InstallationOperation

Maintenance

P3/EP3Modular Linear Positioner

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Contents

1. Introduction ................................................................................................................... 3 Safety instruction ............................................................................................................... 32. Storage ............................................................................................................................ 4 General .............................................................................................................................. 4 Storage indoors .................................................................................................................. 4 Storage outdoors or for a longer period ............................................................................. 4 Storage in a warm place .................................................................................................... 43. Design.............................................................................................................................. 54. Variants ........................................................................................................................... 6 Standard designs ................................................................................................................ 6 Optional equipment ........................................................................................................... 65. Function .......................................................................................................................... 7 General .............................................................................................................................. 7 Increase in signal pressure ................................................................................................. 7 Decrease in signal pressure ............................................................................................... 76. Installation...................................................................................................................... 8 Air supply requirements .................................................................................................... 8 Mounting ........................................................................................................................... 9 Connections ..................................................................................................................... 11 Direct / Reverse function ................................................................................................. 11 Single acting positioner ................................................................................................... 12 Electrical connections ...................................................................................................... 13 Control drawing ............................................................................................................... 147. Adjustments .................................................................................................................. 15 Gain ................................................................................................................................. 15 Default settings ................................................................................................................ 15 Setting the zero position and span ................................................................................... 158. Maintenance/service .................................................................................................... 16 Valve block ...................................................................................................................... 16 Flapper nozzle ................................................................................................................. 17 Gain screw ....................................................................................................................... 17 Integral I/P converter ....................................................................................................... 17 Feedback arm / Spindle ................................................................................................... 189. Trouble shooting .......................................................................................................... 1910. Technical data ............................................................................................................ 2011. Spare Parts List .......................................................................................................... 22

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Safety instructionRead the safety instructions in this

manual carefully before using the product.The installation, operation, andmaintenance of the product must be doneby staff with the necessary training andexperience.

PMV P3 basic unit

1. IntroductionThe PMV P3 is a modular Positioner sys-

tem designed for use on control valves withlinear motion. The basic unit is the P3 posi-tioner, 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 pressure

PMV P3 withexplosion proof I/P

4

2. StorageGeneral

The PMV positioner is a precision in-strument. 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 original

packaging. The storage environment mustbe clean, dry and cool, (15 to 26°C,59 to 79°F).

Storage outdoors or for alonger period

If the positioner must be stored

outdoors, 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 warm

place 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.

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Figure shows P3 positioner with integral I/P converter and cover removed

3. Designlocated externally (explosion proof), seesection ”Variants”.

The adjusting screws and knobs areaccessible under the removable sealed alu-minium cover.

The P3 positioner comprises a basicmodule with a single acting valve block. Italso includes a sealed chamber with termin-als for the electrical input signals.

The I/P unit can be built into the mainhousing (as shown in the figure below) or

Spanadjustment

Adjustingscrew, gain

Adjusting screw,damping

Zero positionadjustment

Balance arm

Flapper nozzle

Feedback spring I/Pconverter

Electricalconnection

Feedback arm

C+

Supply

Input3-15 psi

➠

➠

6

4. VariantsStandard designs

P3/EP3 is available single acting.

I/P converter can be integral or locatedelsewhere.

P3Pneumatic, single acting, to be

connected to an external I/P converter.

EP3, EP3ISElectro-pneumatic, single , with integral

I/P converter. Intrinsically safe model alsoavailable.

EP3EXExplosion proof model, I/P converter

located in separate, sealed enclosure.

Optional equipmentP3 / EP3 positioner can be equipped

with connection blocks and pressure gaugesfor:

- input signal pressure- input air supply pressure- output pressure

P3/EP3

EP3 EX

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5. Function

Signal diaphragm Balance arm Flapper nozzle

To/fromactuator

Feedback arm

GeneralThe 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.

Relaydiaphragm

Signalpressure

Decrease in signal pressureWhen the air pressure on the signal

diaphragm 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 posi-tion.

Increase in signal pressureWhen the air pressure on the signal

diaphragm increases, the balance arm is pres-sed 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 posi-tion.

Single action

Plugvalve

Airsupply

Venting

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6. InstallationAir supply requirements

Max. 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 con-tamination to be blown out. Direct the air jetinto a large paper bag to trap any water, oil,or other foreign materials. If this indicates

that the air system is contaminated, it shouldbe properly cleaned.

