Flowserve PM15 User Manual

Worcester Controls

CONTENTS

Page

1. STORAGE INSTRUCTIONS........................................................................................................................................................................2

2. INSTALLATION..........................................................................................................................................................................................2

A. Mounting Guide....................................................................................................................................................................................2

B. Mounting Instructions ..........................................................................................................................................................................3

C. Connections..........................................................................................................................................................................................4

3. OPERATION ..............................................................................................................................................................................................4

4. AIR REQUIREMENTS................................................................................................................................................................................4

5. SPAN AND ZERO ADJUSTMENT...............................................................................................................................................................5

6. CAM ADJUSTMENT ..................................................................................................................................................................................6

7. REVERSE-ACTING AND SPLIT-RANGE.....................................................................................................................................................6

8. MAINTENANCE .........................................................................................................................................................................................7

A. Pilot Valve.............................................................................................................................................................................................7

B. Diaphragm............................................................................................................................................................................................7

C. Feedback Spring...................................................................................................................................................................................8

D. Balance Arm.........................................................................................................................................................................................8

E. Lower Arm............................................................................................................................................................................................9

F. O-Rings ................................................................................................................................................................................................9

9. TROUBLESHOOTING ..............................................................................................................................................................................10

10. TECHNICAL DATA ...................................................................................................................................................................................10

11. SPARE PART LIST ..................................................................................................................................................................................11

12. EXPLODED DRAWING ............................................................................................................................................................................11

WCAIM2016

(Part 12506)

PM15 Pneumatic Valve Positioner

Installation, Operation and Maintenance Instructions

1. STORAGE INSTRUCTIONS

PM15 Positioner Storage and Handling Procedures

PM15 positioners are precision instruments which should be stored and handled accordingly to avoid problems or damage.

Warehouse Storage

Stored in original 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.

Positioners 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.

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 to 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 housing.

Dependent on the local temperature variations, humidity and dew points and time in storage, condensation could occur and accumulate inside pilot valve 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 your nearest Worcester distributor.

2. INSTALLATION

Before mounting the positioner, the relationship of the actuator to the valve must be determined. The actuator can be mounted inline or cross-line to the valve. In addition, the actuator can be mounted rightside-up or inverted. If a spring-return actuator is used, the actuator can be set up to fail with the valve closed or with the valve open. This gives the end user a total of eight possible set-up configurations.

A. MOUNTING GUIDE

The following notes pertain to Positioner Mounting Guide on next page:

1. “Inverted” Actuator Position and “Cross-Line” Actuator Mounting applies to sizes 10-20 39 Series actuators only. On sizes 25 and larger, the output shaft is square, which allows for the coupling to be indexed 90˚ to the actuator shaft. Normal actuator position means that the actuator is mounted “right-side-up”.

2. For Spring-Return actuators only. “Fail-Open” actuators have a “9” in position 3 of the ordering code.

3. To change cam to Reverse-Acting, remove and reinstall upside down (see Section 7).

4. For Double-Acting actuators only. Normal hose positions refer to those described in Section 2.C, Connections.

B. MOUNTING INSTRUCTIONS

Mounting instructions for a Direct-Acting PM15 to a SpringReturn or Double-Acting 39 Actuator:

The most common installation configuration is with the actuator mounted inline, direct-acting, and with spring-return set for failclosed. Direct-acting means that as the signal increases, the valve travels in the open direction.

1) Close the valve/actuator assembly if it is not already closed (fully CW).

2) Remove the position indicator, if any, from the actuator shaft.

3) Attach the mounting bracket to the top of the actuator such that the indicating scale is upright and on the same side of the actuator as the actuator nameplate. Use four (4) screws and lockwashers supplied with mounting kit.

4) Place coupling on actuator shaft. DO NOT tighten set screws at this time.

5) Install the indicating arm and locknut on the coupling such that the end of the arm points downward.

6) Place the positioner on the bracket so that the actuator nameplate and the side of the positioner with the zero adjustment are on the same side. Positioner is mounted to bracket using mounting adapter and screws (5).

2 PM15 Pneumatic Valve Positioner Installation, Operation and Maintenance Instructions WCAIM2016

Flow Control Division

Worcester Controls

Installation

WCAIM2016 PM15 Pneumatic Valve Positioner Installation, Operation and Maintenance Instructions 3

(

Flow Control Division

Worcester Controls

POSITIONER MOUNTING GUIDE

ACTUATOR POSITIONER

Actuator

Mounting

(Note 1)

Inline

Cross-Line

Inline

Cross-Line

Failure

Mode

(Note 2)

Fail-Close

Fail-Open

Actuator Position (Note 1)

Normal

Inverted

Normal

Rotation

Open

CCW

Positioner

Operation

Direct-Acting

Reverse-Acting

Direct-Acting

Reverse-Acting

Direct-Acting

Reverse-Acting

Direct-Acting

Reverse-Acting

Cam

(Note 3)

Direct-Acting

Reverse-Acting

Direct-Acting

Reverse-Acting

Direct-Acting

Cam Setting

0˚ (Min. Signal)

When Valve is Closed

90˚ (Max.Signal)

When Valve is Closed

0˚ (Min. Signal)

When Valve is Closed

90˚ (Max.Signal)

When Valve is Closed

90˚ (Max.Signal)

When Valve is Open

0˚ (Min. Signal)

When Valve is Open

90˚ (Max.Signal)

When Valve is Open

0˚ (Min. Signal)

When Valve is Open

Actuator

Supply Hoses

(Note 4)

Normal

Reverse

Normal

Reverse

Normal

Valve

Position at

Min. Signal

Closed

Open

Closed

Open

Closed

Open

Closed

Open

7) Align the mounting holes and then use the two

16-18 socket

head cap screws, lockwashers, hex nuts, and rubber washers (between bracket and positioner) supplied with the mounting kit to fasten the positioner to the bracket.

8) Tighten the set screw at the upper end of the coupling to the positioner shaft (seat the set screw in the positioner shaft groove). The other two set screws will be tightened after the actuator is cycled 90˚. 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.

C. CONNECTIONS

Air connections are tapped for

4" NPT male connectors and are

clearly marked. We recommend use of tape, Loctite®577 or similar user preferred for sealing.

Port I Input instrument pneumatic signal 20–100 kPa (3–15 psi)

Port S Supply air, maximum 0.9 MPa (125 psi)

Port C1, C2 Actuator connections (0.2–0.9 MPa). C2 opening port.

Connect the air supply line to port S.

For double-acting operation, connect the right-hand and left-hand ports of the actuator end cap (right-hand end cap when facing actuator nameplate) to port C2 and C1 respectively.

For single-acting operation, plug port C1 for increasing signal to open or close. Plug port C2 for decreasing (reverse) signal to close.

3. OPERATION

The PM15 operates on a force balance principal. Force is originated by the signal pressure transmitted through a diaphragm onto 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 is 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.

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 two forces are equal and the unit is an equilibrium position.

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