Flowserve PMV D3 D User Manual

D3
Digital Positioner
Manual
Contents
1.Introduction ...................................................................................................... 3
Safety instruction................................................................................................ 3
2. Storage .............................................................................................................. 4
Storage indoors ................................................................................................... 4
Storage outdoors or for a longer period.............................................................. 4
Storage in a warm place ..................................................................................... 4
3. Design................................................................................................................ 5
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
2
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.
3
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.
4
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
5
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.
6
5. Function
Control signal 4 - 20 mA
Potentiometer
Piezo-valve 2
C
D
Actuator
E
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
B
F
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.
G
H
Air supply 2 - 6 bar
When both the piezo-valves open, valve
Piezo-valve 1
A
Diaphragm
1.2 bar Pressure
regulator
Replaceable Filter
Single action function
Valve B is used for the supply air and
valve F for venting.
7
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.
8
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
C
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
C
Rotary movement Linear movement
9
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.
A
B
C
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.
10
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+
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+
11
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.
D3
The terminal block (below) for the posi­tioner is accessible when the aluminium cover and inner cover is removed, see Section 8.
12
+ – + – + – + –
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
13
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.
OK
To confirm selection or change of para­meters.
MENU INDICATOR
Displays the position of the current menu row in the menu.
14
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.
OK
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.
15
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
16
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.
17
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
18
CALIBRATE AutoCal
AutoCal Start tune
LOSE PREV
OK
VALUE?OK?
CALIBRATE TravelCal
CALIBRATE Perform
TravelCal Start cal
LOSE PREV VALUE?OK?
OK
Calibration in
progress
IN SERVICE ? Press OK
OK
OK
OK
Actuator? rotating
Actuator? linear
OK
OK
Actuator single act
Actuator single act
Direction? direct
Direction? reverse
Calibration in
progress
IN SERVICE ? Press OK
OK
Perform normal
OK
OK
CALIBRATE ExpertCal
All these values are set at the
factory before delivery and
Set point LO: Use the calibrator set to 4 mA (or set another value on the display). Press OK. Set point HI: Use a calibrator of 20 mA (or set another value on the display). Press OK. Pressure read out only possible on D3 with built in pressure sensor. Pressure LO: Use a supply of 2 bar (30 psi) (or set another value on the display). Press OK. Pressure HI: Use a supply of 7 bar (105 psi) (or set another value on the display). Press OK.
Temp: Calibrate using a known temperature. Aux input LO: Use the calibrator
and a power supply of 4 mA (or set another value on the display). Press OK. Aux input HI: Use a supply of 20 mA (or set another value on the display). Press OK. Pot: Potentiometer setting, if its position relative to the gear segment has been changed. See Section 8.
should not normally be changed.
Full reset: Resets all the set values.
Perform 50%
25%
12%
L
M
S
Perform Factory set
OK OK OK OK OK
19
The menu contents are shown in the figures on the right and the texts are described below:
BASIC MENU READ
Current values can be read using the Read Menu and some values can be reset.
Pos Shows current position
READ
Set&pos Set point and position
pos
Set&dev Set point and deviation
Temp Shows current temperature
Aux Shows auxinput signal valve.
External pot or similar
Statistics n cycles Shows number of movements
(turns)
Acc travel Shows accumulated
movement
mean dev Shows accumulated deviation
in %
runtime Shows accumulated runtime
since last reset
Extr temp Shows extreme min and max
temperature
Histogram Shows position and time for
PV
READ set&pos
READ set&dev
READ temp
READ aux
READ Statistics
READ Alarms
Statistics n cycles
Statistics acc travel
Statistics mean dev
Statistics runtime
Statistics extr. temp
Statistics histogram
Alarms Displays tripped alarms
20
Statistics Reset stat
Reset stat yes
Reset stat no
BASIC MENU MAN/AUTO
The Man/Auto menu is used to change between manual and automatic modes.
The menu contents are shown in the figures on the right and the various texts are described below:
AUT, OK = MAN
Positioner in automatic mode
MAN, OK = AUT
Positioner in manual mode
In the MAN mode, the value of POS can be changed using . The push­buttons increase/decrease the value in steps. The value can also be changed in the same way as for the other parameter values, as described on page 15.
