Palmstiernas D3 User manual

Manual

Digital

Positioner

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. Design................................................................................................................ 5

4. Variants............................................................................................................. 6

5. Function............................................................................................................ 7

Double action function ....................................................................................... 7

Single action function......................................................................................... 7

6. Installation........................................................................................................ 8

Air supply requirements ..................................................................................... 8

Mounting ............................................................................................................ 9

Connections ........................................................................................................ 10

Air ....................................................................................................................... 10

Electrical connection .......................................................................................... 10

Dimensions ......................................................................................................... 10

Single action positioner (Direct function) .......................................................... 11

Actuator with closing spring............................................................................... 11

Actuator with opening spring ............................................................................. 11

Double action positioner (Direct function)......................................................... 11

Double action actuator........................................................................................ 11

Electrical connections......................................................................................... 12

7. Control............................................................................................................. 14

Menus and pushbuttons ...................................................................................... 14

Other functions ................................................................................................... 14

Menu indicator.................................................................................................... 15

Menus ................................................................................................................. 15

Changing parameter values ................................................................................ 15

Menu system....................................................................................................... 16

First start ............................................................................................................. 17

8. Maintenance/service ........................................................................................ 37

Disassembling PMV D3 ..................................................................................... 37

Silencer ............................................................................................................... 39

Spindle adapter ................................................................................................... 39

Potentiometer...................................................................................................... 40

Transmitter boards .............................................................................................. 41

Disassembling PMV D3 Ex................................................................................ 44

Filter change ....................................................................................................... 45

Converting for remote control ............................................................................ 46

9. Trouble shooting .............................................................................................. 47

10. Technical data ................................................................................................ 48

Certificates.......................................................................................................... 48

11. Spare parts ..................................................................................................... 56

1. Introduction

The PMV D3 is a digital positioner de-

signed primarily for controlling adjustable

valves.

The positioner can be used with single or

double action actuators with either rotary or

linear movement.

The D3 can be equipped with modules

for feedback, limit switches, and a pressure

gauge block.

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 package moves when in operation and can cause personal injury or damage

if handled incorrectly.

• If the input signal fails or is switched off, the valve moves quickly to its end position.

• If the compressed air supply fails or is turned off, fast 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 a 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 move 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 because C- is

still under pressure even after the air supply is turned off.

• Always work in an ESD protected area when servicing the PCB´s. Make sure the

input signal is switched off.

• The air supply must be free from moisture, water, oil and particles.

The modules can be factory assembled

before delivery or fitted later.

The modules for feedback and limit

switches can contain the following:

Feedback 4-20 mA and one of the

following functions:

- Two mechanical contacts

- Two reed switches

- Two inductive sensors, DIN 19234

2. Storage

General

The PMV positioner is a precision in-

strument. Therefore it is essential that it is

handledand stored in theright way.Always

follow the instructions below!

N.B. As soon as the positioner is

connected and started, internal air leakage

will provide protection against corrosion

andprevent the ingress of moisture.Forthis

reason, the air supply pressure should

always be kept on.

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 connections

are properly sealed. 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 in a warm

place with a high relative humidity and is

subjectedto daily temperaturevariations, 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,andotherfactors, condensation and

corrosion can occur inside the unit, which in

turn can give rise to functional disorders or

a failure.

3. Design

Filter Display, control push buttons

Positional feedback Processor and motherboard

Terminal block

Adjusting-

screws,

damping

Valve block

The D3 positioner contains:

• Electronic board with microprocessor,

HART modem, display, etc.

• Valve block

• Positional feedback with potentiometer

• Sealed compartment for electrical

connections

The push buttons and display are

accessible underneath the aluminium

cover, which is sealed with an O-ring.

The figure shows the D3 with the cover

removed.

4. Variants

D3 270°deg.

D3 up to 270°deg for extended travel

range is available. It features all benefits and

options similar to the standard D3.

Communication with HART or Profibus is

possible.

D3 Explosion proof

The digital positioner D3 is available in

explosion proof enclosure. It features the

same easy to use user interface for local con-

figuration as D3. Communication with Hart

or Profibus is possible.

Further features are gauge ports and local

graphic LCD display.

D3 Intrinsically safe

The digital positioner D3 is available in

intrinsically safe version for installation in

hazardous areas. It features the same easy to

use user interface for local configuration as

D3. Communication with HART or Profibus

ispossible. It features all benefitsandoptions

similar to the Standard D3 positioner, gauge

block, local graphic LCD display and feed-

back option etc.

D3 remote mounted

The D3 with remote mount is now

available on the market for order. This ver-

sion is suitable for installations in severe

applications e.g. vibrations, high or low

temperature corrosive environment, high

mountings or difficult of access, etc. A flat

or dome style indicator can be fitted on the

feedback box installed on the actuator. Max

recommended distance between D3 and

remote unit is 5 m.

