Instruction Manual

INS/8013/REV-B/03-2006 MIL 8013

Electropneumatic Valve Positioner

ISO 9001 : 2000

Certificate : 04100 2002 0157

Purchase Order No. :

The following instructions should be thoroughly

reviewed and understood prior to installing,
operating or performing maintenance on this
equipment. Throughout the text, safety and/or
caution notes will appear and must be strictly adhered to,
otherwise, serious injury or equipment malfunction could result.

MIL Controls Limited

Installation**

Caution : The equipment has left the factory in a perfect
condition as regard safety. The notes and warnings
in these "Instructions" must be observed by the user
if this state is to be maintained and hazard-free
operation of the equipment assured.
The positioner may be used for either direct (air-to-
close) or reverse (air-to-open) diaphragm actuators. The
direction of actuator stem motion for an increase in
diaphragm pressure determines the mounting of the
positioner on the actuator.

On direct actuators, the positioner is mounted to the

Caution: For flame proof instruments, the positioner
cover should not be opened in the hazardous area,
when energised.
Location
Two factors should be considered for the location of
the positioner:
1. Temperature: Avoid locations which are subject
to wide ambient temperature variations. If control
valve is subject to subfreezing temperature, special
provision must be made for drying positioner air
supply.
2. Vibration: If possible, avoid locations where vibration
occurs.
left of the actuator stem and the positioner backlever
extends to the right of the positioner.
On reverse actuators, the mounting bracket is turned
over; the positioner is mounted to the right of the
actuator stem and the backlever is positioned to extend
to the left of the positioner.
Air Piping (Fig. 1)
Supply Air: The 1/4" NPT air supply connection is
located on the relay and is marked by an arrow. Use
1/4" OD tubing for piping supply air to the positioner.
On long runs, use larger diameter tubing or pipe. If

Figure 1 - Mounting

Caution: Do not place watches or delicate instruments the air supply contains large amounts of moisture, make
near the positioner since it employs a powerful Alnico provision to remove it before the air reaches the filter-
V Magnet. regulator in the supply piping. Adjust the regulator
to required reduced actuator supply pressure.\

Mounting (Fig. 1)
The positioner is rigidly mounted on the actuator
mounting pad by means of a mounting plate.
Output Air: The 1/4" NPT output pressure connection
is located on the relay and is marked by an arrow. Use
1/4" OD tubing between this connection and the
connection in the actuator diaphragm case.

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

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

2
Installation (Cont....)
Linkage Assembly (Fig. 2)
Turnbuckle (60)
When the positioner has been mounted Clevis (28)
on the actuator, the take-off clamp is Turnbuckle Screw (62)
Locknut (61)
attached to the actuator stem at a point
which permits full actuator stem travel.
The turnbuckle is installed in a vertical
position between the clamp rod and Clamp Rod (63)
(Take-Off-Linkage)
the clevis. The lower end of the
turnbuckle has been machined round
to identify the right hand thread which Clamp Screw(64)
Take-off Clamp

engages the turnbuckle screw.

Figure 2 - Take-Off Clamp S/A

Operation (Fig. 3,4)

General Direct Action

The positioner is a force-balance With direct positioner action, an increase
electropneumatic device which provides in the input signal produces a force on
an accurate means of obtaining a valve the beam, moving the flapper to cover
stem position directly proportional to the nozzle. The increase in nozzle back
a DC input signal. In addition, the pressure increases positioner output
positioner provides a convenient means pressure to the actuator. The resultant
of split-ranging controller output signal valve stem motion is transmitted to the
for sequential operation of two control force-balance spring, extending the
valves by a single controller. It may spring until the force exerted on the
have either direct or reverse action on beam balances the opposing force of
Figure 3 the coil. As these two forces equalize,
either direct or reverse actuators.
Diagrammatic of Operation

