PMV D3 D
D3
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
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
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