitter
The XL 90 Feedback Option allows accurate and reliable moni-
toring of valve position when installed in the XL 90 positioner.
The Feedback Option may be used in any non-hazardous loca-
tion. For hazardous locations utilize the UltraSwitch L explosion
to the desired switch trip point. After releasing, the spring causes
automatic spline engagement, locking the setting.
2-SPDT
Load Capacity: 15 amp & 1/2 HP 125 VAC, 10 amp 250 VAC,
1/2 amp 125 VDC, 1/4 amp 250 VDC
Operating Force: 4.8 ounces
Differential Travel: 0.016 inches minimum
Mechanical Life: 10,000,000 cycles
Option M and N: Proximity Switches
Proximity reed switches offer cost effective contacts for extend-
ed life in corrosive applications. These switches are tripped by
magnets embedded in cams to indicate valve open and closed
positions. Tool-free cam adjustment is accomplished through a
spring-loaded spline arrangement. Simply push or pull the cam,
disengaging the splines, and rotate to desired switch trip point.
After releasing, the spring causes automatic spline engagement,
locking the setting.
SPST Proximity Switches
Load Capacity: 0.35 amp 140 VAC, 1 amp 50 VDC, 50 Watt Max.
contact rating
Contact Material: Rhodium plated
Actuated by magnetic force
SPDT Proximity Switches
Load Capacity: 0.25 amp 120 VAC, 0.25 amp 28 VDC, 3 Watt
Max. contact rating
Contact Material: Ruthenium plated
Actuatore by magnetic force
MOV and 0.25 amp fuse protected
Option Q: Intrinsically Safe Solid State Proximity Switches
With the same mounting as the mechanical switches the
FM/CSA rated I.S. Solid State Proximity Switches can be used to
obtain valve open and closed position. Tool-free cam adjustment
is accomplished through a spring-loaded spline arrangement.
Simply push or pull the cam, disengaging the splines, and rotate
to the desired switch trip point. After releasing, the spring causes
automatic spline engagement, locking the setting.
Load Capacity: ≤ (less than or equal to) 1 mA ≥ (greater than or
equal to) 3 mA
Voltage Range: 5-25 VDC
1800
1600
1400
IMPEDANCE (OHMS)

proof limit switch enclosure.

1200
Voltage Supply Required: 6-30 VDC
1000
Impedance: 300 Ohms at 20 mA
800
Note: Impedance changes with current (see chart). To properly
design the current loop, use 300 Ohms and 20 mA current. 600
400
Option J and K: Mechanical Switches
200
Mechanical switch technology is the oldest yet most cost effec-
0
tive switching method used today. Tool-free cam adjustment is 4 8 12 16 20
accomplished through a spring-loaded spline arrangement. CURRENT (mA)
Simply push or pull the cam, disengaging the splines, and rotate

48-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Troubleshooting XL90 Positioners

Failure Probable Cause Corrective Action

Valve won’t 1. Tubing to wrong ports 1. Re-tube to correct ports (see ‘Installation’ section)
stroke, no 2. Cam action reversed 2. Refer to ‘Installation’ section and reverse cam
excessive air is 3. Feedback lever arm is stuck 3. Work with lever arm until it turns freely
exhausting 4. Low air supply 4. Increase air supply to recommended value
from positioner 5. Relay tube stuck 5. Disassemble relay assembly and work relay tube free. Lightly lubricate
if necessary
6. Balance adjust screw not adjusted 6. Adjust balance pressure with adjusting screw
correctly
7. I/P module filter plugged 7. Remove I/P module and replace filter
8. I/P module failure 8. Replace I/P module
9. I/P mounting bolts loose 9. Tighten mounting bolts
10. I/P pressure signal blocked 10. Remove I/P module and clear passageway; replace O-ring if necessary
Valve won’t 1. A diaphragm in relay assembly burst 1. Replace relay assembly or replace diaphragms
stroke, 2. One of the poppets is stuck 2. Remove relay assembly/poppet cover; free stuck poppet
excessive air 3. Internal control valve problem 3. Refer to instructions or check for actuator tubing leaks
exhausting 4. Damaged relay O-rings on relay tube 4. Disassemble relay and replace O-rings
from positioner 5. Blocked passageways in relay 5. Disassemble relay and check small holes under diaphragms; clean if
clogged
Actuator goes 1. Broken feedback spring 1. Replace feedback spring
to full signal 2. Linkage is disconnected or stuck 2. Check and tighten bolts/nuts in linkage. Make sure linkage
position does not hang up; grease pin that rides in follower arm slot
regardless of 3. Orifice is clogged by water, oil or 3. Remove orifice screw and carefully clean orifice hole
signal dust in air supply
4. Bent flapper, damaged nozzle 4. Straighten flapper or replace damaged parts
5. I/P module failure 5. Replace I/P module
6. Clogged orifice screen 6. Remove relay and clean or replace orifice screen
Calibration 1. Loose positioner mounting 1. Remove cover and check three screws holding positioner to
bracket; check two bolts holding bracket to yoke
2. Loose linkage 2. Tighten nuts and bolts on linkage and stem clamp
3. Loose zero adjustment locking knobs 3. Tighten zero adjustment locking knob; re-calibrate if necessary
4. Wear of arms or pins 4. Replace worn arms, pins; grease appropriately
5. I/P mounting bolts loose 5. Tighten I/P mounting bolts
6. Stroke has changed in valve 6. Refer to valve maintenance instructions
Excessive air 1. Air leakage from manifold rings 1. Tighten screws holding relay assembly together and/or replace O-rings
consumption between relay and base
(other than 2. Air leakage from tubing 2. Tighten or replace tubing fittings
normal 3. Leaky cylinder piston O-rings 3. Replace O-rings in cylinder
exhaust) 4. Air leakage from relay 4. Disassemble relay and check and replace dynamic O-rings next to tube
if necessary
Actuator 1. Connection between signal capsule 1. Adjust gain according to Figure 8 or until actuator strokes approxi-
strokes very and flapper misadjusted mately equal speed in both directions. Verify alignment of upper and
slowly in one lower gain plates. Make sure spacer nut is tightened
direction only 2. Tubing to cylinder is restricted 2. Inspect tubing/fittings for restrictions and replace if necessary
3. Balance pressure low 3. Adjust balance pressure according to page 5
Erratic 1. Dirt buildup on relay poppets or seats 1. Disassemble; clean poppets and seats; add air filter or change filter
operation 2. Dirt buildup on relay tube 2. Disassemble; clean relay and lightly lubricate; replace O-rings if neces-
sary; add air filter or change filter
3. Clogged ports / passageways in relay 3. Disassemble, inspect and clean all ports and passageways
4. Faulty I/P module 4. Replace the I/P module
5. Clogged orifice screw 5. Remove orifice screw and carefully clean orifice
6. Mechanical binding in linkage or 6. Tighten linkage or refer to valve maintenance instructions
internal galling in valve
7. Clogged orifice screen 7. Remove relay and clean or replace orifice screen
Excessive 1. Restricted air flow to positioner 1. Adjust air supply as needed
overshoot 2. Balance pressure not set correctly 2. Adjust balance pressure according to page 5.
3. Gain is set too high 3. Lower gain mechanism until overshoot is minimized

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-9
 119

121
118
119
3
116
2
118
120
3
117
2

23
18
72 19 21 35
17 38 11
73 20 36 10
44 50 3224 25 33
43 49 26 57
45 46 48
106 47 16 33 31
6 40 14 8
117 45 30 27
29 39
69 22 37 28
34
15 32 8
9
107
67 33 28 14 12110
13
15
8
116 7
66 12
128
69 53
31 8
27 29
112 1
30
56
130
200
52
112

Figure 16: XL90 Positioner – Exploded View – Accord Cam

1 Base assembly 26 Adjustable gain lower plate 52 Cam shaft
2 Cover 27 Poppet cover 53 Cam
3 Screw 28 Poppet 55 Nut
6 Pressure gauge 0-160 psi 29 Poppet spring 56 Screw
7 Bottom relay assembly 30 O-ring 57 O-ring
8 O-ring 31 Retaining ring 66 Pneumatic adapter
9 Upper relay assembly 32 Screw 67 Screw
10 Orifice screw 33 Screw 69 O-ring
11 O-ring 34 Adjustable seat 72 I/P module
12 O-ring 35 Rubber cap 73 Screws
13 Relay diaphragm assembly 36 Balance adjust screw 106 Washer
14 Relay plate 37 O-ring 107 Signal gauge
15 Diaphragm retaining plate 38 O-ring 110 Orifice screen
16 Signal diaphragm assembly 39 Adjustable seat spring 112 Snap ring
17 Set screw 40 Span arm 116 Rotor or indicator
18 Spring 43 Pivot bushing 117 O-ring
19 Set screw 44 Pivot screw 118 O-ring
20 Nut 45 Snap ring 119 Dome
21 Adjustable gain upper plate/flapper assembly 46 Zero arm 120 Adapter shaft
22 Pan head screw 47 Feedback spring 121 Screw
23 Socket screw 48 Pivot block 128 Jam nut
24 Washer 49 Adjust zero knob 130 Spring
25 Spacer nut 50 Zero locking knob 200 Relay assembly

All of the above parts are in stock and can be purchased in a spare parts kit. For selecting and ordering the appropriate kit or a new positioner, contact your Flowserve
representative or the factory.

