Manual P4 - PMV Positioners

Manual P4 - PMV Positioners
Manual P4
PMV Positioner P4
–1–
Manufacturers declaration • Hersteller-Erklärung • Déclaration de fabricant
GB
Manufacturers declaration
in compliance with EC directive 89/392/EEC, annex II B.
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.
This manufacturers declaration is applicable to the following Positioner series:
P4.
D
Hersteller-Erklärung
im sinne der EG-richtlinie 89/392/EWG, Anhang II B.
Hiermit erklären wir, daß die in diesem Blatt beschriebenen Geräte entsprechend den gültigen
Normen gebaut und zum Einbau in eine Maschine oder Applikation bestimmt sind, und daß
deren Inbetriebnahme so lange untersagt ist, bis festgestellt wurde, daß diese
Maschine/Applikation ebenfalls der EG-Richtlinie 89/392/EWG entspricht.
Diese Herstellererklärung hat für folgende Stellungsregler-Serien Gültigkeit:
P4.
F
Déclaration de fabricant
au sens dela directive de la CE 89/392/CEE, annexe II B.
Nous 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 macine/application satisfait également
à la directive CE 89/392/CEE.
Cette déclaration de fournisseur est valable pour les types d'appareils suivants:
P4.
Mr. Jan-Eric Andersson
President, Palmstiernas Instrument AB
–2–
General storage and handling instructions
Positioner storage and handling procedures
Positioners are precision instruments which should be stored and handled accordingly to
avoid problems or damage.
Appropriate precautions should be taken to protect units while in storage.
Warehouse storage
Stored in original 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.
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 housing. Dependent on
the local temperature variations, humidity and dew points
and time in storage, condensation could occur and accumulate inside 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 retail office.
–3–
Contents
Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Introduction
Function
Air requirements
Installation
Connections and Cam setting
Calibration
Maintenance
5
6
7
7
8-9
10-11
12-15
Pilot valve
12
Feedback spring
13
Diaphragm
13
Balance arm
14
Lower arm
15
O-rings
15
Exploded drawing
Spare part list
Trouble shooting
Technical Data
Dimensional drawing
16
17
18
18
19
–4–
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.
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. Together with the unit, a wide range of mounting kits are
offered 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
blade screw driver.
For installation of gauges T-connectors are required.
Option
Option
–5–
2.
Function
The unit 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 feed back 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.
With 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.
I
S
7
8
1
3
5
2
6
4
–6–
3.
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. Bad air quality leads to inprecise control or
malfunction.
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 the
positioner as possible to ensure proper supply air quality.
4.
Installation
The unit features ISO F05 mounting foot print 4 and with the
additional enclosed mounting adapter 5, PMV standard foot print.
Mounting adapter 5 is fitted to the unit with two screws and makes it
easy to retrofit the unit on actuators with existing PMV positioners and
mounting kit.
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.
A loose fit between positioner spindle and actuator shaft leads to
imprecise control and excessive wear of the coupling.
5
4
–7–
5.
Connections and Cam setting
Air connections are tapped for 1/4" NPT or 1/4" G male connectors and
are clearly marked.
We recommend use of Loctite® 577 or similar user prefered for sealing.
Port I
Port S
Port C1, C2
Input instrument pneumatic signal 20-100kPa (3-15 psi)
Supply air, maximum 1 MPa (150 psi).
Actuator connections.
Direct function
Reverse function
I
S
C1
C2
I
S
C1
C2
O
Double acting
Double acting
Air to close
Air to close
Air to open
Air to open
I
C1
O
C
C1
I
S
X = Port plugged
I
C2
C2
C2
C1
C
S
S
Direct function
–8–
2
With the cover and indicator removed,
loosen the screw 1 and turn the cam
locking nut 2 counterclockwise until the
cam loosen. Adjust the cam 3 as desired
making sure that the ball bearing 4
always 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. Proceed with
calibration or cover.
")
1-2
mm
6
(1/1
1
correct
3
incorrect
4
Cam setting for direct action, increasing signal 0-100% (20-100 kPa, 3-15 Psi) to open.
Ball bearing to ride on loob D, 0-100%.
Cam setting for reverse action,
decreasing signal 100-0%
(100-20 kPa, 15-3 Psi) to open.
Ball bearing to ride on loob R,
0-100%.
Split range
Used to achieve a high resolution. Only a
portion of the signal is used to obtain full
travel. Example:
For 90 deg rotation, input signal 0-50%
(20-60 kPa, 3-9 Psi).
Ball bearing to ride on split range 0-50%
90 deg loob.
