GE Masoneilan 4700P, Maintenance Manual

Page 1: ...GE Oil Gas Masoneilan 4700P 4700E 4800P 4800E Pneumatic and Electropneumatic Positioners Maintenance Manual Rev C GE Data Classification Public...

Page 2: ...DING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS THEREFORE THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION W...

Page 3: ...to be accurate at the time of publication and is subject to change without notice All other trademarks and copyrights are properties of their respective corporations Copyright 2015 by GE Oil Gas All r...

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Page 5: ...Actuator 26 Mounting 4700P 4800P and 4700E 4800E on Series 87U 88U Actuators 26 Positioner Mounting and Orientation 28 Camflex II Varimax MiniTork II Ball II and HPBV 28 Pneumatic Installation 31 Ele...

Page 6: ...55 Air to Close Reverse Acting Positioner 4700P 4800P only 56 Damping Adjustment 56 Positioner Action Change 4700P 4800P Only 57 From Air to Open Direct to Air to Open Reverse 57 From Air to Open Rev...

Page 7: ...nting Travel Settings 25 7 87U 88U Actuator 27 8 Camflex II and Varimax 29 9 Ball II and MiniTork II 29 10 High Performance Butterfly Valve 30 11 Pneumatic Installation 33 12 Electrical Connections 35...

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Page 9: ...pany All rights reserved Tables 1 Mounting Parts Reference 87 88 22 2 Mounting Parts Reference 87U 88U 26 3 Mounting Parts Reference 28 4 Split Range Operation 64 5 Parts Reference 4700P 4800P 3 15 an...

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Page 11: ...re installation and operation Safety Symbols 4700 4800 instructions contain WARNINGS CAUTIONS labels and Notes where necessary to alert you to safety related or other important information Total compl...

Page 12: ...es General installation maintenance or replacement Products must be installed in compliance with all local and national codes and standards by qualified personnel using safe site work practices Person...

Page 13: ...table training for instrumentation used in areas with potentially explosive atmospheres WARNING Before using these products with fluids compressed gases other than air or for non industrial applicatio...

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Page 15: ...sitioner is not available with reverse action The Model 4700P 4700E and 4800P 4800E pneumatic positioner design is based on the force balance principle the signal pressure exerted on a diaphragm is op...

Page 16: ...ristics are available by selection of proper lobe on cams supplied for Camflex II Varimax 87 88 and 87U 88U actuators Cams supplied on Ball and Butterfly valves maintain the inherent valve characteris...

Page 17: ...ypassed Moreover if the positioner with a high supply pressure is bypassed suddenly the high pressure in the actuator may damage the diaphragm and or the control instrument Therefore the bypass valve...

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Page 19: ...on the desired air failure action This subject is dealt with in separate actu ator instructions The positioner can operate either by direct action increasing instrument signal produces an increase in...

Page 20: ...al Electric Company All rights reserved 20 GE Oil Gas The 4700 series positioners have the same mounting and link age attachment dimensions as the 4600 4600A 4600B and 4700B series positioners but hav...

Page 21: ...rights reserved Figure 3 Rotary Figure 4 Reciprocating For 4700P 4800P model only positioner action can be reversed by simply engaging the proper lobe on the cam and reversing the follower arm number...

Page 22: ...Retaining 103 Back Lever 113 Cap Screw 38 Cap Screw 104 Clevis Pin 114 Lockwasher 39 Lockwasher 105 Retaining Clip 115 Mounting Bracket 40 Washer 531 ID 106 Turnbuckle 122 Washer 41 Post Hub 107 Lock...

Page 23: ...Masoneilan 4700P E 4800P E Positioners Manual 23 2015 General Electric Company All rights reserved Figure 5 87 88 Actuator...

Page 24: ...the back lever Location is based on valve stroke required 5 Check Figure 6 for proper mounting location for positioner on bracket 6 Mount positioner on bracket using socket head screws 29 and lockwas...

Page 25: ...Masoneilan 4700P E 4800P E Positioners Manual 25 2015 General Electric Company All rights reserved Figure 6 87 88 Actuator Bracket Mounting Travel Settings...

Page 26: ...and lockwasher 39 6 Attach bracket 5U to positioner with screws 29 and lockwashers 30 7 Mount positioner and bracket assembly to actuator yoke using cap screws 12U and lockwashers 30 8 Attach clevis...

Page 27: ...ers Manual 27 2015 General Electric Company All rights reserved Figure 7 87U 88U Actuator 37 Ring Retaining 122 Washer 38 Cap Screw 135 Inst Plate Table 2 Mounting Parts Reference 87U 88U Continued Re...

Page 28: ...om actuator on Ball II Figure 9 MiniTork II Figure 9 and HPBV Figure 10 The intermediate mounting plate 171 is held by two flat head screws 172 to the bracket NOTE The cam take off hole must be center...

Page 29: ...an 4700P E 4800P E Positioners Manual 29 2015 General Electric Company All rights reserved Figure 8 Camflex II and Varimax Figure 9 Ball II and MiniTork II For detail of Positioner Mounting Parts see...

