PALMSTIERNAS PMV P4 User manual

IOM Instructions
P4 • P5/EP5
alve Control System

2
Contents
1. Introduction ..............................................................................................4
2. Storage instructions..................................................................................6
PMV Positioner and feedback module storage and handling procedures ....6
Warehouse storage ........................................................................................6
Field storage .................................................................................................6
Pneumatic positioners...................................................................................6
Potential damage mechanism .......................................................................6
Storage Seal (P5/EP5) ..................................................................................7
3. Function.....................................................................................................8
4. Installation.................................................................................................9
Air requirements ...........................................................................................9
Installation ....................................................................................................9
5. Connections .............................................................................................10
6. Cam adjustment......................................................................................12
7. Calibration ..............................................................................................13
Calibration procedure .................................................................................13
8. Indicator adjustment..............................................................................14
9. Front cover and indicator cover............................................................14
10. Dampers.................................................................................................15
11. I/P Unit (P5/EP5)...................................................................................16
12. How to mount the I/P Unit to the positioner unit (P5/EP5) ..............17
13. Maintenance ..........................................................................................18
Pilot valve ...................................................................................................18
Diaphragm ..................................................................................................19
Feedback spring..........................................................................................20
Balance arm ................................................................................................20
Lower arm ..................................................................................................21
O-rings ........................................................................................................22
Filter plug (EP5) .........................................................................................22
14. Feedback unit (P5 or EP5)...................................................................23
15. Trouble shooting ...................................................................................24
16. Technical data .......................................................................................25
Dimensional drawing (P4)..........................................................................27
17. Spare parts, P4......................................................................................28
17. Spare parts, P5/EP5..............................................................................30
18. Certificates ............................................................................................34

3
Manufacturers declaration • Hersteller-Erklärung • Déclaration de fabricant
G B
Manufacturers declaration
in compliance with EC directive 89/ 392/ EEC, annex I I B and 89/ 336/ EEC.
We hereby confirm that the appliances described in this sheet has been manufactured in
compliance with the applicable standards and is intended for installation in a
machine/ application, and that commissioning is strictly prohibited until evidence has
been provided that the machine/ application in question is also in compliance
with EC directive 89/ 392/ EEC and 89/ 336/ EEC.
This manufacturers declaration is applicable to the following PMV-Positioner series:
P4, P5, EP5, F5.
D
Herstel ler-Erkärung
im sinne der EG-richtlinie 89/ 392/ EWG, A nhang I I B und 89/ 336/ EWG.
H iermit erklären wir, da§ die in diesem Blatt beschriebenen Geräte entsprechend den
gültigen Normen gebaut und zum Einbau in eine Maschine oder Applikation bestimmt
sind, sowie daß deren Inbetriebnahme so lange untersagt ist, bis festgestellt wurde, daß
diese Maschine/Applikation ebenfalls der EG-Richtlinie 89/ 392/ EWG und 89/ 336/
EWG entspricht. Diese H erstellererklärung hat für folgende PMV-Stellungsregler-Serien
Gültigkeit:
P4, P5, EP5, F5.
F
Déclaration de fabricant
au sens dela directive de la CE 89/ 392/ CEE, annexe I I B et CE/ 89/ 336/ CEE.
N ous déclarons par la présente que les appareils décrits sur cette page sont construits en
conformité avec les normes en vigueur et qu’ils sont destinés à être montés dans une
machine ou une application, nous déclarons également que leur mise en service est
interdite tant qu’il n’a pas été constaté que cette machine/application satisfait également à
la directive CE 89/ 392 CEE et CE/ 89/ 336/ CEE.
Cette déclaration de fournisseur est valable pour les types d’appareils PMV suivants:
P4, P5, EP5, F5.
Mr. Roland Wedebrand
President, Palmstiernas Instrument AB

4
1. Introduction
Option
Option
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.
ATEX: II 2 G
Itfeaturesastandardized foot print, external zero adjustment,goldplatedspool 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.
Special Conditions for Safe Use
The enclosure is made of aluminium and any impact or friction caused by external
objects shall be avoided in the application.
Rubbing of the window with dry fabrics shall be avoided when the positioner is used in
an hazardous atmosphere in order to avoid potentially incendive static discharges.