Other functions
C+ can be fully opened by pressing and then immediately OK simultaneously.
C- can be fully opened by pressing and OK simultaneously.
C+ and C- can be fully opened for blowing clean by pressing and OK simultaneously.
AUT, OK=MAN POS= 12,3%
When changing between
MAN and AUT mode, the OK button must be depressed for 3 seconds.
MAN, OK=AUT
OK
POS= 12,3%
21
BASIC MENU SHIFT MENU
The Shift Menu is used to choose between the basic menu and the full menu.
The menu contents are shown in the figures on the right and the various texts are described below:
No Full menu selected.
Yes Basic menu selected.
Full Menu can be locked with a passcode, see Setup menu.
FULL MENU PROTECTION
The Write Protect menu is used to protect all essential settings.
The menu contents are shown in the figures on the right and the various texts are described below:
Full menu no
Full menu yes
PROTECTION no
OK
OK
OK
No Entered values are not write
protected. ”Unprotected” is displayed in the lower left­hand corner.
Yes Entered values are write
protected. Passcod needed for change to No (Applicable when a passcode has been set up in SETUP menu).
22
.
PROTECTION yes
When changing between Yes and No mode, the OK button must be depressed for 3 seconds.
OK
FULL MENU STATUS
The Status Menu is used to select whether or not the positioner is in service.
The menu contents are shown in the figures on the right and the various texts are described below:
o o service Not in service. Flashing
indicator in upper left­hand corner of display.
in service Positioner in service.
Critical parameters cannot be changed.
STATUS o o service
STATUS in service
When changing between
In service and Out of ser­vice, the OK button must be
depressed for 3 seconds.
OK
OK
23
FULL MENU SETUP
The Setup Menu is used for various settings.
The menu contents are shown in the chart on the next page and the various texts are
described below:
Actuator Type of actuator Size of actuator Time out Rotating Rotating actuator. Small 10 s Linear Linear actuator. Medium 25 s
Large 60 s Texas 180 s
Lever Only for linear actuator. Lever stroke Stroke length to achieve correct display. Level cal Calibration of positions to achieve correct display.
Direction
Direct Direct function (signal increase opens). Indicator/spindle rotates counter-clockwise. Reverse Reverse function.
Character Curves that show position as a function of input signal. Linear Equal % See diagram. Quick open Sqr root Custom Create own curve.
Cust chr
# of point Specify number of points (3, 5, 9,
17, or 33)
Cust curve Enter values on X and Y axes.
y
Qo Sqr Lin Eq%
Movement
Curr range 0%=4.0 mA 100%=20.0 mA Possibility of selecting which input signal values will correspond to
0% and 100% movement respectively. Examples of settings: 4 mA = 0%, 12 mA = 100%, 12 mA = 0%, 20 mA = 100%.
24
Signal
x
SETUP Actuator
Actuator type
Type linear
OK
SETUP Lever
SETUP Direction
SETUP Character
SETUP Cust chr
SETUP curr range
Actuator function
Actuator size
Lever Stroke
Lever Lever cal
Direction direct
Direction reverse
Cust chr # of point
Cust chr Cust curve
Curr range 0%=4,0 mA
Curr range 100%=20 mA
OK
OK
Function single act
Function Double act
OK
OK
Character linear
Character equal %
See text!
Character quick open
Character custom
Character sqr root
Type
OK
rotating
OK
Size Medium
Size Small
Size Large
Size Texas size
Stroke LEN=
OK
OK
OK
OK
OK
XX,Xmm
Set lever at max...
OK
Set lever at center...
OK
Set lever at min...
OK
Set lever at center...
OK
Lever cal Done
OK
OK
OK
OK
OK
OK
OK
25
TRVL range Setting end positions 0%=0.0% Select Out of Service.
Set percentage value for desired end posi­tion (e.g. 3%).
Set 0% Select In Service.
Connect calibrator. Move forward to desired end position (0%) and press OK.
100%=100.0% Select Out of Service.