Page 30: ...2015 General Electric Company All rights reserved 30 GE Oil Gas Figure 10 High Performance Butterfly Valve For detail of Positioner Mounting Parts see Figure 8...

Page 31: ...ioner is reversed 4700P 4800P only then the supply and exhaust connections must be interchanged With reverse action the Supply gauge must be removed and replaced by a 1 8 NPT plug installed in the sup...

Page 32: ...or 207 1862 mbar Split ranges are available Positioners with 24 psig signal span i e 6 30 psig and 3 27 psig require a different diaphragm assembly as shown in Figure 19 on page 68 Maximum allowable a...

Page 33: ...Masoneilan 4700P E 4800P E Positioners Manual 33 2015 General Electric Company All rights reserved Figure 11 Pneumatic Installation...

Page 34: ...Resistance across the output of the controller and verifying that at 100 controller output 20 mA is obtainable CAUTION Do not use a voltage source to drive the positioner as it may cause permanent dam...

Page 35: ...ner indicates correct areas of use WARNING Installation of any hazardous area equipment must be made in accordance with the appropriate hazardous area installation codes and the manufacturer s install...

Page 36: ...ng 97 055 Figure 22 on page 77 Non Incendive Class I Division 2 Groups A B C and D S Class II and III Division 2 Groups F and G Temperature classification T4 40 C ambient T3B 70 C ambi ent T3A 85 C am...

Page 37: ...ss 1 Division 2 Groups A B C and D with a temperature code T6 75 C T5 85 C Install as per drawing 97 055 Figure 22 on page 77 Installation must be in accordance with the current edition of the Canadia...

Page 38: ...c tions Housing protection rating IP 66 WARNING Do not open when energized Do not open when an explosive gas atmosphere is present Use cables rated to 5 C above ambient For flameproof Ex d protection...

Page 39: ...ainst falling water The installer shall ensure that the Model 4000 I P Converter is installed in a location where there is a low risk of mechanical impact to the plastic baffle Ex ia IIIC Da T90 C Ta...

Page 40: ...2015 General Electric Company All rights reserved 40 GE Oil Gas Figure 13 FM Installation...

Page 41: ...Masoneilan 4700P E 4800P E Positioners Manual 41 2015 General Electric Company All rights reserved Figure 14 CSA Installation...

Page 42: ...2015 General Electric Company All rights reserved 42 GE Oil Gas Figure 15 ATEX Installation...

Page 43: ...e 4 20 mA control signal To accomplish this with the 4700E 4800E the two positioners are connected in series as shown in Figure 16 with the actual split ranging done by proper cam segment selection pe...

Page 44: ...nal line is properly adjusted on the cam follower 4A Proper adjustment is achieved when The desired cam lobe s low signal line is in alignment with the raised reference line on the positioner Figure 1...

Page 45: ...te Calibration Reciprocating Valves using 87 88 Actuators on page 54 If lever S A 3 must be changed remove screw 28 and washer 27 and cam 26 from cam shaft Remove retaining ring 17 and flat washer 16...

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Page 47: ...d mounting maintenance etc it is necessary to follow all steps of the calibration instructions according to desired actuator ac tion and positioner action For proper performance when the valve is inst...

Page 48: ...djustment See Figure 19 on page 68 and Figure 20 on page 71 If the valve does not fully stroke for a full signal span the feedback spring rate is too high Loosen screw 8 and turn spring 5 on the sprin...

Page 49: ...be and replace cam 26 on cam shaft with low signal line of desired lobe against cam follower Ensure the newly selected cam lobe is in the same relative position as the lobe noted in Step 2 4 Replace w...

Page 50: ...her 27 and screw 28 Check zero and span adjustment Refer to Zero Adjustment on page 48 and Span Adjustment on page 48 Air to Close Reverse Acting Positioner See Figure 19 on page 68 1 Shut off supply...

Page 51: ...screw 28 while holding the cam 26 5 With the valve closed place the desired cam lobe s low signal line on the cam follower 4A With the low signal line resting on the cam follower sight across the fac...

Page 52: ...ct Acting Positioner See Figure 19 on page 68 and Figure 20 on page 71 1 Do not connect air supply or signal to the positioner Valve is now open 2 Note the valve position The travel indicator should b...

Page 53: ...26 into the cam holder 36 so that the selected cam lobe is facing forward and will rest on the cam follower Secure cam to cam holder with washer 27 and screw 28 Tighten screw 28 while holding the cam...

Page 54: ...case raised reference line and the travel indicator shows closed position Retighten both locknuts 3 Apply full scale value of instrument signal i e 15 psi or 20 mA and note position of travel indicat...

Page 55: ...ory re tighten the spring locking screw 8 zero locknut 4C and turnbuckle locknut 107 Air to Close Direct Acting Positioner See Figure 19 on page 68 and Figure 20 on page 71 1 Apply lower value of inst...