48-10 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 119

121
118
119
3
116
2
118
120
3
117
2
125 23
18
72 19 21 35
126 17 38 11
73 44 24 20 36 10
50 32 25 33
43 127 49 26 57
45 46 48
106 47 16 33 31
6 40 14 8 30 27
117 45
29 39
28
69 22 37
34
15 32 8
9
107
67 33 28 14 12110
13
15
8
116 7
66 12
128
69 53
31 8
27 29
112 1
30
56
130
200
52
112

Figure 17: XL90 Positioner – Exploded View – Sereg Cam

1 Base assembly 27 Poppet cover 55 Nut
2 Cover 28 Poppet 56 Screw
3 Screw 29 Poppet spring 57 O-ring
6 Pressure gauge 0-160 psi 30 O-ring 66 Pneumatic adapter
7 Bottom relay assembly 31 Retaining ring 67 Screw
8 O-ring 32 Screw 69 O-ring
9 Upper relay assembly 33 Screw 72 I/P module
10 Orifice screw 34 Adjustable seat 73 Screws
11 O-ring 35 Rubber cap 106 Washer
12 O-ring 36 Balance adjust screw 107 Signal gauge
13 Relay diaphragm assembly 37 O-ring 110 Orifice screen
14 Relay plate 38 O-ring 112 Snap ring
15 Diaphragm retaining plate 39 Adjustable seat spring 116 Rotor or indicator
16 Signal diaphragm assembly 40 Span arm 117 O-ring
17 Set screw 43 Pivot bushing 118 O-ring
18 Spring 44 Pivot screw 119 Dome
19 Set screw 45 Snap ring 120 Adapter shaft
20 Nut 46 Zero arm 121 Screw
21 Adjustable gain upper plate/flapper assembly 47 Feedback spring 125 Cam
22 Pan head screw 48 Pivot block 126 Cam clip
23 Socket screw 49 Adjust zero knob 127 Screw
24 Washer 50 Zero locking knob 128 Jam nut
25 Spacer nut 52 Cam shaft 130 Spring
26 Adjustable gain lower plate 53 Cam 200 Relay assembly

All of the above parts are in stock and can be purchased in a spare parts kit. For selecting and ordering the appropriate kit or a new positioner, contact your Flowserve
representative or the factory.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-11
XL90 Part Numbering System Input Temp-
Conduit
Thread
Prefix Model Indication Gages erature Cam Connection Option

PREFIX
■■ ■■ ■ ■ ■ ■ ■ ■
Selection Code
Automax Manufacture - Black Epoxy MB
Automax Manufacture - White Food Grade Epoxy MW
Accord Manufacture - Black Epoxy AB
Accord Manufacture - White Food Grade Epoxy AW
Sereg Manufacture - White Epoxy SW
Valtek Manufacture - White Epoxy VW

INPUT MODEL
Selection Code
Pneumatic Input 3-15 psi 90
Electro-Pneumatic Input 4-20mA 91
General Purpose NT3000
Electro-Pneumatic Input 4-20mA 92
FM/CSA Explosion Proof and Intrins. Safe NT3000
Electro-Pneumatic Input 4-20mA 93
CENELEC EExd (Explosion Proof) NT3000
Electro-Pneumatic Input 4-20mA 94
CENELEC EExia & EExib (Intrinsically Safe) NT3000

INDICATION
Selection Code
Flat Lens with Green Indicator 1
(Standard)
Ultradome with Green Indicator U
Cover for top-mounted Namur UltraSwitch T
(includes UltraSwitch mounting kit)

GAGES
Selection Code
3 Stainless Steel Gages with Brass Fittings 2
(Standard)
2 Stainless Steel Gage with Brass Fitting 3
(Standard)
3 Stainless Steel Gages 4
2 Stainless Steel Gages 5
No Gages 6

TEMPERATURE
Selection Code
Standard Temperature (Buna-N soft goods) 7
Extended Temperature (Fluorosilicone soft goods) 8

CAM
Selection Code
Accord Linear Cam A
Accord 30, 45, 60 & 90 Degree Linear Cam B
Accord Linear, Square, Square Root (Damper) Cam C
Accord 0-60 Degree Cam (Butterfly Valves) D
Sereg Linear and =% Cam - Diaphragm Actuator E
Valtek Linear Cam - Piston Actuator F
Valtek =% Cam-Piston Actuator-Rotary Valve G

CONDUIT THREAD CONNECTION

Selection Code
1/2" NPT (Standard) P
M20 Threads R

OPTIONS - As Needed (See notes 1-4 below)

ANALOG OUTPUTS
Selection Code
4-20mA Transmitter F
or
INTERNAL LIMIT SWITCHES
2-SPDT Mechanical Switches with High Resolution Cams J
2-SPDT Mechanical Switches K
2-SPST Proximity Switches M
2-SPDT Proximity Switches N
2-Intrinsically Safe Solid State Proximity Switches Q

Notes: 1. Internal limit switches and an internal transmitter cannot be used simultaneously.
2. When options F, J, K, M, or N are used with an I/P transducer, input model number 91 must be used.
3. When option Q is used with an I/P transducer, input model numbers 90 or 92 must be used.
4. Internal limit switches or an internal transmitter cannot be used in an explosion proof environment. As an alternative, the explosion proof UltraSwitch may be mounted on
top of the positioner. (Use option T.)
5. Namur shaft end connections are standard for Automax and Accord positioners, Double “D” shaft end connections are standard for Sereg and Valtek positioners. Contact
factory for exceptions to this standard.

48-12 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
General Spare Parts Kits
Standard O-ring Kit – Part No. 10094526 Ext. Temp. O-ring Kit – Part No. 10094527
Item No. Description Quantity Item No. Description Quantity
8 Relay/base O-ring and relay tube O-ring 6 8 Relay/base O-ring and relay tube O-ring 6
11 Orifice screw O-ring 1 11 Orifice screw O-ring 1
12 Relay/base O-ring 2 12 Relay/base O-ring 2
30 Relay retainer O-ring 2 30 Relay retainer O-ring 2
37 Adjustable seat O-ring 1 37 Adjustable seat O-ring 1
38 Adjustable screw O-ring 1 38 Adjustable screw O-ring 1
57 Orifice face O-ring 1 57 Orifice face O-ring 1
69 Input signal O-ring 2 69 Input signal O-ring 2
117 Cover O-ring 1 117 Cover O-ring 1

Standard Diaphragm Kit – Part No. 10094528 Ext. Temp. Diaphragm Kit – Part No. 10094529
Item No. Description Quantity Item No. Description Quantity
13 Relay diaphragm assembly (Includes 1 13 Relay diaphragm assembly (Includes 1
item No. 78, 79, 80, 81, 82, 83) item No. 78, 79, 80, 81, 82, 83)
16 Signal diaphragm assembly (Includes 1 16 Signal diaphragm assembly (Includes 1
item No. 78, 79, 80, 83, 85, 86) item No. 78, 79, 80, 83, 85, 86)

Standard Relay Kit – Part No. 10094530 Cover Kit, Ultradome, White – Part No. 10118702
Item No. Description Quantity Item No. Description Quantity
200 Relay assembly (Includes item Nos. 1 2 Cover 1
7-39, 56, 57, 110) 3 Screw 4
117 O-ring 1
Shaft Kit, Double D End Connection – Part No. 10118747 119 Dome 1
Item No. Description Quantity 122 Sticker, Rotor 1
52 Cam Shaft 1 120 Adapter Shaft 1
112 Retaining Ring 2 121 Screw 4
128 Jam Nut 1 118 O-ring 1
54 Lock Washer 1 116 Rotor 1
55 Nut 1

Cover Kit, Ultradome, Black – Part No. 10118719

Ext. Temp. Relay Kit – Part No. 10094531 Item No. Description Quantity
Item No. Description Quantity 2 Cover 1
200 Relay assembly (Includes item Nos. 1 3 Screw 4
7-39, 56, 57, 110)
117 O-ring 1
119 Dome 1
122 Sticker, Rotor 1
120 Adapter Shaft 1
121 Screw 4
118 O-ring 1
116 Rotor 1

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-13
Shaft Kit, NAMUR End Connection – Part No. 10118753 Cover Kit, Lens, White, Valtek – Part No. 10118690
Item No. Description Quantity Item No. Description Quantity
52 Cam Shaft 1 2 Cover 1
112 Retaining Ring 2 3 Screw 4
128 Jam Nut 1 117 O-ring 1
119 Valtek Lens 1
Feedback Spring Kit – Part No. 10094524 116 Indicator 1
Item No. Description Quantity 118 O-ring 1
47 Feedback spring assembly (Includes 1
item Nos. 103, 104) Cover Kit, Lens, Black, Automax – Part No. 10118698
48 Pivot block 1 Item No. Description Quantity
49 Adjustment knob 1 2 Cover 1
50 Lock knob 1 3 Screw 4
117 O-ring 1
Manufacturer-Specific Spare Parts Kits 119 Dome 1
Sereg Cam Kit – Part No. 10116036 116 Indicator 1
Item No. Description Quantity 118 O-ring 1
53 Direct Acting Cam 1
125 Reverse Acting Cam 1 Electronic Spare Parts Kits
126 Cam Cover Clip 1 WARNING: Internal electronic kits cannot be used in applica-
127 Screw 1 tions requiring explosion-proof components.

130 Cam Spring 1 As an alternative, the explosion-proof UltraSwitch position

indicator may be mounted to the top of the positioner. Consult
131 Screw 1 your local Flowserve representative for ordering information.
132 Sticker, Cam 1

Transmitter Kit, 4-20mA Output, Double D Shaft End

Cover Kit, Lens, White, Sereg – Part No. 10118691 Connection – Part No. 10118423
Item No. Description Quantity Item No. Description Quantity
2 Cover 1 52 Cam Shaft 1
3 Screw 4 112 Retaining Ring 2
117 O-ring 1 128 Jam Nut 1
119 Sereg Lens 1 54 Lock Washer 1
116 Indicator 1 55 Nut 1
118 O-ring 1 130 Electronics Kit (Includes shaft gear, 1
circuit board and mounting screws)
Cover Kit, Lens, Black, Accord – Part No. 10118697
Item No. Description Quantity
2 Cover 1
3 Screw 4
117 O-ring 1
119 Accord Lens 1
116 Indicator 1
118 O-ring 1

48-14 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Transmitter Kit, 4-20mA Output, NAMUR Shaft End Mechanical Limit Switch Kit, NAMUR Shaft End Connection –
Connection – Part No. 10118427 Part No. 10118454
Item No. Description Quantity Item No. Description Quantity
52 Cam Shaft 1 52 Cam Shaft 1
112 Retaining Ring 2 112 Retaining Ring 2
128 Jam Nut 1 128 Jam Nut 1
130 Electronics Kit (Includes shaft gear, 1 130 Electronics Kit (Includes shaft cams, 1
circuit board and mounting screws) spring, circuit board and mounting
spacers and screws)
High Resolution Mechanical Limit Switch Kit, Double D
Shaft End Connection – Part No. 10118432 Proximity Limit Switch Kit, SPST, Double D Shaft End
Connection – Part No. 10118444
Item No. Description Quantity
Item No. Description Quantity
52 Cam Shaft 1
52 Cam Shaft 1
112 Retaining Ring 2
112 Retaining Ring 2
128 Jam Nut 1
128 Jam Nut 1
54 Lock Washer 1
54 Lock Washer 1
55 Nut 1
55 Nut 1
130 Electronics Kit (Includes shaft cams, 1
spring, circuit board and mounting 130 Electronics Kit (Includes shaft cams, 1
spacers and screws) magnets, spring, circuit board and
mounting spacers and screws)
High Resolution Mechanical Limit Switch Kit, NAMUR Shaft
End Connection – Part No. 10118451 Proximity Limit Switch Kit, SPST, NAMUR Shaft End
Connection – Part No. 10118455
Item No. Description Quantity
Item No. Description Quantity
52 Cam Shaft 1
52 Cam Shaft 1
112 Retaining Ring 2
112 Retaining Ring 2
128 Jam Nut 1
128 Jam Nut 1
130 Electronics Kit (Includes shaft cams, 1
spring, circuit board and mounting 130 Electronics Kit (Includes shaft cams, 1
spacers and screws) magnets, spring, circuit board and
mounting spacers and screws)
Mechanical Limit Switch Kit, Double D Shaft End
Connection – Part No. 10118439 Proximity Limit Switch Kit, SPDT, Double D Shaft End
Connection – Part No. 10118446
Item No. Description Quantity
Item No. Description Quantity
52 Cam Shaft 1
52 Cam Shaft 1
112 Retaining Ring 2
112 Retaining Ring 2
128 Jam Nut 1
128 Jam Nut 1
54 Lock Washer 1
54 Lock Washer 1
55 Nut 1
55 Nut 1
130 Electronics Kit (Includes shaft cams, 1
spring, circuit board and mounting 130 Electronics Kit (Includes shaft cams, 1
spacers and screws) magnets, spring, circuit board and
mounting spacers and screws)

