P3/EP3 Modular Linear Positioner Operation Maintenance
P3/EP3Modular Linear PositionerInstallationOperationMaintenance
2Contents1. Introduction . 3Safety instruction . 32. Storage . 4General . 4Storage indoors . 4Storage outdoors or for a longer period . 4Storage in a warm place . 43. Design . 54. Variants . 6Standard designs . 6Optional equipment . 65. Function . 7General . 7Increase in signal pressure . 7Decrease in signal pressure . 76. Installation . 8Air supply requirements . 8Mounting . 9Connections . 11Direct / Reverse function . 11Single acting positioner . 12Electrical connections . 13Control drawing . 147. Adjustments . 15Gain . 15Default settings . 15Setting the zero position and span . 158. Maintenance/service . 16Valve block . 16Flapper nozzle . 17Gain screw . 17Integral I/P converter . 17Feedback arm / Spindle . 189. Trouble shooting . 1910. Technical data . 2011. Spare Parts List . 22
31. IntroductionThe PMV P3 is a modular Positioner system designed for use on control valves withlinear motion. The basic unit is the P3 positioner, which is available for single acting.The I/P converter can be integral, located ina separate mounted module (Ex), or locatedelsewhere. The P3 can be equipped withconnection blocks for pressure gauges toindicate:- actuator pressure- air supply pressure- input signal pressureSafety instructionRead the safety instructions in thismanual carefully before using the product.The installation, operation, andmaintenance of the product must be doneby staff with the necessary training andexperience.PMV P3 basic unitPMV P3 withexplosion proof I/P
42. StorageGeneralThe PMV positioner is a precision instrument. Therefore it is essential that it ishandled and stored in the correct way.Always follow the instructions below!N.B. As soon as the positioner isconnected and started, an internal air bleedwill provide protection against corrosionand prevent the ingress of moisture. For thisreason, the air supply should always be kepton.Storage indoorsStore the positioner in its originalpackaging. The storage environment mustbe clean, dry and cool, (15 to 26 C,59 to 79 F).Storage outdoors or for alonger periodIf the positioner must be storedoutdoors, it is important that all the coverscrews are tightened and that all connectionsare properly sealed. The unit should bepacked with a desiccant in a plastic bag orsimilar, covered with plastic, and not exposedto sunlight, rain, or snow.This is also applicable for long-termstorage (more than 1 month) and for longtransport by sea.Storage in a warm placeWhen a positioner is stored in a warmplace with a high relative humidity and issubjected to daily temperature variations, theair inside the unit will expand and contract.This means that air from outside the unitmay be drawn into the positioner. Dependingon the temperature variations, relativehumidity, and other factors, condensation andcorrosion can occur inside the unit, which inturn can give rise to functional disorders ora failure.
53. DesignThe P3 positioner comprises a basicmodule with a single acting valve block. Italso includes a sealed chamber with terminals for the electrical input signals.The I/P unit can be built into the mainhousing (as shown in the figure below) orI/PconverterFeedback springlocated externally (explosion proof), seesection ”Variants”.The adjusting screws and knobs areaccessible under the removable sealed aluminium cover.Balance armFeedback armFlapper nozzle C Supply Input3-15 psiAdjustingscrew, gainElectricalconnectionZero positionadjustmentAdjusting screw,dampingSpanadjustmentFigure shows P3 positioner with integral I/P converter and cover removed
64. VariantsStandard designsP3/EP3 is available single acting.I/P converter can be integral or locatedelsewhere.P3Pneumatic, single acting, to beconnected to an external I/P converter.P3/EP3EP3, EP3ISElectro-pneumatic, single , with integralI/P converter. Intrinsically safe model alsoavailable.EP3EXExplosion proof model, I/P converterlocated in separate, sealed enclosure.Optional equipmentP3 / EP3 positioner can be equippedwith connection blocks and pressure gaugesfor:- input signal pressure- input air supply pressure- output pressureEP3 EX
75. FunctionGeneralThe P3 positioner operates on the force balance principle. Changes are initiated by thesignal pressure from the I/P converter. The functionality is described briefly below.Single actionRelaydiaphragmFeedback armVentingSignalpressureSignal diaphragmTo/fromactuatorPlugvalveAirsupplyBalance armIncrease in signal pressureWhen the air pressure on the signaldiaphragm increases, the balance arm is pressed down and the flapper nozzle closes. Thepressure on the relay diaphragm thenincreases and the plug valve opens.Air is now supplied to the actuator, thespindle movement rotates the feedback arm,the balance arm is lifted, and the flappernozzle opens. The pressure on the relaydiaphragm is reduced and the plug valvereduces the air flow to the actuator. Anequilibrium position is thus reached and thevalve being controlled is in the desired position.Flapper nozzleDecrease in signal pressureWhen the air pressure on the signaldiaphragm is reduced, the balance arm islifted and the flapper nozzle opens. Thepressure on the relay diaphragm is thenreduced and the plug valve upper seal opensand vents.Air is now ventilated from the actuatorand its spindle moves. The actuatormovement goes back through the armmechanism (see figure) to the positionerspindle, which rotates the feedback arm. Thebalance arm is now lowered by the reducedspring force and closes the flapper valve. Anequilibrium position is thus reached and thevalve being controlled is in the desired position.