50 39
16 46 8 12 41 6 52B 49 44 40 5B 5A 5C
59 74 11

20 14 32 22 15 31G 31A 31B

24 72 71 35
31D

3 -
Cover 12 - Force Balance Spring \ 31B - Pin (Lever stroke adj.) 49 -
Flexure
5A -
Upper pole piece Adjusting Nuts 31D - Pinion 50 -
Flexure
5B -
Lower pole piece 14 - Case 31G - Index lockscrew 52B -
Biasing spring
5C -
Magnet 15 - Terminal board (S/A) 32 - Stroke lever (S/A) 59 -
Metering tube (S/A)
6 -
Adjusting screw 16 - Nozzle 35 - Back lever adapter (S/A) 71 -
Bearing post
(Force balance spring) 20 - Relay (S/A) 39 - Spring bracket (Back lever adapter)
8 - Spring (Force balance) 22 - Mounting bracket 40 - Coil (S/A) 72 - Bearing post
11 - Biasing Spring 24 - Cover plate 41 - Beam (Lever stroke adjustment)
Adjusting (Stroke adjustment) 44 - Machine screw (Coil stop) 74 - Flame arrestor
Screw (Zero) 31A - Lever (Stroke adjustment) 46 - Flapper

Figure 4 - Cross Sectional View

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

nozzle back pressure decreases. The system then is in
equilibrium and positioner output is stabilized at an
amount necessary to maintain the desired control valve
plug position.
When the forces on beam are in equilibrium, there is,
theoretically, no flow of air into or out from the relay.
Actually, a small bleed is provided between supply and
output to increase relay responsiveness.
Reverse Action
With reverse positioner action, an increase in the input
signal produces a decrease in output pressure.

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

Figure 4A

CIRCLIP
BACK LEVER

PINION
(31D)
LEVER (31A)
(STROKE
INDEX LOCK SCREW ADJUSTMENT)
(31G)
INDEX

STROKE
LEVER (S/A)
(32)

RELAY (S/A)
(20)

Figure 4B
TERMINAL BIASING BIASING SPRING ADJUSTING
BOARD (S/A) (15) BEAM SPRING SCREW (ZERO)
(41) (52B) (11)

FLAPPER(46) (40) COIL S/A

(12) (8) (16)

FORCE BALANCE SPRING SPRING FORCE BALANCE SPRING (5C)
(FORCE BALANCE) MAGNET
ADJUSTING NUTS ADJUSTING SCREW

4
Adjustments (Fig.2, 4, 4A, 4B)
Stroke: Matches the valve stem travel to a given
range of positioner input signal. This adjustment is
accomplished by loosening the index lockscrew (31 G)
and rotating the pinion (31 D) with a screwdriver until
the index is at the correct stroke value.
Force-Balance Spring: Primarily an adjustment for
calibrating the stroke scale to compensate for variation
in coil strength. A full input signal change should fully
stroke the valve stem when the index is at the correct
stroke value. If valve stem travel is less than rated stroke,
loosen locknut and turn adjusting screw (6) counter-
clockwise. Retighten locknut.
Calibration
MIL 8013 Positioners, when furnished with MIL valves,
are factory mounted and calibrated for the rated stroke,
the action and the DC input signal range specified.
Note: No further calibration is required in the field.
In the event a positioner is supplied for field mounting,
or reversal of the positioner action in the field is
required, the following steps should be taken after first
making certain the valve is properly adjusted:
Step 1. Mount positioner, connect input signal leads,
air piping and linkage assembly as directed
under installation.
Step 2. Loosen index lockscrew (31 G) and rotate the
pinion (31 D) with a screwdriver until the
stroke index is opposite the marking on the
stroke scale corresponding to the rated
stroke of the valve.
Step 3. With proper supply pressure to the positioner;
set controller for midpoint of positioner input
signal range; e.g., 12 mA for a signal range
of 4-20 mA.
Step 4. Adjust biasing spring (52 B) (See
"Adjustments") until the inside edge of the
stroke lever (32) is parallel to the slot in the
stroke adjustment lever (31 A).
Step 5. Rotate the turnbuckle (60) until the valve
is at midstroke and recheck parallelism of
Maintenance
Relay (Fig. 5)
Metering Tube
The metering tube for the nozzle air supply is furnished
with a clean-out plunger which forces a small wire
through the jewel orifice.
5
Biasing Spring: Exerts a force on the beam to
establish proper position of the stroke levers with respect
to the positioner Input signal range. The stroke lever
(32) should be parallel to the slot in the stroke adjust-
ment lever (31 A) at midpoint of the positioner input
signal. This parallelism is obtained by adjusting of biasing
spring adjusment screw (11).
Turnbuckle: Matches valve stem position with
input signal. This adjustment is made, with controller
output signal at midrange, by rotating the turnbuckle
(60) until the valve stem is at midstroke. After making
adjustment, tighten the locknut (61)
stroke and stroke adjustment levers. If nece-
ssary, repeat Steps 4 and 5 until the levers
are parallel and the valve is at midstroke
with the controller at midpoint of output
signal range.
Step 6. Set controller for minimum of positioner input
signal range (eg: 4 mA) and observe valve
position as indicated on the valve travel plate.
Step 7. Change controller setting for maximum of
positioner input range (eg: 20 mA) and check
valve stem travel. If more than rated stroke,
loosen lock-nut and turn force-balance spring
adjusting screw (6) clockwise; If less than
rated stroke, turn adjusting screw
counterclockwise, until valve indicator disk
indicates correct valve position. Tighten
locknut.
Step 8. Set controller for midpoint of positioner input
signal range and check to make certain that
stroke lever is still parallel to the slot in the
stroke adjustment lever and valve is at mid-
stroke. If incorrect, repeat Steps 4 to 8 until
the positioner input signal range matches the
rated stroke of the valve and, with positioner
input signal at midrange, the levers are parallel
when the valve is at midstroke.
Disassembly
The metering tube body may be removed without remo-
ving the relay from the instrument case. If further
disassembly of the relay is required, proceed as follows:
Step 1. Disconnect air supply and output tubing.
Maintenance (Cont ....)

