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P5
User Instructions
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Flowserve P4, P5, EP5, APEX 7000 User Instructions

USER INSTRUCTIONS
P4, P5, EP5, APEX 7000 Pneumatic Positioners
FCD PMENIM0006-00-A5 12/18
Installation
Operation
Maintenance
1
Contents
1. Introduction 4
2. Storage instructions 6
3. Function 8
4. Installation 9
5. Connections 10
6. Cam adjustment 12
7. Calibration 13
8. Indicator adjustment 14
9. Front cover and indicator cover 14
10. I/P Unit (EP5/APEX 7000) 15
11. How to mount the I/P Unit to the positioner unit (P5/EP5) 16
12. Main tenan ce 17
13. Feedback unit (P5 or EP5) 22
14. Trouble shooting 23
15. Technical data 24
16. Spare parts 27
Apendix A 33
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EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
Warning!
Special Conditions for Safe Use
The enclosure is made of aluminum and impact or friction caused by external objects shall be avoided in the application.
Rubbing of the windows with dry fabrics shall be avoided when the positioner is used in an IIC atmosphere in order to avoid potentially incendive static discharges.
The ambient temperature range for the positioner is -20˚C <Ta 85˚C
The I/P converter has to be installed in an enclosure that satisfies the following clauses:
Complies with ”electrostatic charge” requirements in EN 60079-0, clause 7.4
A suitable degree of protection minimum IP20 according to 6.1 in EN 60079-11
Shall not contain by mass, more than, 7.5% in total of magnesium according to clause 8.1 in EN 60079-0
According to descriptive document: IP-653.
Shall withstand dielectric strength test with 500V AC for 1 minute according 6.3.12 in EN 6007 9 -11.
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1. Introduction
P4
The P4 is a pneumatic valve positioner for double acting actuators, rotary or linear. It can also be used for single acting applications by simply plugging one of the outlet ports, C1 or C2.
It features a standardized foot print, external zero adjustment, gold plated spool valve, positive internal pressure and a bright visible position indicator. The simple, sturdy design with few moving parts together with the well proven spool valve design provides long and trouble free operation. Together with the unit, a wide range of mounting kits are offered for quarter turn and linear applications.
Calibration and set up is quick and simple, all done by thumb wheels. The unit requires a minimum of maintenance and the only tool needed is a flat screw driver.
For installation of gauges T-connectors are required.
Option
Option
4
EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
P5
The base unit of the system is the pneumatic positioner, used in either single or double acting applications. P5 comes standard with a high gain spool valve assembly, gauge ports and an O-ring sealed housing.
The modular design concept allows for easy addition of accessories such as I/P converter and/or a feedback package, both which are isolated from the basic pneumatic unit. These accessories can be factory or field mounted.
Ease of calibration and maintenance are built into to the design with easily accessible span and zero adjustment, and very simple parts replacement.
EP5
The EP5 has same features and benefits as the P5 positioner. It’s modular to suit several applications, General applications, intrinsically safe, explosion proof and fail freeze versions are offered.
Standard or I/S I/P-converter module
Dome indicator
Gauges
Explosionproof I/P module
P5 pneumatic positioner
Spindles
Mounting bracket
5
Mounting adapter plate
Fail Freeze I/P Module
F5 feedback module
F5 Explosion Proof
2. Storage instructions
PMV Positioner and feedback module storage and handling procedures
PMV Positioners and feedback modules are precision instruments which should be stored and handled accordingly to avoid problems or damage.
Electro-pneumatic positioners/feedback modules contain electronic components which can be damaged by exposure to water. Appropriate precautions should be taken to protect units while in storage.
Warehouse storage
Stored in original PMV shipping containers, units should be stored in an environmentally controlled area, i.e. clean, cool (15-26°C, 60-80°F) and dry, out of direct sunlight or weather exposure.
Field storage
Note: Once the air supply to the positioner is connected and turned on, internal air bleed will
prevent the ingress of moisture and protect the unit from corrosion. It is recommended that the air supply be left on at all times.
• If units are installed immediately, turn, and leave on, the air supply.
• If positioners must be stored outdoors, tighten all covers which may have loosened in shipment, make sure all open enclosure entry points are sealed.
Feedback modules should have cover tightened and conduits entries sealed. Positioners/Feedback modules should be wrapped and sealed air and watertight with desiccant inside the plastic, units should be securely covered with an opaque cover and not exposed to direct sunlight, rain or snow.
Pneumatic positioners
Units should have all ports sealed and be protected from direct exposure to weather.
For long term storage (>1 month) or overseas shipment units should be protected with plastic and desiccant.
Potential damage mechanism
When units are stored in hot, humid climates, the daily heating/cooling cycle will cause air to expand/contract and be drawn in and out of the positioner/feedback housing.
Dependent on the local temperature variations, humidity and dew points and time in storage condensation could occur and accumulate inside on the I/P Converter causing erratic operation or failure due to water and corrosion. The potential for condensation damage is especially high in southern climates and aggravated if units are exposed to direct sunlight.
For further assistance, please contact you nearest PMV ofce.
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EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
Storage Seal (P5/EP5)
P5/EP5 is supplied with all enclosure entry points sealed. The seal is only a storage seal, not to be used as seal when P5/EP5 is in operation. If Storage Seal is removed or damaged, make sure all open enclosure entry points are proper resealed before further shipping or storage.