86. InstallationAir supply requirementsMax. air supply pressure, see the sectionTechnical Data on page 20.The supply air must be free frommoisture, water, oil, and particles.The supply air must be dried or be treatedin such a way that its dew point is at least10 C (18 F) below the lowest expectedambient temperature.Before the air supply is connected to thepositioner, we recommend the hose is openedfreely for 2 to 3 minutes to allow any contamination to be blown out. Direct the air jetinto a large paper bag to trap any water, oil,or other foreign materials. If this indicatesthat the air system is contaminated, it shouldbe properly cleaned.To ensure a stable and problem-free operation, we recommend the installation of afilter/pressure regulator 40µ as close to thepositioner as possible.WARNING. Do not direct theopen air jet towards people orobjects because it may causepersonal injury or damage.Poor air quality is the main source ofproblems in pneumatic systems.
9Mounting according to IEC 534-6N.B. If the positioner is installed in ahazardous environment, it must be of atype approved for this purpose.inches. The scale is used to adjust the pin(D) so its position corresponds to the strokeof the valve stem.The positioner has an ISO F05 footprint(A). The holes are used to attach it to themounting bracket (B), which is suitable formost types of linear actuators.It is important that the positioner’sspindle and the arms, that transfer theactuator movements, are correctly mounted.Any tension between these parts can causeincorrect operation and abnormal wear.The arm (C) is graduated in mm andABCD
10Mounting instructions for P3/EP3 with mounting kit 30168S
11Connections C Air:Supply airConnection to actuatorPneumatic input signal(external I/P)Electrical connectionPort IEElectric input signal Port SPort C Port IP4-20 mAData for air and electricalconnections, see sectionTechnical Data on page 20.DimensionsAir connections: 1/4" NPT alt. G 1/4"Electrical connection: M20 x 1.5 alt.NPT 1/2"Loctite 577 or equivalent isrecommended as a sealant.Flapper valve positionDirect / Reverse functionIt is simple to adapt the positioner fordirect or reverse function. Unscrew theflapper valve nozzle and reverse it, andchange the mounting on the actuator. Seefigure page 12.SupplyInput3-15 psi
12Single action positionerActuator with closing spring, flappernozzle set for reverse functionWhen the signal from the I/P unitincreases, the pressure C to the actuator isincreased. The valve stem moves upwards.Actuator with closing spring, flappernozzle set for direct functionWhen the signal from the I/P unitincreases, the pressure C to the actuator isreduced. The spring forces move the valvestem downwards.SC SC Actuator with opening spring, flappernozzle set for reverse functionWhen the signal from the I/P unitincreases, the pressure C to the actuator isincreased. The valve stem movesdownwards.SC Actuator with opening spring, flappernozzle set for direct functionWhen the signal from the I/P unitincreases, the pressure C to the actuator isreduced. The spring forces move the valvestem upwards.SC
13Output signalfrom controller –Terminals inpositioner EP3Electrical connections –On positioners with an integral I/P unit,the electric cables are connected to theterminals as shown in the figure.Hazardous areasWarning! In a hazardousenvironment where there is arisk of explosion, electricalconnections must complywith the relevant regulations.Please see www.pmv.nu/products/ forcopies of certificates for hazardousapprovals.Model codeA B C D E F G H I Model noPP3XXLinear positioner, PneumaticEP3XXLinear positioner, ElectropneumaticEP3ISLinear positioner, Electropneumatic, Intrin.Safe ATEX, IECEP3EXLinear positioner, Electropneumatic, Explosion proof ATEX, IEC, FMFunctionSSingle actingConnections Air - ElectricalM1/4" NPT - M20x1,5N1/4" NPT - 1/2" NPTSurface treatmentUPowder epoxy, blackSpindle05Male dia. 10 mm39Male D type incl nutCoverPVPMV cover, black, no indicatorInput signal33-15 psi44-20 mATemperatureZ-40 to 85 deg COptionXNo gauge blockMGauge manifold 1/8" GNGauge manifold 1/8" NPTP3-U-PV-PP3EP3ZSignsLogotypeFlowserve Sweden, Palmstierna International Solna Swedenwww.flowserve.com3625Intrinsically safe when installedaccording to document: IP-653Type:E5-ISInput Signal:Input Pressure:Output Pressure:Temp. Range:Action:Prod. year:xxxxII 2G Ex ia IIC T6/T5/T4NEMKO 08ATEX1144X0470Type
