ap pneumatic positioner

®

AP Pneumatic Positioner

The AP pneumatic positioner combines the smoothness and accuracy of Kinetrol’sproven mechanical positioner technology (using a proportional spool valve driven bya simple, accurate and robust force balance mechanism) with new advances inconvenience and simplicity of use, derived from the unique innovative design bothof the internal mechanism and of the overall package.The result is a positioner with unparalleled performance and real industrialrobustness, sweet and easy to calibrate and characterize, and adaptable to thewhole range of applications with its unbeatable list of options – highflow valves, direct mount or industry standard discrete mounthousings, 4-20mA angle retransmit, limit switches, Clear Coneposition monitor and I/P convertors (either simple or withvarious explosion proof options).

AIRFLOW CHANGEOVER BLOCK –allows selection of direction in which positionermoves (for direct mount models).

AP Pneumatic Positioner LID – shown with optional Clear Cone sealed anglemonitor. Epoxy coated die–cast metal held on by fourcaptive screws gives quick access to the interior.

SPOOL VALVE– highly reliable,all metal, 5 portproportionalvalve controlsthe air flow.Three versions,with differentflowrates, areeasilyinterchangeable.

INTERCHANGEABLE PORTPLATES – easily convertible fordifferent flow rate options.

3–TERMINAL DIN PLUG – retrofittable option availablefor 4-20mA angle retransmit. Allows fully externalconnection with rapid connect/disconnect capability.

GAUGE PORT –as standard.

EXHAUST SNUBBER SCREWS – allow travel speed reduction downto 1/3 x full speed, independently in each direction, by screwing in torestrict exhaust air flow.

INTERNAL ANGLE SCALE – with adjustable indicator foreasy field calibration.

SPAN ADJUSTMENT –quick and easythumbwheel setting withslotted locking screw.

UNIT IDENTIFICATION – eachpositioner carries a unique serialnumber and is CE marked.

ZERO ADJUSTMENT – quick and easy thumbwheelsetting with slotted locking screw.

STRAIGHT–LINE MECHANISM –unique geometry allows cw/ccwchange over by simple cam inversion.

FEEDBACK POT DRIVE – zero backlash,proven trouble free for life.

OPTIONAL ANGLE RETRANSMIT CIRCUIT –externally powered (8–30v DC) linear 4-20mAfeedback, rangeable down to 30º for full4-20mA span. Easily accessible zero and spanadjustment.

FEEDBACK SHAFT –innovative colletconnection permits quick–fit/release of the actuatorinterface and eliminatesbacklash.

FEEDBACK CAM –quick and easyreversal (for rotationalsense handing) orreplacement (tochange the responsecharacteristic) of thecam is facilitated by aspring loadedretention device.

ACTUATOR INTERFACE– options include NAMURstandard (shown), Kinetrolmale square or Kinetroldirect mount femalesquare. Quick externalconversion allows bracketmounting to any rotary orlinear actuator.

SEALING CAP

CARRIER PLATE ASSEMBLIES – integratedassemblies carrying the feedback shaft and camplus angle retransmit drive and pot (when specified).Easily removed for conversion or maintenance.

ENCLOSURE – robust die-cast metal withtough corrosion-resistant epoxy coating andO-ring sealing. Layout gives easy access toall adjustments on removal of lid.

RETRANSMIT POT – high qualityconductive plastic servo–type with ballbearings. Proven long life and highprecision.

OPERATING PRINCIPLES

• The AP positioner is designed to drive arotary or linear actuator to a position set bya 315 psi (0.2 1.0 bar) signal and hold itthere until the signal changes.

• When a signal pressure is applied to thediaphragm it moves the force balance leverclockwise against the tension of thefeedback spring. This moves the spoolvalve, supplying air pressure to one side ofthe actuator while exhausting trapped airfrom the other side. The feedback shaftfollows the movement of the actuator andturns the cam counter clockwise, pushingthe cam follower and increasing the tensionon the feedback spring until it balances theforce on the diaphragm and moves thespool valve to its central ‘hold’ position.

