Flowserve P4 User manual

1
USER INSTRUCTIONS
Installation
Operation
Maintenance
P4, P5, EP5, APEX 7000
Pneumatic Positioners
FCD PMENIM0006-00-A5 12/18

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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Contents
1. Introduction 4
2. Storage instructions 6
3. Function 8
4. Installation 9
5. Connections 10
6. Cam adjustment 12
7. Calibration 13
8. Indicator adjustment 14
9. Front cover and indicator cover 14
10. I/P Unit (EP5/APEX 7000) 15
11. How to mount the I/P Unit to the positioner unit (P5/EP5) 16
12. Maintenance 17
13. Feedback unit (P5 or EP5) 22
14. Trouble shooting 23
15. Technical data 24
16. Spare parts 27
Apendix A 33

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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Warning!
Special Conditions for Safe Use
The enclosure is made of aluminum and impact or friction caused by external objects
shall be avoided in the application.
Rubbing of the windows with dry fabrics shall be avoided when the positioner is used in
an IIC atmosphere in order to avoid potentially incendive static discharges.
The ambient temperature range for the positioner is -20˚C <Ta 85˚C
The I/P converter has to be installed in an enclosure that satisfies the following clauses:
Complies with ”electrostatic charge” requirements in EN 60079-0, clause 7.4
A suitable degree of protection minimum IP20 according to 6.1 in EN 60079-11
Shall not contain by mass, more than, 7.5% in total of magnesium according to clause 8.1
in EN 60079-0
According to descriptive document: IP-653.
Shall withstand dielectric strength test with 500V AC for 1 minute according 6.3.12 in EN
60079-11.

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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1. Introduction
P4
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 flat screw driver.
For installation of gauges T-connectors are required.
Always check www.pmv.nu for latest edition of manual.
Option
Option

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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P5
The base unit of the system is the pneumatic positioner, used in either single or double acting
applications. P5 comes standard with a high gain spool valve assembly, gauge ports and an O-ring
sealed housing.
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.
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.
Explosionproof I/P module
Mounting
adapter
plate
P5 pneumatic positioner
Gauges
Spindles
Mounting bracket
F5 feedback module
Standard or I/S
I/P-converter
module
Fail Freeze
I/P Module
F5 Explosion Proof
Dome
indicator

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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2. Storage instructions
PMV Positioner and feedback module storage and handling procedures
PMV Positioners and feedback modules are precision instruments which should be stored and
handled accordingly to avoid problems or damage.
Electro-pneumatic 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 ofce.

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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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.
P5
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
P5 seal

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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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 1down, compressing the feedback spring
3. The balance arm 2moves the spool 7in the pilot valve 8furnishing 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 . With the increased supply air, the actuator rotates (or moves linearly)
moving the positioner spindle 6. The spindle and cam 5rotate, forcing the lower arm 4upwards
compressing the feedback spring 3. This motion will continue until the two forces are equal and the
unit is in an equilibrium position.
I7312
S4658

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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5 4
2
1
3
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. The air shall comply with standard: DIN/ISO 8573-1-2001 3.2.3.
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 excessive 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 premature 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. To 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

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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 IEInput electric signal (4-20 mA) (On the I/P unit.)
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.
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 Iis automatically sealed off and protected. No
connection shall be made to this port. See pages 13 and 14 for more
information.

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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C1
C2
S
C1
C2
S
C1
C2
S
III
Direct function
Air to open
Reverse function
Air to close
Spring
Return
Double
acting
Direct function
X = Port plugged

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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6. Cam adjustment
With the cover and indicator removed, loosen the screw 1and turn the cam locking nut 2
counterclockwise until the cam loosens. Adjust the cam 3as desired making sure that the ball
bearing 4always 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 2then finger tighten the locking nut and tighten screw 1. Install
and adjust the indicator and reinstall cover.
3
1
2 4
1-2 mm (1/16")
Correct
Incorrect
Splined cam
As an option it is possible to configure the P5 with a splined cam. This design improves how
the cam is engaged to the shaft and will improve performance. The splined cam will generate an
increased safety in critical applications. See order code for more information how to order.

