Flowserve D30 User manual

®USER INSTRUCTIONS
Installation
Operation
Maintenance
D30 Compact Digital Positioner
FCD PMENIM0030-05-A5 - 12/15

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Contents
1 Introduction ....................................................................................................................................... 3
Safety instruction ............................................................................................................................... 3
2. Storage .............................................................................................................................................. 4
General ............................................................................................................................................... 4
Storage indoors.................................................................................................................................. 4
Storage outdoors or for a longer period ............................................................................................. 4
Storage in a warm place ..................................................................................................................... 4
3. Installation......................................................................................................................................... 5
Removal of covers.............................................................................................................................. 5
Tubing ................................................................................................................................................ 5
Air supply requirements ..................................................................................................................... 5
Mounting............................................................................................................................................ 6
Connections ....................................................................................................................................... 7
Single action positioner, Direct function and Reverse function........................................................... 8
Double action positioner, Direct function............................................................................................ 8
Mounting the positioner on ¼ turn actuators ..................................................................................... 9
Gauge block........................................................................................................................................ 9
Electrical connections......................................................................................................................... 10
Type signs .......................................................................................................................................... 11
D30 Digital Positioner model code ..................................................................................................... 12
4. Control ............................................................................................................................................... 13
Menus and pushbuttons..................................................................................................................... 13
Other functions................................................................................................................................... 13
Menu indicator ................................................................................................................................... 14
Menus ................................................................................................................................................ 14
Changing parameter values ................................................................................................................ 14
Menu system, Basic vs Full ................................................................................................................ 15
First start (with calibration sequence) incl. Profibus and Fieldbus...................................................... 16
Feedback option ................................................................................................................................. 20
Basic Menu Read................................................................................................................................ 22
Basic Menu Man/Auto ........................................................................................................................ 23
Basic Menu Shift, Full Menu Status.................................................................................................... 24
Full Menu Setup ................................................................................................................................ 25
Full Menu Tuning ............................................................................................................................... 27
Full Menu Alarms ............................................................................................................................... 28
Expert Calibration and Fact Set........................................................................................................... 30
Menu tree – graphical overview.......................................................................................................... 31
5. Maintenance/service ......................................................................................................................... 32
Disassembling D30............................................................................................................................. 32
Potentiometer..................................................................................................................................... 35
Transmitter boards ............................................................................................................................. 35
6. Trouble shooting................................................................................................................................ 36
7. Technical data ................................................................................................................................... 37
8. Dimensions........................................................................................................................................ 39
9. Spare parts ........................................................................................................................................ 40
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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. If any questions arise during installation, contact the supplier/sales office before
continuing work.
Warning
The valve can open or close very quickly when in operation and, if handled incorrectly, may
cause damages to fingers. There may also be unintentional effects due to it fully opening or
shutting off the flow in the process pipe. Please note the following:
• If the input signal fails or is switched off, the valve operates quickly to its default position.
• If the compressed air supply fails or is turned off, rapid movements can occur.
• The valve is not controlled by the input signals when in the Out of Service mode. It will open/
close in the event of an internal or external leak.
• If a high value is set for Cut off, fast movements can occur.
• When the valve is controlled in the Manual mode, the valve can operates quickly.
• Incorrect settings can cause self-oscillation, which can lead to damage.
Important
• Always turn off the compressed air supply before removing or disconnecting the air supply
connection or the integral filter. Remove or disconnect with care as air connection ”C-” is
still under pressure even after the air supply is turned off.
• Always work in an ESD (Emergency Shutdown) protected area when servicing the Printed
circuit boards (PCB´s). Make sure the input signal is switched off.
• The air supply must be free from moisture, water, oil and particles according to DIN/ISO
8573-1-2001 3.2.3.
delivery or fitted later.
The modules for feedback and limit switches
can contain 4-20 mA feedback and one of
the following:
• Two mechanical contacts
• Two proximity switches
• Two inductive sensors
See page 12 for more options available
1. Introduction
The D30 is a digital positioner designed
primarily for controlling modulating valves.