Set percentage value for desired end position (e.g. 97%).
Set 100% Select In Service.
Connect calibrator. Move forward to desired end position (100%) and press OK.
Trvl ctrl Behaviour at set end
position
Set low Choose between Free (go
to mechanical stop), Limit (stop at set end position), and Cut off (go directly to mechanical stop at set end position).
Set high Similar to Set low. Values Select position for Cut off
and Limit at the respective end positions.
Passcodes Setting passcodes for
various functions
Full menu Passcode for access to
full menu.
Write pr ot Passcode for removing
write protect.
Expert Passcode for access to
Expert menu
Fact set Passcode to return to
default values applicable when positioner was
26
delivered.
(TUNING).
Numbers between 0000 and 9999 can be used as passcodes. 0 = no passcode required.
Appearance On display Language Select menu language. Units Select units. Def. Display Select value(s) to be
displayed during service. The display reverts to this value 10 minutes after any change is made.
Start menu Start in Basic menu or
Full menu.
Contrast Adjust display contrast. Orient Orientation of text on
display.
Par mode Display of control para
meters such as P, I, D or K, Ti, Td.
Devicedata
HW rew SW rew General parameters. Capability HART Menu with HAR T para-
meters. Only amendable with HART communi­cator. It is possible to read from display.
Profibus Status Indicates present status Device ID Serial number Address 1-126 Tag Allotted ID Descriptor ID description Date N/A Failsafe Value = preset pos
Time = Set time +10sec= time before movement Valve act = failsafe (preset pos) or lastvalue (present pos) Alarm out= On/Off
SETUP Trvl range
Trvl range 0%= 0,0%
OK
SETUP Trvl ctrl
SETUP Passcodes
SETUP Appearance
SETUP Devicedata
Trvl ctrl Set low
Trvl ctrl Set high
Trvl ctrl Values
Devicedata HW rew
Devicedata SW rew
Devicedata Capability
Devicedata Hart
Devicedata Profibus
See text!
Appearance Language
Appearance Units
Appearance Def. Displ
Appearance Start menu
See text!
Appearance Contrast
Appearance Orient.
Appearance Par mode
Trvl range Set 0%
Trvl range 100%=100,0%
Trvl range Set 100%
Passcodes full menu
Passcodes protection
Passcodes expert
Passcodes fact set
See text!
See text!
OK
OK
OK
See text!
27
FULL MENU TUNING
The menu contents are shown in the chart on the next page and the various texts are
described below:
Close time Minimum time from fully open to closed. Open time Minimum time from closed to fully open. Deadband Setting deadband. Min. 0.2%.
Expert Advanced settings. Togglestep Test tool for checking functions. Overlays a square wave on the
set value.
K, Ti, Td Setting K, Ti, and Td parameters.
Self test Test of processor, potentiometer, etc.
Leakage Air leakage detected can be either connections, positioner
tubing or actuator.
Undo You can read last 20 changes.
28
TUNING Close time
Close time Min= 0,05
OK
TUNING Open time
TUNING Deadband
TUNING Expert
Open time Min= 0.05
Deadband D= 0,2%
Expert Togglestep
Expert K,Ti,Td
Expert Self test
Expert Leakage
Expert Undo
OK
OK
Togglestep Runtimetime
Togglestep Cycletime
Togglestep size
Togglestep start
Togglestep Abort step
29
FULL MENU ALARMS
The menu contents are shown in the chart on the next page and the various texts are
described below:
Deviation Alarm generated when deviation occurs On/Off Alarm on/off. Distance Allowed distance before alarm is generated. Time Total deviation time before alarm is generated. Alarm out Select ON/OFF offers output on terminals 13 and 14.
Valve act Behaviour of valve when alarm is generated.
Limit 1 Alarm above/below a certain level. On/Off Alarm on/off. Minipos Setting of desired min. position. Maxpos Setting of desired max. position. See diagram below! Hysteresis Desired hysteresis. Alarm on Select ON/OFF offers output on terminals 13 and 14. Valve act Behaviour of valve when alarm is generated.
Limit 2 See Limit 1.
