Flowserve PMV P4 User Manual

P4 • P5/EP5

alve Control System

IOM Instructions

Contents

1. Introduction ..............................................................................................4

2. Storage instructions..................................................................................6

PMV Positioner and feedback module storage and handling procedures ....6

Warehouse storage ........................................................................................ 6

Field storage .................................................................................................6

Pneumatic positioners...................................................................................6

Potential damage mechanism .......................................................................6

Storage Seal (P5/EP5) ..................................................................................7

3. Function.....................................................................................................8

4. Installation.................................................................................................9

Air requirements ........................................................................................... 9

Installation ....................................................................................................9

5. Connections .............................................................................................10

6. Cam adjustment......................................................................................12

7. Calibration ..............................................................................................13

Calibration procedure .................................................................................13

8. Indicator adjustment..............................................................................14

9. Front cover and indicator cover............................................................14

10. Dampers.................................................................................................15

11. I/P Unit (P5/EP5)...................................................................................16

12. How to mount the I/P Unit to the positioner unit (P5/EP5) ..............17

13. Maintenance .......................................................................................... 18

Pilot valve ................................................................................................... 18

Diaphragm ..................................................................................................19

Feedback spring..........................................................................................20

Balance arm ................................................................................................20

Lower arm ..................................................................................................21

O-rings ........................................................................................................ 22

Filter plug (EP5) .........................................................................................22

14. Feedback unit (P5 or EP5)...................................................................23

15. T r ouble shooting ...................................................................................24

16. Technical data .......................................................................................25

Dimensional drawing (P4)..........................................................................27

17. Spare parts, P4......................................................................................28

17. Spare parts, P5/EP5..............................................................................30

18. Certificates ............................................................................................34

Manufacturers declaration • Hersteller-Erklärung • Déclaration de fabricant

G B

Manufacturers declaration

in compliance with EC directive 89/ 392/ EEC, annex I I B and 89/ 336/ EEC.

We hereby confirm that the appliances described in this sheet has been manufactured in

compliance with the applicable standards and is intended for installation in a

machine/ application, and that commissioning is strictly prohibited until evidence has

been provided that the machine/ application in question is also in compliance

with EC directive 89/ 392/ EEC and 89/ 336/ EEC.

This manufacturers declaration is applicable to the following PMV-Positioner series:

P4, P5, EP5, F5.

Herstel ler-Erkärung

im sinne der EG-richtlinie 89/ 392/ EWG, A nhang I I B und 89/ 336/ EWG.

H iermit erklären wir, da§ die in diesem Blatt beschriebenen Geräte entsprechend den

gültigen Normen gebaut und zum Einbau in eine Maschine oder Applikation bestimmt

sind, sowie daß deren Inbetriebnahme so lange untersagt ist, bis festgestellt wurde, daß

diese Maschine/Applikation ebenfalls der EG-Richtlinie 89/ 392/ EWG und 89/ 336/

EWG entspricht. Diese H erstellererklärung hat für folgende PMV-Stellungsregler-Serien

Gültigkeit:

P4, P5, EP5, F5.

Déclaration de fabricant

au sens dela directive de la CE 89/ 392/ CEE, annexe I I B et CE/ 89/ 336/ CEE.

N ous déclarons par la présente que les appareils décrits sur cette page sont construits en

conformité avec les normes en vigueur et qu’ils sont destinés à être montés dans une

machine ou une application, nous déclarons également que leur mise en service est

interdite tant qu’il n’a pas été constaté que cette machine/application satisfait également à

la directive CE 89/ 392 CEE et CE/ 89/ 336/ CEE.

Cette déclaration de fournisseur est valable pour les types d’appareils PMV suivants:

P4, P5, EP5, F5.

Mr. Roland Wedebrand

President, Palmstiernas Instrument AB

Special Conditions for Safe Use

The enclosure is made of aluminium and any impact or friction caused by external objects shall be avoided in the application. Rubbing of the window with dry fabrics shall be avoided when the positioner is used in an hazardous atmosphere in order to avoid potentially incendive static discharges.

Always check www.pmv.nu for latest edition of manual.

1. Introduction

The P4 is a pneumatic valve positioner for double acting actuators, rotary or linear. It can also be used for single acting applications by simply plugging one of the outlet ports, C1 or C2.

ATEX: II 2 G

It features a standardized foot print, external zero adjustment, gold plated spool valve, positive internal pressure and a bright visible position indicator. The simple, sturdy design with few moving parts together with the well proven spool valve design provides long and trouble free operation. T ogether with the unit, a wide range of mounting kits are of fered for quarter turn and linear applications.

Calibration and set up is quick and simple, all done by thumb wheels. The unit requires a minimum of maintenance and the only tool needed is a flat screw driver.

For installation of gauges T-connectors are required.

Option

The base unit of the system is the pneumatic positioner, used in either single or double acting applications. P5 comes standard with built in dampers, a high gain spool valve assembly, gauge ports and an O-ring sealed housing. The housing utilizes a unique O-ring seal that can be adjusted to a sealed or drained position.