The positioner can be used with single or
double acting actuators with either rotary or
linear movement.
The D30 can be equipped with modules for
feedback, limit switches and pressure gauges.
Pressure sensors can be installed to offer
advanced diagnostics.
The modules can be factory assembled before
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2. Storage
General
The D30 positioner is a precision instrument.
Therefore it is essential that it is handled and
stored in the correct way. Always follow the
instructions in this IOM!
Note: As soon as the positioner is connected
and started, internal air venting will provide
protection against corrosion and prevent
the ingress of moisture. For this reason,
the air supply pressure should always be
kept on unless repair/maintenance work of
the positioner, actuator or valve equipment
is in progress.
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 open ports/connec-
tions are properly sealed and/or plugged.
The red shipping plugs are not intended as
a permanent outdoor plug. The unit should
be packed with a desiccant (silica gel) 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 the positioner is stored - without air
supply pressure applied - 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
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Tubing
It is recommended to use tubes with a mini-
mum inner diameter of Ø 6 mm (¼”).
Air supply requirements
Poor quality air supply is the main cause
of problems in pneumatic systems.
The air supply must be free from moisture,
water, oil and particles and delivered @ 1.4-8
bar (20-115 psi)
Standard: DIN/ISO 8573-1-2001 3.2.3
Filtered to 5 Micron, dew point -40°C/F
Oil 1mg/m³ (0,83 ppm by weight)
The air must come from a refrigeration dried
supply or be treated in such a way that its dew
point is at least 10°C (18°F) below the lowest
expected ambient temperature.
To ensure a stable and problem-free air
supply, we recommend the installation of a
coalescing filter/regulator <5µ as close to the
positioner as possible.
Before the air supply is connected to the po-
sitioner, we recommend the hose is opened
freely for 2 to 3 minutes to allow any conta-
mination 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 before continuing.
WARNING! Do not direct the
open air jet towards people or
objects because it may cause
personal injury or damage.
3. Installation
Removal of cover
General purpose / Intrinsically safe
Remove cover by first loosening the screw 1
and then the two screws 2.
To install cover, first tighten the screw 1, then
the two screws 2.
Tighten to 1.5 Nm ± 15%.
2
1
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Mounting
Note: If the positioner is installed in a
hazardous environment, it must be of a
type approved for this purpose.
All versions of the D30 positioner have an ISO
F05 footprint. The holes are used to attach the
D30 to the mounting bracket B. Please contact
PMV or your local distributor representative
with actuator specifics for the proper moun-
ting bracket and hardware.
The spindle shaft adapter C can be changed
to suit the actuator in question.
It is important that the positioner’s spindle
shaft and the lever arms, that transfer the
actuatormovements,are correctly mounted. Any
tension between these parts can cause incorrect
operation and abnormal wear.
Assembly examples A
C
C
Rotary movement Linear movement
Spindle shafts
S09 S23 S39
B
NOTE: There are many spindle options available depending
on the actuator. Please contact your local PMV supplier
for all options available.
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C+ C- S
For data on air and electrical
connections, see section
Technical Data on page 37/38.
Rotary actuators VDI/VDE 3485
(Namur)
Fit bracket on actuator and secure
with 4 x screws.
Mount positioner to bracket. Secure
with 4 x M6 screws using 2.5 Nm (1.8 lb ft)
torque.
Install tubing between actuator and
positioner.
Connections
Air:
Port S Supply air, 1.4-8 bar (20-115 psi)
Port C+ Connection to actuator, opening
Port C- Connection to actuator, closing
(only for double action)
Plug for single action, see below
Electrical connection
See page 10.
Dimensions
Air connections:
¼” NPT alt. G ¼”
Electrical connection:
M20 x 1.5 alt. NPT ½”
Loctite 577 or equivalent is recommended
as a sealant.
Must be plugged when converting to
single action function.
