Flowserve PMV D3 D User Manual

Digital Positioner

Manual

Contents

1.Introduction ...................................................................................................... 3

Safety instruction................................................................................................ 3

2. Storage .............................................................................................................. 4

General ............................................................................................................... 4

Storage indoors ................................................................................................... 4

Storage outdoors or for a longer period.............................................................. 4

Storage in a warm place ..................................................................................... 4

3. Design................................................................................................................ 5

4. Variants............................................................................................................. 6

5. Function............................................................................................................ 7

Double action function ....................................................................................... 7

Single action function......................................................................................... 7

6. Installation........................................................................................................ 8

Air supply requirements ..................................................................................... 8

Mounting ............................................................................................................ 9

Connections ........................................................................................................ 10

Air....................................................................................................................... 10

Electrical connection .......................................................................................... 10

Dimensions ......................................................................................................... 10

Single action positioner (Direct function) .......................................................... 11

Actuator with closing spring............................................................................... 11

Actuator with opening spring ............................................................................. 11

Double action positioner (Direct function)......................................................... 11

Double action actuator........................................................................................ 11

Electrical connections......................................................................................... 12

7. Control............................................................................................................. 14

Menus and pushbuttons ...................................................................................... 14

Other functions ................................................................................................... 14

Menu indicator.................................................................................................... 15

Menus ................................................................................................................. 15

Changing parameter values ................................................................................ 15

Menu system....................................................................................................... 16

First start ............................................................................................................. 17

8. Maintenance/service ........................................................................................ 37

Disassembling PMV D3 ..................................................................................... 37

Silencer ............................................................................................................... 39

Spindle adapter ................................................................................................... 39

Potentiometer...................................................................................................... 40

Transmitter boards.............................................................................................. 41

Disassembling PMV D3 Ex................................................................................ 44

Filter change ....................................................................................................... 45

Converting for remote control ............................................................................ 46

9. T r ouble shooting .............................................................................................. 47

10. Technical data ................................................................................................ 48

Certificates.......................................................................................................... 48

11. Spare parts ..................................................................................................... 56

1. Introduction

The PMV D3 is a digital positioner designed primarily for controlling adjustable valves.

The positioner can be used with single or double action actuators with either rotary or linear movement.

The D3 can be equipped with modules for feedback, limit switches, and a pressure gauge block.

The modules can be factory assembled

before delivery or fitted later.

The modules for feedback and limit

switches can contain the following:

Feedback 4-20 mA and one of the

following functions:

- Two mechanical contacts

- Two reed switches

- Two inductive sensors, DIN 19234

Safety instruction

Read the safety instructions in this manual carefully before using the product. The installation, operation, and maintenance of the product must be done by staff with the necessary training and experience. If any questions arise during installation, contact the supplier/sales office before continuing work.

Warning

• The valve package moves when in operation and can cause personal injury or damage if handled incorrectly.

• If the input signal fails or is switched off, the valve moves quickly to its end position.

• If the compressed air supply fails or is turned off, fast movements can occur.

• The valve is not controlled by the input signals when in the Out of service mode. It will open/close in the event of a leak.

• If a high value is set for Cut off, fast movements can occur.

• When the valve is controlled in the Manual mode, the valve can move quickly.

• Incorrect settings can cause self-oscillation, which can lead to damage.

Important

• Always turn of f the compressed air supply before removing or disconnecting the air supply connection or the integral filter. Remove or disconnect with care because C- is still under pressure even after the air supply is turned off.

• Always work in an ESD protected area when servicing the PCB´s. Make sure the input signal is switched off.

• The air supply must be free from moisture, water, oil and particles.

2. Storage

General

The PMV positioner is a precision instrument. Therefore it is essential that it is handled and stored in the right way . Always follow the instructions below!

N.B. As soon as the positioner is connected and started, internal air leakage will provide protection against corrosion and prevent the ingress of moisture. For this reason, the air supply pressure should always be kept on.

Storage indoors

Store the positioner in its original packaging. The storage environment must be clean, dry, and cool (15 to 26°C, 59 to 79°F..

Storage outdoors or for a longer period

If the positioner must be stored

outdoors, it is important that all the cover screws are tightened and that all connections are properly sealed. The unit should be packed with a desiccant (silica gel) in a plastic bag or similar, covered with plastic, and not exposed to sunlight, rain, or snow.

This is also applicable for long-term storage (more than 1 month) and for long transport by sea.

Storage in a warm place

When the positioner is stored in a warm place with a high relative humidity and is subjected to daily temperature variations, the air inside the unit will expand and contract.