14Control drawing
157. AdjustmentsGainDefault settingsThe positioner is supplied from thefactory with default settings.If the settings have been changed, thedefault settings can be reset as follows: Apply an input signal equivalent to maximum stroke (100%). Screw in (clockwise) the setting screw Afor gain to its bottom position. Unscrew (counter clockwise) the samescrew until the actuator is at max. stroke andthen a further 1/4 of a turn. Press on the flapper nozzle lightly (seearrow) to ensure that it is sealing properly. Adjust the input signal to approx. 50%. Ifresonance occurs, turn the setting screw Acounter clockwise a little more. Theadjusting screw for damping B can also bescrewed in a little if necessary. However,this will slow down the actuator movements.Setting the zero position and spanIf the zero position and span have beenchanged, adjust them as follows: Apply an input signal equivalent to the zeroposition. Turn the setting screw C for zero positionuntil the actuator is at its zero position. Apply the maximum input signal. Turn the adjusting screw D for range untilthe actuator moves to max. stroke Adjust the input signal again to minimumand check the zero position. BADC
168. Maintenance/serviceWhen service or rebuilding is required,it may be necessary to remove and refitvarious parts of the positioner. This isdescribed on the following pages.Cleanliness is essential when workingwith the positioner. Contamination inthe air ducts will lead to operationaldisturbances. Do not disassemble theunit further than that described here.Do not take the valve block apartbecause its function will be impaired.Do not remove any screws other thanthose described here.Valve blockThe valve block is mounted on the basewith three screws. It is sealed against the airducts in the base with O-rings.Remove the valve block as follows: Remove the spring from its attachment holeA in the balance arm. Unscrew the screws holding the block assy. Lift the lower edge of the valve block andpull it away from the base in the direction ofthe arrow in the figure. Check all the O-rings on the rear side ofthe valve block and replace if necessary. Refit in the reverse order.A
17Flapper nozzleThe flapper valve holder can be mountedin two different ways, depending on therequired function. This is described on page11. Change the function or replace the Orings as follows:CED Unscrew the screws C and D and removethe holder E. Check both the O-rings andreplace them if necessary. Replace the holder in the desired positionand tighten the screws.FGain screwThe sleeve F can be unscrewed to replacethe O-ring G. Let the adjusting screw remainin the sleeve.GIntegral I/P converterThe I/P converter can be removed if it isnecessary to replace it, to replace the O-rings,or to rebuild the positioner. First unscrew the two screws H that holdthe terminal block. Release part of the rubberseal so that the cables to the terminal blockcan be pulled free from the grommet and theterminal block can be pulled through. Remove the I/P unit with its cable and terminal block. Replace the O-rings if necessary and refitthe I/P unit or the rebuilding parts.H
18Feedback arm / SpindleJ, K, LThe feedback arm is mounted on thespindle with a friction clutch comprisingseveral disc springs. Remove the feedbackarm/spindle as follows: Remove the circlip J, the washer K behindit, and the O-ring L. Release the spring from its upperattachment M. Pull out the spindle with the feedback arm.Remove the feedback arm as follows:M Clamp the spindle in such a way that itssurfaces cannot be damaged. Undo the bolt N and remove the feedbackarm and the seven disc springs O. Refit in the reverse order. The disc springsO must be fitted in the way shown in thefigure below. Lubricate the O-ring L withsilicone grease. Check whether there is any play on thespindle. If so, replace the teflon bushes P.JKLPON
199. Trouble shootingFault symptomChange in input signal to positioner doesnot affect actuator position.Action Check air supply pressure and connectionbetween 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.Change in input signal to positioner makes actuator move to its end position. Check input signal. Check mounting and connections of positioner and actuator.Inaccurate positioning. 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 positioneron actuator. Defect or leaking diaphragm block.