Figure 5 - Relay

Step 2. Unscrew the four mounting screws and Nozzle

remove relay from instrument case.
To clean nozzle, shut off air supply; loosen screw
Step 3. Remove holding screw and drop spring and holding flapper to beam. Remove flapper and unscrew
plug from relay body. nozzle from case. Clean nozzle with solvent and
blow out hole with clean air, Screw nozzle into case,
Step 4. Remove six screws holding relay cap, dia-
replace flapper on beam and tighten screw.
phragm S/A, bellofram plate S/A. gasket and
spring to relay body.
Beam alignment
Step 5. Clean parts with soft cloth. Use solvent if
The beam has been aligned at the factory and should
oil or grease is present. (Do not use solvent
not require realignment unless the flexures are damaged
on diaphragm or gasket). Blow out port with
or it becomes necessary to replace the coil.
clean air.

Reassembly To Replace Flexures:

Step 1. Remove positioner from valve.
Step 1. Replace spring and position gasket on relay
body. Step 2. Remove positioner cover and disconnect (or
Step 2. Reassemble and align holes in relay cap, unsolder *) coil leads from the terminal board.
diaphragm S/A and bellofram plate S/A. Insert
Step 3. Disengage the end of the force balance spring
two screws, 1800 apart, through this assembly.
attached to the force balance spring
Step 3. Position assembly on spring and then, being adjusting screw.
careful to align holes, exert sufficient down-
Step 4. Remove the two upper pole piece screws and
ward pressure on this assembly to engage
lift the entire operating mechanism from
screws in relay body. Make certain that gasket
the case.
is properly seated before tightening screws.
Step 5. Remove biasing spring screw, releasing biasing
Step 4. Insert remaining screws, replace relay plug,
spring from the beam.
spring and holding screw in relay body.

Step 5. Establish desired relay position and fasten Step 6. Remove four screws joining flexures, upper
relay to instrument case. pole piece and beam.

6
Maintenance (Cont....)

Step 7. Replace damaged flexures and reattach beam
to upper pole piece with flexures and screws.
Do not tighten scews.
Step 8. Replace coil, if necessary, and/or realign beam
as described in following sections.
To Align Beam (Fig. 7)
step 1. Insert 1/8" diameter rod into alignment hole
and underneath the beam, as near as possible
to the the coil, a wedge which is 5/32" high
and 1/32" in thickness (Fig. 7). Rod and
wedge material should be nonmagnetic.