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 48-15
Intrinsically Safe Proximity Limit Switch Kit, NAMUR Shaft Intrinsically Safe Proximity Limit Switch Kit, Double D Shaft
End Connection – Part No. 10118458 End Connection – Part No. 10118450
Item No. Description Quantity Item No. Description Quantity
52 Cam Shaft 1 52 Cam Shaft 1
112 Retaining Ring 2 112 Retaining Ring 2
128 Jam Nut 1 128 Jam Nut 1
130 Electronics Kit (Includes shaft cams, 1 54 Lock Washer 1
magnets, spring, circuit board and
55 Nut 1
mounting spacers and screws)
130 Electronics Kit (Includes shaft cams, 1
Proximity Limit Switch Kit, SPDT, NAMUR Shaft End magnets, spring, circuit board and
Connection – Part No. 10118457 mounting spacers and screws)

Item No. Description Quantity

52 Cam Shaft 1
112 Retaining Ring 2
128 Jam Nut 1
130 Electronics Kit (Includes shaft cams, 1
magnets, spring, circuit board and
mounting spacers and screws)

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this
Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve
products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service condi-
tions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible
applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation
and maintenance of Flowserve products. The purchaser/user should read and understand the Installation, Operation, Maintenance (IOM)
instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the
specific application.

While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes
only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be
construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is continu-
ally improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change
without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any of
its worldwide operations or offices.

For more information about Flowserve and its products, contact

For more information, contact: www.flowserve.com or call USA 972 443 6500.

Regional Headquarters Quick Response Centers

1350 N. Mt. Springs Prkwy. 5114 Railroad Street

Springville, UT 84663 Deer Park, TX 77536 USA
Phone 801 489 8611 Phone 281 479 9500
Facsimile 801 489 3719 Facsimile 281 479 8511

12 Tuas Avenue 20 104 Chelsea Parkway

Republic of Singapore 638824 Boothwyn, PA 19061 USA
Phone (65) 862 3332 Phone 610 497 8600
Facsimile (65) 862 4940 Facsimile 610 497 6680

12, av. du Québec, B.P. 645 1300 Parkway View Drive

91965, Courtaboeuf Cedex, France Pittsburgh, PA 15205 USA
Phone (33 1) 60 92 32 51 Phone 412 787 8803
Facsimile (33 1) 60 92 32 99 Facsimile 412 787 1944
Flowserve and Valtek are registered trademarks of Flowserve Corporation.

48-16 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Valtek Position Pac
GENERAL INFORMATION
The following instructions are designed to assist with
installing, calibrating and troubleshooting the Valtek®
Position Pac™ valve position indicator. Product users
and maintenance personnel should thoroughly review
this bulletin in conjunction with the maintenance bulletin
for the appropriate valve body and actuator being used.
To avoid possible injury to personnel or damage
to valve parts, WARNING and CAUTION notes
must be strictly adhered to. Modifying this prod-
uct, substituting non-factory or inferior parts, or
using maintenance procedures other than out-
lined could drastically affect performance, be
hazardous to personnel and equipment, and may
void existing warranties.
OPERATION
Position Pac is a ‘package’ unit containing a potenti-
ometer and transmitter, two or four limit switches, or a
combination of a transmitter and two limit switches.
The position transmitter utilizes a potentiometer to
measure the valve’s position and a transmitter circuit
that sends a 4 to 20 mA electrical signal to a remote
monitoring device. Position Pac will continuously trans-
mit the position of a control valve as it modulates
between the open and closed positions.
The limit switches in Position Pac can be independently
set to indicate open, closed or any intermediate valve
position.
Valtek No.
Flowserve 62152 Valtek Control Products,
Corporation, Flowserve
Tel.Corporation,
USA 801 489 Valtek
8611Control Products, Tel. USA 801 489 8611
Position Pac’s sealed construction provides protection
from the entry of water, dust and oil as defined by the
National Electrical Manufacturers Association (NEMA)
1, 3, 3R, 4, 12 and 13. Position Pac is also explosion-
proof, providing protection from flammable hydrocarbon
atmospheres, metal dust, coal dust, and grain dust. It is
UL and CSA listed for Class I, Division 1, Groups B, C, D;
Class II, Division 1, Groups E, F, G (See Table I). All
electrical wiring should be installed per NEC articles
501-4 and 501-5.
WARNING: Keep hands, hair, clothing, etc. away
from moving parts when operating the valve. Fail-
ure to do so can cause serious injury.
INSTALLATION INSTRUCTIONS
The following instructions are designed to assist in the
field installation of Position Pac units.
Valtek Linear Actuators
To install Position Pac on Valtek linear actuators, refer
to Figures 1 and 2, and proceed as follows:
1. Remove the name plate from the yoke leg opposite
from the stroke indicator plate.
2. Using the two tapped holes, attach the Position Pac
mounting bracket to the yoke leg using two mounting
bolts. When facing this yoke leg, the bracket will jog
in towards the valve center and protrude to the left.
3. Remove the nut from the stem clamp bolting. Place
the tripper bracket on the bolt so the ‘S’ shape ex-
tends down. Replace the nut and tighten it firmly.
29-1
 Figure 1: Linear Application – Front View Figure 2: Linear Application – Rear View
(cover removed) (cover removed)

Table I: Model Configuration

Electrical Area
Explosion Proof
Sealed Housing
Model Description NEMA Class I Division Class II Division CENELEC Rating
Switches Size
4 1 & 2 (Group) 1 & 2 (Group) Approval
A B C D E F G
Analog Transmitter with two her-
TH2 UL Yes Long
metically sealed SPDT switches
Two hermetically sealed SPDT
H2TS UL Yes Long
switches with terminal switch
TX Analog transmitter UL/CSA No Short
Analog transmitter with two Pending
TA2 UL No Long
SPDT switches
A2 Two SPDT switches UL No Short
A4 Four SPDT switches UL No Long
Two SPDT switches with
A2TS UL No Long
terminal strip

Table II: Linear Mounting Information 4. Mount Position Pac to the bracket using the mount-
ing holes as specified in Table II: Insert the lever
Actuator Valve Spud Kit Hole
onto the switch shaft. On larger actuators (size 50
Size Stroke Size No.* Set
and larger) that use the adjustable lever arm, adjust
(sq. in.) (inch) (inch) (Mounting)
the length so that the center of the roller rests on the
25 0.5-1.0 2.00 37434 bottom of slot center of the tripper bracket. To preload the Position
1.5 2.00 37434 top of slot Pac’s restoring spring, be certain the control valve is
50 0.5-2.5 2.62 37345 bottom holes in its minimum signal position. Loosen the lever arm
3.0 2.62 37345 top holes clamp screw with a 0.14-inch ( 9/ 64) hex wrench,
allowing the arm to turn on the shaft. While holding
100 1.0-3.5 2.62/2.88 37436 bottom holes the arm in contact with the bottom of the tripper
& larger 4.0 3.38 37630 top holes bracket and using a slotted screwdriver to rotate the
4.0 4.75 71636 top holes switch shaft perform the following (all rotation direc-
*Kit includes: bracket, arm, trip lever or stem clamp with trip lever tion instructions are as viewed from the lever arm
nuts and bolts. side of the Position Pac):

