Flowserve PMV P3 User Manual

P3/EP3 Modular Linear Positioner
Installation
Operation
Maintenance
2
Contents
1. Introduction ................................................................................................................... 3
Safety instruction ............................................................................................................... 3
2. Storage ............................................................................................................................ 4
Storage outdoors or for a longer period ............................................................................. 4
Storage in a warm place .................................................................................................... 4
4. Variants ........................................................................................................................... 6
Optional equipment ........................................................................................................... 6
5. Function .......................................................................................................................... 7
Increase in signal pressure ................................................................................................. 7
Decrease in signal pressure ............................................................................................... 7
6. Installation...................................................................................................................... 8
Air supply requirements .................................................................................................... 8
Mounting ........................................................................................................................... 9
Connections ..................................................................................................................... 11
Direct / Reverse function ................................................................................................. 11
Single acting positioner ................................................................................................... 12
Electrical connections ...................................................................................................... 13
Control drawing ...............................................................................................................14
7. Adjustments..................................................................................................................15
Gain ................................................................................................................................. 15
Default settings ................................................................................................................ 15
Setting the zero position and span ................................................................................... 15
8. Maintenance/service .................................................................................................... 16
Valve block ...................................................................................................................... 16
Flapper nozzle ................................................................................................................. 17
Gain screw ....................................................................................................................... 17
Integral I/P converter ....................................................................................................... 17
Feedback arm / Spindle ................................................................................................... 18
9. Trouble shooting .......................................................................................................... 19
10. Technical data ............................................................................................................ 20
11. Spare Parts List .......................................................................................................... 22
1. Introduction
The PMV P3 is a modular Positioner sys­tem designed for use on control valves with linear motion. The basic unit is the P3 posi­tioner, which is available for single acting. The I/P converter can be integral, located in a separate mounted module (Ex), or located elsewhere. The P3 can be equipped with connection blocks for pressure gauges to indicate:
- actuator pressure
- air supply pressure
- input signal pressure
3
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.
PMV P3 basic unit
PMV P3 with explosion proof I/P
4
2. Storage
General
The PMV positioner is a precision in­strument. Therefore it is essential that it is handled and stored in the correct way. Always follow the instructions below!
N.B. As soon as the positioner is connected and started, an internal air bleed will provide protection against corrosion and prevent the ingress of moisture. For this reason, the air supply 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 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 a 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
5
The P3 positioner comprises a basic module with a single acting valve block. It also includes a sealed chamber with termin­als for the electrical input signals.
The I/P unit can be built into the main housing (as shown in the figure below) or
I/P converter
Feedback arm
Feedback spring
located externally (explosion proof), see section ”Variants”.
The adjusting screws and knobs are accessible under the removable sealed alu­minium cover.
Balance arm
Flapper nozzle
C+
Supply
Input 3-15 psi
Electrical connection
Figure shows P3 positioner with integral I/P converter and cover removed
Zero position adjustment
Adjusting screw, damping
Span adjustment
Adjusting screw, gain
6
4. Variants
Standard designs
P3/EP3 is available single acting.
I/P converter can be integral or located
elsewhere.
P3
Pneumatic, single acting, to be
connected to an external I/P converter.
EP3, EP3IS
Electro-pneumatic, single , with integral I/P converter. Intrinsically safe model also available.
EP3EX
Explosion proof model, I/P converter located in separate, sealed enclosure.
Optional equipment
P3 / EP3 positioner can be equipped with connection blocks and pressure gauges for:
- input signal pressure
- input air supply pressure
- output pressure
P3/EP3
EP3 EX
5. Function
General
The P3 positioner operates on the force balance principle. Changes are initiated by the
signal pressure from the I/P converter. The functionality is described briefly below.
Single action
7
Feedback arm
Plug
Signal pressure
Signal diaphragm Balance arm Flapper nozzle
Increase in signal pressure
When the air pressure on the signal diaphragm increases, the balance arm is pres­sed down and the flapper nozzle closes. The pressure on the relay diaphragm then increases and the plug valve opens.