To Replace Coil (Fig. 6) Step 2. Tighten lower screws (two) of inner flexure
and lower screws (two) of outer flexure to
Step 1. Same as Steps 1 to 6 for replacing flexures. beam and upper pole piece, respectively.

Step 2. Unscrew coil and machine screws, freeing coil Step 3. Replace operating mechanism in case. Position
from beam. biasing spring bracket and tighten in position
with two mounting screws.
Step 3. Attach replacement coil loosely to the beam
with coil and machine screws. Step 4. Exerting downward pressure on beam
between 5/32" high wedge and nozzle,
Note: Machine screw (44) should not extend into the tighten four remaining flexure screws.
coil bobbin.
Step 5. Tighten the coil screw and remove alignment
Step 4. Reattach beam to upper pole piece with rod and wedge.
flexures and screws. Do not tighten screws.
Step 6. Adjust machine screw (44) so that flapper
Step 5. Align beam. travel is 1/32".

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

biasing spring nut.

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

balance spring adjusting screw (6).

Figure 6 - Coil Replacement Figure 7 - Beam Alignment

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

7
Maintenance (Cont....)

Terminal Board Replacement Step 3. Install new terminal board and fasten
securely to case.
If it becomes necessary to change the terminal board,
proceed as follows. Step 4. Insert operating mechanism in case and
tighten screws.
Step 1. Remove operating mechanism from case as
described in Steps 1 through 4 for replacing Step 5. Engage the force-balance spring with force
flexures. balance spring adjusting screw.

Step 2. Unscrew the two screws holding terminal Step 6. Connect (or soft-solder *) coil leads.
board to case.

Trouble Shooting

General disassemble and clean relay (see “Main-

tenance”).
The following conditions are necessary for trouble free
operation: Electrical Circuits

1. Proper supply pressure, i.e., 20 psi or 35 psi. After checking pneumatic circuit, the electrical circuit
should be checked with an ohmmeter as follows:
2. Proper electrical current for input signal.

3. Proper size nozzle and metering tube as indicated Step 1. Disconnect controller signal leads from
below and stamped on the component. positioner.

Nozzle Step 2. Connect ohmmeter leads to positioner

MIL
Number terminal posts and check positioner circuit
Actuator
Size resistance with value indicated on serial plate.
20 psi Supply 35 psi Supply

11 11 11 Step 3. Disconnect (or unsolder *) coil lead from

positive terminal and connect it to one of
13 12 11
the ohmmeter leads. Connect other
15 13 12
ohmmeter lead to negative terminal. Coil
18 13 12 resistance value should approximate to 173
24 13 13 Ohms + _ 5%

4. All components fastened firmly as required.
5. Machine screw (44) adjusted to allow approximately
1/32" flapper travel.
Pneumatic Circuit
In the event of faulty operation of the positioner, where
the cause is not readily apparent, check air system as
follows:
Step 1. Exert sufficient force on the flapper to cover
the nozzle. Valve stem should travel its full
stroke.
Step 2. If response is other than indicated in the
above steps, push cleanout plunger of
metering tube. Inspect for plugged nozzle.
Check to see metering tube body is properly
seated in the relay. If difficulty still persists,
Step 4. If coil resistance is approximately correct but
positioner circuit resistance is not, replace
terminal board. If coil resistance is not correct
replace coil.
Step 5. Remove ohmmeter lead from negative
terminal and connect it to machine screw
(44), check for short in coil. Replace coil if
ohmmeter indicates a value other than infinite
resistance.
Caution : All Maintenance work to be carried out outside
the hazardous area if instrument is Flame Proof /
Explosion proof certified.
* Only in case of a positioner incorporated with intrinsic
security circuit. This operation must be carried out outside
of any hazardous location

8
Split Range

In a SPLIT-RANGE assembly, the choice of the type of
connection (in series or parallel) and the characteristics
of the positioners equipping each valve, depend on the
controller output signal and impedance of the circuits.
When the positioner is ordered specifically for split-
range operation, a force balance spring with one-half
the standard rate is supplied.
The table below gives for each case (double or triple
split-range, connection of positioners in series or parallel),
the coefficient to be applied to the actual stroke value
of the equipped valve in order to obtain the adjustment
value to be indicated on the stroke scale of each positioner.
In certain cases it is possible to have standard positio-
ners operating in split-range.
When this is so, our Engineering Department supplies
all the information necessary for the choice of the
material or its eventual transformation.