This means that air from outside the unit may be drawn into the positioner. Depending on the temperature variations, relative humidity , and other factors, condensation and corrosion can occur inside the unit, which in turn can give rise to functional disorders or a failure.

3. Design

The D3 positioner contains:

• Electronic board with microprocessor, HART modem, display, etc.

• Valve block

• Positional feedback with potentiometer

• Sealed compartment for electrical connections

Filter Display, control push buttons

Adjustingscrews, damping

Valve block

Positional feedback Processor and motherboard

The push buttons and display are accessible underneath the aluminium cover, which is sealed with an O-ring.

The figure shows the D3 with the cover removed.

Terminal block

4. Variants

D3 270°deg.

D3 up to 270° deg for extended travel range is available. It features all benefits and options similar to the standard D3. Communication with HART or Profibus is possible.

D3 Explosion proof

The digital positioner D3 is available in explosion proof enclosure. It features the same easy to use user interface for local configuration as D3. Communication with Hart or Profibus is possible.

Further features are gauge ports and local graphic LCD display.

D3 Intrinsically safe

The digital positioner D3 is available in intrinsically safe version for installation in hazardous areas. It features the same easy to use user interface for local configuration as D3. Communication with HART or Profibus is possible. It features all benefits and options similar to the Standard D3 positioner, gauge block, local graphic LCD display and feedback option etc.

D3 remote mounted

The D3 with remote mount is now available on the market for order. This version is suitable for installations in severe applications e.g. vibrations, high or low temperature corrosive environment, high mountings or difficult of access, etc. A flat or dome style indicator can be fitted on the feedback box installed on the actuator. Max recommended distance between D3 and remote unit is 5 m.

5. Function

Control signal 4 - 20 mA

Potentiometer

Piezo-valve 2

Actuator

C– C+

➾

Venting

Double action function

The control signal and the feedback potentiometer position are converted to digital signals that are processed with a PID algorithm in the microprocessor. This provides control signals to the two piezo-valves.

The two piezo-valves are closed in the schematic diagram above and have no effect on the valves A and D. Air from the pressure regulator is lead through the open valve A to the valve B, which opens. The supply pressure can now pass through valve B to the actuator via H. The actuator then moves in the direction of the arrow. At the same

Signal converter

and

microprocessor

Venting

time, air from valve A keeps valve C open and allows venting of the actuator.

A closes but valve D opens and controls valves E and F to that the actuator moves in a direction opposite to the arrow. When only piezo-valve 1 is open, the actuator is stationary.

Air supply 2 - 6 bar

When both the piezo-valves open, valve

Piezo-valve 1

Diaphragm

1.2 bar Pressure

regulator

Replaceable Filter

Single action function

Valve B is used for the supply air and

valve F for venting.

6. Installation

Tubing

Use tubes with an inner diameter of mi-

nimum 6 mm (1/4”).

Air supply requirements

Max. air supply pressure, see the section

Technical Data, Section 10.

The air supply must be free from

moisture, water, oil, and particles.

Before the air supply is connected to the positioner, we recommend the hose is opened freely for 2 to 3 minutes to allow any contamination to be blown out. Direct the air jet into a large paper bag to trap any water, oil, or other foreign materials. If this indicates that the air system is contaminated, it should be properly cleaned.

The air must come from a refrigeration dried supply or be treated in such a way that its dew point is at least 10°C (18°F) below the lowest expected ambient temperature.

To ensure a stable and problem-free air supply, we recommend the installation of a filter/pressure regulator <40µ as close to the positioner as possible.

WARNING! Do not direct the open air jet towards people or objects because it may cause personal injury or damage.

Poor air supplies are the main source

of problems in pneumatic systems.

Mounting

N.B. If the positioner is installed in a

hazardous environment, it must be of a type approved for this purpose.

The D3 positioner has an ISO F05 footprint, A. The holes are used to attach it to the mounting bracket B, which is suitable for most types of linear actuator.

The spindle adapter C can be changed to suit the actuator in question.

Remove the existing adapter using two screwdrivers. Check that the spring ring on the positioner spindle is undamaged and fit the new adapter.

Assembly examples

It is important that the positioner’s spindle and the arms, that transfer the actuator movements, are correctly mounted. Any tension between these parts can cause incorrect operation and abnormal wear.

A B

Rotary movement Linear movement

The D3 Ex positioner has an ISO F05 footprint, A. The holes are used to attach it to the mounting bracket B, which is suitable for most types of linear actuators.

The spindle adapter C can be changed to suit the actuator in question, see previous page.

