GE Masoneilan 4700E Maintenance Manual Download

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Masoneilan 4700P/E & 4800P/E Positioners Manual

Figures

Model 4700P/4700E and 4800P/4800E Positioner Numbering ..........15

Cover Removal ............................................................................................................20

Rotary ..............................................................................................................................21

Reciprocating .............................................................................................................21

87/88 Actuator............................................................................................................23

87/88 Actuator: Bracket Mounting Travel Settings....................................25

87U/88U Actuator .....................................................................................................27

Camflex II and Varimax...........................................................................................29

Ball II and MiniTork II.................................................................................................29

High Performance Butterfly Valve .....................................................................30

Pneumatic Installation.............................................................................................33

Electrical Connections .............................................................................................35

FM Installation .............................................................................................................40

CSA Installation...........................................................................................................41

ATEX Installation.........................................................................................................42

Split Range ....................................................................................................................43

Lobe Identification.....................................................................................................44

Pilot Subassembly......................................................................................................62

4700P/4800P 3-15 and 6-30 Ranges ...............................................................68

4700E/4800E................................................................................................................71

Bypass Option (4700 Only).....................................................................................74

Positioner and Cast Body Assembly .................................................................77

Summary of Contents for Masoneilan 4700E

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

Page 2: ...NDING 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 WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARI...

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 rights reserved PN 720014889 888 0000 Rev C Document Changes Version Date Changes B 08 2014 Added paragraph to first page of Calibration section about post ship ment calibration C 04 2015 Added Discla...

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Page 5: ...U 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 Electrical Installation of 4700E 4800E 34 Hazardous Area Installations 35 Factory Mutual Approved Version 36 CSA Canadian Standards Association Approved Version 37 SIRA Approved Version 38 Split Range O...

Page 6: ...r 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 Reverse to Air to Open Direct 57 From Air to Close Direct to Air to Close Reverse 57 From Air to Close Reverse to Air to Close Direct 57 Maintenance 58 Pilot 58 Disassembly 58 Reassembly 58 Body 59 Disa...

Page 7: ...unting 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 13 FM Installation 40 14 CSA Installation 41 15 ATEX Installation 42 16 Split Range 43 17 Lobe Identification 44 18 Pilot Subassembly 62 19 4700P 4800P 3 15 and 6 30 Ranges 68 20 4700E 4800E 71 21 B...

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Page 9: ...mpany 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 and 6 30 Range 69 6 Parts Reference 4700E 4800E 72 7 Specification Data 75 ...

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Page 11: ...ore 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 compliance with all WARNING and CAUTION notices is required for safe operation Indicates a potentially hazardous situation which if not avoided could result in serious injury or death CAUTION WARNING Safe...

Page 12: ...des 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 Personal Protective Equipment PPE must be used per safe site work practices Ensure proper use of fall protection when working at heights per safe site work practices Use appropriate safety equipment and pr...

Page 13: ...itable 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 applications consult the factory or local representative This product is not intended for use in life support systems WARNING Under certain operating conditions the use of damaged instruments could cause a deg...

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Page 15: ...ositioner 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 opposed by a feedback spring In the balanced state when the pneumatic signal varies the diaphragm assembly moves This movement is followed by the pilot plug which is opposed by the pilot spring Movemen...

Page 16: ...eristics 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 characteristic Custom charac teristics are available on special order Optional bypass valve 4700P Direct Acting Model only During normal operation the instrument signal is applied directly to the positioner dia...

Page 17: ...bypassed 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 should be used only if the positioner supply pressure is 20 psig 140 kPa or 1 4 bar or at most 35 psig 240 kPa or 2 4 bar or if the controller is capable of operating the valve directly When bypassin...

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Page 19: ...s 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 output pressure or reverse action increasing instrument signal produc es a decrease in output pressure See Figure 3 and Figure 4 The 4700E 4800E is not available with reverse action hence if the app...

Page 20: ...ral 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 have a different layout of pneumatic connections They can replace the older models if operational requirements are identical and pneumatic connections are changed The mounting details in this instructio...

Page 21: ...l 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 numbers 1 and 2 above and the supply and exhaust ports number 3 above Option 4700P only ...

Page 22: ...g 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 Locknut 26 Cam 42 Input Shaft 108 Locknut 27 Washer 135 Instruction Plate 109 Elbow 28 Pan Head Screw 2015 General Electric Company All rights reserved 22 GE Oil Gas 87 88 Actuator Ref Nos 109 110 and 11...