Double
Split - Range
(2 Valves)

Stroke Adjustment Actual Stroke Actual Stroke x 2

Valve max. stroke: 3" (76.2 mm) max. stroke: 11/2" (38.1 mm)

Triple
Split - Range
(3 Valves)

Stroke Adjustment Actual Stroke x 1.3 Actual Stroke x 2.6

Valve max. stroke: 2" (50.8 mm) max. stroke: 1" (25.4 mm)

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

Figure 8 - Split Range Options

Protection Standards

Equipment for hazardous atmosphere
These standards are divided into two groups ac-
cording to two types of protection
1. Flameproof housing positoners : If because of a
failure, an internal part of the positioner causes
a spark, this can ignite the hazardous mixture
contained in the case. Thus the characteristics of
this case are calculated in order that it could resist
to the pressure developed during the internal
explosion and prevent the transmission of the
explosion to the environmental hazardous
atmosphere of the housing.
2. Positioners for intrinsically safe circuit : This protection
system which applies to a complete circuit but not
to a single and isolated device, is particularly due
to the fact that no spark, no thermal effect produced
according to the test conditions recommended by
the standard regulation, can produce the ignition
of a given hazardous atmosphere.
3. Tight equipment for non-hazardous atmosphere :
8013 positioner is also available as "Weather Proof"
so as to protect the positioner against dust and
stream of water. Devices manufactured under the
reference "Weather Proof" (protection against dust
and stream of water) meet specification requirements
of IS 13947.
Caution: Do not open loosen screws of the instruments,
in flame proof atmosphere, for any repair or main-
tenance work. The instrument has to be taken outside
the hazardous area.

9
Certifications for 8013 Positioners
a) Hazardous atmosphere 2. Intrinsically safe Gr. IIC as per IS 5780 (With Weather
proof IP65 Certification)
1. Flame proof to Gr. IIA, II B as per IS2148 (With
Weather proof IP55 Certification) b) Non-Hazardous atmosphere

1. Weather proof IP65 as per IS 2147

Electrical Circuits
Electrical circuit

The installation must be in accordance with the The positioner has been factory calibrated for the action
selected standard for the protection against required by the customer. If action is not specified, the
explosion. positioner is factory calibrated for direct action.

CONNECTING SIGNAL LEADS Changing of action :

1. They are introduced in the case through the conduit 1. Reverse the positions of the coil leads to the terminal
connection located on the side. (¾" or ½" NPT) board (See diagram of figure 9)

2. Connections to the terminal board should be made
respecting the polarities engraved on this terminal
board.
Connecting coil leads to the terminal board
This connection determines the device action.
Direct action : A signal increase produces an output
pressure increase.
Reverse action : A signal increase produces and
output pressure decrease.
The diagram of figure-9 shows the position of the coil
leads and the connecting terminals used for the terminal
board for each action of the device.
DIRECT ACTION REVERSE ACTION
2. In case of intrinsically safe circuit replace the coil
by another one corresponding to the new action.
Caution: Incase of flame proof housing device, the
positioner case should not be opened when the device
is energized.
Note 1 : The standards concerning electrical equip-
ment utilized in hazardous atmospheres can
be identified with serial plate fastened to
the side.
Note 2 : Besides the mark corresponding to the
positioner action, coils always have a color
code permitting the identification of the
nominal resistance. In the event of coil removal
be sure that the colour code of the new coil
is identical with the old one eg : 4-20 mA
coil with colour code blue.

Cross the leads over the beam

Note3 : Be sure that leads connecting the coil to the
terminal-board do not block the beam
Figure 9 - Coil Leads Position motion.

10
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