29-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Figure 3: Rotary Application – Rear View
(cover removed; air-to-close valve)
For direct-acting, air-to-open actuators, rotate the
shaft counter clockwise as far as it will go, then back
off approximately 5 to 10 degrees. For direct-acting,
air-to- close actuators, rotate the shaft counter clock-
wise approximately 5 to 10 degrees.
For reverse-acting, air-to-open actuators, rotate the
shaft counter clockwise approximately 5 to 10 de-
grees. For reverse-acting, air-to-close actuators,
rotate the shaft counter clockwise as far as possible,
then back off approximately 5 to 10 degrees. With the
slot in this position, tighten lever arm clamp screw
tightly (until the teller tab will not move). With this pro-
cedure completed, stroke valve to ensure spring is
preloaded throughout the entire valve travel.
5. To make electrical connections, remove the housing
cover.
WARNING: On explosion-proof installations,
disconnect electrical power or be certain the
area is safe from combustible atmospheres be-
fore removing the housing cover.
(Refer to the specifications in Table IV for component
electrical ratings.) Attach transmitter signal wiring to
the transmitter terminal block, using caution to attach
the positive and negative wires to the appropriate
terminal.
CAUTION: Do not apply a voltage greater than 40
volts to the transmitter terminals or the circuit
will be damaged.
Attach limit switch wiring to the ‘COMM’ (common)
and either ‘NC’ (normally closed) or ‘NO’ (normally
open) terminals according to the needed signal.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Figure 4: Rotary Application – Front View
(cover removed; air-to-close valve)
6. To adjust the limit switches and/or position transmit-
ter, remove the housing cover and refer to the Cali-
bration section in this document.
WARNING: On explosion-proof installations,
disconnect electrical power or be certain the
area is safe from combustible atmospheres be-
fore removing the housing cover.
7. Replace the housing cover.
8. Reinstall the name plate to the mounting bracket.
NOTE: Name plate reinstallation is important for
valve identification/servicing purposes.
Valtek Rotary Actuators
To install Position Pac on Valtek rotary actuators, refer
to Figures 3 and 4, and proceed as follows:
1. Mount the bracket to the mounting pad on the back-
side of the actuator using two 0.31-inch (5/16) mount-
ing bolts.
2. Mount the Position Pac to the bracket using four
0.31-inch (5/16) mounting bolts and nuts.
3. Loosely mount the trip lever to the valve shaft within
the yoke.
4. Attach the switch lever to the Position Pac shaft.
5. Connect the linkage assembly to both levers as
shown in Figure 3.
6. Measure the approximate radius of the trip lever from
the center of the valve shaft to the linkage assembly
connection (not the end of the lever). Next, adjust
the switch lever to approximately the same radius
and tighten.
29-3
 Table III: Rotary Mounting Kits ‘NC’ (normally closed) or ‘NO’ (normally open) termi-
nals according to the needed signal.
Actuator Valve Shaft
Size Diameter Kit No.* WARNING: On explosion-proof installations,
(sq. in.) (inches) disconnect electrical power or be certain the
area is safe from combustible atmospheres be-
25 0.62 97556
fore removing the housing cover.
25 0.75 97557
25 0.88 97558 11. To adjust the limit switches and/or the position trans-
mitter, remove the housing cover and refer to the
50 0.62 97559
Calibration section in this document.
50 0.75 97560
50 0.88 97561 12. Replace the housing cover.
50 1.12 97562 CALIBRATION
100 0.88 97563 When a Position Pac is installed in the field or a factory
100 1.12 97564 installed unit needs to have output signal adjustments
100 1.50 97565 made, refer to Figure 5 and proceed as follows:
100 1.75 97566
*Kit includes: bracket, trip lever, switch lever, linkage assembly, Limit Switch
nuts and bolts. Position Pac limit switches are adjusted at the factory
7. With the actuator at its minimum signal position, before shipment and should not require on-site adjust-
slide the trip lever along the shaft until the linkage ment. However, if the mechanical lever has shifted
assembly is parallel to the mounting bracket. At the position, the unit may need readjustment. To readjust
same time, rotate the trip lever until it is at a 45- the limit switch, proceed as follows:
degree angle to the mounting bracket and pointing CAUTION: If the valve cannot be stroked without
toward the top yoke bolt closest to the Position Pac. disturbing the process fluid, bypassing or remov-
Tighten the trip lever on the shaft in this position. ing the valve from the line may be necessary before
8. Adjust the linkage assembly until the switch lever is calibrating the Position Pac.
approximately the same angle as the trip lever and WARNING: Prior to removing the valve from the line,
the linkage assembly is horizontal. To preload the depressurize the line to atmospheric pressure, drain
Position Pac's restoring spring (used to remove all process fluid and, if caustic or hazardous mate-
backlash in the linkage), be certain the actuator is in rial are present, decontaminate the valve. Failure to
its minimum signal position and perform the follow- do so can cause serious injury.
ing using a slotted screw driver to rotate the switch 1. Stroke the valve to the closed position.
shaft (all rotation direction instructions are as viewed
WARNING: Keep hands, hair, clothing, etc. away
from the lever arm side of the Position Pac):
from moving parts when operating the valve.
For direct-acting, air-to-open actuators, rotate the Failure to do so can cause serious injury.
shaft counter clockwise as far as it will go, then back
2. Remove the housing cover from the Position Pac.
off approximately 5 to 10 degrees. For direct-acting,
WARNING: On explosion-proof installations,
air-to-close actuators, rotate the shaft clockwise
disconnect electrical power or be certain the
approximately 5 degrees.
area is safe from combustible atmospheres be-
For reverse-acting, air-to-open actuators, rotate the fore removing the housing cover.
shaft clockwise approximately 5 degrees. For re-
3. Lift the appropriate cam follower lever. Move the
verse-acting, air-to-close actuators, rotate the shaft
cam wheel axially to disengage the teeth on the
counter clockwise as far as possible, then back off
wheel from the teeth on the shaft disc.
approximately 5 to 10 degrees.
4. Turn the cam wheel to the desired position. Each
With the slot in this position, tighten the lever arm
notch on the cam wheel represents an operating
clamp screw tightly (until the teller tab will not move).
point change of 70 20'.
9. If possible, stroke the valve; the linkage assembly
5. When the cam wheel has been rotated to the desired
should travel back and forth remaining horizontal.
location, slide the cam wheel to engage with the
10. To make electrical connections, remove the hous- mating shaft disc. (For finer adjustment, use the
ing cover. (Refer to the specifications in Table IV for setscrew in the cam follower.)
the component electrical ratings.) Attach the trans-
6. Release the cam follower lever.
mitter signal wiring to the transmitter terminal block,
using caution to attach the positive and negative 7. Cycle the valve and check for proper adjustment.
wires to the appropriate terminal. Attach the limit Readjust if necessary.
switch signal wiring to ‘COMM’ (common) and either 8. Replace the housing cover.

29-4 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Transmitter
terms
block
Limit switch
wiring terminal
Transmitter zero
Adjusting Screw
(pot)
Figure 5: Calibration Points
Position Transmitter
1. Remove the housing cover from the Position Pac.
WARNING: On explosion-proof installations,
disconnect electrical power or be certain the
area is safe from combustible atmospheres be-
fore removing the housing cover.
2. Wire the Position Pac transmitter in series with a
12.5-40 VDC power supply and a milliamp meter.
NOTE: Instructions within parenthesis ( ) refer to
older Position Pac models characterized by a white
label.
CAUTION: Do not apply a voltage greater than 40
volts to transmitter terminals or the circuit will be
damaged.
3. Be certain the CW/CCW Switch located next to the
potentiometer (Direct/Reverse Switch located next
to the wire terminal block) is set to provide the de-
sired output signal action. In the CW (DIR) position,
a clockwise rotation of the Position Pac shaft will
cause the output signal to increase. In the CCW
(REV) position, a counterclockwise stem rotation
causes the signal to increase.
4. Stroke the valve to the closed position.
WARNING: Keep hands, hair, clothing, etc. away
from moving parts when operating the valve.
Failure to do so can cause serious injury.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Limit switch
adjustment cams
(not shown)
Transmitter span
adjusting screw
(pot)
Clockwise/counter-
clockwise switch
5. Referring to Figure 5, adjust the ZERO adjusting
screw with a small, straight end screw driver, until the
meter reads 4 mA DC.
6. Stroke the valve to the open position.
7. Adjust the SPAN adjusting screw until the meter
reads 20 mA DC.
8. Stroke valve to the closed position and recheck the
meter for 4 mA DC. Some readjusting of the calibra-
tion may be required. Repeat steps 4-8 until satis-
fied.
9. If calibration is unsuccessful after following this pro-
cedure, one of two problems may exist: (a) The ori-
entation of the Position Pac stem may need to be
adjusted. (b) The ZERO and SPAN potentiometers
may be adjusted out of range.
NOTE: The electrical travel of the potentiometer is
340 (150) degrees. To operate properly, the poten-
tiometer wiper must stay within the center 185 de-
grees of its 340 degree electrical range during the full
stroke of the valve.
9a. To adjust, stroke the valve to its middle position.
Loosen the potentiometer collar nut. While measur-
ing the voltage between pins 1 and 2 on the back of
the potentiometer, rotate the potentiometer until the
voltage is between 0.55 and 0.65 volts. Retighten
the potentiometer being careful to keep the potenti-
ometer oriented in the same position.
29-5
9b. Set the ZERO and SPAN potentiometers to their
approximate middle position. This is accomplished
by first turning each potentiometer clockwise 25
turns or until a ‘click’ is either felt or heard. Then turn
each potentiometer counterclockwise approxi-
mately 12 complete turns. Repeat steps 2 through 8
to complete calibration.
10. Replace the housing cover.
REVERSING POSITION TRANSMITTER
SIGNAL
The following instructions should be used when the sig-
nal being transmitted from the position transmitter is
either incorrect or needs to be reversed. Refer to
Figure 5.
NOTE: Instructions within parenthesis ( ) refer to older
Position Pac models characterized by a white label.
1. Remove the housing cover.
WARNING: On explosion-proof installations,
disconnect electrical power or be certain the
area is safe from combustible atmospheres be-
fore removing the housing cover.
2. Locate the switch next to the position transmitter’s
wiring terminal. Move switch to the opposite posi-
tion, CCW or CW (DIR or REV). Repeat steps 3-9 in
the Calibration section for the position transmitter.
NOTE: The SPAN potentiometer will generally not
need readjustment.
3. Replace the housing cover.

Table IV: Specifications

Analog Output
Power Supply Range 12.5 to 40 VDC (24V DC typical)
Maximum Load Maximum Resistance (ohms) =
Resistance Supply Voltage - 12.5
(see Figure 3) 0.02
Current Signal Output 4-20 mA
Span Adjustable from 5° to 100° of angular
rotation
Null 4 mA position may be set at any angular
position
Linearity ±1.0% full-scale*
Repeatability ±0.25% full-scale
Hysteresis ±1.0% full-scale
Operating -40O to 185O F (-40O to 85O C)
Temperature Range
Ambient Temperature For a 100O F (38O C) change in ambient
Range temperature, maximum zero shift is
±0.4% full scale, maximum span
Figure 6: Wiring Diagram shift is ±0.7% full scale
Power Supply Output signal changes less than
0.05% when supply voltage is varied
Max. Load Resistance, RL(Ω)

1500
between 12.5 and 40 volts dc
1250 RL max = V PS - 12.5V
20 mA Limit Switches
1000
(SPDT) 20 amps, 125, 250, 480 VAC, ind. and
750 UL/CSA Rating (L23) res. 1 Hp. 125 VAC; 2 Hp, 250 VAC, 0.5
amp. 125 VDC; 0.25 amp, 250 VDC res.
500
Operating
250 Mechanical
Region
Input motion ±105O from the center; spring
0
loaded to return to the center
0 10 20 30 40 50 60
Power Supply Voltage, VPS (volts) * Linearity is ±1.0% for 90O rotary shaft input. When mounted to
linear travel valves, linearity is dependent on linkage design and
stroke length. Typical linearity is ±1.5% full-scale on Valtek Mark
Figure 7: Power Supply Requirements One control valves.

29-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Rotary Short Housing Long Housing
1.26 dia. max. 0.88 4.09 max. 0.88 5.71 max.
32 22 104 22 145
1.57
0.72 40 0.37 3.78 max. 0.37 3.78 max.
18 9 96 9 133

4.00
102
3.15 2.38 typ 3.86 dia. 3.82 dia.
80 60 98 0.29 dia. 97
7
2.00
51

0.75 - 14 NPT
0.80 (5 full threads min.) (2) 0.80 0.75 - 14 NPT
0.33 dia. thru (4) 20 20 (5 full threads min.) (2)
8 1.00 Eight side mounting holes 1.00
25 can be tapped 5/16 - 18-inch 25

0.57
0.50 14
13
1.00
0.49 0.75 25
12 19
Lever Actuators Adjust
0.25
6 1.50 - 3.70
38 - 94
4.04
1.50 103
0.16
Front Mounting 38 4
0.27
7

0.39 0.31
10 0.72 8
0.83 18 0.16
21 4
0.74 0.09
19 2

Figure 8: Dimensions

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 29-7
 Troubleshooting
Failure Probable Cause Corrective Action
Operation erratic 1. Loose bracket bolting 1. Tighten bolting bracket to yoke leg or transfer
and inconsistent case: readjust position transmitter and switches
2. Loose Position Pac mounting 2. Tighten mounting screws, readjust position
screws transmitter and switches
3. Loose tripper bracket 3. Tighten tripper bracket or extended spline
(linear actuator) or extended connector
spline connector (rotary
actuator)
4. Internal or electrical 4a. Ensure that terminal block connections are
malfunction tight
4b. Check for foreign material in contact with printed
circuit board or components
4c. Check for components or wires broken loose
from printed circuit board
4d. Check that the switch is fully set in desired
position
Indicating 1. Incorrect adjustment 1. Refer to Calibration section, step 9
incorrect position
2. Internal or electrical 2a. Ensure that terminal block connections are
tight
2b. Check for foreign material in contact with printed
circuit board or components
2c. Check for components or wires broken loose
from printed circuit board
2d. Check that the switch is fully set in desired
position

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its
intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications
under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible
applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of Flowserve products.
The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe
use of Flowserve products in connection with the specific application.
While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or
as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect
to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change
without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any of its worldwide operations or offices.