To ensure a stable and problem-free ope-ration, 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.

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N.B. If the positioner is installed in ahazardous environment, it must be of atype approved for this purpose.

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.

The arm (C) is graduated in mm and

A B

C D

inches. The scale is used to adjust the pin(D) so its position corresponds to the strokeof the valve stem.

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.

Mounting according to IEC 534-6

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Mounting instructions for P3/EP3 with mounting kit 30168S

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Flapper valve position

Data for air and electricalconnections, see sectionTechnical Data on page 20.

Connections

Air:

Port S Supply airPort C+ Connection to actuatorPort I

PPneumatic input signal(external I/P)

Electrical connection

Port IE

Electric input signal

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 functionIt is simple to adapt the positioner for

direct or reverse function. Unscrew theflapper valve nozzle and reverse it, andchange the mounting on the actuator. Seefigure page 12.

C+

Supply

Input3-15 psi

➠

➠

4-20 mA

12

Single action positioner

Actuator with closing spring, flappernozzle set for reverse function

When 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 function

When the signal from the I/P unitincreases, the pressure C+ to the actuator isreduced. The spring forces move the valvestem downwards.

Actuator with opening spring, flappernozzle set for reverse function

When the signal from the I/P unitincreases, the pressure C+ to the actuator isincreased. The valve stem movesdownwards.

Actuator with opening spring, flappernozzle set for direct function

When the signal from the I/P unitincreases, the pressure C+ to the actuator isreduced. The spring forces move the valvestem upwards.

SC+

SC+

SC+

SC+

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+–

+–

Electrical connections

On positioners with an integral I/P unit,the electric cables are connected to theterminals as shown in the figure.

Warning! In a hazardousenvironment where there is arisk of explosion, electricalconnections must complywith the relevant regulations.

Terminals inpositioner EP3

Output signalfrom controller

Hazardous areas

Please see www.pmv.nu/products/ forcopies of certificates for hazardousapprovals.

SignsType

Flowserve Sweden, Palmstierna International Solna Sweden www.flowserve.com

0470

Intrinsically safe when installed

NEMKO 08ATEX1144X

according to document: IP-653

II 2G Ex ia IIC T6/T5/T4

Action:

Logotype

Type: E5-IS Input Signal: Input Pressure: Output Pressure: Temp. Range:

Pro

d. y

ear:

xxxx

36

25

Model codeA= Model no

P P 3 X X Linear positioner, Pneumatic E P 3 X X Linear positioner, ElectropneumaticE P 3 I S Linear positioner, Electropneumatic, Intrin.Safe ATEX, IECE P 3 E X Linear positioner, Electropneumatic, Explosion proof ATEX, IEC, FM

B= FunctionS Single acting

C= Connections Air - ElectricalM 1/4" NPT - M20x1,5N 1/4" NPT - 1/2" NPT

D= Surface treatmentU Powder epoxy, black

E= Spindle0 5 Male dia. 10 mm3 9 Male D type incl nut

F= CoverP V PMV cover, black, no indicator

G= Input signal3 3-15 psi4 4-20 mA

H= TemperatureZ -40 to + 85 deg C

I= OptionX No gauge blockM Gauge manifold 1/8" GN Gauge manifold 1/8" NPT

P 3 - U - P V - Z

PP3 EP3

14

Control drawing

15

7. Adjustments

Gain

Default settingsThe 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 maxi-mum 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 been

changed, 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.

➞

C

D

A

B

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8. Maintenance/service

When service or rebuilding is required,it may be necessary to remove and refitvarious parts of the positioner. This isdescribed on the following pages.

Valve blockThe valve block is mounted on the base

with 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.

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.

A

17

Flapper nozzleThe flapper valve holder can be mounted

in two different ways, depending on therequired function. This is described on page11. Change the function or replace the O-rings as follows:

• 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.

Gain screwThe sleeve F can be unscrewed to replace

the O-ring G. Let the adjusting screw remainin the sleeve.

Integral I/P converterThe 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 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 ter-minal block.

• Replace the O-rings if necessary and refitthe I/P unit or the rebuilding parts.