External air
Connection
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Single acting positioner, Direct function
Actuator with closing spring
When the control signal increases, the pres-
sure C+ to the actuator is increased. The
valve stem moves upward and rotates the
positioner spindle counter-clockwise. When
the control signal drops to zero, C+ is vented
and the valve closes.
Reverse function
Actuator with opening spring
When the control signal increases the press-
ure C+ to the actuator is increased. The valve
stem moves downward and the positioner
spindle rotates clockwise. When the control
signal drops to zero, C+ is vented and the
valve opens.
Double acting positioner,
Direct function
Double acting actuator
When the control signal increases, the pressure
C+ to the actuator is increased. The valve stem
is pressed upward and rotates the positioner
spindle counter-clockwise. When the control
signal is reduced, the pressure C- to the
actuator increases and the valve spindle
is pressed downward. If the control signal
disappears, the pressure goes to C-, C+ vents,
and the valve closes.
C+
C-
S
C+
C-
S
C+
C-
S
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Supply air should meet
requirements specified
on page 5. A coalescing filter/
regulator should be installed in
front of the supply air connection. Now
connect the air supply to the filter, which is
connected to the D30 positioner.
Mounting the positioner
After first attaching the correct mounting bracket
(not included) to the actuator,
mount the positioner to the bracket using 4
each M6 bolts using 2.5 Nm (1.8 lb ft) torque.
Ensure the positioner spindle is correctly
aligned with the actuator shaft.
Gauge block
Gauge blocks are available for D30s with
¼” G or ¼” NPT air connections. To install,
ensure seals are aligned, then use 3 Nm
(2.2 lb ft) of torque when fastening the
gauge block to the positioner using the two
screws supplied with the kit.
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Electrical connections
Terminal block diagram for the D30.
The terminal block (right) for the positioner
is accessible when the aluminum cover is
removed.
The D30 digital positioner has been designed
to operate correctly in electromagnetic (EM)
fields found in typical industrial environments.
Care should be taken to prevent the positio-
ner from being used in environments with
excessively high EM field strengths (greater
than 10 V/m). Portable EM devices such as
hand-held two-way radios should not be used
within 30 cm of the device.
Ensure proper wiring and shielding techniques
of the control lines, and route control lines
away from electro-magnetic sources that may
cause unwanted noise.
An electromagnetic line filter can be used to
further eliminate noise.
In the event of a severe electrostatic discharge
near the positioner, the device should be in-
spected to ensure correct operability. It may be
necessary to recalibrate the D30 positioner to
restore operation.
D30, 10 terminals
Warning! In a hazardous
environment where there is
a risk of explosion, electrical
connections must comply with
the relevant regulations.
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Type sign example
Area for logo type Type and model
Area for switch type
and terminals
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D30 Digital Positioner model code
* Contact PMV for additional versions
A = Model No.
D 30 Full LCD menu, LED status
B = Approvals / Certificate
D General purpose version
C = Air relay
H High Flow Spool Valve
D = Connections Threads
G ¼¨ G air, M20 x 1,5 electrical
M ¼¨ NPT air, M20 x 1,5 electrical
N ¼¨ NPT air, 1/2” NPT electrical
E = Connections Qty and Aux
2 2 Electrical conduits
T 2 Electrical conduits, threaded aux. ventilation
F = Housing material / Surface treatment
U Aluminum / Powder epoxy, black
G = Spindle / Mounting Options
09 Double D type, adaptor spindle
21 NAF Turnex including Mounting bracket
23 VDI/VDE 3845 rotary, Mounting kit not included
30 Adaptor spindle, select between 01/06/26/30/36
39 IEC 534-6, Flat D type, nut incl. Mounting kit not included
H = Cover / Indicator
P V A PMV, Black cover, Arrow indicator
P V D PMV, Black cover, Dome indicator
F W A Flowserve, White cover, Arrow indicator
F W D Flowserve, White cover, Dome indicator
I = Temperature Range
U -40°C to 80°C (-40°F to 176°F)
J = Input signal / Protocol
4 4-20 mA / none
5 4-20 mA / HART
K = Feedback option / Switches
X No feedback option
T 4-20 mA transmitter only
S Limit switches Mechanical SPDT
N Namur V3 type sensor, P+F NJ2-V3-N
P Limit switches Proximity SPDT
4 Slot type Namur sensor, P+F SJ2-S1N
5 Slot type Namur sensor, P+F SJ2-SN
6 Slot type Namur sensor, P+F SJ2-N
L = Options / Add-in electronics
0 Standard diagnostics
M = Accessories
X No accessories
M Gauge block ¼¨ G (3 gauges included / SST, Brass)
N Gauge block ¼¨ NPT (3 gauges included / SST, Brass)
N = Special Options
N No special options
S Exhaust silencers
A A A B C D E - F G G H H H - I J K L M N
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4. Control
Menus and pushbuttons
The positioner is controlled using the five
pushbuttons and the display, which are acces-
sible when the aluminum cover is removed.