–9–
6.
Calibration
▲
▲
The unit is shipped from factory 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 much more critical than the valve open
position. Most attention should be paid at valve closed position. Always start calibration
procedure by applying 0 % input signal, then adjusting zero. The unit is calibrated by
turning thumb wheels 1 & 4.
Arrows on arm 5 indicates turning direction of thumb wheels.
"+" = Increase zero/span
3
"–" = Decrease zero/span
2
5
4
1
Span
Zero
6
7
– 10 –
Calibration procedure
1. Apply 0 % input signal (0% = 20 kPa, 3 psi)
2. Wait for steady state. It is important to wait for steady state, on
very large actuators it can take minutes to establish.
3. Adjust zero by turning the silver (lower) thumb wheel 4 with finger
or with screw driver 7 from the out side.
4. Apply 100% input signal (100% = 100 kPa, 15 psi)
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 and adjust zero.
9. Repeat steps 2 to 8 until desired calibration is achieved.
10. Make sure cover 6 is properly installed.
– 11 –
7.
Maintenance
Pilot valve
To remove the pilot valve for cleaning or inspection, remove the screw
1 and carefully lift out the complete assembly 2. Gently remove the
spool 3 from the block and clean the parts, using methylate cleaner or
similar. Blow the parts dry with compressed air.
Should the parts show signs of wear, a new assembly is recommended.
Mixing spool valves and valve bodies may result in very high bleed
rates and poor performance. Check the O-rings, then secure and install
the pilot valve assembly to the Positioner unit and secure it with the
screw 1. Make sure that the leaf spring 4 on the balance arm 5 is
properly fitted in the groove on the spool 6. Check again to insure
smooth operation of the assembly.
To maintain original factory performance specifications, use only spool
valve assemblies supplied from the factory.
3
6
5
2
4
1
– 12 –
Diaphragm
Loosen screws 1 and remove the diaphragm cover 2. Loosen screw 3,
diaphragm 4 and washers 5 can be removed. The diaphragm can after
have being in use look wrinkled, this is fully normal due to the tension
in it.
When installing the diaphragm make sure to place one washer on each
side of the diaphragm.
Put some Loctite 577 on the thread, install the screw 3 and tighten.
Check the O-ring for the diaphragm cover 2, install the O-ring into the
positioner housing, then install cover 2. Secure with screws 1. Torque
shall be 4,5 Nm (40 in-lbs).
2
3
1
5
4
– 13 –
Feedback spring
2
Once the front cover and
indicator are removed,
the feedback spring can
be easily accessed.
Hold the spring 1 from
the top, pull down and
out.
When installing, hold
the assembly at the top,
guide the lower part to
position on the zero
screw, then press down
until it fits easily under
the balance arm 2. Make
sure that the assembly is
aligned properly against
the lower arm and the
notch is engaged in the
tab on the balance arm 2.
1
3
Balance arm
The balance arm can
only be removed after
diaphragm and feedback spring have been
removed.
Loosen the screws 3 and
the balance arm can be
removed.
When installing the
balance arm make sure
that the leafspring 4 on
the underside of the
balance arm 5 is
properly engaged into
the groove 6 of the spool
in the pilot valve.
Tighten the two screws 3
holding the balance arm
to the positioner.
6
5
4
– 14 –
Lower arm
Once the front cover is removed, the lower arm can be easily accessed.
Remove the indicator, feedback spring and the cam.
Loosen screw 2 and remove twist stop 1.
Remove screw 3, lower arm 4, rod 5 and spring 6.
Check rod and lower arm for wear, replace if necessary. Clean the rod
and install it in the lower arm. The lower arm should move easily and
smoothly.
Install the lower arm and rod assembly into the positioner housing,
making sure that the spring 6 is attached properly to the lower arm
and positioner housing.
Secure the lower arm and rod assembly with the screw 3.
Check again that the lower arm moves smoothly.
Apply a small amount of grease or dry lubricant on the small tongue
on the lower arm, then install and secure the twist stop.
Install cam, feedback spring, indicator and front cover.
4
3
6
O-rings
2
1
5
With time and use, O-rings can become brittle. This can cause poor
operation and even failure of the positioner.
Always check O-rings when performing any work on the positioner
and replace bad O-rings.
A thin layer of silicon grease applied on the NBR (Black) O-rings
prolongs their life.
– 15 –
8.
Exploded Drawing
20
96.1
3
21
20
20
15
18
6
21
16
20
20
10
17
13
1
19
2
20
20
11
20
21
21
12
20
7
8
9
– 16 –
9.