• The relationship between the input signaland desired position (the ‘characteristic’) isdetermined by the cam profile. A linear 315psi (0.2 1.0 bar) signal / 090° outputmovement cam is standard. Split range, fastopening, equal percentage or customizedcharacteristic cams are available.

SCHEMATIC FUNCTIONAL DIAGRAM

90° MotionFeedback Shaft

Feedback Cam

Spool Valve

ZeroAdjuster

FlexibleDiaphragm

FeedbackSpring

RangeAdjuster

Force BalanceLever

ToActuator

Exhaust

Supply

SignalPressure315psi

FeedbackLinkage

KEY FEATURES

• FAST, SMOOTH AND ACCURATERESPONSEFrom stepless cam drive and proportionalspool valve.

• UNIVERSAL APPLICATIONMount on any quarter turn or linearactuator, single or double acting, in anyorientation. Adjustable span may be setanywhere within the 100° range.

• HIGH FLOW / GAIN VERSIONS93 nl/min (3.3 scfm), 283 nl/min (10 scfm)and 764 nl/min (27 scfm) models areavailable.

• INTEGRAL OPTIONS – EASILYRETROFITTED MODULES– two wire 4–20mA angle retransmit insideenclosure– mechanical or inductive position indicationswitches (for general and hazardous areas)in IP65 box– general and hazardous area 4–20mA I/Pconverter modules (intrinsically safe andNEMA 7 explosion proof options available)– high visibility Clear Cone angle monitor onpositioner and switch box versions– DIN plug for external retransmitconnection– High Temperature seals for 100°Cambient applications.

• SIMPLE, TIME SAVING FIELD SETUPEasy calibration and quick reversal ofrotational sense without special tools oradditional parts. Fast change of responsecharacteristic cams.

• COMPACT AND ROBUST METAL

HOUSINGWeatherproof sealed and epoxy painted forharsh industrial environments.

• ATEX CATEGORY 1 APPROVAL

Category 2 approval on some others(Actuators also approved).

• PROVEN FORCE BALANCE SYSTEMEmploying unique straight linemechanism – minimising wear, backlashand friction. Positioning is unaffected bysupply pressure fluctuations.

• VISUAL POSITION INDICATIONExternal pointer / scale or high visibilityClear Cone angle monitor plus internalangle scale for field setup.

• INSTALLATION FLEXIBILITYMount on any actuator using VDI / VDE3845 NAMUR drive, or Kinetrol malesquare, with mounting brackets, or directmount (with integral porting) to Kinetrolactuators.

• VIBRATION AND SHOCK RESISTANTLow mass spool and robust mechanismprovide 4G / 1OOHz industrial vibrationtolerance in any attitude.

• ADAPTATIONS AND ACCESSORIESConsult Kinetrol for:– split range or customized cams– special failure modes eg failfreeze– filters, regulators and gauges– mounting kits for rotary / linear drives.

ORDERING CODES

*

* Not available with ATEX approval

C=Clear Cone MonitorA=Clear Cone Monitor - ATEX

ActuatorModel05 - 60

ActuatorAssembly

0= No actuator4= Act + Pos ccw + IP5= Act + Pos ccw6= Act + Pos cw7= Act + Pos cw + IP

Angle Retransmit

0= None1= AR ccw & Conduit*2= AR cw & Conduit*3= AR ccw & DIN plug*4= AR cw & DIN plug5= AR ccw IS ATEX Approved6= AR cw IS ATEX Approved7= No AR - ATEX Approved

Seals, Diaphragms& Porting

0= Internal Ports NbrV= Internal Ports VitonE= External Piping NbrF= External Piping VitonS= Internal Ports SiliconeG= External Piping Silicone

NAMUR(Discrete Only)

0= KinetrolN= NAMUR

A P C

Spring ReturnOr Discrete

0= No SR2= SR cw3= SR ccw4= Pos only ccw + IP5= Pos only ccw6= Pos only cw7= Pos only cw + IP

Limit Switch0= No LS1= 2 x LS prox ATEX Cat 12= 2 x Pneumatic4= 2 x V3 mech LS5= 20 - 240 V ac prox.6= 5 - 30 V dc prox.7= 4 x V3 mech LS9= 2 x V3 mech LS ATEX Cat 1X= XBox Mount