For normal functioning, the display shows the
current value. Press the ESC button for two
seconds to display the main menu.
Use the pushbuttons to browse through
the main menu and the sub-menus.
The main menu is divided up into a basic menu
and a full menu, see page 15.
Other functions
ESC
Exit the menu without making any changes (as
long as any changes have not been confirmed
with OK).
FUNC
To select function and change parameters.
OK
To confirm selection or change of parameters.
MENU INDICATOR
Displays the position of the current menu row
in the menu.
IN SERVICE
The positioner is following the input signal.
This is the normal status when the positioner
is working.
OUT OF SERVICE
The positioner is not following the input signal.
Critical parameters can be changed.
ESC FUNC
OK
BASIC MENU
MAN/AUTO
OUT OF SERVICE
MANUAL
UNPROTECTED
MANUAL
The positioner can be stroked manually using
the pushbuttons. See section “Man/Auto”,
page 23.
UNPROTECTED
Most of the parameters can be changed when
the positioner is in the “Unprotected” position.
However, critical parameters are locked when
the positioner is in the “In service” position.
LED BLINK CODES
LED color (R = red, Y = yellow, G = green)
Codes during In Service:
R Actual valve position deviates from requested/set position
G Y Fully open/closed valve using Cut Off (=OK)
G Controlling valve position (=OK)
Calibration alarms:
R G
No feedback movement. Check linkage from actuator to positioner.
R Y No air available. If air relay doesn´t work, check black/red
cable inside.
R G G No pot connection. Check pot cable inside positioner.
R Y Y
No air relay sensor. Check yellow/black/red cable inside positioner.
R Y G Pot not calibrated. Calibrate->ExpertCal->Pot.
R R Y
Air relay problem. Replace it (located below positioner motherboard).
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Menu indicator
There are indicators at both sides of
the display window and they indicate as
follows:
Flashing in position Out of service
Flashing in position Manual
Displayed in position Unprotected
The indicators on the right-hand side show
the position in the current menu.
Menus
To display the menus you can select:
- Basic menu, which means you can browse
through four different menu items
- Full menu, which comprises ten steps.
Use the Shift Menu to browse through the
menu items
Full Menu can be locked out using a passcode.
The main menus are shown on the next page
and the sub-menus on the subsequent pages.
FULL MENU
CALIBRATE
FULL MENU
MAN/AUTO
FULL MENU
SHIFT MENU
Changing parameter values
Change by pressing until the desired
figure is flashing.
Press to step to the desired figure.
Confirm by pressing OK.
A change can be undone by pressing the ESC
button, which returns you to the previous
menu.
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BASIC MENU
READ
BASIC MENU
MAN/AUTO
BASIC MENU
CALIBRATE
BASIC MENU
SHIFT MENU
FULL MENU
READ
FULL MENU
MAN/AUTO
FULL MENU
CALIBRATE
FULL MENU
SHIFT MENU
FULL MENU
STATUS
FULL MENU
SETUP
FULL MENU
TUNING
FULL MENU
ALARMS
FULL MENU
FACT SET
Menu system
The menus are described
on the following pages.