Set alarm and hysteresis values
100%
Alarm Limit 1 on
Alarm Limit 1 off
Limit 1, max Hysteresis
Alarm Limit 2 on
Travel
30
Alarm Limit 2 off
Alarm Limit 2 on
Alarm Limit 1 on
alarm Limit 2 off
Alarm Limit 1 off
Limit 2, max Hysteresis
Hysteresis Limit 2, min
Hysteresis Limit 1, min
0%
ALARMS Deviation
Deviation On/off
On/off on
OK
ALARMS Limit 1
Deviation Distance
Deviation Time
Deviation Alarm Out
Deviation Valve act
Limit 1 On/off
Limit 1 Minpos
Limit 1 Maxpos
Alarm Out on
Alarm Out off
On/off on
On/off off
Minipos P= 0,0%
Maxpos P= 0,0%
OK
OK
OK
OK
OK
OK
On/off off
Distance D = 10.0%
Time T=0.00s
Valve act no action
Valve act goto open
Valve act goto close
Valve act manual
OK
OK
OK
OK
OK
OK
OK
ALARMS Limit 2
Limit 1 Hysteresis
Limit 1 Alarm
See Limit 1
Hysteresis H= 0,0%
Alarm out OFF
Alarm out ON
Limit 1 Valve act
OK
OK
OK
Valve act no action
Valve act goto open
Valve act goto close
Valve act manual
OK
OK
OK
OK
31
Pos=aux External potentiometer
On/Off Function on/off.
Max diff Max. allowed deviation between internal and external potentiometer.
Alarm out Select ON/OFF offers output on terminals 13 and 14.
Valve act Behaviour of valve when alarm is generated.
Aux input External input signal 4-20 mA.
On/Off Alarm on/off.
Minipos Setting of desired min. position.
Maxpos Setting of desired max. position.
Hysteresis Desired hysteresis.
Valve act Behaviour of valve when alarm is generated.
32
Function similar to Limit 1 and 2. See chart on previous page.
ALARMS Pos=aux
Pos=aux On/off
On/off on
OK
ALARM Aux input
Pos=aux Max diff
Pos=aux Alarm out
Pos=aux Valve act
Aux input On/off
Aux input Minpos
Aux input Maxpos
On/off on
On/off off
Minipos P= 0,0%
Maxpos P= 0,0%
OK
OK
OK
OK
On/off off
Max diff P= 0,0%
Alarm out OFF
Alarm out ON
Valve act do nothing
Valve act goto open
Valve act goto close
Valve act manual
OK
OK
OK
OK
OK
OK
OK
OK
Aux input Hysteresis
Aux input Alarm out
Hysteresis H= 0,0%
Alarm out OFF
Alarm out ON
Aux input Valve act
OK
OK
OK
Valve act do nothing
Valve act goto open
Valve act goto close
Valve act manual
OK
OK
OK
OK
33
Temp Alarm based on temperature On/Off Temperature alarm on/off. Low temp Temperature setting. High temp Temperature setting. Hysteresis Allowed hysteresis. Alarm out Select ON/OFF offers output on terminals 13 and 14. Valve act Behaviour of valve when alarm is generated.
Valve act
No action Alarm generated only. Operations not affected.
Goto open C+ gives full pressure and valve moves to fully
open position. Positioner changes to position Manual.
Goto close C- gives full pressure and valve moves to fully
closed position. Positioner changes to position Manual.
Manual Valve stays in unchanged position. Positioner
moves to position Manual.
FULL MENU FACT SET
The menu contents are shown in the chart on the next page and the various texts are
described below:
The default values that were set on delivery can be reset using the Fact Set menu. Values
from calibration and from other settings will then be lost.
34
ALARMS temp
Temp On/off
On/off on
OK
Temp Low temp
Temp High temp
Temp Hysteresis
Temp Alarm out
Temp Valve act
On/off off
Low temp Min=0,0°C
High temp Max=100,0°C
Hysteresis H=
Alarm out OFF
Alarm out ON
OK
OK
OK
OK
OK
OK
Valve act no action
Valve act goto open
Valve act goto close
OK
OK
OK
FACT SET no
FACT SET yes
OK
OK
Discard settings?