F

G

H

C

E

D

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Feedback arm / SpindleThe feedback arm is mounted on the

spindle 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:

• 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.

J, K, L

J K L O

P N

M

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9. Trouble shooting

Fault symptom

Change in input signal to positioner doesnot affect actuator position.

Change in input signal to positioner ma-kes actuator move to its end position.

Inaccurate positioning.

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 po-sitioner and actuator.

• Check function of diaphragm block.

• Check input signal.

• Check mounting and connections of po-sitioner 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 positioneron actuator.

• Defect or leaking diaphragm block.

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10. Technical dataCommon data

Repeatability <0,3%Air delivery Supply at 600 kPa 125 nl/minAir delivery Exhaust at 600 kPa 125 nl/minAir supply pressure range 140-600kPaGain % / % acc. to ISA S75 5 to 30 %/%Temperature range -40°C to +85°CTemperature sensitivity < 0.4% per 10°CStroke length 6 - 60 mm, option 3 mm

Other data

P3Linearity <±1%Hysteresis + Deadband <0.5%Deadband <0.15%Air consumption (depending on gain setting) 2-8 nl/minSupply pressure sensitivity <0.20%Input signal 0.2 - 1 bar (3 - 15 psi)

EP3Linearity <±1.5%Hysteresis + Deadband <1%Deadband <0.2%Air consumption (depending on gain setting) 4-10 nl/minSupply pressure sensitivity <0.3%Input signal 4 - 20 mA

EP3EXLinearity <±1.5%Hysteresis + Deadband <1%Deadband <0.2%Air consumption (depending on gain setting) 4-10 nl/minSupply pressure sensitivity <0.3%Input signal 4 - 20 mA

21

22

11. Spare Parts List

1

4 3 2

23

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

Pos. Part no. Description

FCD

PM

EN

IM00

12-0

2

GermanyFlowserveSperberweg 16D-41468 NeussGERMANYTel: +49 (0) 2131 795 74 80Fax: +49 (0) 2131 795 74 99E-mail: pmvgermany@flowserve.com

UKFlowserveAbex RoadNewbury, Berkshire, RG14 5EYUKTel: +44 (0) 1635 46 999Fax: +44 (0) 1635 36 034E-mail: pmvukinfo@flowserve.com

ScandinaviaPalmstiernas Svenska ABBox 21663 21 SkoghallSwedenTel: +46 (0)54 52 14 70Fax: +46 (0)54 52 14 42e-mail: info@palmstiernas.se

Palmstierna International ABKorta Gatan 9SE-171 54 SolnaSWEDENTel: +46 (0) 8 555 106 00Fax: +46 (0) 8 555 106 01E-mail: infopmv@flowserve.com

www.pmv.nu

ItalyFlowserve SpaVia Prealpi, 3020032 Cormano (Milano)ITALYTel: +39 (0) 2 663 251Fax: +39 (0) 2 615 18 63E-mail: infoitaly@flowserve.com

USA, MexicoPMV-USA1440 Lake Front Circle, Unit 160The Woodlands, TX 77380USATel: +1 281 292 7500Fax: +1 281 292 7760E-mail: pmvusa@flowserve.com

CanadaCancoppas Limited2595 Dunwin Drive, Unit 2Mississuga, Ont L5L 3N9CANADATel: +1 905 569 6246Fax: +1 905 569 6244E-mail: controls@cancoppas.com

Asia Pacific HeadquartersFlowserve Pte Ltd.No. 12 Tuas Avenue 20REPUBLIC OF SINGAPORE 638824Tel: +65 (0) 687 98900Fax: +65 (0) 686 24940E-mail: fcdasiaprocess@flowserve.com

South AfricaFlowserveUnit 1, 12 Director RoadSpartan Ext. 21613 Kempton Park, GautengSOUTH AFRICATel: +27 (0) 11 397 3150Fax: +27 (0) 11 397 5300

The NetherlandsFlowserve Flow Control BeneluxB.VPostbus 15014700 RoosendaalTHE NETHERLANDSTel: + 31 (0)165 598898Fax: + 31 (0)165 555670

ChinaFlowserveHanwei BuildingNo. 7 Guanghua RoadChao Yang District100004 BeijingCHINATel: +86 (10) 6561 1900Fax: +86 (10) 6561 1899