PMV P5 User manual

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Manual P5/EP5 23740/98.10
Manual P5/EP5
PMV
Valve
Control
System
alve Control System

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Manual P5/EP5 23740/98.10
Manufacturers declaration • Hersteller-Erklärung • Déclaration de fabricant
GB
Manufacturers declaration
in compliance with EC directive 89/392/EEC, annex II 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:
P5, EP5, F5.
D
Hersteller-Erklärung
im sinne der EG-richtlinie 89/392/EWG, Anhang II B und 89/336/EWG.
Hiermit erklären wir, daß 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 Herstellererklärung hat für folgende PMV-Stellungsregler-Serien Gültigkeit:
P5, EP5, F5.
F
Déclaration de fabricant
au sens dela directive de la CE 89/392/CEE, annexe II B et CE/89/336/CEE.
Nous 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:
P5, EP5, F5.
Mr. Jan-Eric Andersson
President, Palmstiernas Instrument AB

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Manual P5/EP5 23740/98.10
Contents
1. Introduction 4
1.a Storage Instructions, Storage Seal 5-6
2. Function 7
3. Air requirements 8
4. Installation 8
5. Connections 9
6. Front cover and the indicator cover 10
7. Span and zero adjustment 11
8. Indicator adjustment 12
9. Cam adjustment 12
10. Dampers 12
11. I/P Unit, EP5 13
12. How to mount the I/P Unit 14
13. Maintenance 15-19
Pilot valve 15
Diaphragm 16
Feedback spring 17
Balance arm 17
Lower arm 18
O-rings 18
Filter plug 19
14. Feedback Unit 20
15. Trouble shooting 21
16. Technical Data 21
17. Exploded Drawing 22
18. Spare part list 23
Approvals 24-27
Page

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Manual P5/EP5 23740/98.10
1. Introduction
The P5 Valve Control System is a valve positioning system from PMV
with a modular design concept.
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 5 mm 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.
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 in last position
I/P Module

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Manual P5/EP5 23740/98.10
1.a Storage instructions
PMV Positioner and feedback module storage
and handling procedures
PMVPositionersandfeedbackmodulesareprecisioninstrumentswhichshouldbestored
and handled accordingly to avoid problems or damage.
Electropneumatic positioners/feedback modules contain electronic components which
canbedamagedbyexposuretoexcessivewater.Appropriateprecautionsshouldbetaken
to protect units while in storage.
Warehouse storage
Storedin original PMVshippingcontainers,unitsshould be storedinanenvironmentally
controlledarea,i.e.clean,cool(15-26°C,60-80°F)anddry,outofdirectsunlightorweather
exposure.
Field storage
Note: Once the air supply to the positioner is connected and turned on, internal air bleed
willpreventtheingressofmoistureandprotecttheunitfromcorrosion.Itisrecommended
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.
Feedbackmodulesshouldhavecovertightened and conduits entries sealed. Positioners/
Feedbackmodulesshouldbewrappedandsealedairandwatertightwithdesiccantinside
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
andtimeinstoragecondensationcouldoccurandaccumulateinsideontheI/PConverter
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 office.

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Manual P5/EP5 23740/98.10
Storage Seal
P5/EP5 is supplied with all enclosure entry
pointssealed.Thesealisonlyastorageseal,not
to be usedas seal when P5/EP5 is inoperation.
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, Sand 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 9).
CalibratespanandZeroaccordingto section 7,
(Page 11).
Clean any oil/debris off the connecting block,
then reseal open enclosure entry ports, use
circularstickersmarkedI,SandOUT,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

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Manual P5/EP5 23740/98.10
2. Function
1 2
7
8
3
5 6 4
The P5 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 posi-
tion is determined by the position of the cam which is secured to the
spindle and connected to the actuator shaft thus providing the feed-
back 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.

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Manual P5/EP5 23740/98.10
3. Air requirements
4. Installation
Maximum supply pressure is 1 MPa (150 psi).
Supplyairshallbeclean,dryandfreefromoil,water,moisture,foreignpartsand
debris.
Theairshallbe freeze-driedorsimilartoadewpointof atleast10°C(18°F)below
lowest expected ambient temperature.
A <40µfilter/regulator is recommended to be installed as close to P5/EP5 as
possible to ensure proper supply air quality.
Before making pneumatic connections to the positioner, it is recommended that
thesupplyairlinesareopenedupandallowedtoventfor2-3minutestoclearany
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 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.
Poor air quality is one of the major causes of premature failure of pneumatic
equipment.
P5 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.
The spindle/positioner shaft assembly allows for quick and simple spindle
changes. To ensure the proper connection, the spindle 3has 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.
5 4
2
1
3

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Manual P5/EP5 23740/98.10
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 tape, 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.
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.
We recommend use of tape, Loctite®577
or similar user preferred for sealing.
Port OUT is for venting the unit. All air
from the positioner, actuator and
I/Punitisventedtoatmospherethrough
this port. Donot blockthis port. A high
flow silencer or an exhaust pipe can be
connected to this port to prevent foreign
objects from entering and blocking the
unitsexhaust. Connectorinexhaustport
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 I is automaticly sealed off and
protected. No connection shall be made
tothisport. See pages 13and 14formore
information.
For single acting operation plug port C1
forincreasing signal toopen valve. Plug
C2fordecreasing(reverse)signaltoopen
valve.