The modular design concept allows for easy addition of accessories such as I/P converter and/or a feedback package, both which are isolated from the basic pneumatic unit. These accessories can be factory or field mounted.

Ease of calibration and maintenance are built into to the design with easily accessible span and zero adjustment, and very simple parts replacement.

ATEX: II 2 GD

EP5

The EP5 has same features and benefits as the P5 positioner. It’s modular to suit several applications, General applications, intrinsically safe, explosion proof and fail freeze versions are offered.

Intrinsically Safe: ATEX: EEX ia IIC T4 II 1 GD

CSA, FM Class I, Div, Group ABCD

Explosion proof: ATEX: EEX d IIB+H2, T4-T6 II 2 GD

CSA, FM Div I, Class 1,2 & 3 Group BCDEFG

Fail Freeze I/P Module

Standard or I/S I/P-converter module

Explosion proof I/P module

Dome indicator

Gauges

P5 pneumatic positioner

Spindles

Mounting bracket

Mounting adapter plate

F5 feedback module

F5 Explosion Proof

2. Storage instructions

PMV Positioner and feedback module storage and handling pr ocedur es

PMV Positioners and feedback modules are precision instruments which should be stored and handled accordingly to avoid problems or damage.

Electropneumatic positioners/feedback modules contain electronic components which can be damaged by exposure to water. Appropriate precautions should be taken to protect units while in storage.

Warehouse storage

Stored in original PMV shipping containers, units should be stored in an environmentally controlled area, i.e. clean, cool (15-26°C, 60-80°F) and dry, out of direct sunlight or weather exposure.

Field storage

Note: Once the air supply to the positioner is connected and turned on, internal air bleed

will prevent the ingress of moisture and protect the unit from corrosion. It is recommended that the air supply be left on at all times.

• If units are installed immediately, turn, and leave on, the air supply.

• If positioners must be stored outdoors, tighten all covers which may have loosened in shipment, make sure all open enclosure entry points are sealed.

Feedback modules should have cover tightened and conduits entries sealed. Positioners/ Feedback modules should be wrapped and sealed air and watertight with desiccant inside the plastic, units should be securely covered with an opaque cover and not exposed to direct sunlight, rain or snow.

Pneumatic positioners

Units should have all ports sealed and be protected from direct exposure to weather. For long term storage (>1 month) or overseas shipment units should be protected with plastic and desiccant.

Potential damage mechanism

When units are stored in hot, humid climates, the daily heating/cooling cycle will cause air to expand/contract and be drawn in and out of the positioner/feedback housing.

Dependent on the local temperature variations, humidity and dew points and time in storage condensation could occur and accumulate inside on the I/P Converter causing erratic operation or failure due to water and corrosion. The potential for condensation damage is especially high in southern climates and aggravated if units are exposed to direct sunlight.

For further assistance, please contact you nearest PMV office.

Storage Seal (P5/EP5)

P5/EP5 is supplied with all enclosure entry points sealed.The seal is only a storage seal, not to be used as seal when P5/EP5 is in operation. If Storage Seal is removed or damaged, make sure all open enclosure entry points are proper resealed before further shipping or storage.

Use circular stickers marked I, S and OUT, supplied on Storage Seal or vapour proof tape.

Remove Storage Seal from connection block, mount positioner on actuator/valve, make connections according to section 5, (Page 10). Calibrate span and Zero according to section 7, (Page 13).

Clean any oil/debris off the connecting block, then reseal open enclosure entry ports, use circular stickers marked I, S and OUT, supplied on Storage Seal or vapour proof tape.

EP5

Follow P5 instructions as above. Remove Storage Seal for conduit entry IE, connect input signal cable and install proper cable gland to secure the units sealing.

IP5-SEAL

IP5 seal

P5-SEAL

P5 seal

3. Function

The P4 and P5/EP5 operates on a force balance principal. Force is originated by the signal pressure transmitted through a diaphragm on to the balance arm. The opposing force is achieved through the feedback spring and is proportional to the position of the lower arm.

The lower arm position is determined by the position of the cam which is secured to the spindle and connected to the actuator shaft thus providing the feedback from the actuator/ valve. When these two forces are equal, the balance arm and the spool in the pilot valve are in a neutral position — the complete unit is in a balanced position. Air is supplied to the pilot valve through port S, and controls the air flow through ports C1 and C2

Assume an equilibrium position.

An increased control pressure will deflect the diaphragm 1 down, compressing the feedback spring 3. The balance arm 2 moves the spool 7 in the pilot valve 8 furnishing supply air to the actuator, while at the same time air is exhausted from actuator and is vented to atmosphere through the pilot valve and the OUT port . W ith the increased supply air, the actuator rotates (or moves linearly) moving the positioner spindle 6. The spindle and cam 5 rotate, forcing the lower arm 4 upwards compressing the feedback spring 3. This motion will continue until the two forces are equal and the unit is in an equilibrium position.

7312

856 4

4. Installation

Air requirements

Maximum supply pressure is 1 MPa (150 psi). Supply air shall be clean, dry and free from oil, water, moisture, foreign parts and debris.