Page 24: ...n 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 lockwashers 30 NOTE Back lever must be behind bracket 7 Mount cam 26 on input shaft using washer 27 and screw 28 with desired lobe against cam follower Do not mount cam if positioner is reverse action 8 Con...

Page 26: ...8 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 102 to back lever 103 using clevis pin 104 retaining clip 105 and washer 122 9 Mount cam 26 on input shaft with desired lobe against cam follower using screw 28 and washer 27 Table 2 Mounting Parts R...

Page 27: ...ners 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 Ref No Description Ref No Description ...

Page 28: ...rom 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 centered about the shaft Table 3 Mounting Parts Reference Ref No Description Ref No Description 29 Socket Head Screw 172 Mounting Plate Screws 171 Mounting Plate 30 Lockwashers NOTE The remainder of the mo...

Page 29: ...lan 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 Figure 8 ...

Page 31: ...tioner 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 supply connection Since the new supply connection has no gauge port connect the removed Supply gauge to the filter regulator to indicate regulator output pres sure Figure 11 shows pneumatic connections ...

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 air supply pressure to the positioner varies according to actuator valve size and type See pressure drop tables in valve catalog to determine correct positioner supply pressure WARNING Never exceed ac...

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 damage CAUTION The positioner must be installed in accordance with local and national codes of practice in both general purpose and hazardous area locations The electrical components are fully isolated ...

Page 35: ...oner 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 installation and operating instructions You must make no changes or attempt any repairs of a certified instrument since this invalidates the certified design If a certified instrument should fail it must be...

Page 36: ...ing 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 ambient Installation must be in accordance with the current edition of the National Electrical Code ANSI NFPA 70 any applicable local codes and manufacturer s instructions Intrinsically Safe Class I II...

Page 37: ...ass 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 Canadian National Electrical Code Part I any applicable local codes and manufacturer s instructions Intrinsically Safe Class I Groups A B C and D Class II Groups E F and G Class III rated at 30 mA maximum 2...

Page 38: ...uc 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 concept The marking of the equipment shall include the following Sira 02ATEX1274 II 2GD Ex d IIC T6 Gb Ta 40 C to 55 C Ex d IIC T5 Gb Ta 40 C to 70 C Ex d IIC T4 Gb Ta 40 C to 85 C Ex t IIIC T90 Db T...

Page 39: ...gainst 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 40 C to 80 C Pi 1 1 W Special Conditions for Safe Use denoted by X after the certificate number This enclosure is made from light metal which could cause ignition due to impact This shall be taken in...

Page 43: ...ne 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 per tables in Cam Lobe Selection and Lever Arm Orientation on page 65 NOTE With this configuration the voltage burden of the 4 20 mA controller is 10 V instead of 5 V Figure 16 Split Range ...

Page 44: ...gnal 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 19 on page 68 The cam is centered between the two arms of the cam lever S A 3 Figure 19 on page 68 Figure 17 Lobe Identification Lever S A Orientation See Field Mounting and Complete Calibration Rotar...

Page 45: ...ete 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 Remove lever S A 3 from pivot post Lift and ro tate lever S A 3 on spring end 180 to desired position Do not rotate spring end socket head screw on spring must face outward Replace flat washer 16 and...

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Page 47: ...ld 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 installed calibrate the positioner as part of the normal installation procedure Shipping handling and installation can cause some changes in the calibration Calibration may entail just a simple adjustmen...

Page 48: ...Adjustment 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 spring end 4 to increase the number of active coils and de crease the spring rate Conversely if full stroke is reached prior to full signal span turn the spring to decrease the number of active coils and ...

Page 49: ...obe 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 washer 27 and screw 28 Turn on supply pressure and signal to positioner Check zero and span adjustment Refer to Zero Adjustment on page 48 and Span Adjustment on page 48 Air to Open Reverse Acting Pos...

Page 50: ...sher 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 pressure and signal to positioner Valve is now open and cam 26 is at high signal line on lobe Do not remove 2 Run an independent regulated air line to the valve actuator in place of positioner output...

Page 51: ...e 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 face of the cam to the raised reference line on the positioner case and align Low signal line and reference line Center cam between the two arms of the lever S A 3 then tighten set screws 35 to 87 inch ...

Page 52: ...ect 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 be approximately aligned with the open end of the travel scale If not aligned consult proper valve instruction for travel adjustment 3 With valve open place lever S A 3 to proper side left or right as...