For more information, contact: For more information about Flowserve, contact www.flowserve.com or call USA 972 443 6500

Regional Headquarters
1350 N. Mt. Springs Prkwy.
Springville, UT 84663
Phone 801 489 8611
Facsimile 801 489 3719
12 Tuas Avenue 20
Republic of Signapore 638824
Phone (65) 862 3332
Facsimile (65) 862 4940
Flowserve and Valtek are registered trademarks of Flowserve Corporation.
12, av. du Québec, B.P. 645
91965, Courtaboeuf Cedex,
France
Phone (33 1) 60 92 32 51
Facsimile (33 1) 60 92 32 99
Quick Response Centers
5114 Railroad Street
Deer Park, TX 77536 USA
Phone 281 479 9500
Facsimile 281 479 8511
104 Chelsea Parkway
Boothwyn, PA 19061 USA
Phone 610 497 8600
Facsimile 610 497 6680
1300 Parkway View Drive
Pittsburgh, PA 15205 USA
Phone 412 787 8803
Facsimile 412 787 1944

29-8VLAIM029-04
FCD Flowserve Corporation,
© 2000 Flowserve Corporation. Flowserve Corporation, Valtek
Valtek Control ControlTel.
Products, Products, Tel.
USA 801 489USA 801 489 8611
8611
Installation & Maintenance Instructions SERIES
3-WAY, 2-POSITION DIRECT-ACTING SOLENOID VALVES
8327
NORMALLY CLOSED, NORMALLY OPEN OR UNIVERSAL OPERATION
1/4I NPT - 1/4I ORIFICE - BRASS OR STAINLESS STEEL CONSTRUCTION
Form No.V6943R1
Temperature Limitations
NOTICE: See separate solenoid installation and maintenance
instructions for information on: Wiring, Solenoid Temperature, Temperature Ranges
Cause of Improper Operation and Solenoid Replacement. Catalog No. 8327G1 & 8321G2
Ambient
-4_F (-20_C) to 131_F (55_C)
DESCRIPTION Catalog No. 8327G1
Series 8327 valves are 3-way, 2-position (3/2) solenoid valves -4_F (-20_C) to 176_F (80_C)
designed for general service. Valves are made of rugged brass or Fluid
stainless steel. Series 8327 valves may be provided with a general Catalog No 8327G2
purpose or explosionproof/watertight solenoid. -4_F (-20_C) to 248_F (120_C)
Ambient Catalog No. 8327G11 & 8327G12
OPERATION & Fluid -40_F (-40_C) to 131_F (55_C)
Normally Closed: Applies pressure when solenoid is energized.
Positioning
Solenoid De-energized: Flow is from Port 2 to Port 1. Port 3 is This valve is designed to perform properly when mounted in any
closed. position. However, for optimum life and performance, the solenoid
Solenoid Energized: Flow is from Port 3 to Port 2. Port 1 is closed. should be mounted vertically and upright to reduce the possibility of
Normally Open: Applies pressure when solenoid is de-energized. foreign matter accumulating in the solenoid base sub-assembly area.
Solenoid De-energized: Flow is from Port 1 to Port 2. Port 3 is Mounting
closed. For mounting dimensions, refer to Figure 1.
Solenoid Energized: Flow is from Port 2 to Port 3. Port 1 is closed. Piping
Universal Connect piping to valve according to markings on valve body. Apply
For normally closed, normally open, selection or diversion flow. pipe compound sparingly to male pipe threads only. If applied to
Pressure can be applied at any port. valve threads, the compound may enter the valve and cause
operational difficulty. Avoid pipe strain by properly supporting and
aligning piping. When tightening the pipe, do not use valve or
Flow Diagrams solenoid as a lever. Locate wrenches applied to valve body or piping
as close as possible to connection point.
OPERATION DE-ENERGIZED ENERGIZED

CAUTION: To protect the solenoid valve, install a strainer

NORMALLY 1 2 1 2 or filter suitable for the service involved in the inlet side as
CLOSED close to the valve as possible. Clean periodically depending
PRESSURE AT 3 3 3 on service conditions. See ASCO Series 8600, 8601 and 8602
for strainers.
NORMALLY 1 2 1 2 MAINTENANCE
OPEN
PRESSURE AT 1 3 3 WARNING: To prevent the possibility of death,
serious injury or property damage, turn off electrical
power, depressurize valve, and vent fluid to a safe area
UNIVERSAL 1 2 1 2 before servicing the valve.
PRESSURE AT
ANY PORT 3 3 NOTE: It is not necessary to remove the valve from the pipeline for
repairs.
Cleaning
INSTALLATION All solenoid valves should be cleaned periodically. The time between
Check nameplate for correct catalog number, pressure, voltage, cleanings will vary depending on the medium and service conditions.
frequency, and service. Never apply incompatible fluids or exceed In general, if the voltage to the coil is correct, sluggish valve operation,
pressure rating of the valve. Installation and valve maintenance to be excessive noise or leakage will indicate that cleaning is required. In
performed by qualified personnel. the extreme case, faulty valve operation will occur and the valve may
fail to shift. Clean strainer or filter when cleaning the valve.
Future Service Considerations Preventive Maintenance
Provision should be made for performing seat leakage, external S Keep the medium flowing through the valve as free from dirt and
leakage, and operational tests on the valve with a nonhazardous, foreign material as possible.
noncombustible fluid after disassembly and reassembly.

e MCMXCIX All Rights Reserved. Printed in U.S.A. Page 1 of 2

ASCO Valves 50-60 Hanover Road, Florham Park, New Jersey 07932
S While in service, the valve should be operated at least once a
month to insure proper opening and closing.
S Depending on the medium and service conditions, periodic
inspection of internal valve parts for damage or excessive wear is
recommended. Thoroughly clean all parts. If parts are worn or
damaged, install a complete ASCO Rebuild Kit.
Causes of Improper Operation
S Incorrect Pressure: Check valve pressure. Pressure to valve must
be within range specified on nameplate.
S Excessive Leakage: Disassemble valve and clean all parts. If parts
are worn or damaged, install a complete ASCO Rebuild Kit.
Valve Disassembly
1. Disassemble valve in an orderly fashion using exploded views
for identification and placement of parts.
2. Remove solenoid, see separate instructions.
3. Unscrew solenoid base sub-assembly from valve body and
remove solenoid base gasket.
4. Remove core spring from top of core/insert sub-assembly.
5. Pull core/insert sub-assembly from valve body cavity and
remove insert gasket.
6. All parts are now accessible for cleaning or replacement. If
parts are worn or damaged, install a complete ASCO Rebuild
Kit.
Valve Reassembly
1. Lubricate all gaskets with DOW CORNINGr 111 Compound
lubricant or an equivalent high-grade silicone grease.
2. Snap insert gasket into the groove of the core/insert
sub-assembly. Be sure to use the proper size gasket.
3. Install core/insert sub-assembly into body cavity and push it
gently down until the gasket of the insert just seals in the cavity
of the body.
4. Install core spring in top of core/insert sub-assembly. Close
end of core spring protrudes from top of core.
5. Install solenoid base gasket and solenoid base sub-assembly.
Torque solenoid base sub-assembly to 260 ± 25 in-lbs [30 ±3
Nm].
6. Install solenoid. See separate instructions.
WARNING: To prevent the possibility of death,
serious injury or property damage, check valve for
proper operation before returning to service. Also
perform internal seat and external leakage tests with
a nonhazardous, noncombustible fluid.
7. Restore line pressure and electrical power supply to valve.
8. After maintenance is completed, operate the valve a few times
to be sure of proper operation. A metallic click signifies the
solenoid is operating.
ORDERING INFORMATION
FOR ASCO REBUILD KITS
Parts marked with an asterisk (*) in the exploded view are supplied in
Rebuild Kits. When Ordering Rebuild Kits for ASCO valves, order
the Rebuild Kit number stamped on the valve nameplate. If the
number of the kit is not visible, order by indicating the number of kits
required, and the Catalog Number and Serial Number of the valve(s)
for which they are intended.

Torque Chart
Part Name Torque Value Inch-Pounds Torque Value Newton-Meters
Solenoid base sub-assembly 260 ± 25 30 ± 3

Indicates Parts Supplied

In ASCO Rebuild Kits solenoid base
sub-assembly

solenoid base gasket Valve Body

Mounting Dimensions
core spring
(closed end of core spring [Ø5,5]
.216 diameter
protrudes from top of core) mounting hole through
(2 places)
core/insert
sub-assembly
[12]
.47 [23]
.91
insert gasket
[27]
1.06 [30]
valve body [13] 1.18
.51

Figure 1. Series 8327 valve without solenoid.

Page 2 of 2 Form No. V6943R1

ASCO Valves 50-60 Hanover Road, Florham Park, New Jersey 07932
 USER INSTRUCTIONS
NT3000 Series Installation
Electro-Pneumatic Transducer Module Operation
FCD VLAIM0047-02 – 09/04 Maintenance

Experience In Motion
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Contents
General Information 3
Transducer Operation 4
Converting Positioner Input Signal 4
Calibration 4
Adjusting the Pressure Regulator Output 6
Adjusting the Pressure Modulator 6
Maintenance 9
Inspection and Replacement of the Transducer Orifice 9
Service and Replacement of the Transducer Filter 9
Service and Replacement of the Transducer Vent Element
(not applicable for vented model) 9
Service and Maintenance of the Transducer Circuit Board 10
Disassembly and Reassembly
of the Transducer Pressure Regulator 11
Removal and Replacement
of the Transducer Pressure Modulator 12
Parts List 13
Spare Part Kits 14
Standard Explosion Proof EMI / RFI Wiring
Installation Procedures (using conduit) 15
Troubleshooting 16
NT 3000 Model Numbers 17
Adjusting the Minimum Pressure Cutoff Feature
on Old Transducers 18

2
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

General Information The NT 3000 series transducer is certified for the following locations:

This bulletin is designed to assist in installing, calibrating, trouble- Intrinsically Safe: See Figure 1
shooting and performing maintenance as required for the Flowserve Class I, Div. 1, Groups A, B, C, D
Valtek® NT 3000 series electro-pneumatic transducer. Class II, Groups E, F, G
FM/CSA
Explosion-proof:
Product users and maintenance personnel should read thoroughly and
Class I, Div. 1, Groups B, C, D
follow exactly the instructions contained in this bulletin prior to opera-
Class II, Div. 1, Groups E, F, G
tion of the transducer. If there is any question concerning this bulletin,
call a Flowserve representative.