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BASIC MENU
CALIBRATE
First start
“Calibrate” is displayed in the basic menu
automatically, the first time power is applied.
It can be selected from the basic or full menu
at any time.
A complete auto-calibration takes up to 10
minutes depending on size of actuator and
includes end limit calibration (zero and span),
auto-tuning (dynamically sets the control
parameters for the actuated package the
positioner is controlling) and a check of the
movement speed. Start the automatic calibra-
tion by selecting Auto-Cal and then answer
the questions in the display by pressing OK or
the respective arrow. More detail about these
questions can be found on page 19.
Calibration error messages
If a fault occurs during calibration, one of the
following error messages can be displayed:
No movement/press ESC to abort
Typically the result of an air delivery issue to
the actuator, a stuck valve or actuator, or in-
correct mounting and/or linkage arrangement.
Check for proper supply air to the positioner,
pinched tubing, proper actuator sizing, proper
linkage and mounting arrangement.
Pot uncalibrated/press ESC to abort
The potentiometer is out of range. The poten-
tiomenter is aligned using the Calibrate - Ex-
pert cal - pot Menu. The calibration sequence
must be restarted after the fault is corrected.
Tip! Instant quick calibration
The D30 can be instantly calibrated by pres-
sing the top + bottom buttons for 5 seconds
(see picture). This function is available from
any menu position.
First start, Profibus PA
For Profibus PA, connect the input signal
at pos 1 and 2 on the terminal block. See
Electrical connections in the manual.
In the SETUP/Devicedata/Profibus: change
the address from 126 to any number between
1-125.
Never use the same number with more than
one unit. Install values in failsafe mode, for
communication when loss of signal.
Calibrate the unit.
GSD files are available at our web-page
www.pmv.nu
To install the D30_PROFIBUS.DDL file to
Siemens SIMATIC PDM.
1. Move the files to the directory where the
DeviceInstall.exe is located.
2. Run DeviceInstall.exe
For Expert Calibration
parameters - see page 30!
Instant quick calibration
For further information on
calibrating the pot - see page 35
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Parameter Description BYTE
SP Setpoint The SP has 5 bytes, 4 bytes for the float value 4+1=5
and one status byte. The status byte needs to be
128 (0x80Hex) or higher for the D30 to accept it.
READBACK Position The READBACK has 5 bytes, 4 bytes for the 4+1=5
float value and one status byte.
POS_D Digital position Returns actual position as a digital value with 2
definitions as below
0 = Not initialized
1 = Closed
2 = Opened
3 = Intermediate
CHECKBACK Detailed information of the device, coded bit wise. 3
Several messages can occur at the same time.
RCAS_IN Remote Cascade The RCAS_IN has 5 bytes, 4 bytes for the 4+1=5
float value and one status byte.
RCAS_OUT Remote Cascade The RCAS_OUT has 5 bytes, 4 bytes for 4+1=5
the float value and one status byte.
Status Byte Table
MSB LSB Meaning D30 info
0 0 0 0 1 0 x x Not connected
0 0 0 0 1 1 x x Device failure PROFIbus PA module failure
0 0 0 1 0 0 x x Sensor failure No sensor value
0 0 0 1 1 1 x x Out of service AI Function Block in O/S mode
1 0 0 0 0 0 x x Good - Non cascade Measured value OK
All Alarm values used
1 0 0 0 0 0 0 0 OK
1 0 0 0 1 0 0 1 Below low limit Lo Advisory alarm
1 0 0 0 1 0 1 1 Above high limit Hi Advisory alarm
1 0 0 0 1 1 0 1 Lo-Lo Critical alarm
1 0 0 0 1 1 1 1 Hi-Hi Critical alarm
Example SP = 43.7% and 50%
Float Hex Status
43.7 42 2E CC CD 80
50.0 42 48 00 00 80
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(FF) Foundation Fieldbus function
blocks
Function blocks are sets of data sorted by
function and use. They can be connected to
each other to solve a control process, or to a
controlling DCS. To get a good introduction
and understanding of FF look at www.fieldbus.
org and download the “Technical Overview”
from the About FF pages.