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Manual P5/EP5 23740/98.10
6. 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 2 in 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 5 are now removable.
When installing indicator cover and identification cover make sure that
the O-ring is properly engaged.
4315 2
1

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Manual P5/EP5 23740/98.10
7. Calibration
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. Alwaysstartcalibrationprocedureby
applying 0 % input signal, then adjusting zero.
P5/EP5iscalibratedbyturningthumbwheels1
& 4.
Arrows on arm 5 indicate turning direction of
thumb wheels.
< “+“ = Increase zero/span
>“-“ = Decrease zero/span
Calibration procedure
Check cam seating, section 9 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 4 with finger or with screw
driver 7 from 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 2
1
45
6
7

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Manual P5/EP5 23740/98.10
8. Indicator adjustment
9. Cam adjustment
10. Dampers
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.
With the cover and indicator removed, loosen the screw 1and turn the
cam locking nut 2counterclockwise 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.
The standard built in dampers 5
locatedontheconnectingblockprov-
ide a simple means of adjusting the
actuator travel speed.
For maximum actuator travel speed
dampers shall be adjusted to mini-
mum damping position. (Fig).
Double acting actuators – adjust
only OUTLET damper, set SUPPLY
damperin minimumdampingposi-
tion.
Singleactingactuators–adjustboth
dampers for desired operation.
3
1correct
incorrect
5
2 4
1-2 mm (1/16")

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Manual P5/EP5 23740/98.10
11. I/P Unit, EP5
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
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.
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
12

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Manual P5/EP5 23740/98.10
12. How to mount the I/P Unit to the positioner Unit
Switch off supply air and disconnect input signal – port I.
Loosen screws 3 and remove connection block 1, the gauge or plug from
port Ip, the fitting from port I and existing gasket 4. Carefully install
gasket 6supplied together with I/P unit. When correct installed port I
will be blocked by the gasket.
Make sure that relief valve spring 5 is installed properly. Install the
connection block 1 to 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 13) Screw 1 first, screw 2 last.
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 13). Adjust the O-ring on the I/P Unit housing to desired posi-
tion - sealed or drained. (See fig 3 on page 13 or section 6 on page 10).
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 13).
2
4
5
1
3
6

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Manual P5/EP5 23740/98.10
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 move 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

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Manual P5/EP5 23740/98.10
Diaphragm
2 1
If P5 is equipped with I/P unit (EP5), the I/P unit must be removed to
access the diaphragm.
Loosen screws 1and remove the diaphragm cover 2. Loosen screw 3,
diaphragm 4and washers 5can be removed. The diaphragm can after
have being in use look wrinkled, this is fully normal due to the tension
in it.
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.
Check the O-ring for the diaphragm cover 2, install the O-ring into the
positioner housing, then install cover 2. Secure with screws 1. Torque
shall be 4,5 Nm (40 in-lbs).
3 5 4

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Manual P5/EP5 23740/98.10
Feedback spring
1
2
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
3
The balance arm can
only be removed after
I/P unit, diaphragm and
feedback spring have
been removed. (See
sections above and on
page 13, 14 and 16).
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 3
holding the balance arm
to the positioner.
65
4

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Manual P5/EP5 23740/98.10
Lower arm
O-rings
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.
With time and use, O-rings can become brittle. This can cause poor
operation and even failure of the positioner.
Always check O-rings when performing any work on the positioner
and replace bad O-rings.
A thin layer of silicon grease applied on the NBR (Black) O-rings
prolongs their life. On Q (red) O-rings, use a non silicon based grease.
6
2 1 5
4
3

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Manual P5/EP5 23740/98.10
Caution! Do not operate the unit without filter and filter plug
installed. Do not attempt to unscrew filter plug while positioner is
pressurized.
EP5 is equipped with a built in secondary filter located on the
side of the I/P unit.
For replacement or inspection, make sure that positioner unit is not
pressurized, then unscrew filter plug 1. Remove filter 3and install a
new into the filter plug . Check condition of O-ring 2and filter
compartment. If moisture is found, check upstream filters/oil-water
separators. Moisture can cause I/P failure.
Reinstall filter plug.
Filter plug
1
2
3

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Manual P5/EP5 23740/98.10
14. Feedback Unit
See feedback module instructions for connections and calibration.
The P5 or EP5, Valve Control System, can easily be equipped with a Feedback
unit, model F5. This unit will mount directly on top of the Pneumatic positio-
ner replacing the positioner front cover. The O-ring located on the bottom of
the Feedback unit, F5, will provide the same sealing or draining capabilities
as the front cover. The indicator and front cover from the positioner unit can
then be installed on to the Feedback unit.
WARNING! Units installed in hazardous locations must have proper
approvals.
Installing the feedback unit.
— Remove the front cover, indicator, and Allen head screw from
the top of the positioner spindle.
— Install the drive coupling 4 and adjust the O-ring seal on the bottom in
either sealed or draining position. (See section 6, page 10).
— Install the Feedback unit 9on top of the Positioner unit, making
sure the coupling is properly engaged before tightening the four
screws 5.
— Make electrical connections and tighten cable glands.
(See F5 manual for details).
— Adjust cams and/or potentiometer to desired position.
— Install the indicator and front cover.
95
O-ring seal
43
2