Air is now supplied to the actuator, the spindle movement rotates the feedback arm, the balance arm is lifted, and the flapper nozzle opens. The pressure on the relay diaphragm is reduced and the plug valve reduces the air flow to the actuator. An equilibrium position is thus reached and the valve being controlled is in the desired posi­tion.
valve
Decrease in signal pressure
diaphragm is reduced, the balance arm is lifted and the flapper nozzle opens. The pressure on the relay diaphragm is then reduced and the plug valve upper seal opens and vents.
and its spindle moves. The actuator movement goes back through the arm mechanism (see figure) to the positioner spindle, which rotates the feedback arm. The balance arm is now lowered by the reduced spring force and closes the flapper valve. An equilibrium position is thus reached and the valve being controlled is in the desired posi­tion.
Relay diaphragm
Venting
When the air pressure on the signal
Air is now ventilated from the actuator
To/from actuator
Air supply
8
6. Installation
Air supply requirements
Max. air supply pressure, see the section Technical Data on page 20.
The supply air must be free from moisture, water, oil, and particles.
The supply air must be dried or be treated in such a way that its dew point is at least 10°C (18°F) below the lowest expected ambient temperature.
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.
To ensure a stable and problem-free ope-
ration, 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 quality is the main source of
problems in pneumatic systems.
Mounting according to IEC 534-6
9
N.B. If the positioner is installed in a hazardous environment, it must be of a type approved for this purpose.
The 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 arm (C) is graduated in mm and
AB
inches. The scale is used to adjust the pin (D) so its position corresponds to the stroke of the valve stem.
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.
C D
10
Mounting instructions for P3/EP3 with mounting kit 30168S
Connections
11
Air:
Port S Supply air Port C+ Connection to actuator Port IPPneumatic input signal
(external I/P)
Electrical connection
Port I
E
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.
Direct / Reverse function
It is simple to adapt the positioner for direct or reverse function. Unscrew the flapper valve nozzle and reverse it, and change the mounting on the actuator. See figure page 12.
Electric input signal
4-20 mA
Data for air and electrical connections, see section Technical Data on page 20.
Flapper valve position
C+
Supply
Input 3-15 psi
12
Single action positioner
Actuator with closing spring, flapper nozzle set for reverse function
When the signal from the I/P unit increases, the pressure C+ to the actuator is increased. The valve stem moves upwards.
Actuator with closing spring, flapper nozzle set for direct function
When the signal from the I/P unit increases, the pressure C+ to the actuator is reduced. The spring forces move the valve stem downwards.
S C+
S C+
Actuator with opening spring, flapper nozzle set for reverse function
When the signal from the I/P unit increases, the pressure C+ to the actuator is increased. The valve stem moves downwards.
Actuator with opening spring, flapper nozzle set for direct function
When the signal from the I/P unit increases, the pressure C+ to the actuator is reduced. The spring forces move the valve stem upwards.
S C+
S C+
Electrical connections
On positioners with an integral I/P unit, the electric cables are connected to the terminals as shown in the figure.
Terminals in positioner EP3
+ –
13
Output signal from controller
+ –
Warning! In a hazardous
Hazardous areas
environment where there is a risk of explosion, electrical connections must comply with the relevant regulations.
copies of certificates for hazardous approvals.
Model code
A= Model no
PP3XX Linear positioner, Pneumatic EP3XX Linear positioner, Electropneumatic EP3IS Linear positioner, Electropneumatic, Intrin.Safe ATEX, IEC EP3EX Linear positioner, Electropneumatic, Explosion proof ATEX, IEC, FM
B= Function
S Single acting
C= Connections Air - Electrical
M 1/4" NPT - M20x1,5 N 1/4" NPT - 1/2" NPT
D= Surface treatment
U Powder epoxy, black
E= Spindle
05Male dia. 10 mm 39Male D type incl nut
F= Cover
PV PMV cover, black, no indicator
G= Input signal
3 3-15 psi 4 4-20 mA
H= Temperature
Z -40 to + 85 deg C
I= Option
X No gauge block M Gauge manifold 1/8" G N Gauge manifold 1/8" NPT
P3 - U- PV- Z
Please see www.pmv.nu/products/ for
PP3 EP3
Signs
Logotype
II 2G Ex ia IIC T6/T5/T4 NEMKO 08ATEX1144X
Intrinsically safe when installed according to document: IP-653
Type: E5-IS Input Signal: Input Pressure: Output Pressure: Temp. Range: Action:
Flowserve Sweden, Palmstierna International Solna Sweden www.flowserve.com
36
Type
0470
25
Prod. year:xxxx
14
Control drawing
7. Adjustments
Gain
Default settings
The positioner is supplied from the factory with default settings.