OK
Press OK for 3 sek
OK
Input accepted
Valve act manual
OK
FACT SET Done
OK
OK
35
36
8. Maintenance/service
When carrying out service, replacing a circuit board, etc., it may be necessary to remove and refit various parts of the positioner. This is described on the following pages.
Read the Safety Instructions on page 3 before starting work on the positioner.
Cleanliness is essential when working with the positioner. Contamination in the air ducts will infallible lead to operational disturbances. Do not disassemble the unit more than that described here.
Do not take the valve block apart because its function will be impaired.
When working with the D3 positioner, the work place must be equipped with
ESD protection before the work is started.
Always turn off the air and electrical supplies before starting any work.
Disassembling PMVD3
Removing cover and inner cover
• Unscrew the screws A and remove the cover.
• Pull off the arrow pointer, B.
• Unscrew the screws C, pull the inner cover slightly in the direction of the arrow, and remove the cover.
A
B C
37
Circuit boards (pcb)
Disconnect or switch off the electric power supply before starting any work.
• Lift off the display pcb.
• Unscrew the spacers E, release the cable connections F and G, and lift up the proces­sor pcb.
• Remove the terminal board by unscrewing the spacers H.
D
F E
G
H
38
Valve block
Turn off the air and electric power supply before starting any work.
• R elease the connector F from the proces­sor pcb.
¥ Remove the four screws I .
¥ Lift out the valve block
N.B . Do not disassemble the valve block
¥ W hen installing the valve block Ñ torque the four screws to 1,4 Nm and sealwith L ocktite 222.
I
F
Silencer
A silencer, L (option) can be mounted under the plate M on the D3. Contact PMV .
Spindle adapter
The spindle adapter can be changed to suit the actuator in question, see page 9.
M L
Potentiometer
90° and 270° spring loaded potentiometer
The spring-loaded potentiometer K can be removed from the gearwheel for calibration or replacement.
1
If the potentiometer is replaced or the set­ting is changed, it must be calibrated.
• Select the menu Calibrate - Expert - Cal pot. The display shows Set gear (1).
• Turn the spindle shaft (2) cw to end posi­tion and press OK. Turn ccw to the end and press OK.
• Unmesh the potentiometer (3) and turn it according to display until OK is shown. Press OK.
2
K
3
OK
Transmitter boards
The equipment for transmitter feedback consists of a circuit board A, cam assembly B and screws.
The circuit board exists in four:
- with mecanical switches, SPDT
- with namur sensors, DIN 19234
- with proximity switches
- with feedback transmitter only 40
A
B
Transmitter board installation
Caution! T urn off the power and air supply starting the installation.
Important for D3 Intrinsically safe units: Transmitter boards NOT for on site mounting by customer. FM, CSA and ATEX certificate only valid when trans­mitter board is mounted by manufacturer .
• Remove the cover, indicator and inner cover according to the description on page
37.
• Check that both spacers C are installed.
• Carefully mount the circuit board in its position. The pins D should fit in the connector and the positioners motherboard. Make sure that the feed back PC board is properly connected.
C
C
D
E
• Secure the circuit board with the enclosed screws E.
• Install the cam asssembly B on the shaft and push it down to its position. If the board has microswitches, be careful not to damage the levers.
B
41
• Tighten the screws F, on the cam assembly . Do not tighten the screws to hard. The cams should be able to move in relation to each other.
• Install the inner cover with the two screws, G.
• Connect the wiring for the transmitter feed­back on the terminal block, according to the drawing on next page.
F
G
• Adjust the position where the switches/ sensors should be affected, by turning the cams with a screwdriver.
• Tighten the cam assembly screws F when the cams are correctly adjusted.
• Install the indicator and cover. To calibrate the feedback transmitter, see drawing on next page.
42
F
.
43
Disassembling PMV D3 Ex
• Loosen the screws A and B and remove the caps C och D.
A D
F
• Remove the inner display cover E by loosening the four screws F.
• Carefully remove the display board and loosen the connections H and I.