Use circular stickers marked I, S and OUT, supplied on Storage Seal or vapour proof tape.
P5
Remove Storage Seal from connection block, mount positioner on actuator/valve, make connections according to section 5, (Page 10). Calibrate span and Zero according to section 7, (Page 13).
Clean any oil/debris off the connecting block, then reseal open enclosure entry ports, use circular stickers marked I, S and OUT, supplied on Storage Seal or vapour proof tape.
EP5
Follow P5 instructions as above. Remove Storage Seal for conduit entry IE, connect input signal cable and install proper cable gland to secure the units sealing.
IP5 seal
P5 seal
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3. Function
The P4 and P5/EP5 operates on a force balance principal. Force is originated by the signal pressure transmitted through a diaphragm on to the balance arm. The opposing force is achieved through the feedback spring and is proportional to the position of the lower arm.
The lower arm position is determined by the position of the cam which is secured to the spindle and connected to the actuator shaft thus providing the feedback from the actuator/valve. When these two forces are equal, the balance arm and the spool in the pilot valve are in a neutral position — the complete unit is in a balanced position. Air is supplied to the pilot valve through port S, and controls the air flow through ports C1 and C2
Assume an equilibrium position.
An increased control pressure will deflect the diaphragm 1 down, compressing the feedback spring
3. The balance arm 2 moves the spool 7 in the pilot valve 8 furnishing supply air to the actuator,
while at the same time air is exhausted from actuator and is vented to atmosphere through the pilot valve and the OUT port . With the increased supply air, the actuator rotates (or moves linearly) moving the positioner spindle 6. The spindle and cam 5 rotate, forcing the lower arm 4 upwards compressing the feedback spring 3. This motion will continue until the two forces are equal and the unit is in an equilibrium position.
I
S
7312
4658
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EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
4. Installation
Air requirements
Maximum supply pressure is 1 MPa (150 psi). Supply air shall be clean, dry and free from oil, water, moisture, foreign parts and debris.
The air shall be freeze-dried or similar to a dew point of at least 10°C (18°F) below lowest expected ambient temperature. The air shall comply with standard: DIN/ISO 8573-1-2001 3.2.3.
A <40μ filter/regulator is recommended to be installed as close to P4/P5/EP5 as possible to ensure proper supply air quality.
Before making pneumatic connections to the positioner, it is recommended that the supply air lines are opened up and allowed to vent for 2-3 minutes to clear any debris from the line. It is further recommended that a large paper bag is used to collect any oil or humidity that may be present in the line during this purging, direct the air flow into the bag. Should excessive amounts of oil and/or humidity be present at this stage, a review of the pneumatic system should be carried out and the problem corrected.
Poor air quality is one of the major causes of premature failure of pneumatic equipment.
Installation
P4 and P5/EP5 mounts on to the actuator using either the ISO F05 holes 4 and a PMV ISO mounting kit or by using the optional mounting adaptor and screws 5 to mount P5 on to existing PMV mounting kits.
Proper alignment of the positioner spindle to the actuator shaft is very important since improper alignment can cause excessive wear and friction to the positioner.
P5/EP5 only
The spindle/positioner shaft assembly allows for quick and simple spindle changes. To ensure the proper connection, the spindle 3 has a spring clip 2 that must be properly installed. A solid ”click” should be felt when assembling the two pieces insuring that the two flats 1 are engaged into the positioner shaft groove.
The spindle can be removed, by inserting two screwdrivers under the two tapered surfaces of the spindle and bending carefully. When the spring clip releases the spindle will eject.
P4/P5 P5/EP5
2 1
3
5 4
9
5. Connections
Air connections are tapped for 1/4” G or NPT male connectors and are clearly marked.
Gauge ports are for 1/8” G or NPT.
We recommend use of Loctite® 577 or similar user preferred for sealing.
Electrical connection on I/P unit accepts 1/2” NPT or PG 13,5 (M20) cable gland.
Port I Input instrument pneumatic signal 20-100kPa (3-15 psi) Port S Supply air, maximum 1 MPa (150 psi) Minimum 0,15 MPa
(21 psi) for EP5 Port C1, C2 Actuator connections (0,2-1 MPa). C2 opening port. For single acting operation plug port C1 for increasing signal to open valve. Plug C2 for decreasing (reverse) signal to open valve.
OUT Exhaust air port. Do not block! Exhaust filter optional. Port Ip Gauge port for pneumatic input signal. Port I
Input electric signal (4-20 mA) (On the I/P unit.)
E
Port P Gauge port for I/P unit output pressure ( On the I/P unit)
Ports Ip, P, S, C1 and C2 are sealed with plugs. To install gauges, unscrew plugs and replace with gauges.
P5/EP5 only
Port OUT is for venting the unit. All air from the positioner, actuator and I/P unit is vented to atmosphere through this port. Do not block this port. A high flow silencer or an exhaust pipe can be connected to this port to prevent foreign objects from entering and blocking the units exhaust. Connector in exhaust port must not have less than 9 mm (3/8“) orfice.
When using gases other than air for supply — Please contact PMV.
On EP5 (P5 with I/P unit installed) I/P unit is supplied with air from port S. Port I is automatically sealed off and protected. No connection shall be made to this port. See pages 13 and 14 for more information.
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EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
Reverse function
C1
C2
S
X = Port plugged
I
Direct function Air to open
C1
C2
S
C1
C2
II
S
Direct function
Air to close
Spring Return
Double
acting
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