5
P5
The base unit of the system is the pneumatic positioner, used in either single or double acting
applications. P5 comes standard with built in dampers, a high gain spool valve assembly,
gauge ports and an O-ring sealed housing. The housing utilizes a unique O-ring seal that
can be adjusted to a sealed or drained position.
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.
ATEX: II 2 GD
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.
Intrinsically Safe: ATEX: EEX ia IIC T4 II 1 GD
CSA, FM Class I, Div, Group ABCD
Explosion proof: ATEX: EEX d IIB+H2, T4-T6 II 2 GD
CSA, FM Div I, Class 1,2 & 3 Group BCDEFG
Explosion proof 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

6
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.
Electropneumatic 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.
2. Storage instructions

7
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 opera-
tion 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 office.
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.
P5-SEAL
IP5-SEAL
IP5 seal P5 seal

8
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
theactuator, 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.
3. Function
I7312
S856 4

9
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.
A <40µfilter/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
maybepresent in the line during this purging,direct the air flow into the bag. Should exessive
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.
Poorairqualityisone of the majorcausesofpremature failureofpneumaticequipment.
Installation
P4 and P5/EP5 mounts on to the actuator using either the ISO F05 holes 4and a PMV ISO
mounting kit or by using the optional mounting adaptor and screws 5to 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
Thespindle/positionershaftassemblyallowsforquickandsimplespindlechanges.To ensure
the proper connection, the spindle 3has a spring clip 2that 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.
4. Installation
5 4
2
1
3
P4/P5 P5/EP5

10
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)
5. Connections
P5/EP5 only
Ports Ip, P, S, C1 and C2 are sealed with plugs. To install gauges,
unscrew plugs and replace with gauges.
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 automaticly sealed off and protected. No connection
shall be made to this port. See pages 13 and 14 for more information.

11
X = Port plugged
C1
C2 S
C1
C2
S
C1
C2
S
III
Direct function

12
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 1is backed out from the locking nut 2then finger tighten the locking nut and
tighten screw 1. Install and adjust the indicator and reinstall cover.
6. Cam adjustment
3
1correct
incorrect
2 4
1-2 mm (1/16")

13
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)
thumbwheel4withfingerorwith 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.
7. Calibration
3 2
1
45
6
7

14
P5/EP5: To adjust the indicator, take off front cover and pull the indicator upwards until it
comes off theAllen screw.
Before installing the indicator make sure that theAllen 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.
8. Indicator adjustment
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.
9. Front cover and indicator cover
4315 2
1

15
The standard built in dampers 5located on the connecting block prov-ide a simple means of
adjusting the actuator travel speed.
For maximum actuator travel speed dampers shall be adjusted to mini-mum damping posi-
tion. (Fig).
Double acting actuators – adjust only OUTLET damper, set SUPPLY damper in minimum
damping position.
Single acting actuators – adjust both dampers for desired operation.
10. Dampers (P5/EP5)
5

16
WARNING! Units installed in hazardous
areas must have proper approvals.
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 positio-
ner unit.
Port I on 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.
11. I/PUnit (P5/EP5)
12
The I/P unit is equipped with a built in 30
micron filter (Fig 4).
Caution:Do not operate the unit without fil-
ter and filterplug installed.
Ensure that wiring between I/P and termin-
als are properly seated in rubber clamp.
Do not unscrew filterplug when the positio-
ner is pressurized.
Span and Zero for the I/P converter is factory
set and can not be adjusted
Fig 3

17
12. 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.
WARNING! Units installed in hazardous areas must have proper approvals.
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 posi-tion - sealed or drained. (See fig 3
on page 16 or section 9 on page 14).
A gauge indicating output signal from the I/Pconverter 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).
2
4
5
1
3
6

18
13. 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 5is 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
When upgrading electronically parts inside a PMV positioner approved for
installationinHazardouslocationsspecialproceduresapply,permissionfrom
PMV is required prior to the start of work.
Please contact your local PMV Sales office for information regarding
proper procedures. www.pmv.nu or [e-mail]

19
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).

20
1
2
3
65
4
Feedback spring
Once the front cover and indicator are remo-
ved, the feedback spring can be easily
accessed.
Hold the spring 1from the top, pull down
and out.
Wheninstalling,holdthe assembly at the top,
guide the lower part to position on the zero
screw, then press down until it fits easily un-
der 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/Punit,diaphragmandfeedback spring have
been removed. (See sections above and on
page 16, 18 and 19).
Loosen the screws 3and the balance arm can
be removed.
installing the balance arm make sure that the
leafspring 4on the underside of the balance
arm 5is properly engaged into the groove 6
of the spool in the pilot valve. Tighten the
two screws 3holding the balance arm to the
positioner.