Spare part list
96.1
DWG PMV
No
Part no
Description
Qty
1.
Housing
1
2.
3.
P4-xx
P4-7
Front cover
Diaphragm cover incl. O-ring
1
1
4.
5.
P5-8
P5-9
Diaphragm
Diaphragm washer
1
2
6.
7.
P5-10
P5-AS13/315
Balance arm
Feedback spring 3-15 Psi assembly
1
1
7.
8.
P5-AS13/630
P4-AS18
Feedback spring 6-30 Psi assembly
Lower arm assembly
1
1
9.
10.
P5-19
P5-20
Rod
Spring
1
1
11.
12.
P5-24
P4-AS25
Twist stop
Pilot valve incl. O-rings
1
1
13.
15.
P5-27
P5-31
Cam locking nut incl. screw
Mounting adapter incl. screws
1
1
16
17.
P5-32
P5-K1
Ball bearing
Cam K1 90°/180° Linear 0-100%,
1
17.
P5-Kxx
split range 0-50-100%
Cam special, K2-K10 (ConsultPMV)
1
1
18.
19.
P4-Cxx
12013
Spindle (Consult PMV)
Indicator Arrow type
1
1
20.
21.
P4-SCREW
Screw set
P4-SEAL NBR Seal and O-ring set NBR, Nitrile rubber.
Set
Remarks
N/A
(Green)
Set
Set
(4, 21)
– 17 –
10.
Trouble shooting
Note: All positioners are serialized. Please note down,
and provide the serial number when contacting the
factory for trouble shooting or service.
Signal change has no effect on the actuator position.
— Check indicator and screw.
— Check air supply to positioner and tubing to the
actuator.
— Check input signal to positioner.
— Check diaphragm for damage or leakage.
— Check pilot valve function.
— Check cam for correct setting.
11.
Signal change results in actuator running to end positions.
— Check coupling between positioner and actuator.
— Check cam position and locking screw.
— Check input signal.
Inaccurate positioning.
— Dirty or worn pilot valve.
— Defective or leaking diaphragm.
— Input signal fluctuates.
— Incorrect sizing of actuator.
— Valve/actuator "stiction".
— High valve/actuator breakaway torque.
— Loose cam.
Technical Data
Input Signal
Linearity (%)*
Hysteresis+deadband (%)*
Repeatability (%)*
Pressure gain at load 20% (%/%)
(kPa/kPa)
Air consumption at supply pressure:
0,6 MPa/87 Psi
Air delivery at supply pressure:
0,2 MPa/29 Psi
0,4 MPa/58 Psi
0,6 MPa/87 Psi
Supply Pressure
Temperature range
Connector threads
Weight std.
20-100 kPa/3-15 Psi (6-30 Psi optional)
0,7
0,8
0,5
20 %/% ISA 75.13 1989
300
8 nl/min
(0.31 SCFM)
140 nl/min (5.46 SCFM)
245 nl/min (9.55 SCFM)
350 nl/min (13.65) SCFM
Max 1 MPa/150 Psi
-20°C to +85°C (-4°F to 185°F)
1/4" NPT
0,9 kg/2 lbs
* % of full scale.
– 18 –
12.
Dimensional drawing
96.1
– 19 –
SUBSIDIARIES:
Palmstiernas Instrument 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: [email protected]
Internet: www.pmv.nu
PMV GmbH
Postfach 2310
D-41554 Kaarst
GERMANY
Tel: +49 (0) 2131 667 081/82
Fax: +49 (0) 2131 667 083
E-mail: [email protected]
Internet: www.pmv-germany.de
PMV-USA, Inc
1440 Lake Front Circle
Unit 160
The Woodlands, Texas 77380
USA
Tel: +1 281 292 7500
Fax: +1 281 292 7760
E-mail: [email protected]
Internet: www.pmvusa.com
Palmstiernas Svenska AB
Box 21
SE-663 21 Skoghall
SWEDEN
Tel: +46 (0) 54 52 14 70
Fax: +46 (0) 54 52 14 42
E-mail: [email protected]
Internet: www.palmstiernas.se
23745/2001.3 Ekvator
PMV Controls Ltd
Headlands Business Park
Ringwood
Hampshire BH24 3PB
ENGLAND
Tel: +44 (0) 1425 48 08 88
Fax: +44 (0) 1425 48 08 89
E-mail: [email protected]
Internet: www.pmv-controls.ltd.uk
(The information in this brochure is subject to change without notice.)
Distributor
(The information in this manual is subject to change without notice.)
– 20 –
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