• Release the wide cable from the connector J on the terminal board.
• Loosen the three screws K.
E
G
B C
J
H
I
K
L
M
• Remove the circuit board package L, con­sisting of terminal and processor board.
• Remove he four screws M and lift the block N.
44
N
Filter change, D3 and D3 Ex
Turn off the compressed air supply before starting any work. Otherwise the filter can be uncontrollably blown out of the positioner by the air pressure, which can be dangerous.
• Remove the filter cap using a coin of
suitable size.
Note! Do not use a screwdriver. The fil-
ter cap might crack and cause air leakage.
45
Converting for remote control
Disconnect or switch off the electric power supply before starting any work.
• Remove cover and inner cover, see page
37.
D
• Lift off the display pcb, D.
• Disconnect and secure the pot cable.
• Install transmitter board D3-AS38T , F.
• Install the enclosured wire between G and O on the transmiter board.
• Connect the wiring between terminals 3, 4, 5 in the D3 unit and 3, 4, 5 in the remote unit.
Use a shielded wire and ground it in the D3 unit only.
Avoid longer distance than 5 m between D3 unit and remote unit.
F
O
G
5
4
3
46
3 4 5
9. Trouble shooting
Fault symptom
Change in input signal to positioner does not affect actuator position.
Change in input signal to positioner ma­kes actuator move to its end position.
Inaccurate regulation.
Action
• Check air supply pressure, air cleanliness, and connection between po­sitioner and actuator.
• Check input signal to positioner.
• Check mounting and connections of po­sitioner and actuator.
•Check input signal.
•Check mounting and connections of po­sitioner and actuator.
• Implement auto-tuning. Check for any leaks.
• Uneven air supply pressure.
• Uneven input signal.
• Wrong size of actuator being used.
• High friction in actuator/valve package.
• Excess play in actuator/valve package.
• Excess play in mounting of positioner on actuator.
• Dirty/humid supply air.
Slow movements, unstable regulation.
• Implement auto-tuning.
• Adjust the pressure adjusting screws.
• Increase the deadband (Tuning menu).
• Adjust Performance (Calibrate menu).
47
10. Technical data
Rotation angle min. 30° max 100° Stroke 5 - 130 mm (0.2” to 5.1”) Input signal 4 - 20 mA Air supply 2 - 7 bar (30 - 87 psi) Free from oil, water
and moisture. Filtered to min. 30 micron Air delivery 400 nl/min (13.8 scfm) Air consumption <0.3 nl/min (0.01 scfm) Air connections 1/4” G or NPT Cable entry 3 x M20 or 1/ 2” NPT Electrical connections Screw terminals 2.5 mm2 /AWG14 Linearity <1% Repeatability <0.5% Hysteresis <0.4% Dead band 0.2-10% adjustable Display Graphic, view area 15 x 41mm (0.6 x 1.6”) UI 5 push buttons Processor 16 bit, M 16C CE directives 93/68EEC, 89/336/EEC, 92 /31/EEC EMC EN 50 081-2, EN 50 082-2 Voltage drop <10.1V Vibrations <1% up to 10 g at frequency 10 - 500 Hz Enclosure IP66/NEMA 4X Material Die-cast aluminium, A2/A4 fasteners Surface treatment Powder epoxy Temperatur range –30 to +80°C (–22 to 176° F) Weight D3X, 1.4 kg (3 lbs). D3E, 3 kg (6.6 lbs) Alarm output Transistor Ri 1K Alarm Supply Voltage 8 - 28 V