2010. Technical dataCommon dataRepeatabilityAir delivery Supply at 600 kPaAir delivery Exhaust at 600 kPaAir supply pressure rangeGain % / % acc. to ISA S75Temperature rangeTemperature sensitivityStroke length 0,3%125 nl/min125 nl/min140-600kPa5 to 30 %/%-40 C to 85 C 0.4% per 10 C6 - 60 mm, option 3 mmOther dataP3LinearityHysteresis DeadbandDeadbandAir consumption (depending on gain setting)Supply pressure sensitivityInput signal 1% 0.5% 0.15%2-8 nl/min 0.20%0.2 - 1 bar (3 - 15 psi)EP3LinearityHysteresis DeadbandDeadbandAir consumption (depending on gain setting)Supply pressure sensitivityInput signal 1.5% 1% 0.2%4-10 nl/min 0.3%4 - 20 mAEP3EXLinearityHysteresis DeadbandDeadbandAir consumption (depending on gain setting)Supply pressure sensitivityInput signal 1.5% 1% 0.2%4-10 nl/min 0.3%4 - 20 mA
21
2211. Spare Parts List1432
23Pos.Part no.Description1E5-STDI/P Converter general purpose1E5-ISI/P Converter intrinsically safe2E3-EXI/P Converter explosion proof, incl bracket3P3-SP15Air relay module, single acting47-SP25BCover incl screws
Palmstierna International ABKorta Gatan 9SE-171 54 SolnaSWEDENTel: 46 (0) 8 555 106 00Fax: 46 (0) 8 555 106 01E-mail: infopmv@flowserve.comwww.pmv.nuItalyFlowserve SpaVia Prealpi, 3020032 Cormano (Milano)ITALYTel: 39 (0) 2 663 251Fax: 39 (0) 2 615 18 63E-mail: infoitaly@flowserve.comSouth AfricaFlowserveUnit 1, 12 Director RoadSpartan Ext. 21613 Kempton Park, GautengSOUTH AFRICATel: 27 (0) 11 397 3150Fax: 27 (0) 11 397 5300UKFlowserveAbex RoadNewbury, Berkshire, RG14 5EYUKTel: 44 (0) 1635 46 999Fax: 44 (0) 1635 36 034E-mail: pmvukinfo@flowserve.comUSA, MexicoPMV-USA1440 Lake Front Circle, Unit 160The Woodlands, TX 77380USATel: 1 281 292 7500Fax: 1 281 292 7760E-mail: pmvusa@flowserve.comThe NetherlandsFlowserve Flow Control BeneluxB.VPostbus 15014700 RoosendaalTHE NETHERLANDSTel: 31 (0)165 598898Fax: 31 (0)165 555670ScandinaviaPalmstiernas Svenska ABBox 21663 21 SkoghallSwedenTel: 46 (0)54 52 14 70Fax: 46 (0)54 52 14 42e-mail: info@palmstiernas.seCanadaCancoppas Limited2595 Dunwin Drive, Unit 2Mississuga, Ont L5L 3N9CANADATel: 1 905 569 6246Fax: 1 905 569 6244E-mail: controls@cancoppas.comChinaFlowserveHanwei BuildingNo. 7 Guanghua RoadChao Yang District100004 BeijingCHINATel: 86 (10) 6561 1900Fax: 86 (10) 6561 1899Asia Pacific HeadquartersFlowserve Pte Ltd.No. 12 Tuas Avenue 20REPUBLIC OF SINGAPORE 638824Tel: 65 (0) 687 98900Fax: 65 (0) 686 24940E-mail: fcdasiaprocess@flowserve.comFCD PMENIM0012-02GermanyFlowserveSperberweg 16D-41468 NeussGERMANYTel: 49 (0) 2131 795 74 80Fax: 49 (0) 2131 795 74 99E-mail: pmvgermany@flowserve.com
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