To avoid possible injury to personnel or damage to equipment, users II 2 G, EEx d IIB + H2

must strictly adhere to WARNING and CAUTION notes. Modifying EEx ia IIC
this product, substituting non-factory or inferior parts, or using II 2G EEx d IIB+H2
maintenance procedures other than outlined could drastically affect II 1G EEx ia IIC
CENELEC
performance, be hazardous to personnel and equipment, and may void II 1D EEx ia IIC (90°C)
existing warranties. II 3G EEx nL
II 3D EEx nL (70°C)
c WARNING: This product has electrical conduit connections in T6, Tamb -40°C to 40°C
thread sizes ½-inch NPT or M20 (distinguished by the letter
T5, Tamb -40°C to 75°C
“M” stamped on the conduit port) which appear identical but
T4, Tamb -40°C to 110°C
are not interchangeable. Forcing dissimilar threads together
Ex d, IIB + H2 T6 IP65
will damage equipment, cause personal injury and void SAA
Ex ia IIC T5 IP 65
hazardous location certifications. Conduit fittings must match
equipment housing threads before installation. If threads do
Since the positioner is insensitive to supply pressure changes and
not match, obtain suitable adapters or contact a Flowserve
can handle supply pressures from 30 to 150 psi, a supply regulator is
office.
usually not required; however, a coalescing air filter is highly recom-
NOTE: Numbers in parenthesis correspond to the part item numbers in mended.
Figure 8.
c WARNING: Substitution of components may impair intrinsic
The Valtek NT 3000 series electro-pneumatic transducer is used with safety.
a milliampere electrical control signal. It is interchangeable with the XL
series or Beta series pneumatic positioners and can be mounted on NOTE: The air supply should conform to ISA-7.0.01 (a dew point at
either Valtek linear or rotary actuators without modification. least 18°F / -7.8°C below ambient temperature, particle size below five
microns, oil content not to exceed one part per million).

flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04
Transducer Operation
The NT 3000 is considered an ‘active’ I/P transducer. An active
device has gain and controls the current through transistors, diodes,
capacitors, resistors, and integrated circuits. A ‘passive’ transducer
has no gain characteristics and consists of a large coil with a fixed
resistance (i.e., fixed voltage drop). The effective impedance of an active
transducer varies with the input current. The NT 3000 transducer is a
current-powered device that can be modeled as a 5.7 V zener diode in
series with a 17-ohm resistor. For a DCS system output of 4-20 mA,
the voltage drop across the transducer varies between 5.7 V and 6.1
V while the impedance varies between 1330 ohms and 270 ohms.
Flowserve recommends an operating voltage of 6.5 VDC (i.e. the DCS
system should allow for at least 6.5 V loop load across the NT 3000
terminals; not that a 6.5 V supply is connected to the transducer.)
The transducer receives a 4 to 20 mA signal and converts it to a
3-15 psi output signal.
The supply pressure to the NT 3000 is filtered as it passes through
a field-replaceable, coalescing filter element in the transducer. The
air then passes through an internal pressure regulator that regulates
the pressure to approximately 23 psi. The supply pressure then goes
through an orifice that restricts the flow and air consumption. Refer to
Figures 2 and 3.
The air is further controlled to 3-15 psi using a diaphragm flapper that
is attracted by an electromagnet to a nozzle. A temperature-compen-
sated piezoresistive pressure sensor mounted on a circuit board senses
the transducer output pressure. The pressure sensor and circuitry
create a feedback loop that determines how much current to send to the
electromagnet for a desired pressure output. The electromagnet in the
feedback loop varies the nozzle-flapper spacing, which regulates the I/P
output pressure to 3-15 psi.
Converting Positioner Input Signal
XL series or Beta series positioners can be adapted to
4 to 20 mA (I/P) or pneumatic signal (3-15 psi). For pneumatic opera-
tion, the positioner is fitted with the pneumatic adapter. For electrical
operation, the positioner is equipped with the NT 3000 transducer.
Refer to the appropriate Flowserve Installation, Operation, Maintenance
Instructions.
4
Calibration
Valtek positioners mounted on valves are calibrated at the factory;
however, it may be necessary to recalibrate the transducer before oper-
ating the valve. The zero and span of the NT 3000 transducer are set to
close tolerances at the factory and normally do not need adjustment.
If required, the NT 3000 transducer can be recalibrated either while
mounted on the XL or Beta positioner or while mounted on a calibra-
tion manifold. Calibration manifolds are available from the factory
(PN 097370.999.000). To calibrate the I/P transducer zero and span
settings, refer to Figures 4 or 5 and proceed as follows.
NOTE: Although calibration can be accomplished using the output
pressure gauge on the I/P transducer, its accuracy is ±3 percent. It is
recommended that the standard gauge be removed for calibration and
that more accurate calibration equipment of ±0.1 percent of span be
used. The pressure gauge port is 1⁄8-inch NPT.
1. Connect the 30-150 psi supply pressure to the positioner or calibra-
tion manifold.
2. Remove the I/P transducer housing cover.
c WARNING: Disconnect power to the I/P module before
removing the housing cover in explosive atmospheres;
otherwise, personal injury may occur.
3. Connect an adjustable current source to the terminal block on the
circuit board.
NOTE: The zero and span adjustments are multi-turn
potentiometers (pots) that have no stops on the ends of their travel;
however, they have a slip clutch to prevent damage from over-
adjustment. The pots also make a clicking noise when they have
reached the limits of their adjustment.
4. Apply a 4 mA signal to the input. Adjust the zero trim pot to achieve
a 3 psi output. The output will increase with clockwise rotation of
the zero trim pot.
5. Increase the input signal to 20 mA. Adjust the span trim pot to
achieve a 15 psi output. The output will increase with clockwise
rotation of the span.
6. Recheck the zero setting by repeating Step 4. The span adjustment
may affect the zero setting.
7. Repeat Steps 4, 5 and 6 until the proper adjustments are obtained.
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Figure 1 – Intrinsically Safe Installation Schematic

��������������������������������������������������������������������������������������
������������������������������������������������������������������������������������
������
���������������
�������������
�� ��������������
����
������ ��������������
����������
�����������
������� ����������
�����
���
���������������� ��������������� ������������
���������������� ��
���� ����
��������������� ������ ���������
���������������
����������� �����������
�������
�������� �����������
�������������� �����
���������
�������������
���������������� ��������
���������
��
���� ���
���������
����������� �����������
������������������

������
����������
���������
������������������ ��������������
���������

Figure 2 – NT 3000 Transducer Schematic Figure 3 – NT 3000 Transducer Orifice Screw

�������
���������
�����
�������

�������
�����

��������
��������
���������
������

��������
������

�����

�������� ������
���������
5

�����������
��������������

flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04
Adjusting the Pressure
Regulator Output
The setpoint of the internal pressure regulator is set at the factory
and normally does not need adjustment. However, if it is necessary to
check or adjust the pressure regulator, refer to Figure 8 then proceed as
follows.
1. Disconnect the positioner’s air supply (or calibration manifold).
2. Detach the vent cover (20) and unscrew the vent element (21). For
vented models, the pipe fitting replaced the vent cover and element.
3. Plug the vent port with a 1⁄8-inch NPT plug, being certain the plug is
airtight.
4. Plug the electrical port with a ½-inch NPT plug, being certain the
electrical port is airtight.
5. Be certain housing cover (1) is screwed on airtight.
6. Reconnect or turn on the supply pressure to the positioner or
calibration manifold.
7. Observe pressure indicated by the pressure gauge on the NT 3000
transducer. With the ports plugged and cover on, the indicated
pressure is the setpoint of the internal pressure regulator. Its value
should be 23 psi (±3 psi). If the setpoint is within this range it
needs no further adjustment, proceed to Step 9. If it is not within
this range, continue with Step 8.
8. Remove pressure regulator setscrew (40). Apply a drop of thread
locking compound (Loctite No. 222 or equivalent) to the setscrew.
Install and turn the setscrew clockwise until the pressure indicated
by the I/P transducer pressure gauge on the NT 3000 transducer is
23 psi (±3 psi).
9. Disconnect the air supply pressure to the positioner (or calibration
manifold).
10. Remove the 1⁄8-inch NPT plug from the vent port and reinstall the
vent element (21) and the vent cover (20) into the I/P transducer
housing. If vented model is used, replace pipe fitting instead of vent
cover and element.
11. Remove the ½-inch NPT plug from electrical port.
12. Reconnect the air supply pressure to the positioner.
6
Adjusting the Pressure Modulator
The pressure modulator is factory set and normally does not need
adjustment; however, if adjustment is necessary refer to Figures 6 and
7, proceed as follows.
NOTE: Although the pressure modulator can be adjusted using the
standard output pressure gauge on the NT 3000 transducer, its
accuracy is ±3 percent. It is recommended that the standard gauge be
removed for calibration and more accurate calibration equipment of
±0.1 percent of span be used or use a manifold block with an accurate
pressure sensor. The pressure gauge port is 1⁄8-inch NPT.
1. Remove the NT 3000 transducer housing cover (1).
c WARNING: Disconnect power to the I/P transducer before
removing the housing cover in explosive atmospheres;
otherwise, personal injury may occur.
2. Disconnect the loop power electrical connection from the circuit
board.
3. Apply supply air pressure to the NT 3000 transducer and observe
the pressure indicated by the NT 3000 transducer pressure gauge.
If the indicated pressure is 2.00 ±0.20 psi the pressure modulator is
adjusted correctly; reconnect the loop power electrical connection
to the circuit board and reinstall the housing cover. If the indicated
pressure is not 2.0 ±0.20 psi, turn off the supply pressure and
continue with step 4.
4. Remove the three screws (3) holding the circuit board in place and
carefully pull the circuit board straight out of the housing. Discon-
nect the pressure modulator electrical connector from the bottom
of the circuit board.
5. Securely plug the pressure sensor port with a .188 inch diameter
rod. Be careful not to damage the pressure sensor O-ring (46) in
the pressure sensor port.
c WARNING: Rod may be ejected from port with high
pressures. Use care to avoid personal injury.
A damaged O-ring must be replaced with the appropriate part from
Soft Goods Kit 5. Remove O-ring with a small screwdriver.
6. Connect the air supply pressure to the positioner.
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

7. Remove the “Factory Calibrated” sticker from the pressure modu-
lator cover (8). Turn the setscrew (6) until the pressure indicated
on the pressure gauge on the NT 3000 transducer is 2.0 psi (±0.20
psi). This is the correct pressure modulator adjustment.
8. Disconnect the air supply pressure to positioner.
9. Remove the rod plugging the pressure sensor port.
10. Reconnect the pressure modulator electrical connector to the
bottom of the circuit board.
11. Reinstall the circuit board by engaging the pressure sensor tube
and pressing it straight into the housing. Be careful not to damage
the pressure sensor O-ring or pinch the modulator connector wires
while installing the circuit board. Apply thread locking compound to
the three circuit board screws and replace.
12. Reinstall the housing cover and reconnect the air supply pressure.
13. Check the span and zero calibration.