I/P0= No I/P1= Non hazardous + DIN plug2= Exd (Cat 2)3= FM/CSACLI/ DIV 1 XP or IS*4= Non hazardous + Conduit*5= Exia (Cat 2)

Valve SizesA= StandardM= Medium FlowH= High Flow

‘A’ Valve is supplied withall sizes up to and inc’ 09‘M’ Valve is supplied with10-15‘H’ Valve is supplied withsizes 16-60

UNLESS SPECIFICALLY REQUESTED OTHERWISERecommended spring unit for model 14 actuator is 4900 type.This should be coded 12 49AP or 13 49AP instead of theusual 12 AP or 13 AP. The same applies to other speciallycoded spring assemblies.

SPECIFICATIONAir Supply instrument quality (dry,

clean, oil free) 3.5 to 7 bar,(50 psi to 100 psi) standard.Consult Kinetrol for lowpressure application

Signal 3-15psi (0.2-1.0 bar)standard. Consult Kinetrolfor split range, 6-30 psi etc.

Control Response 0-90° linear outputstandard. Consult Kinetrolfor other characteristic camoptions

Sensitivity better than 0.7% of span*

Hysteresis better than 0.7% of span*

Deviation less than 1% of span*from linearity

Flowrates @ 5.5 bar AP: 3.3 scfm (93nl/min)MP: 10.0 scfm (283nl/min)HP: 27.0 scfm (764nl/min)

Operating -20° to +80°C StandardTemperature Range -20° to +100°C High Temp

-40° to +80°C Low Temp

Weight 2.8 kg/6.2 lb

Materials • case and cover - zincalloy• spool and liner - stainlesssteel• diaphragm:- reinforced polyurethane

(standard)- fluorocarbon rubber

(high temp)- silicone rubber (low temp)

Finish epoxy stove enamel

Enclosure Rating IP54

Output Torque same as double acting orspring return actuator.When controlling fastmovement of inertia loadsconsult Kinetrol

Maximum Vibration Tolerance 4G, 100Hz

* These refer to the combination of Kinetrol actuator with AP positioner - not just the positioner performance

Mechanical(Base unit, No Switches or AR) - Ex II 1G IIC T4 c (-20°C < Ta < +80°C)

Mechanical Low Temperature(Base Unit, No Switches or AR) - Ex II 3G c IIC T4 (-40°C < Ta < +80°C)

Electrical(includes Limit Switches and AR) - Ex II 1 G Ex ia IIC T4 Ga (-20°C < Ta < +80°C)

ATEX APPROVED OPTIONS

TRAVELTIMES

Giving typical control characteristics. ContactKinetrol for details of other options or see TD112.

CAM OPTIONS

Air Signal ElectricalSignal

OutputMovement Characteristic Cam No.

3-15 psi0.2-1.0 bar 4-20mA 0-90° Linear 5-1A

3-9psi0.2-0.6 bar 4-12mA 0-90° Linear 5-2A


9-15psi0.6-1.0 bar 12-20mA 0-90° Linear 5-4A



3-15 psi0.2-1.0 bar 4-20mA 0-90° Proportional

Flow 5-7A


Flow 5-8A


Flow 5-22A



Input Control

*Externally piped from AP positioner to actuator

Maximum velocity (no load) at 80 psi / 5.5 barModel 05 07 08 09 10 12 14 15Deg/Sec 180 90 53 45 33 25 10.6 6.0

Model 12* 14* 15* 16* 18* 21* 30* 60*Deg/Sec 32 13.8 7.5 22.5 11.3 5.9 3.8 1.9

Switch Type 0012 intrinsically safe 2 wire inductive proximity sensorsfor hazardous areas (ATEX CAT 1),normally closed.Ambient temperature range -20°C to +80°C

Switch Type 0022 pneumatic switches with 4mm (5.32”) push infittings (ATEX CAT 2), normally closed.Ambient temperature range -15°C to +60°C