(TB) Transducer Block
The TB contains unit specific data. Most of the
parameters are the same as parameters found
on the display. The data and the order of data
varies between different products.
The AO-block setpoint (SP) and process value
(PV) parameters are transceived to the TB
through a channel. The TB has to be in AUTO
for the AO-block to be in AUTO.
The positioner has to be in menu-auto mode
and in service to be controlled from the
fieldbus.
If the positioner is placed in menu-manual
mode then the transducer block will be forced
to (LO) local override. In this way a person in
the field will be able to control the positioner
from the keypad, without collision with a
control loop.
(RB) Resource Block
The RB is a set of parameters that looks the
same for all units and products. The values of
the RB define unit information that concerns
the Fieldbus Protocol such as
MANUFAC_ID which informs the unique
manufacturer id. For Flowserve it is 0x464C53.
The RB has to be in AUTO for the AO-block
to be in AUTO.
(AO) Analogue Output Block
The AO follows Fieldbus Foundation’s stan-
dard on content and action. It is used for
transferring (SP) setpoints from the bus to
the positioner.
CAS_IN (cascade input) and RCAS_IN (remo-
te cascade input) are selected as inputs to the
AO block depending on the MODE_BLK para-
meter. The selected input will be relayed to the
SP parameter of the AO block. BKCAL_OUT
(back calculated output) is a calculated output
that can be sent back to a controlling object
so that control bumps can be avoided. Usually
the BKCAL_OUT is set to be the (PV) process
value of the AO-block, i.e. the actual measured
position of the valve.
OUT is the primary calculated output of the
AO block. During a limited action (ramping)
of the AO block the RCAS_OUT parameter
will supply the final setpoint and the OUT
parameter will be the limited output.
The transducer block is connected through a
channel to the AO block. Through this channel
the OUT value and SP are transceived.
In order to set the AO block to AUTO, the TB
and the RB have to be in AUTO. Further the
AO block has to be scheduled. Using National
Instruments Configurator; scheduling can be
done by adding the unit to a project and then
click on the “upload to device” icon.
To write a setpoint value by hand, add Man
to MODE->Permitted parameter, and then
choose MODE->Target to Man. Make sure
that the unit is scheduled.
Example
A typical FF block loop control might look like
the following:
Where the positioner is represented by the
AO-block.
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The contents of the menu are shown on the next page. The various menu texts are described
below.
Auto-Cal Auto-tuning and calibration of end positions
Start tune Starts the tuning. Questions/commands are displayed during
calibration. Select the type of movement, function, etc. with
and confirm with OK as shown in the chart on the next
page.
Lose prev value? OK? A warning that the value set previously will be lost (not during
the first auto-tuning).
Direction? Air-to-open. Select for direct function.
Direction? Air-to-close. Select for reverse function.
In service? Press OK Calibration finished. Press OK to start positioner functioning.
(If ESC is pressed, the positioner assumes the ”Out of service”
position but the calibration is retained).
TravelCal Calibration of end positions
Start cal Start end position calibration.
Lose prev value? OK? A warning that the previously set value will be lost.
Confirm with OK.
The calibration sequence starts.
In service? Press OK Calibration finished. Press OK to start positioner functioning.
(If ESC is pressed, the positioner assumes the ”Out of service”
position but the calibration is retained).
Perform Setting gain
Normal 100% gain
Perform G, F, E D,
C, B, A Possibility to select a lower gain in steps.
Note. Original P. I. D. will always be shown in display
BASIC MENU
CALIBRATE
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Feedback option
When installing the transmitter/switch card, make sure it is placed correctly over
the connector pins before gently pushing it down until it rests on the supports.
Secure the PC board with the two screws. Make sure the holes are centred before
tightening the screws.
Note! When installing the cam assembly for mechanical switches, retract both
switch arms first.
Install the cam assembly and tighten the screws loosely to obtain enough friction
to lock the cams.
Adjust the lower cam first, then the upper cam.
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