Figure 4 – Beta Positioner with NT 3000 Transducer

��������
�������������������� ���������

���������������
�������
����
�����
����������
�������
�����

�����
����������
����
����
���� ����������
����������

���

��������� �����������
�����

����������
������
������� ��������
������

��������
������

������������
��������������� ������������ ��������������
���������������
7

flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Figure 5 – XL Positioner with NT 3000 Transducer

��������
�������������������� ���������
���������������
������������

�����
����������
�������
�����

�����
����������
����
����
���� ����������
����������

���

���������
����� �����������

���������� ��������
������ ������
�������

��������
������

������������
��������������� ������������ ��������������
���������������

8
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04
Figure 6 – NT 3000 Transducer Circuit Board (housing cover removed)
��������������� ���������������
��������
�����
���������
�����
Maintenance
Inspection and Replacement
of the Transducer Orifice
To service or replace the NT 3000 transducer orifice, refer to Figures 3
and 8 then proceed as follows:
1. Disconnect air supply pressure to the positioner.
2. Remove the orifice screw (44) from the transducer housing (12).
Examine the O-rings (42, 43) on the orifice screw for wear. Replace
if necessary (see spare parts kits for ordering.)
3. Examine the orifice for blockage. If blocked, the orifice must be
replaced.
4. Tightly replace cleaned or new orifice screw and
O-rings into housing.
5. Reconnect the air supply pressure to the positioner.
Service and Replacement of the
Transducer Filter
The coalescing filter element in the NT 3000 module should be checked
every six months and replaced when necessary. To check or replace
filter, refer to Figure 8 and proceed as follows:
1. Disconnect air supply pressure to the positioner.
2. Remove the filter cover (24) from the housing (45), being careful
not to damage the O-ring (23).
������������
���������������
������������
���������������
��������
�����
3. Remove the filter element (22) from the housing and examine it; if
plugged or dirty, replace with a new filter.
4. Reinstall the filter after first cleaning the sealing surfaces. Install the
filter in the housing, and tightly fasten on the filter cover.
5. Reconnect the air supply pressure to the positioner.
Service and Replacement of
the Transducer Vent Element
(not applicable for vented model)
To disassemble and reassemble the NT 3000 vent element, refer to
Figure 8 and proceed as follows:
1. Disconnect air supply pressure to the positioner.
2. Remove the two vent cover screws (19) from the housing (45).
Remove the vent cover (20) from the housing.
3. Examine the vent element (21) by unscrewing it from the housing;
if plugged or dirty, replace with a new vent element.
4. Reinstall the vent element. Place a small amount of thread locking
compound on the vent cover screws and tightly secure the vent
element cover.
5. Reconnect the air supply pressure to the positioner. 9
flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Figure 7 – NT 3000 Transducer Pressure Modulator (circuit board removed)

��������
�����������

���������
�����
������������������
�����������������

Service and Maintenance of the
Transducer Circuit Board
To replace the circuit board, refer to Figures 6 and 8 then proceed as
follows.
c WARNING: The circuit board is an electrostatic sensitive
device. Use appropriate ESD protective devices when handling.
1. Disconnect air supply pressure to the positioner.
2. Remove the NT 3000 transducer housing cover (1).
WARNING: Disconnect power to the I/P transducer before
c
removing the housing cover in explosive atmospheres;
otherwise, personal injury may occur.
3. Disconnect the loop power electrical connections from the circuit
board (4).
4. Remove the three circuit board mounting screws (3) and carefully
pull the circuit board straight out of the housing.
10
5. Disconnect the pressure modulator (11) electrical connector from
the bottom of the circuit board.
6. If the plastic enclosure in the circuit board assembly (see Figure 8)
is separated, O-ring should be installed in the hole in the housing
base (position B), and not on the post on the bottom of the circuit
board (position A), prior to reassembling.
7. Reconnect the pressure modulator electrical connector to the circuit
board.
8. Reinstall the circuit board by engaging the pressure sensor tube
and pressing it straight into the housing. Be careful not to damage
the O-ring with the pressure sensor or pinch the modulator
connector wires while installing the circuit board. Apply thread
locking compound to the three circuit board mounting screws,
replace and tighten.
9. Reconnect the loop power electrical connections to the terminal
block noting polarity.
10. Reinstall the housing cover and reconnect the air supply pressure.
11. Check the span and zero calibration (see Calibration).
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04
Disassembly and Reassembly of the
Transducer Pressure Regulator
To disassemble and reassemble the NT 3000 module, refer to Figure 8,
and proceed as follows:
1. Disconnect air supply pressure to the positioner.
2. Remove the regulator setscrew (40) from the pressure regulator
cover (38).
c WARNING: The pressure regulator has an internal spring that
is preloaded. Removing the setscrew relieves this preload.
This must be done before the pressure regulator cover is
removed; otherwise personal injury may occur.
3. Remove the pressure gauge (41).
4. Remove the pressure regulator cover (38) by evenly removing its
two mounting screws (39). The pressure regulator preload will be
further reduced as these screws are removed. If vented model is
used, remove the regulator cover gasket.
5. Remove the regulator spring button (37), the regulator spring (36),
and diaphragm retainer (35).
6. Gently remove the regulator diaphragm assembly (assembly
comprising items 31, 32, 33, and 34).
7. Using a 7⁄16-inch socket wrench, remove the poppet guide screw
(30), its O-ring (29), the regulator poppet (28), and the poppet
spring (27).
8. Before reassembly, clean the regulator cavity. Replace or clean
necessary parts before reassembly.
9. To reassemble, place the poppet spring (27) into the housing cavity.
Place the poppet guide O-ring (29) on the poppet guide screw (30)
and insert the regulator poppet (28) through the bottom of the
guide screw. Screw the guide screw into the housing being careful
not to overtighten. A maximum torque of 5 to 6 inch-pounds is
sufficient. Make sure the poppet is free to move up and down and
has spring load.
10. Gently push the diaphragm assembly (assembly comprising items
31, 32, 33, and 34) into the bore.
11. Install the regulator spring (36) and the diaphragm retainer (35)
in the bore and then place the regulator spring button (37) on the
spring. Place a small amount of thread locking compound (Loctite
222 or equivalent) on the regulator cover screws (39) and tightly
secure the pressure regulator cover (38). If vented model is used,
make sure the regulator cover gasket is installed.
12. Place a small amount of thread sealant compound on the threads of
the pressure gauge (41) and tightly thread it into the housing.
13. Apply a small amount of thread locking compound (Loctite 222
or equivalent) on the regulator setscrew (40) and install it into the
regulator cover (38).
14. Adjust setpoint of the pressure regulator by following the instruc-
tions as outlined in the “Adjusting Pressure Regulator Output”
section of this manual.
15. Reconnect the air supply to the positioner.
11
flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Removal and Replacement of the Transducer Pressure Modulator

Removal and replacement of the NT 3000 pressure modulator should only be performed by a certified service center.

Figure 8 – NT 3000 Transducer, Exploded View

������������������������������������������ �

���������

��������������

�������
�������������
���� �
�
������������� �

� � ������
�
������������ �

� �����������������

��������������������������� �

� � �����������������

�� ��
� ��
��
��
�� ��
�� �� �� ��

��
��
�� ��

�� ��
��
��
�� �� ��
��
�� ��
��
��
��
�� ��

�� ��
��
��
��
12 �� ��

��
��������������������������������������������������������������
�� �����������������������������������������������������������
���������������������������������
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Parts List
Item Description Item Description
1 Transducer housing cover 25 Lock screw for CENELEC I/P
2 Housing cover O-ring 26 I/P to positioner attachment screws
3 Circuit board mounting screws 27 Poppet spring
4 Circuit board 28 Regulator poppet
5 Stickers 29 Poppet guide O-ring
6 Modulator set screw 30 Regulator poppet guide screw
7 Modulator screws 31 Poppet seat
8 Pressure modulator cover 32 Orifice retainer
9 Spring diaphragm assembly 33 Regulator diaphragm
10 Pressure modulator cover 34 Spring guide
11 Coil assembly 35 Diaphragm retainer
12 Pressure modulator body 36 Regulator spring
13 Pressure modulator nozzle 37 Regulator spring button
14 Foam filter 38 Regulator cover
15 Coil O-ring 39 Regulator screws
16 Ground screw 40 Regulator setscrew
17 Flame arrestor 41 Pressure gauge (0-30 psi)
18 I/P to positioner housing air connection O-rings 42 Orifice O-ring
19 Vent cover screws 43 Orifice screw O-ring
20 Vent cover 44 Orifice screw
21 Vent element 45 Transducer housing
22 Filter 46 Sensor O-ring
23 O-ring 47 O-ring retainer
24 Filter cover

13

flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Spare Part Kits

Kit 1 – Regulator Assembly Kit 4 – Vent Element
PN 138727.999.000 PN 098335.999.000
Item No. Description Quantity Item No. Description Quantity
27 Poppet Spring 1 19 Vent Cover Screws 2
28 Regulator Poppet 1 20 Vent Cover 1
29 Poppet Guide O-ring 1 21 Vent Element 1
30 Regulator Poppet Guide 1
31, 32,
33, 34
Diaphragm Assembly 1 Kit 5 – Soft Goods
PN 171270.999.000 – Buna N
36 Regulator Spring 1 PN 188562.999.000 – Fluorosilicon
37 Regulator Spring Button 1 PN 188563.999.000 – Viton
38 Regulator Cover 1 Item No. Description Quantity
39 Regulator Screw 2 2 Housing Cover O-ring 1
40 Regulator Set Screw 1 15 Modulator O-ring 1
23 Filter Cover O-ring 1
29 Poppet Guide O-ring 1
Kit 2 – Orifice
PN 098333.999.000 31 Poppet Seat 1
Item No. Description Quantity 33 Regulator Diaphragm 1
42 Orifice O-ring 1 42 Orifice O-ring 1