Switch Type 0042 x 3 wire microswitches for SPDT.Ambient temperature range -40°C to +80°C

Switch Type 0052 x 2 wire proximity sensors 20-250 volts AC,normally open.Ambient temperature range -25°C to +70°C

Switch Type 0062 x 2 wire proximity sensors 5-60 volts DC, normallyopen, with Led switch status indicators.Ambient temperature range -20°C to +80°C

Switch Type 0074 x 3 wire microswitches for DPDT.Ambient temperature range -40°C to +80°C

Switch Type 0092 x 3 wire microswitches for SPDT. ATEX CAT 1.Ambient temperature range -40°C to +80°C

SWITCH OPTIONS

The Kinetrol Explosion Proof Limit Switch Box can be mounted to an AP Positioner using a special lid and bracket.The AP should be ordered with an “X” in the limit switch option, the Explosion Proof Switch Box then can beordered with any standard switch or electrical option using the explosion proof switch box order coding- See KF-84 or KF-619 for options.

Explosion Proof Switch Box Option

AP POSITIONER MODULAR BUILD ARRANGEMENT

10 ACTUATOR(WITH 07 SQUARE)

12,14 & 15 UNIVERSAL ACCESSORYMOUNTING ADAPTOR KITSSP/ASP1608 & SP/ASP1609 12 ACTUATOR

(WITH 07 SQUARE)14 ACTUATOR

(WITH 07 SQUARE)15 ACTUATOR

(WITH 07 SQUARE)

07 ACTUATOR 08 ACTUATOR(WITH 07 SQUARE)

09 ACTUATOR(WITH 07 SQUARE)

07 MP POSITIONER

05 ACTUATOR

NOTE: Model 05 Actuators are the smallestsize actuator available with an AP Positioner

07/05 SQUARE REDUCERFOR POSITIONERSP1602P

16 UNIVERSAL ACCESSORYMOUNTING KIT SP/ASP389

16 ACTUATOR

20 / 30 & 60 UNIVERSAL ACCESSORYMOUNTING KIT SP/ASP400

KINETROL DISCRETE 05DRIVE SP1601 (INCLUDEDWITH DISCRETE HP)

18 UNIVERSAL ACCESSORYMOUNTING KIT SP/ASP329

18 ACTUATOR

KINETROL DISCRETE HP POSITIONER

60 ACTUATOR

30 ACTUATOR

21 ACTUATOR

07 AP POSITIONER

DIMENSIONS*55 (2.2") 19 (0.75")

Signal pressurePort G1/8(1/4 NPT)

Air SupplyPort G1/4(1/4 NPT)

External PortG1/4(1/4 NPT)

AP Positionershown direct mounted on a

Kinetrol 07 Actuator

GaugePort G1/8(1/8 NPT)

137.5 (5.41")

68 (2.7") 55 (2.2")

129.

5 (5

.1")

170

(6.7

")

External PortG1/4(1/4 NPT)

18 (0.7")46

(1.78")

11.5

(0.4

5")

16 (0.63")

Angle Retransmit:ISO/DIN models M16 conduit entryANSI models 3/8 NPSOptional DIN plug if required

ActuatorModel

*AdditionalAdaptor Dim.

AdditionalAdaptor Weight

12, 14 & 15 15.5 (0.61") 0.56 kg / 1.21 lbs

4.954.8536

.0

15.0

4.0

Ø

Ø 11.5

M16 Conduit Entry(3/8-18 NPS)

4.0

A/F

4 Mount Holes:M6 x 5 deepequi-spacedon 50 PCD

NAMUR DISCRETE

177

(6.9

6")

71(2

.79"

)76

(2.9

9")

External Port:G3/8 (3/8 NPT)

Exhaust Port:

9.53/9.48 A/F (0.375/0.373")Adjustable

Inlet Port:G3/8 (3/8 NPT)

G3/8 (3/8 NPT) fittedwith regular silencers.