48
Mechanical switches
Type SPDT Size Sub Sub miniature Rating 3 A/125 V AC
2 A/30 V DC
Namur sensors
Type Proximity DIN 19234 NAMUR Load current ≤ 1 mA ≤ 3 mA Voltage range 5 - 25 VDC Hysteresis 0.2 % Temp –20°C to 85°C (–4°F to 185°F)
Proximity switches
Type SPDT Rating 5 W/250 mA/30 V DC/125 V AC Operating time 0.7 ms Breakdown voltage 200 VDC Contact resistance 0.1 Mechanical/electrical life >50 x 106 operations
4 - 20 mA transmitter
Supply 9 - 28 VDC Output 4 - 20 mA Resolution 0.1 % Linearity full span +/–0.5 % Output current limit 30 mA DC Load impedance 800 @ 24 VDC
49
505152
Certificates
53
4-20mA input signal
Pin 1;2
AUX input 4-20 mA
Pin 9;10
4-20 mA Output
Pin 11;12
Alarm
Pin 13;14
NAMUR switches Pin 3;4 : Switch 1 Pin 6;7 : Switch 2
NON HAZARDEOUS AREA
HAZARDEOUS AREA
3
5
Isolator
D3
Ui : 10,6V Ii : 29,7mA Pi : 79mW Ci : 1 nF
Li : 1 µH
NON HAZARDEOUS AREA
HAZARDEOUS AREA
6
8
Isolator
D3
Ui : 10,6V Ii : 29,7mA Pi : 79mW
Ci : 1 nF Li : 1 µH
Mechanical or Proximity switches
Pin 3;5 : Switch 1 Pin 6;8 : Switch 2
NON HAZARDEOUS AREA
HAZARDEOUS AREA
4+
3-
Isolator
D3
Ui : 10,6V Ii : 29,7mA Pi : 79mW Ci : 35 nF Li : 50 µH
NON HAZARDEOUS AREA
HAZARDEOUS AREA
7+
6-
Isolator
D3
Ui : 10,6V Ii : 29,7mA Pi : 79mW
Ci : 35 nF
Li : 50 µH
HART-
connection
Mechanical or Proximity switches
Pin 3;5 : Switch 1 Pin 6;8 :Switch 2
Normally Open
NON HAZARDEOUS AREAHAZARDEOUS AREA
3
5
Safety Barrier
/PA
/PA
NON HAZARDEOUS AREA
HAZARDEOUS AREA
6
8
Safety Barrier
/PA
/PA
NON HAZARDEOUS AREA
HAZARDEOUS AREA
9+
10-
Safety Barrier
/PA
/PA
NON HAZARDEOUS AREAHAZARDEOUS AREA
4
5
Safety Barrier
/PA
/PA
NON HAZARDEOUS AREAHAZARDEOUS AREA
7
8
Safety Barrier
/PA
/PA
Mechanical or Proximity switches
Pin 4;5 : Switch 1 Pin 7;8 : Switch 2
Normally Closed
NON HAZARDEOUS AREAHAZARDEOUS AREA
1+
2-
Safety Barrier
D3
Ui : 28V Ii : 93mA
Pi : 653mW
Ci : 4 nF Li : 5 µH
/PA
/PA
NON HAZARDEOUS AREAHAZARDEOUS AREA
13+
14-
Safety Barrier
/PA
/PA
NON HAZARDEOUS AREAHAZARDEOUS AREA
11+
12-
Safety Barrier
/PA
/PA
1. Input signal
2. 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 NC
9. AUX 4-20 mA + Input
10. AUX 4-20 mA - Input
11. 4-20 mA +
12. 4-20 mA -
13. Alarm Output +
14. Alarm Output -
7
1
2
3
5
14
8
9
10 11
12
13
4
6
+- +- - -++
Option
Option
D3
Li : 1 µH
Ci : 1 nF
Pi : 315mW
Ii : 45mA
Ui : 28V
D3
Li : 1 µH
Ci : 1 nF
Pi : 315mW
Ii : 45mA
Ui : 28V
D3
Li : 1 µH
Ci : 1 nF
Pi : 315mW
Ii : 45mA
Ui : 28V
D3
Li : 1 µH
Ci : 1 nF
Pi : 315mW
Ii : 45mA
Ui : 28V
D3
Li : 5 µH
Ci : 5,7 nF
Pi : 315mW
Ii : 45mA
Ui : 28V
D3
Li : 5 µH
Ci : 5,7 nF
Pi : 525mW
Ii : 75mA
Ui : 28V
D3
Li : 5 µH
Ci : 5,7 nF
Pi : 315mW