5. Function

Control signal 4 - 20 mA

Potentiometer

Piezo-valve 1

Piezo-valve 2

Diaphragm

Pressure

regulator

Replaceable

Filter

Air supply 2 - 6 bar

1.2 bar

Venting

Venting H

Double action function

The control signal and the feedback

potentiometer position are converted to di-

gital signals that are processed with a PID

algorithm in the microprocessor. This prov-

ides control signals to the two piezo-valves.

The two piezo-valves are closed in the

schematic diagram above and have no effect

on the valvesAand D.Air from the pressure

regulator is lead through the open valveAto

the valve B, which opens. The supply

pressure can now pass through valve B to

the actuator via H. The actuator then moves

in the direction of the arrow. At the same

Signal converter

and

microprocessor

DEF

➾

time, air from valve A keeps valve C open

and allows venting of the actuator.

When both the piezo-valves open, valve

A closes but valve D opens and controls

valves E and F to that the actuator moves in

a direction opposite to the arrow. When only

piezo-valve 1 is open, the actuator is

stationary.

Single action function

Valve B is used for the supply air and

valve F for venting.

C– C+

Actuator

6. Installation

Tubing

Use tubes with an inner diameter of mi-

nimum 6 mm (1/4”).

Air supply requirements

Max. air supply pressure, see the section

Technical Data, Section 10.

The air supply must be free from

moisture, water, oil, and particles.

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

filter/pressure regulator <40µas close to the

positioner as possible.

Before the air supply is connected to the

positioner, werecommendthe hose is opened

freely for 2 to 3 minutes to allow any con-

tamination 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.

WARNING! Do not direct the

open air jet towards people or

objects because it may cause

personal injury or damage.

Poor air supplies are the main source

of problems in pneumatic systems.

Mounting

N.B. If the positioner is installed in a

hazardous environment, it must be of a

type approved for this purpose.

The D3 positioner has an ISO F05

footprint, A. The holes are used to attach it

to the mounting bracket B, which is suitable

for most types of linear actuator.

The spindle adapter C can be changed to

suit the actuator in question.

Remove the existing adapter using two

screwdrivers. Check that the spring ring on

the positioner spindle is undamaged and fit

the new adapter.

Itisimportantthatthepositioner’s spindle

and the arms, that transfer the actuator

movements, are correctly mounted.Any ten-

sion between these parts can cause incorrect

operation and abnormal wear.

Assembly examples A B

Rotary movement Linear movement

C– S C+

For data for air and electrical

connections, see section

Technical Data on page 48.

Connections

Air:

Port S Supply air, 2-7 bar

Port C+ Connection to actuator

Port C- Connection to actuator

(only for double action)

Electrical connection

See page 12, 13.

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.

Must be plugged when converting to

single action function.

The D3 Ex positioner has an ISO F05

footprint, A. The holes are used to attach it

to the mounting bracket B, which is suitable

for most types of linear actuators.

The spindle adapter C can be changed to

suit the actuator in question, see previous

page.

Single action positioner

(Direct function)

Actuator with closing spring

When the control signal increases, the

pressure C+ to the actuator is increased. The

valve spindle moves upward and rotates the

positioner spindle counter-clockwise.When

the control signal drops to zero, C+ is vented

and the valve closes.

Actuator with opening spring

When the control signal increases, the

pressure C+ to the actuator is reduced. The

springs press the valve spindle upward and

the positioner spindle rotates counter-

clockwise. When the control signal drops to

zero, C+ is vented and the valve opens.

Double action positioner

(Direct function)

Double action actuator

When the control signal increases, the

pressure C+ to the actuator is increased. The

valve spindle 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+

C–

C+

C–

C+

Option

HART-

connection

14-20 mA + input signal

24-20 mA – input signal

3Switch 1 NO

4Switch 1 NC

5Switch 1 COM

6Switch 2 NO

7Switch 2 NC

8Switch 2 COM

9AUX input 4-20 mA +

10 AUX input 4-20 mA –

11 4-20 mA + Feedback, 10-28 V DC

12 4-20 mA – Feedback, 10-28 V DC

13 Alarm output +

14 Alarm output –

+ – + – + – + –

1234567891011 12 13 14

Remote-

unit

+ –

123456

345

Shielded cables,

grounded on the D3

Connecting a

remote unit

D3 The terminal block (below) for the posi-

tionerisaccessiblewhen the aluminium cover

and inner cover is removed, see Section 8.

Warning! In a hazardous

environment where there is a

risk of explosion, electrical

connectionsmust comply with

the relevant regulations.

Electrical connections

The diagrams show the terminal blocks

in D3 and D3 Ex.

Remote unit

The remote unit shall be connected

between terminals3, 4 and 5 in the D3 and 3,

4 and 5 in the remote unit. Use a shielded

cable and ground it in the D3 only. Max

recommended distance between D3 and

remote unit: 5 m.