Connections

Air:

Port S Supply air, 2-7 bar Port C+ Connection to actuator Port C- Connection to actuator

(only for double action)

Electrical connection

See page 12, 13.

Dimensions

Air connections: 1/4" NPT alt. G 1/4" Electrical connection: M20 x 1.5 alt. NPT 1/2"

Loctite 577 or equivalent is recommended as a sealant.

Must be plugged when converting to single action function.

C– S C+

For data for air and electrical connections, see section Technical Data on page 48.

Single action positioner (Direct function)

Actuator with closing spring

When the control signal increases, the pressure C+ to the actuator is increased. The valve spindle moves upward and rotates the positioner spindle counter-clockwise. When the control signal drops to zero, C+ is vented and the valve closes.

Actuator with opening spring

When the control signal increases, the pressure C+ to the actuator is reduced. The springs press the valve spindle upward and the positioner spindle rotates counterclockwise. When the control signal drops to zero, C+ is vented and the valve opens.

Double action positioner (Direct function)

C– S C+

Double action actuator

When the control signal increases, the pressure C+ to the actuator is increased. The valve spindle is pressed upward and rotates the positioner spindle counter-clockwise. When the control signal is reduced, the pressure C- to the actuator increases and the valve spindle is pressed downward. If the control signal disappears, the pressure goes to C-, C+ vents, and the valve closes.

C– S C+

Electrical connections

The diagrams show the terminal blocks in D3 and D3 Ex.

Remote unit

The remote unit shall be connected between terminals3, 4 and 5 in the D3 and 3, 4 and 5 in the remote unit. Use a shielded cable and ground it in the D3 only. Max recommended distance between D3 and remote unit: 5 m.

Note! When converting D3/D3 Ex for use with remote unit, some changes have to be done inside the positioner, see Section 8.

When installing D3 Intrinsically safe unit, always consider cdwg D3-70.

HARTconnection

1234567891011 12 13 14

Warning! In a hazardous environment where there is a risk of explosion, electrical connections must comply with the relevant regulations.

The terminal block (below) for the positioner is accessible when the aluminium cover and inner cover is removed, see Section 8.

+ – + – + – + –

Option

1 4-20 mA + input signal 2 4-20 mA – input signal

3 Switch 1 NO 4 Switch 1 NC 5 Switch 1 COM 6 Switch 2 NO 7 Switch 2 NC 8 Switch 2 COM 9 AUX input 4-20 mA + 10 AUX input 4-20 mA – 11 4-20 mA + Feedback, 10-28 V DC 12 4-20 mA – Feedback, 10-28 V DC 13 Alarm output + 14 Alarm output –

Connecting a remote unit

123456

+ –

Shielded cables, grounded on the D3

345

Remoteunit

D3 Ex

The terminal block (below) for the positioner is accessible when the terminal cover is removed, see Section 8.

Warning! In a hazardous environment where there is a risk of explosion, electrical connections must comply with the relevant regulations.

1 4-20 mA + input signal 2 4-20 mA – input signal

3 (Remote unit) 4 (Remote unit) 5 (Remote unit) 9 AUX input 4-20 mA + 10 AUX input 4-20 mA – 11 4-20 mA + Feedback, 10-28 V DC 12 4-20 mA – Feedback, 10-28 V DC 13 Alarm output +, 8-28 V DC 14 Alarm output –, 8-28 V DC

Optional

7. Control

Menus and pushbuttons

The positioner is controlled using the five pushbuttons and the display, which are accessible when the aluminium cover is removed.

For normal functioning, the display shows the current value. Press the ESC button for two seconds to display the main menu.

Use the pushbuttons to browse through the main menu and the sub-menus.

The main menu is divided up into a basic menu and a full menu, see page 16.

Other functions

ESC

Exit the menu without making any changes (as long as any changes have not been confirmed with OK).

FUNC

To select function and change parameters.

To confirm selection or change of parameters.

MENU INDICATOR

Displays the position of the current menu row in the menu.

OUT OF SERVICE

MANUAL

BASIC MENU MAN/AUTO

UNPROTECTED

ESC FUNC

IN SERVICE

The positioner is following the input signal. This is the normal status when the positioner is working.

OUT OF SERVICE

The positioner is not following the input signal. Critical parameters can be changed.

MANUAL

The positioner can be adjusted manually using the pushbuttons. See section ”Man/ Auto”, page 21”.

UNPROTECTED

Most of the parameters can be changed when the positioner is in the ”Unprotected” position. However, critical parameters are locked when the positioner is in the ”In service” position.