Page 56: ...15 psi signal range Unlock zero locknut 4C and turnbuckle locknut 107 Adjust zero by turning both the zero nut 4B and turnbuckle 106 until the low signal line of the cam is aligned with the positioner...

Page 57: ...removed 2 Slowly reduce pressure applied to actuator to zero If handwheel was used to place valve in open position back it off completely Valve is now closed Remove independent regulated air line from...

Page 58: ...Note Turn the pilot subassembly while removing it to prevent damage to the O rings 2 Remove end plug and withdraw the spring plug and extension pin If necessary use a penetrating oil to free parts CAU...

Page 59: ...ring 17 washer 16 lever S A 3 and spring 5 4 On 4700E 4800E only remove 4 screws 21 to separate I P module from body CAUTION Do not damage or lose the three O rings on bottom of module 5 Remove cap sc...

Page 60: ...mbly 11 and pressure gauges 5 Install the positioner on the actuator Reconnect air lines electrical leads if 4700E 4800E and coupling linkage if mounted on reciprocating valve 6 Assemble cam to shaft...

Page 61: ...ioner from valve to assemble bypass 1 Remove air connections vent plug and instrument gauge 2 Clean surface of body and remove any thread sealant left in threaded ports 3 Install O rings 50 in each of...

Page 62: ...grease on silicone O rings 2 To replace valve 48 O ring seals remove retaining ring 49 and slide valve out of block Remove O rings 46 and 47 replace with new rings which have a thin coat of Krytox or...

Page 63: ...connections must be correct for the positioner action i e direct or reverse Air tight connections Correct position of the bypass In case of malfunction check following in order given 1 Check zero adju...

Page 64: ...r 9 15 psig The following table shows for example the plug positions of two valves both air to close action open on air failure operating in split range with a 3 15 psig instrument signal Table 4 Spli...

Page 65: ...Masoneilan 4700P E 4800P E Positioners Manual 65 2015 General Electric Company All rights reserved Cam Lobe Selection and Lever Arm Orientation...

Page 66: ...2015 General Electric Company All rights reserved 66 GE Oil Gas...

Page 67: ...Masoneilan 4700P E 4800P E Positioners Manual 67 2015 General Electric Company All rights reserved...

Page 68: ...2015 General Electric Company All rights reserved 68 GE Oil Gas Parts Reference 4700P 4800P 3 15 and 6 30 Range Figure 19 4700P 4800P 3 15 and 6 30 Ranges...

Page 69: ...End 29 Socket Head Screw 4A Cam Follower 30 Lockwasher 4B Zero Nut 31 Gasket 4C Zero Lock Nut 32 Socket Head Screw 5 Spring Feedback 33 Lockwasher 6 Clamp 34 Coupling 7 Lockwasher 35 Socket Head Set S...

Page 70: ...ic Company All rights reserved 70 GE Oil Gas 19 Vent Plug 20 Screw Sealing Set 5 16 24 x 5 21 22 23 24 25 Table 5 Parts Reference 4700P 4800P 3 15 and 6 30 Range Continued Continued Ref No Description...

Page 71: ...Masoneilan 4700P E 4800P E Positioners Manual 71 2015 General Electric Company All rights reserved Parts Reference 4700E 4800E Figure 20 4700E 4800E...

Page 72: ...30 Lockwasher 4B Zero Nut 31 Gasket 4C Zero Lock Nut 32 Socket Head Screw 5 Spring Feedback 33 Lockwasher 6 Clamp 34 Coupling 7 Lockwasher 35 Socket Head Set Screw 8 Socket Head Screw 36 Cam Holder 9...

Page 73: ...aling Set 5 16 24 x 5 21 Screw 8 32 x 1 25 22 O ring 81 ID 23 O ring 1 31 ID 24 O ring 2 38 ID 25 Breather Ref No Description 19 Vent Plug 21 Screw 8 32 x 1 25 SEMS 45 Bypass S A 46 O ring 47 O ring 4...

Page 74: ...2015 General Electric Company All rights reserved 74 GE Oil Gas Figure 21 Bypass Option 4700 Only...

Page 75: ...ble only on the 4700P 4800P Pneumatic Positioner Characteristics Linear Equal Percentage Custom Maximum Air Consumption 0 3 scf min 25 psig supply 4700 0 5 scf min 25 psig supply 4800 Temperature Effe...

Page 76: ...an 0 5 of span Hysteresis 0 2 of span 0 5 of span Repeatability Within 0 2 of span Within 0 5 of span Sensitivity Better than 0 2 of span Better than 0 3 of span Conformity 1 of span 1 of span Input R...

Page 77: ...Masoneilan 4700P E 4800P E Positioners Manual 77 2015 General Electric Company All rights reserved Figure 22 Positioner and Cast Body Assembly Drawings...

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Page 80: ...NETHERLANDS Phone 31 15 3808666 Fax 31 18 1641438 Skelmersdale Phone 44 1695 526 00 Fax 44 1695 526 01 FRANCE Courbevoie Phone 33 1 4904 9000 Fax 33 1 4904 9010 RUSSIA Veliky Novgorod Phone 7 8162 55...