13 (0

.51"

)

Mount Holes sameas Namur discrete

KINETROL DISCRETE / HIGH FLOW VERSION

47(1.85")

124 DIA(4.88" DIA)

SIGN

AL

K I N E T RO L

106

(4.2

")20

(0.7

8")

Conduit EntryISO M20 x 1.5ANSI 1/2 -14 NPS

Where drawing information is not given - it is the same as the direct mount version

SWITCH BOX VERSION

The optional Kinetrol I/P Controller is mounted inplace of the standard diaphragm housing on theside of the AP positioner case. The AP positionercan still be mounted in any orientation and givesan angular output position which is proportional tothe input current control signal between 4-20mA.

The 4-20mA signal is converted to an airpressure by a coil and magnet and flapper valvearrangement. This air pressure controls thepositioner in the normal way.

Zero and range adjustment is done within thepositioner in the same way as with a standardpneumatic positioner. No adjustment isnecessary within the I/P Controller. The cover isremoved only to connect the two wires - this isnot necessary with the DIN plug option.

I/P CONTROLLER OPTIONS

Electrical Control 4-20mASignal

Coil Impedance 20 ohms typical

Cable Entry 16mm conduit or gland(mini DIN plug, IP 65with Pg9 cable gland,6-8mm dia optional)

Air Supply 80 psi/5.5 bar nominal

Air Entry G1/8 (fitted with 6mmpipe dia. push inconnector

Weight 1.2 kg

Linearity 1.5%*

Hysteresis less than 1%*

Sensitivity/Deadband less than 1%*

Supply Pressure 0.2% per psi between 80Influence and 60 psi

Quiescent Air 3.5 l/min free air maxConsumption

Working Temperature -20°C to +80°CRangeInstrument quality dry, clean air obligatory (Class6.4.4 ISO8573.2001)* These refer to the combination of Kinetrol actuator with I/Pcontroller - not just the positioner performance

I/P SPECIFICATION - SAFE AREA


210

(8.2

7")

132 (5.19")

88Ø(3.46")

Air Supply

DIN plugoption

91.0

(3.5

8")

47(1

.85"

)

I/P DIMENSIONS - SAFE AREA

K in e tro l L td, Tradin g E s tate , F arn h am , Su rre y GU9 9NU, E n g lan dTe le p h o n e : 0 1 2 5 2 7 3 3 8 3 8 F ax : 0 1 2 5 2 7 1 3 0 4 2

e -m ail: s ale s @k in e tro l.co mw w w .k in e tro l.co m Copyright 2020 Kinetrol Ltd KF-391 NOV/21

The policy of Kinetrol is one of continuous improvement. We reserve the right to alter the product as described and illustrated without notice.

Kinetrol is a registered trade mark

Kinetrol offers various optional I/P converters which are explosion proof or intrinsically safe certified for use inATEX Zones 1 & 2 or NEC and CSA CLASS I DIVISION 1. They are mounted directly onto Kinetrol AP positionerswith integral air supply.

Electrical Control 4-20mASignal

Input Resistance 260 ohms at 24°C

Cable Entry Exd - M20 x 1.5 conduitentryFM/CSA - 1/2 NPTconduit entry

Air Supply 50-100 psi/3.5 to 7 bar

Air Entry Exd (AP & MP) G1/4 (1/4 NPT)(HP) G3/8 (3/8 NPT)

Working Temperature -40°C to 75°C for Exd-55°C to 85°C for Exia

Instrument quality dry, clean air obligatory (Class3.4.4 ISO 8573.1)

I/P CONTROLLER HAZARDOUS AREA

195

(7.6

8") A

P &

MP

190

(7.5

") H

P 112

(4.4

1")

1/8 NPTGAUGE PORT

M20 x 1.5(1/2 NPT)


I/P DIMENSIONS - HAZARDOUS AREA

I/P Intrinsically Safe - Ex II 1G Ex ia IIC T4 Ta=-55ºC to +85ºC

I/P Explosion Proof - Ex II 2G Ex d IIB+H2 T6 Ta=-40ºC to +75ºCEx II 2D Ex tD A21 IP65 T85ºC Ta=-40ºC to +75ºC

6I/P HAZARDOUS AREA APPROVED OPTIONS

ap pneumatic positioner

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