The air shall be freeze-dried or similar to a dew point of at least 10°C (18°F) below lowest expected ambient temperature.

A <40µ filter/regulator is recommended to be installed as close to P4/P5/EP5 as possible to ensure proper supply air quality.

Before making pneumatic connections to the positioner, it is recommended that the supply air lines are opened up and allowed to vent for 2-3 minutes to clear any debris from the line. It is further recommended that a large paper bag is used to collect any oil or humidity that may be present in the line during this purging, direct the air flow into the bag. Should exessive amounts of oil and/or humidity be present at this stage, a review of the pneumatic system should be carried out and the problem corrected.

Poor air quality is one of the major causes of pr emature failure of pneumatic equipment.

Installation

P4 and P5/EP5 mounts on to the actuator using either the ISO F05 holes 4 and a PMV ISO mounting kit or by using the optional mounting adaptor and screws 5 to mount P5 on to existing PMV mounting kits.

Proper alignment of the positioner spindle to the actuator shaft is very important since improper alignment can cause excessive wear and friction to the positioner.

P5/EP5 only

The spindle/positioner shaft assembly allows for quick and simple spindle changes. T o ensure the proper connection, the spindle 3 has a spring clip 2 that must be properly installed. A solid ”click” should be felt when assembling the two pieces insuring that the two flats 1 are engaged into the positioner shaft groove.

The spindle can be removed, by inserting two screwdrivers under the two tapered surfaces of the spindle and bending carefully. When the spring clip releases the spindle will eject.

P4/P5 P5/EP5

2 1

5 4

5. Connections

Air connections are tapped for 1/4" G or NPT male connectors and are clearly marked.

Gauge ports are for 1/8" G or NPT.

We recommend use of Loctite® 577 or similar user preferred for sealing.

Electrical connection on I/P unit accepts 1/2" NPT or PG 13,5 (M20) cable gland.

Port I Input instrument pneumatic signal 20-100kPa (3-15 psi) Port S Supply air, maximum 1 MPa (150 psi) Minimum 0,15 MPa

(21 psi) for EP5

Port C1, C2 Actuator connections (0,2-1 MPa). C2 opening port. For single acting operation plug port C1 for increasing signal to open valve. Plug C2 for decreasing (reverse) signal to open valve.

OUT Exhaust air port. Do not block! Exhaust filter optional. Port Ip Gauge port for pneumatic input signal. Port I

Port P Gauge port for I/P unit output pressure ( On the I/P unit)

Ports Ip, P, S, C1 and C2 are sealed with plugs. To install gauges, unscrew plugs and replace with gauges.

Input electric signal (4-20 mA) (On the I/P unit.)

P5/EP5 only

Port OUT is for venting the unit. All air from the positioner, actuator and I/P unit is vented to atmosphere through this port. Do not block this port. A high flow silencer or an exhaust pipe can be connected to this port to prevent foreign objects from entering and blocking the units exhaust. Connector in exhaust port must not have less than 9 mm (3/8“) orfice.

When using gases other than air for supply — Please contact PMV.

On EP5 (P5 with I/P unit installed) I/P unit is supplied with air from port S. Port’I is automaticly sealed off and protected. No connection shall be made to this port. See pages 13 and 14 for more information.

X = Port plugged

Direct function

6. Cam adjustment

With the cover and indicator removed, loosen the screw 1 and turn the cam locking nut 2 counterclockwise until the cam loosens. Adjust the cam 3 as desired making sure that the ball bearing 4 always is riding on an active lobe on the cam. To secure the cam, make sure that screw 1 is backed out from the locking nut 2 then finger tighten the locking nut and tighten screw 1. Install and adjust the indicator and reinstall cover.

correct

incorrect

1-2 mm (1/16")

7. Calibration

P4/P5/EP5 is when shipped from PMV precalibrated for 90 ±0,5 deg rotation, (can also be 30, 45 or 60 deg, see installed cam). For most applications the valve closed position is more critical than valve open position, most attention should be paid at valve closed position. Always start calibration procedure by applying 0 % input signal, then adjusting zero. P4/P5/EP5 is calibrated by turning thumb wheels 1 & 4.

Arrows on arm 5 indicate turning direction of thumb wheels.

< “+“ = Increase zero/span > “–“ = Decrease zero/span

Calibration procedure

Check cam seating, section 6 before starting calibration procedure.

1. Apply 0 % input signal (0% = 20 kPa/3 psi or 4 mA)

2. Wait for steady state.

3. Adjust zero by turning the silver (lower) thumb wheel 4 with finger or with screw- driver 7 from the outside.

4. Apply 100% input signal (100% = 100 kPa/ 15 psi or 20 mA)

5. Wait for steady state then memorize result.

6. Apply 0% input signal.

7. Adjust span if necessary. This is done by first loosing screw 2, then turning the yellow (upper) thumb wheel 1 “+“ or “–“ and finally tighten screw 2. Spring top must not be in contact with spring guide 3.

8. Check zero and adjust if needed.

9. Repeat steps 2 to 8 until desired calibration is achieved.

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