If the settings have been changed, the default settings can be reset as follows:
• Apply an input signal equivalent to maxi­mum stroke (100%).
• Screw in (clockwise) the setting screw A for gain to its bottom position.
• Unscrew (counter clockwise) the same screw until the actuator is at max. stroke and then a further 1/4 of a turn.
• Press on the flapper nozzle lightly (see arrow) to ensure that it is sealing properly.
• Adjust the input signal to approx. 50%. If resonance occurs, turn the setting screw A counter clockwise a little more. The adjusting screw for damping B can also be screwed in a little if necessary. However, this will slow down the actuator movements.
15
B
A
D
Setting the zero position and span
If the zero position and span have been changed, adjust them as follows:
• Apply an input signal equivalent to the zero position.
• Turn the setting screw C for zero position until the actuator is at its zero position.
• Apply the maximum input signal.
• Turn the adjusting screw D for range until the actuator moves to max. stroke
• Adjust the input signal again to minimum and check the zero position.
C
16
8. Maintenance/service
When service or rebuilding is required, it may be necessary to remove and refit various parts of the positioner. This is described on the following pages.
Valve block
The valve block is mounted on the base with three screws. It is sealed against the air ducts in the base with O-rings.
Remove the valve block as follows:
• Remove the spring from its attachment hole A in the balance arm.
• Unscrew the screws holding the block assy.
Cleanliness is essential when working with the positioner. Contamination in the air ducts will lead to operational disturbances. Do not disassemble the unit further than that described here.
Do not take the valve block apart because its function will be impaired.
Do not remove any screws other than those described here.
A
• Lift the lower edge of the valve block and pull it away from the base in the direction of the arrow in the figure.
• Check all the O-rings on the rear side of the valve block and replace if necessary.
• Refit in the reverse order.
Flapper nozzle
The flapper valve holder can be mounted in two different ways, depending on the required function. This is described on page
11. Change the function or replace the O­rings as follows:
• Unscrew the screws C and D and remove the holder E. Check both the O-rings and replace them if necessary.
• Replace the holder in the desired position and tighten the screws.
17
C
E
D
Gain screw
The sleeve F can be unscrewed to replace the O-ring G. Let the adjusting screw remain in the sleeve.
Integral I/P converter
The I/P converter can be removed if it is necessary to replace it, to replace the O-rings, or to rebuild the positioner.
• First unscrew the two screws H that hold the terminal block. Release part of the rubber seal so that the cables to the terminal block can be pulled free from the grommet and the terminal block can be pulled through.
• Remove the I/P unit with its cable and ter­minal block.
• Replace the O-rings if necessary and refit the I/P unit or the rebuilding parts.
F
G
H
18
Feedback arm / Spindle
The feedback arm is mounted on the spindle with a friction clutch comprising several disc springs. Remove the feedback arm/spindle as follows:
• Remove the circlip J, the washer K behind it, and the O-ring L.
• Release the spring from its upper attachment M.
• Pull out the spindle with the feedback arm.
Remove the feedback arm as follows:
• Clamp the spindle in such a way that its surfaces cannot be damaged.
• Undo the bolt N and remove the feedback arm and the seven disc springs O.
• Refit in the reverse order. The disc springs O must be fitted in the way shown in the figure below. Lubricate the O-ring L with silicone grease.
J, K, L
M
• Check whether there is any play on the spindle. If so, replace the teflon bushes P.
J K L O
PN
9. Trouble shooting
19
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 positioning.
Action
• Check air supply pressure and connection between positioner and actuator.
• Check input signal to positioner.
• Check output signal from I/P converter.
• Check mounting and connections of po­sitioner and actuator.
• Check function of diaphragm block.
• Check input signal.
• Check mounting and connections of po­sitioner and actuator.
• 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.