Ii : 45mA
Ui : 28V
Profibus PA input signal
Pin 1;2
NON HAZARDEOUS AREA
HAZARDEOUS AREA
Ui : 15V
Ii : 208mA
Pi : 1,93W
Ci : 4 nF Li : 5 µH
D3
2
1
Safety Barrier
/PA
/PA
Pin 1: Isrc Pin 2: Irtn
54
55
23 24 25 26
4 3 31 17 11 12 13 14 15 16 2 1
9 10 5 7 8
20
27 28 21 22
56
6 19 18
Pos P art no. Description 1 D3-SP6 Cover incl.screws 2 D3-SP11 I nternal cover incl.screws 3 P3-SP13 Cover plate incl. screws 4 P5-Sxx Spindle adapter 5 D3-SP1 B lock compl incl. cable, rubber seal, filter-plug 6 D3-SP9 Filter-plug incl. O-ring, filter 7 D3-SP8 Potentiometer compl incl. spring, holder, cable 8 D3-SP8-270 Potentiometer compl incl. spring, holder, cable, 270deg 9D3-SP20 Shaft compl incl. gearwheel, friction clutch 10 D3-SP20-270 Shaft compl.incl. gearwheel, friction clutch, 270deg 11 D3-SP37 Pcb display assy 12 D3-SP35X PCB s (terminal and processor) 13 D3-SP35H PCB s (terminal and processor) HART 14 D3-SP35I PCBs (terminal and processor) intrinsically safe 15 D3-SP35IH PCB s (terminal and processor)intrinsically safe, HA RT 16 D3-SP35P PC Bs (terminal and processor) Profibus 17 P48A Arrow pointer 18 D3-SP/SC R EW K it, bag with screws 19 D3-SP/SE AL K it, bag with O-rings, seals 20 D3-SP42 Cables and PC boards to pneumatic block 21 D3-SP34G Gaugeblock G, complete 22 D3-SP34N Gaugeblock N, complete 23 D3-A S38M Transmitter board, M echanical switches, assy 24 D3-A S38N Transmitter board, Namur sensors, assy 25 D3-A S38P Transmitter board, Proximity switches, assy 26 D3-A S38T Transmitter board 4-20, assy 27 D3-SP46G Dumpvalve valve assy ÓGÓ for single acting 28 D3-SP46N Dumpvalve valve assy ÓNÓ for single acting 30 D3-SP6W C C over incl. screws, Worcester 31 D3-67 Silencer
57
12
13
1
3
11
5
9
10
4
58
7 8
19
2
18
17
20
14 15 16 6
Pos Part no. Description
1 D3E-SP2 Front cover incl. screw 2 D3E-SP3 Terminal cover incl. screw 3 D3E-SP4 Internal cover incl. screws 4 P5-Sxx Spindle adapter 5 D3-SP1 Block compl. incl. cable, rubber seal, filter-plug 6 D3-SP9 Filter plug incl.O-ring, filter 7 D3E-SP8 Potentiometer compl. incl. spring, holder, cable 8 D3E-SP8-270 Potentiometer compl. incl. spring, holder, cable 9 D3E-SP20 Shaft compl. incl. gearwheel, friction clutch 10 D3E-SP20-270 Shaft compl. incl. gearwheel, friction clutch 11 D3-SP37 Display pcb 12 D3E-SP35X All PCB´s, (processor, mother, terminal) 13 D3E-SP35H All PCB´s, HART, (processor, mother, terminal) 14 D3E-SP40 Terminal PCB 15 D3E-SP/Screw Kit with screws D3E 16 D3E-SP/Seal Kit with O-rings 17 D3E-SP42 Cable for pneumatic block, incl. 2 x PCB 18 D3E-SP46G Dump valve G assy for D3E 19 D3E-SP46N Dump valve NPT assy for D3E 20 D3E-SP18 Adapter complete for dump valv assy
59
Palmstiernas Instrument AB
Korta Gatan 9 • 171 54 Solna
Tel: +46 (0)8-555106 00 • Fax: +46 (0)8-555106 01
E-mail: info@pmv.nu • www.pmv.nu
PMW PN 22549/02
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