Menu indicator

There are indicators at both sides of the

display window and they indicate as follows:

Flashing in position Out of service

FULL MENU MAN/AUTO

Flashing in position Manual

Displayed in position Unprotected

The indicators on the right-hand side

show the position in the current menu.

Menus

To display the menus you can select:

- Basic menu, which means you can browse through four different steps

- Full menu, which comprises ten steps. Use the Shift Menu to browse through the steps

Full Menu can be locked out using a

passcode.

The main menus are shown on the next page and the sub-menus on the subsequent pages.

FULL MENU CALIBRATE

FULL MENU SHIFT MENU

Changing parameter values

Change by pressing until the desired figure is flashing.

Press to step to the desired figure. Confirm by pressing OK.

A change can be undone by pressing the ESC button, which returns you to the previous menu.

Menu system

BASIC MENU READ

BASIC MENU MAN/AUTO

BASIC MENU CALIBRATE

BASIC MENU SHIFT MENU

The menus are described on the following pages.

FULL MENU READ

FULL MENU MAN/AUTO

FULL MENU CALIBRATE

FULL MENU SHIFT MENU

FULL MENU PROTECTION

FULL MENU STATUS

FULL MENU SETUP

FULL MENU TUNING

FULL MENU ALARMS

FULL MENU FACT SET

BASIC MENU CALIBRATE

First start

Calibrate in the basic menu is displayed automatically the first time the positioner is connected up, and can be selected from the basic/main menu at any later time.

A complete calibration takes about 3 minutes and includes end limit calibration, auto-tuning, leak test, and a check on the speed of movement. Start the automatic calibration by selecting Auto-Cal and then answer the questions on the display by pressing OK or the respective arrow. The menu is described on the next page.

Calibration error messages

If a fault occurs during calibration, one of the following error messages can be displayed:

Invalid movement/press ESC to abort

No movement because the air is incorrectly connected, for example. After the fault is corrected, the calibration sequence must be restarted.

Pot unaligned/press ESC to abort

The potentiometer has been set to an illegal value. The potentiomenter is aligned using the Calibrate - Expert cal - pot Menu. The calibration sequence must be restarted after the fault is corrected.

Air leak detected/ESC = abort OK = go on

An air leak has been detected. The calibration sequence should be restarted after the fault is corrected.

Increase C- damper/ESC = abort OK to retry Increase C+ damper/ESC = abort OK to retry

Speed of movement is too fast. Adjust with the damper screws (see page 5). Press OK. Repeat the adjustment and press OK until the speed is correct. If there is an abort, the calibration sequence must be restarted.

First start, Profibus

Connect the input signal at pos 1 and 2 on the terminal block. See Electrical connections in the manual.

In the SETUP/Devicedata/Profibus: change the address from 126 to any number between 1-125.

Do never use the same number to more than one unit. Install values in failsafe mode, for communication when loss of signal.

Calibrate the unit.

GSD files are available at our homepage www.pmv.nu

C+

(C–)

Clockwise = Increased damping/Less flow CCW = Decreased damping/Mor e flow 3 revsCCW = Max flow

Note! To much increased damping (low flow) might cause irregular actuator function.

BASIC MENU CALIBRATE

The contents of the menu are shown on the next page. The various menu texts are described below.

Auto-Cal Auto-tuning and calibration of end positions Start tune Starts the tuning. Questions/commands are displayed during

calibration. Select the type of movement, function, etc. with

and confirm with OK as shown in the chart on the next

page.

Lose prev value? OK? A warning that the value set previously will be lost (not during

the first auto-tuning).

Actuator? rotating Select for rotating actuator. Actuator? linear Select for linear actuator. Actuator single act Select for single act. Actuator double act Select for double act. Direction? direct Select for direct function. Direction? reverse Select for reverse function.

In service? Press OK Calibration finished. Press OK to start positioner functioning.

(If ESC is pressed, the positioner assumes the ”Out of service” position but the calibration is retained).

TravelCal Calibration of end positions Start cal Start end position calibration. Lose prev value? OK? A warning that the previously set value will be lost.

Confirm with OK. The calibration sequence starts.

In service? Press OK Calibration finished. Press OK to start positioner functioning.

(If ESC is pressed, the positioner assumes the ”Out of service” position but the calibration is retained).

Perform Setting gain Normal 100% gain Perform 50%, 25%, 12%, L, M, S Possibility to select a lower gain in steps. L, M, S Preset values for L, M, S actuators Factory set Resets all set values and enters Factory Mode. Should only

be used by authorized staff.

Note. Original P. I. D. will always be shown in display

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