Flowserve PM15E User Manual

Worcester Controls

WCAIM2017

(Part 12508)

Model PM15E Electro-Pneumatic Valve Positioner

Installation, Operation and Maintenance Instructions

1. STORAGE INSTRUCTIONS 2

2. INSTALLATION 2

A. Mounting Guide 2

B. Mounting Instructions 3

C. Connections 3

3. OPERATION 4

4. AIR REQUIREMENTS 4

5. FRONT COVER AND INDICATOR COVER 4

6. SPAN AND ZERO ADJUSTMENT 5

7. INDICATOR ADJUSTMENT 5

8. CAM ADJUSTMENT 5

9. REVERSE-ACTING AND SPLIT RANGE 6

10. DAMPERS 6

11. I/P UNIT, PM15E 6

12. REMOVING AND MOUNTING THE I/P UNIT

TO THE POSITIONER UNIT 7

13. MAINTENANCE 8

A. Pilot Valve 8

B. Diaphragm 8

C. Feedback Spring 8

D. Balance Arm 9

E. Lower Arm 9

F. O-Rings 9

G. Filter Plug 9

14. TROUBLESHOOTING 10

15. TECHNICAL DATA 10

Exploded Drawing 11

Spare Part List 12

1. STORAGE INSTRUCTIONS

PM15E Positioner Storage and Handling Procedures

PM15E positioners are precision instruments which should be stored and handled accordingly to avoid problems or damage.

Electro-pneumatic positioners contain electronic components which can be damaged by exposure to excessive water. Appropriate precautions should be taken to protect units while in storage.

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 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 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 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 in-line 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 below.

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 9).

4) For double-acting actuators only: Normal hose positions refers to that described in Section 2.C, Connections.

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2 Model PM15E Electro-Pneumatic Valve Positioner WCAIM2017

Actuator Valve Actuator Failure Actuator Supply Position Mounting Mode Position Rotation Positioner Cam Hoses at Min. (Note 1) (Note 2) (Note 1) to Open Operation (Note 3) Cam Setting Note 4 Signal

In-Line Fail-Close Normal CCW Direct-Acting Direct-Acting 0° (Min. Signal) When Valve is Closed Normal Closed

In-Line Fail-Close Normal CCW Reverse-Acting Reverse-Acting 90° (Max. Signal) When Valve is Closed Reverse Open

Cross-Line Fail-Close Inverted CW Direct-Acting Reverse-Acting 0° (Min. Signal) When Valve is Closed Reverse Closed

Cross-Line Fail-Close Inverted CW Reverse-Acting Direct-Acting 90° (Max. Signal) When Valve is Closed Normal Open

In-Line Fail-Open Inverted CCW Direct-Acting Direct-Acting 90° (Max. Signal) When Valve is Open Normal Closed

In-Line Fail-Open Inverted CCW Reverse-Acting Reverse-Acting 0° (Min. Signal) When Valve is Open Reverse Open

Cross-Line Fail-Open Normal CW Direct-Acting Reverse-Acting 90° (Max. Signal) When Valve is Open Reverse Closed

Cross-Line Fail-Open Normal CW Reverse-Acting Direct-Acting 0° (Min. Signal) When Valve is Open Normal Open

Actuator

Positioner

B. Mounting Instructions for a Direct-Acting PM15E to a Spring-

Return or Double-Acting 39 Actuator:

The most common installation configuration is with the actuator mounted in-line, 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). See illustration below.

7) Align the mounting holes and then use the two (2)

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. Gauge ports Ip, P, S, C1, C2 are

8" NPT. We

recommend use of tape, Loctite®577 or similar for sealing.

Electrical connection on I/P unit accepts

2" NPT cable gland.

Port I Not used and will be plugged.

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

minimum 0.15 MPa (21 psi) for PM15E.

Port C1, C2 Actuator connections (0.2-0.9 MPa).

C2 opening port.

OUT Exhaust air port. Do Not Block!

Port Ip Used as air passage to I/P unit.

Port IE Input electric signal (4-20 mA)

(on the I/P unit).

Port P Gauge port for I/P unit output pressure

(on the I/P unit).

Ports P, S, C1 and C2 are sealed with plugs. To install gauges, unscrew plugs and replace with gauges. Gauges for these ports are supplied by customer.

We recommend use of tape, Loctite

577 or similar for sealing.

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. If port is covered or plugged, remove

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WCAIM2017 Model PM15E Electro-Pneumatic Valve Positioner 3

before pressurizing. A high flow silencer or an exhaust pipe can be connected to this port to prevent foreign objects from entering and blocking the unit’s exhaust.

When using gases other than air for supply, please contact Worcester.

Connect the air supply line to port S.

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

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

The 4-20 mA signal wires will be connected to the terminal block by passing the wires through port I

. Be certain that you observe proper polarity when making the connections. Remove cover (62) for access.

3. OPERATION

The PM15E 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 are in 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 two forces are equal and the unit is an equilibrium position.

4. AIR REQUIREMENTS

Maximum supply pressure is 0.9 MPa (125 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.

A < 40 micron filter/regulator is recommended to be installed as close to PM15E as possible to ensure proper supply air quality.

5. FRONT COVER AND INDICATOR COVER

The front cover of the PM15E is secured to the pneumatic unit with four captured screws and sealed with an O-ring (1). The O-ring can be looped over notches (2) in the front cover to allow for drainage. There are eight locations on the front cover where the O-ring can be looped. This O-ring system is common to the pneumatic unit and I/P unit in the PM15E. This unique sealing system allows for complete sealing or draining of the units by changing the position of the O-ring.

The indicator cover (3) is O-ring sealed and secured by a bayonet coupling. The indicator cover is also used to secure the identification cover (4).

To remove the indicator cover, turn it slightly counterclockwise until it loosens. Identification cover and O-ring (5) are now removable. When installing indicator cover and identification cover, make sure that the O-ring is properly engaged.

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4 Model PM15E Electro-Pneumatic Valve Positioner WCAIM2017

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