43 Orifice Screw O-ring 1 43 Orifice Screw O-ring 1

46 Sensor O-ring 1
44 Orifice Screw 1
Regulator Cover Gasket
1
(for vented models only)
Kit 3 – Filter Element
PN 098334.999.000
Kit 6 – Electronics and Maintenance Kit
Item No. Description Quantity PN 217591.999.000
23 Filter Cover O-ring 1 Item No. Description Quantity
22 Coalescing Filter Element 1 3 Circuit Board Mounting Screws 3
4 Circuit Board 1
16 Grounding Screw 1

14
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04
Standard Explosion Proof EMI / RFI
Wiring Installation Procedures
(using conduit)
The NT 3000 transducer has been tested by an independent testing
laboratory to comply with the following industry standards:
EN 61000-4-2 Electromagnetic Compatibility (EMC) Part 4: Testing
and measurement techniques, Section 2 Electrostatic Discharge
immunity test, 1995.
EN 61000-4-3 Electromagnetic Compatibility (EMC) Part 4: Testing
and measurement techniques, Section 3 Radiated, radio frequency,
electromagnetic field immunity test, 1995.
EN 61000-4-4 Electromagnetic Compatibility (EMC) Part 4: Testing
and measurement techniques, Section 4 Electrical fast transient/burst
immunity test, 1995.
EN 61000-4-5 Electromagnetic Compatibility (EMC) Part 4: Testing
and measurement techniques, Section 5 Surge immunity test, 1995.
EN 61000-4-6 Electromagnetic Compatibility (EMC) Part 4: Testing
and measurement techniques, Section 6 Immunity to conducted
disturbances, induced by radio frequency fields immunity test.
The NT 3000 transducer complies with these standards when installed
following the minimum wiring procedures.
The housing must be grounded. Normally the housing is grounded
through the valve to the local superstructure. When the positioner is
grounded, the on-board filtering will be effective. Therefore, a green
internal ground screw is provided. The ground wire should be as short
as possible.
Proper NT 3000 field wiring includes three elements: conductive
conduit (armor), drain wire, and shielded wire.
Conductive Conduit The conduit can be rigid or flexible and must
be conductive. The conduit provides additional protection in the event
the shield contains an opening and is required to be within six feet of
the NT 3000 transducer and within six feet of any radios or microwave
sources. The conduit system includes an aluminum fitting at the NT
3000 transducer.
Figure 9 – NT 3000 Transducer, Drain Wire
��
����
�������
�����
Drain wire The drain looks like a bare ground wire and is not a
shield. The drain wire is provided by the cable manufacturer and
provides a path to ground for any noise, or can be a path for ground
loops. Therefore, the drain should be terminated only at one end of the
loop (normally the source). The drain extends from the source to the
NT 3000.
Figure 10 – NT 3000 Transducer, Shielded Wire
��
������� ����
�����
������
Shielded Wire This is standard insulated instrumentation wire with
a conductive aluminum foil wrapped around the conductors. The
shield provides a protective metal barrier to keep out electrical noise.
Shield weak points are found at the beginning, end and other openings.
Sometimes the foil wrap is outside of the cable manufacturer’s speci-
fication for overlap. Any openings in the shield (i.e. bends with under
tolerance overlap) provide a path for electrical noise to infect the current
signal. The shield extends from the source to the NT 3000 transducer.
Grounding of the shield should be at one end only (the same end as the
drain wire).
NOTE: Cable tray or ladder will not provide protection from electrical
noise.
This procedure will protect against noise generated close to the NT
3000 transducer. However, generating electrical noise at the source
power supply (DCS, etc.) is possible and can be due to ground loops in
the source power supply or other contamination. Any noise generated
at the source can affect the NT 3000 transducer.
15
flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Troubleshooting
Failure Probable Cause Corrective Action
1. Supply pressure is low or not connected properly 1. Set supply pressure to recommended value

Transducer output is 2. Pressure gauge is faulty 2. Replace gauge

less than 1.5 psig with 3. Orifice is plugged 3. Replace orifice
no input signal (output
pressure should be 2.0 4. Transducer filter needs servicing 4. Service filter
psig ±0.5 psig) 5. Transducer pressure regulator adjusted improperly 5. Adjust pressure regulator
6. Transducer pressure modulator adjusted improperly 6. Adjust pressure modulator
1. Transducer pressure modulator adjusted improperly 1. Adjust Transducer pressure modulator
Transducer output pres-
sure is greater than 3.0 2. Transducer pressure regulator adjusted improperly 2. Adjust pressure regulator
psig with no input signal
3. Pressure gauge is faulty 3. Replace gauge
Low pressure output with 1. Zero and span out of calibration 1. Recalibrate zero and span settings
a signal above minimum
input signal 2. MPC is enabled (Old style NT 3000 models only) 2. Disable MPC
1. Input signal not connected properly 1. Connect input signal to circuit board
Transducer output is 2.0
psig ±0.5 psig, regardless 2. Pressure modulator assembly not connected to circuit board 2. Connect pressure modulator to circuit board
of input signal
3. Circuit board is defective 3. Replace circuit board
1. Supply pressure is low or not connected properly 1. Set supply pressure to recommended value
2. Zero and span out of calibration 2. Recalibrate zero and span settings
3. Pressure gauge is faulty 3. Replace gauge
Output will not reach 15.0
psig with maximum input 4. Orifice is plugged 4. Replace orifice
signal
5. Transducer filter needs servicing 5. Service filter
6. Transducer pressure regulator adjusted improperly 6. Adjust pressure regulator
7. Transducer pressure modulator adjusted improperly 7. Adjust pressure modulator
1. Tighten port mounting screws. Be certain correct
1. Air leakage from input port
O-rings are in place.
2. Air leakage from filter cover 2. Service filter
Excessive air consumption
3. Remove gauge, clean threads, apply hydraulic
3. Air leakage from pressure gauge
sealant to threads and replace
4. Air leakage from orifice 4. Replace orifice
1. Circuit board leads are loose 1. Tighten circuit board leads
2. Orifice is plugged 2. Replace orifice
Erratic operation
3. Pressure modulator adjusted improperly 3. Adjust pressure modulator
4. Circuit board is defective 4. Replace circuit board

16
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

NT 3000 Model Numbers

Selection Option Code Example
NT
Series/Prefix 3000 Series 3 3
Communications 4-20 mA 0 0
Diagnostics None 0 0
Aluminum 0
Material 0
Stainless Steel 1
I/P 4-20 mA EExia EExib intrinsically safe NT 3000 ATEX II 1 GD 04
I/P 4-20 mA SAA Explosion Proof Ex d, Intrinically safe Ex ia Ex N , (SAA) NT3000 05
Certification I/P 4-20 mA EExd Exp proof NT 3000 ATEX II 2 GD 07 04
I/P 4-20 mA Exp proof/intrinsically safe NT 3000 FM/CSA 10
I/P 4-20 mA General purpose NT 3000 14
(1) / Stainless steel gauges with brass fittings / psi bar kPa 2
(1) / Stainless steel gauges with Stainless steel fittings / psi bar kPa 4
Gauges
(1) / Stainless steel gauges with brass fittings / kg cm2 psi 6 2
(qty / material / units of measure)
(1) / Stainless steel gauges with Stainless steel fittings / kg cm psi
2
8
No gauges (Stainless steel plugs) 9
(Standard) Buna-N, Fluorosilicone / -40° to +185°F (-40° to +85°C) S
Soft Goods / Temperature Viton / -20° to +185°F (-29° to +85°C) V S
EPDM / -40° to +185°F (-40° to +85°C) E
½" NPT N
Conduit Connection N
M20 M
Non-Vented 1
Vent 1
Vented 2
White W
Black B
Paint W
Food Grade F
No paint (Stainless steel) S

17

flowserve.com
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

Adjusting the Minimum Pressure which the output pressure is to fall to approximately 2.0 psi. This
signal can range from the factory setting of 3.7 to
Cutoff Feature on Old Transducers 8 mA. See Figure 11.

Older models of the NT 3000 Transducer have a “Minimum Pressure 4. Turn the minimum pressure cutoff pot clockwise until the output
Cutoff” feature. This allows the user to set a trip-point to activate when pressure drops off.
the input signal falls below a certain point. This results in the pressure
5. Fine-tune the pressure drop-off point by increasing the input signal
output falling rapidly to approximately 2.0 psi, causing the valve to
and then decreasing it through the desired shut off signal. Observe
close on an air-to-open valve. This feature is generally used when the
the signal value at which the pressure drops off. If the pressure
service requires a tight shutoff or to prevent throttling near the valve
drops off at a lower mA signal than desired, turn the MPC pot
seat. To adjust this feature, refer to Figure 12 and perform the following
slightly clockwise. If the pressure drops off at a higher signal than
steps:
desired, turn the MPC pot slightly counterclockwise.
NOTE: The zero and span settings of both the positioner and NT 3000
6. Repeat step 5 until the pressure drops off at the desired input
transducer should be verified to be accurate before the minimum
signal.
pressure cutoff feature is enabled and adjusted. Instructions for setting
the zero and span settings are described in the calibration section on 7. To disable the MPC feature turn the minimum pressure cutoff pot
Page 4. (marked “MPC”) 20 turns counterclockwise or until it makes a
clicking noise.
NOTE: Complete the following steps only when using the minimum
pressure cutoff feature.
Figure 11 – I/P Minimum Pressure Cutoff Adjustment Range
1. Connect the NT 3000 transducer to the 30 to 150 psi air supply
��
pressure.
�������������������������

��
2. Remove the NT 3000 transducer housing cover.
�
�������
c WARNING: Disconnect I/P module power before removing
�
housing cover in explosive atmospheres; otherwise personal ������� �������
injury may occur. �
�������
����������������
3. Connect an adjustable current source to the terminal block on the �
� � � �� �� ��
circuit board. Apply the desired input signal to the positioner at �������������������

Figure 12 – Old Style NT 3000 Transducer Circuit Board (housing cover removed)

���������������

��������
�����

���� ������������
���������� ���������������

����
18 ���������� ������������
���������������

�������
��������
������
����������
��������������
 NT 3000 Series Electro-Pneumatic Transducer Module FCD VLAIM0047-00 - 09/04

This page is intentionally blank.

19

flowserve.com
 United States
Flowserve Corp.
Flow Control
Valtek Control Products
1350 N. Mt. Springs Parkway
Springville, UT 84663
Phone: 801-489-8611
Fax: 801-489-3719

FCD VLAIM0047-02 Printed in USA.

To find your local Flowserve representative:

For more information about Flowserve Corporation, visit

www.flowserve.com or call USA 1 800 225 6989

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended
function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide
variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The pur-
chaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should
read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in
connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as
a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this
product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice.
Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.

© 2004 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.

flowserve.com