Flowserve APEX 8000 High-Performance Positioner - Manual (Page 10)

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), 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 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).
Apex 8000 High-Performance Positioner AXENIM0130-06 11/10
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