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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7. Calibration
P4/P5/EP5 is when shipped from PMV pre-calibrated 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 5indicate 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
4with finger or with screw- driver 7from 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.
3
1
2
4
5
6
7
For calibration of APEX 7000 please see
appendix A Calibration Procedure APEX 7000

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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8. Indicator adjustment
P5/EP5: To adjust the indicator, take off front cover and pull the indicator upwards until it comes off
the Allen screw.
Before installing the indicator make sure that the Allen screw is tightened. Press the indicator on the
screw and adjust it by rotating clockwise to desired position.
P4: Loose screw, adjust indicator, tighten screw.
9. Front cover and indicator cover
The front cover of P5 is secured to the pneumatic unit with four captured screws and sealed with an
O-ring 1. The O-ring can be looped over notches 2in the front cover to allow for drainage. There are
eight locations on the front cover where the O-ring can be looped. This O-ring system is common
to the Pneumatic unit , I/P unit and Feedback unit in the PMV Valve Control System P5. This unique
sealing system allows for complete sealing or draining of the units by changing the position of the
O-ring.
The indicator cover 3is O-ring sealed and secured by a bayonet coupling. The indicator cover is
also used to secure the identification cover 4.
To remove the indicator cover turn it slightly counterclockwise until it loosens. Identification cover
and O-ring 5are now removable.
When installing indicator cover and identification cover make sure that the O-ring is properly
engaged.
4315
2
1

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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The I/P unit is mounted directly on top of the
positioner unit.
No external air supply is needed since the I/P
unit is supplied with air from the positioner
unit.
Port Ion the positioner unit will be plugged
when the I/P unit and the appropriate gauge
block gasket installed. The I/P unit accepts a
4-20 mA input signal.
The I/P unit is equipped with a built in 30
micron filter (Fig 4).
Caution: Do not operate the unit without filter
and filterplug installed.
Ensure that wiring between I/P and terminals
are properly seated in rubber clamp.
Do not unscrew filterplug when the positioner is
pressurized.
Span and Zero for the I/P converter is factory
set and can not be adjusted
Fig 3
Fig 1
Fig 2
Fig 4
Fig 5
Fig 6
10. I/P Unit (EP5/APEX 7000)
WARNING!
Units installed in hazardous areas must
have proper approvals.

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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11. How to mount the I/P Unit to the positioner unit (P5/EP5)
Switch off supply air and disconnect input signal – port I.
Loosen screws 3and remove connection block 1, the gauge or plug from port Ip, the fitting from
port Iand existing gasket 4. Carefully install gasket 6supplied together with I/P unit. When correct
installed port Iwill be blocked by the gasket.
Make sure that relief valve spring 5is installed properly. Install the connection block 1to the
positioner unit 2.
Remove cover on I/P unit.
Install the I/P unit to the top of the Positioner unit, making sure that the four O-rings are present
and properly seated. Tighten the unit with the three screws. (See fig. 1 and 2 page 16) Screw 1first,
screw 2last.
Connect input signal cable to port IEand tighten the cable gland (see fig 5 on page 16). Adjust the
O-ring on the I/P Unit housing to desired position - sealed or drained. (See fig 3 on page 16 or
section 9 on page 14).
A gauge indicating output signal from the I/P converter can be installed in port P. Make sure that the
filter plug is tightened before supply air is switched on (Fig 4 on page 16).
WARNING!
Units installed in hazardous areas must have proper approvals.
2
4
5
1
3
6

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12. Maintenance
Pilot valve
To remove the pilot valve for cleaning or inspection, remove the screw 1and carefully lift out
the complete assembly 2. Gently remove the spool 3from the block and clean the parts, using
methylate cleaner or similar. Blow the parts dry with compressed air. Install the spool into the pilot
valve housing, place it on a flat surface, then lift it carefully in one end. Before reaching 20 deg
angle the spool should slide by itself.
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 into positioner unit, press it towards the positioner
housing wall and secure it with screw 1. Make sure that the leaf spring 4on 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
by PMV.
3
2
1
65
4
<20 Deg

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Diaphragm
If P5 is equipped with I/P unit (EP5), the I/P unit must be removed to access the diaphragm. 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 3and tighten.
Make sure the diaphragm is centered.
Check the O-ring for the diaphragm cover 2, install the O-ring into the positioner housing, then install
cover 2. Secure crosswise with screws 1, first turn loosely. Torque shall be 4,5 Nm (40 in-lbs).

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Feedback spring
Once the front cover and indicator are removed,
the feedback spring can be easily accessed.
Hold the spring 1from 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.
Balance arm
The balance arm 3can only be removed after
I/P unit, diaphragm and feedback spring have
been removed. (See sections above and on
page 16, 18 and 19).
Loosen the screws 3and the balance arm can
be removed.
When installing the balance arm make sure
that the leafspring 4on the underside of the
balance arm 5is properly engaged into the
groove 6of the spool in the pilot valve. Tighten
the two screws 3holding the balance arm to the
positioner.
1
2
3
6
5
4

EP5 Electro Pneumatic Digital Positioner FCD PMENIM0006-00-A5 12/18
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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 2and remove twist stop 1.
Remove screw 3, lower arm 4, rod 5and 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 6is
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 on the small tongue on the lower arm, then install and secure the
twist stop.
Install cam, feedback spring, indicator and front cover.
P4
6
2
4
3
4
3
2
6
5
1
5
1
P5/EP5