Page 53: ...m 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 26 7 With the valve closed place the desired cam lobe s low signal line on the cam follower With the low signal line resting on the cam follower sight across the face of the cam to the raised refere...

Page 54: ...r 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 indicator If travel is not correct perform span adjustment Refer to Span Adjustment on page 48 4 Repeat zero and span adjustments per Zero Adjustment on page 48 and Span Adjustment on page 48 until travel r...

Page 55: ...tory 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 instrument signal i e 3 psi if 3 15 psi 4700P 4800P or 4 mA if 4 20 mA 4700E 4800E 2 Unlock zero locknut 4C and turnbuckle locknut 107 Adjust zero by turning both the zero nut 4B and turnbuckle 106 until...

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 case raised reference line and the travel indicator shows closed position Refer to Figure 5 on page 23 and Figure 19 on page 68 Re tighten both locknuts 6 Apply full scale value of instrument signal...

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 actuator 3 Proceed to Field Mounting and Calibration section for Air to Open Direct Acting Positioner and proceed as stated From Air to Close Direct to Air to Close Reverse 1 Perform Steps 1 and 2 f...

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 CAUTION Do not disassemble or adjust extension pin 3 Wipe the parts with a clean soft lint free cloth and blow compressed air through the orifices Use isopropyl alcohol to clean Do not use chloride base...

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 screws 10 and separate body S A from the case S A 6 Remove the diaphragm assembly 9 and reducer plate if 6 30 psi range 4700P 4800P 7 Clean the body 1 Avoid the use of detergents that might deteriorate...

Page 60: ...embly 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 per procedure under Cam Lobe Change on page 49 Recalibrate per appropriate Valve Action Positioner Action calibration section Diaphragm If the diaphragm has deteriorated replace the diaphragm assembl...

Page 61: ...tioner 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 the four recesses on the rear surface of the module 45 making sure they are seated in the bottom of the recess 4 Assemble to positioner using four 8 32 x 1 25 long screws 21 5 Reinstall vent plug in...

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 other silicone compatible lubricant Replace valve in block and secure with retaining ring 49 3 Reassemble bypass module to positioner Figure 18 Pilot Subassembly ...

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 adjustment and adjust the zero nut 4B if necessary Lock with locknut 4C 2 Check span adjustment and adjust if necessary 3 Adjust instrument signal pressure from minimum to maximum and observe the corresp...

Page 64: ...or 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 Split Range Operation Instrument Signal Air Signal to Close No 1 Valve Plug Position 3 9 psig Air Signal to Close No 2 Valve Plug Position 9 15 psig psig mbar 3 207 Full Open Full Open 6 414 Half Open Fu...

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 Screw 8 Socket Head Screw 36 Cam Holder 9 Diaphragm S A 37 Truarc Ring 10 Screw 38 Cap Screw 11 Pilot S A 39 Lockwasher 12 Supply Gauge 40 Washer 13 Output Gauge 41 Post Hub 14 Instrument Gauge 42 Inp...

Page 70: ...ric 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 Ref No Description ...

Page 72: ...r 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 3 15 Diaphragm S A 37 Truarc Ring 10 Screw 38 Cap Screw 11 Pilot S A 39 Lockwasher 12 Supply Gauge 40 Washer 13 Output Gauge 41 Post Hub 14 42 Input Shaft 15 43 Plug Pipe 1 4 NPT 16 Washer 44 I P Mo...

Page 73: ...ealing 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 48 Valve Bypass 49 Ring Retaining 50 O ring Table 6 Parts Reference 4700E 4800E Continued Ref No Description Ref No Description ...

Page 75: ...able 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 Effects Span Error Typical Temp Range C 40 to 20 20 to 60 60 to 85 Error 31 per C 06 per C 11 per C Supply Pressure Influence Less than 0 25 stroke change per psi supply change Maximum Air Supply Rating ...

Page 76: ...pan 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 Resistance 4 20 mA signal 170 Ohms nominal Table 7 Specification Data Continued Item Description ...

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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 7898 Fax 7 8162 55 7921 UNITED STATES Massachusetts Phone 1 508 586 4600 Fax 1 508 427 8971 GERMANY Ratingen Phone 49 2102 108 0 Fax 49 2102 108 111 Moscow Phone 7 495 585 1276 Fax 7 495 585 1279 Cor...

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