• Defect or leaking diaphragm block.
20
10. Technical data
Common data
Repeatability <0,3%
Air delivery Supply at 600 kPa 125 nl/min
Air delivery Exhaust at 600 kPa 125 nl/min
Air supply pressure range 140-600kPa
Gain % / % acc. to ISA S75 5 to 30 %/%
Temperature range -40°C to +85°C
Temperature sensitivity < 0.4% per 10°C
Stroke length 6 - 60 mm, option 3 mm
Other data
P3
Linearity <±1%
Hysteresis + Deadband <0.5%
Deadband <0.15%
Air consumption (depending on gain setting) 2-8 nl/min
Supply pressure sensitivity <0.20%
Input signal 0.2 - 1 bar (3 - 15 psi)
EP3
Linearity <±1.5%
Hysteresis + Deadband <1%
Deadband <0.2%
Air consumption (depending on gain setting) 4-10 nl/min
Supply pressure sensitivity <0.3%
Input signal 4 - 20 mA
EP3EX
Linearity <±1.5%
Hysteresis + Deadband <1%
Deadband <0.2%
Air consumption (depending on gain setting) 4-10 nl/min
Supply pressure sensitivity <0.3%
Input signal 4 - 20 mA
21
22
11. Spare Parts List
1
4 3 2
Pos. Part no. Description
1 E5-STD I/P Converter general purpose
1 E5-IS I/P Converter intrinsically safe
2 E3-EX I/P Converter explosion proof, incl bracket
3 P3-SP15 Air relay module, single acting
4 7-SP25B Cover incl screws
23
Palmstierna International AB
Korta Gatan 9 SE-171 54 Solna SWEDEN Tel: +46 (0) 8 555 106 00 Fax: +46 (0) 8 555 106 01 E-mail: infopmv@flowserve.com
www.pmv.nu
Germany
Flowserve Sperberweg 16 D-41468 Neuss GERMANY Tel: +49 (0) 2131 795 74 80 Fax: +49 (0) 2131 795 74 99 E-mail: pmvgermany@flowserve.com
UK
Flowserve Abex Road Newbury, Berkshire, RG14 5EY UK Tel: +44 (0) 1635 46 999 Fax: +44 (0) 1635 36 034 E-mail: pmvukinfo@flowserve.com
Scandinavia
Palmstiernas Svenska AB Box 21 663 21 Skoghall Sweden Tel: +46 (0)54 52 14 70 Fax: +46 (0)54 52 14 42 e-mail: info@palmstiernas.se
Italy
Flowserve Spa Via Prealpi, 30 20032 Cormano (Milano) ITALY Tel: +39 (0) 2 663 251 Fax: +39 (0) 2 615 18 63 E-mail: infoitaly@flowserve.com
USA, Mexico
PMV-USA 1440 Lake Front Circle, Unit 160 The Woodlands, TX 77380 USA Tel: +1 281 292 7500 Fax: +1 281 292 7760 E-mail: pmvusa@flowserve.com
Canada
Cancoppas Limited 2595 Dunwin Drive, Unit 2 Mississuga, Ont L5L 3N9 CANADA Tel: +1 905 569 6246 Fax: +1 905 569 6244 E-mail: controls@cancoppas.com
Asia Pacific Headquarters
Flowserve Pte Ltd. No. 12 Tuas Avenue 20 REPUBLIC OF SINGAPORE 638824 Tel: +65 (0) 687 98900 Fax: +65 (0) 686 24940 E-mail: fcdasiaprocess@flowserve.com
South Africa
Flowserve Unit 1, 12 Director Road Spartan Ext. 2 1613 Kempton Park, Gauteng SOUTH AFRICA Tel: +27 (0) 11 397 3150 Fax: +27 (0) 11 397 5300
The Netherlands
Flowserve Flow Control Benelux B.V Postbus 1501 4700 Roosendaal THE NETHERLANDS Tel: + 31 (0)165 598898 Fax: + 31 (0)165 555670
China
Flowserve Hanwei Building No. 7 Guanghua Road Chao Yang District 100004 Beijing CHINA Tel: +86 (10) 6561 1900 Fax: +86 (10) 6561 1899
FCD PMENIM0012-02
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