Note!When converting D3/D3 Exforuse

with remote unit, some changes have to be

done inside the positioner, see Section 8.

When installing D3 Intrinsically safe unit, always consider cdwg D3-70.

14-20 mA + input signal

24-20 mA – input signal

3(Remote unit)

4(Remote unit)

5(Remote unit)

9AUX input 4-20 mA +

10 AUX input 4-20 mA –

11 4-20 mA + Feedback, 10-28 V DC

12 4-20 mA – Feedback, 10-28 V DC

13 Alarm output +, 8-28 V DC

14 Alarm output –, 8-28 V DC

Optional

D3 Ex

The terminal block (below) for the posi-

tioner is accessible when the terminal cover

is removed, see Section 8. Warning! In a hazardous

environment where there is a

risk of explosion, electrical

connectionsmust comply with

the relevant regulations.

7. Control

Menus and pushbuttons

Thepositioneriscontrolled using the five

pushbuttons and the display, which are

accessible when the aluminium 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 pushbuttonsto 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 16.

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.

To confirm selection or change of para-

meters.

MENU INDICATOR

Displays the position of the current menu

row in the menu.

ESC FUNC

BASIC MENU

MAN/AUTO

OUT OF SERVICE

MANUAL

UNPROTECTED

IN SERVICE

The positioner is following the input sig-

nal. This is the normal status when the posi-

tioner is working.

OUT OF SERVICE

The positioner is not following the input

signal. Critical parameters can be changed.

MANUAL

The positioner can be adjusted manually

using the pushbuttons. See section ”Man/

Auto”, page 21”.

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 ser-

vice” position.

Menu indicator

There are indicators at both sides of the

displaywindow and they indicate asfollows:

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:

- Basicmenu, which means you can browse

through four different steps

- Fullmenu,which comprises ten steps. Use

the Shift Menu to browse through the steps

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.

AchangecanbeundonebypressingtheESC

button, which returns you to the previous

menu.

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

PROTECTION

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.

BASIC MENU

CALIBRATE

First start

Calibrate in the basic menu is displayed

automatically the first time the positioner is

connected up, and can be selected from the

basic/main menu at any later time.

A complete calibration takes about 3

minutes and includes end limit calibration,

auto-tuning, leak test, and a check on the

speed of movement. Start the automatic

calibration by selecting Auto-Cal and then

answer the questions on the display by pres-

sing OK or the respective arrow. The menu

is described on the next page.

Calibration error messages

If a fault occurs during calibration, one

of the following error messages can be dis-

played:

Invalid movement/press ESC to abort

No movement because the air is

incorrectly connected, for example.After the

fault is corrected, the calibration sequence

must be restarted.

Pot unaligned/press ESC to abort

The potentiometer has been set to an il-

legal value. The potentiomenter is aligned

using the Calibrate - Expert cal - pot Menu.

The calibration sequence must be restarted

after the fault is corrected.

C+

(C–)

Clockwise = Increased damping/Less flow

CCW = Decreaseddamping/More flow

3 revsCCW = Max flow

Note! To much increased damping (low flow)

might cause irregular actuator function.

Air leak detected/ESC = abort

OK = go on

An air leak has been detected. The

calibrationsequence should be restartedafter

the fault is corrected.

Increase C- damper/ESC = abort

OK to retry

Increase C+ damper/ESC = abort

OK to retry

Speed of movement is too fast. Adjust

with the damper screws (see page 5). Press

OK. Repeat the adjustment and press OK

until the speed is correct. If there is an abort,

the calibration sequence must be restarted.

First start, Profibus

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.

Do never use the same number to more

than one unit. Install values in failsafe mode,

for communication when loss of signal.

Calibrate the unit.

GSD files are available at our homepage

www.pmv.nu

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).

Actuator? rotating Select for rotating actuator.

Actuator? linear Select for linear actuator.

Actuator single act Select for single act.

Actuator double act Select for double act.

Direction? direct Select for direct function.

Direction? reverse 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 50%, 25%,

12%, L, M, S Possibility to select a lower gain in steps.

L, M, S Preset values for L, M, S actuators

Factory set Resets all set values and enters Factory Mode. Should only

be used by authorized staff.

Note. Original P. I. D. will always be shown in display

BASIC MENU

CALIBRATE

AutoCal

Start tune

Actuator?

rotating

TravelCal

Start cal

Perform

normal

LOSE PREV

VALUE?OK?

CALIBRATE

TravelCal

LOSE PREV

VALUE?OK?

IN SERVICE

? Press OK

Direction?

direct

Direction?

reverse

Calibration in

progress

Calibration in

progress

Perform

Factory set

Perform

50%

25%

12%

Actuator?

linear

Actuator

single act

Actuator

single act

IN SERVICE

? Press OK

Set point LO: Use the calibrator set to 4 mA