FlowServe PMV D3

8/18/2019 FlowServe PMV D3

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Contents1.Introduction ...................................................................................................... 3 Safety instruction ................................................................................................ 32. Storage .............................................................................................................. 4 General ............................................................................................................... 4 Storage indoors ................................................................................................... 4 Storage outdoors or for a longer period .............................................................. 4 Storage in a warm place ..................................................................................... 43. Design................................................................................................................ 54. Variants ............................................................................................................. 65. Function ............................................................................................................ 7 Double action function ....................................................................................... 7 Single action function ......................................................................................... 76. 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 ............................................................................................................. 178. 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 ............................................................................ 469. Trouble shooting .............................................................................................. 4710. Technical data ................................................................................................ 48 Certificates .......................................................................................................... 4811. Spare parts ..................................................................................................... 56


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1. Introduction

The PMV D3 is a digital positioner de-signed primarily for controlling adjustablevalves.

The positioner can be used with single ordouble action actuators with either rotary orlinear movement.

The D3 can be equipped with modulesfor feedback, limit switches, and a pressuregauge block.

Safety instructionRead 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 thenecessary 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 damageif 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 airsupply connection or the integral filter. Remove or disconnect with care because C- isstill under pressure even after the air supply is turned off.• Always work in an ESD protected area when servicing the PCB´s. Make sure theinput signal is switched off.• The air supply must be free from moisture, water, oil and particles.

The modules can be factory assembledbefore delivery or fitted later.

The modules for feedback and limitswitches can contain the following:

Feedback 4-20 mA and one of thefollowing functions:

- Two mechanical contacts- Two reed switches- Two inductive sensors, DIN 19234


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2. Storage

GeneralThe PMV positioner is a precision in-

strument. Therefore it is essential that it ishandled and stored in the right way. Alwaysfollow the instructions below!

N.B. As soon as the positioner isconnected and started, internal air leakagewill provide protection against corrosionand prevent the ingress of moisture. For thisreason, the air supply pressure shouldalways be kept on.

Storage indoorsStore the positioner in its original

packaging. The storage environment must

be clean, dry, and cool (15 to 26 °C, 59 to79°F..

Storage outdoors or for a longerperiod

If the positioner must be stored

outdoors, it is important that all the coverscrews are tightened and that all connectionsare properly sealed. The unit should bepacked with a desiccant (silica gel) in aplastic bag or similar, covered with plastic,and not exposed to sunlight, rain, or snow.

This is also applicable for long-termstorage (more than 1 month) and for longtransport by sea.

Storage in a warm placeWhen the positioner is stored in a warm

place with a high relative humidity and issubjected to daily temperature variations, the

air inside the unit will expand and contract.

This means that air from outside the unitmay be drawn into the positioner. Dependingon the temperature variations, relativehumidity, and other factors, condensation andcorrosion can occur inside the unit, which inturn can give rise to functional disorders ora failure.


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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 electricalconnections

The push buttons and display areaccessible underneath the aluminiumcover, which is sealed with an O-ring.

The figure shows the D3 with the coverremoved.


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4. Variants

D3 270 °deg.D3 up to 270 ° deg for extended travel

range is available. It features all benefits andoptions similar to the standard D3.Communication with HART or Profibus ispossible.

D3 Explosion proof The digital positioner D3 is available in

explosion proof enclosure. It features thesame easy to use user interface for local con-figuration as D3. Communication with Hartor Profibus is possible.

Further features are gauge ports and localgraphic LCD display.

D3 Intrinsically safeThe digital positioner D3 is available inintrinsically safe version for installation inhazardous areas. It features the same easy touse user interface for local configuration asD3. Communication with HART or Profibusis possible. It features all benefits and optionssimilar to the Standard D3 positioner, gaugeblock, local graphic LCD display and feed-

back option etc.

D3 remote mountedThe D3 with remote mount is now

available on the market for order. This ver-sion is suitable for installations in severeapplications e.g. vibrations, high or lowtemperature corrosive environment, highmountings or difficult of access, etc. A flator dome style indicator can be fitted on thefeedback box installed on the actuator. Maxrecommended distance between D3 andremote unit is 5 m.


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5. FunctionControl 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

G

Double action functionThe control signal and the feedback

potentiometer position are converted to di-gital signals that are processed with a PIDalgorithm in the microprocessor. This prov-ides control signals to the two piezo-valves.

The two piezo-valves are closed in theschematic diagram above and have no effecton the valves A and D. Air from the pressureregulator is lead through the open valve A tothe valve B, which opens. The supplypressure can now pass through valve B tothe actuator via H. The actuator then movesin the direction of the arrow. At the same

Signal converter and

microprocessor

A B

C D E F

➾

time, air from valve A keeps valve C open

and allows venting of the actuator.

When both the piezo-valves open, valveA closes but valve D opens and controlsvalves E and F to that the actuator moves ina direction opposite to the arrow. When onlypiezo-valve 1 is open, the actuator isstationary.

Single action functionValve B is used for the supply air and

valve F for venting.

C– C+

Actuator


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6. InstallationTubing

Use tubes with an inner diameter of mi-nimum 6 mm (1/4”).

Air supply requirementsMax. air supply pressure, see the section

Technical Data, Section 10.

The air supply must be free frommoisture, water, oil, and particles.

The air must come from a refrigerationdried supply or be treated in such a way thatits dew point is at least 10 °C (18 °F) belowthe lowest expected ambient temperature.

To ensure a stable and problem-free air

supply, we recommend the installation of afilter/pressure regulator


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Mounting

N.B. If the positioner is installed in ahazardous environment, it must be of atype approved for this purpose.

The D3 positioner has an ISO F05footprint, A. The holes are used to attach itto the mounting bracket B, which is suitablefor most types of linear actuator.

The spindle adapter C can be changed tosuit the actuator in question.

Remove the existing adapter using twoscrewdrivers. Check that the spring ring onthe positioner spindle is undamaged and fitthe new adapter.

It is important that the positioner’s spindleand the arms, that transfer the actuatormovements, are correctly mounted. Any ten-sion between these parts can cause incorrectoperation and abnormal wear.

Assembly examples A B

C

C

Rotary movement Linear movement


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C– S C+

For data for air and electrical connections, see sectionTechnical Data on page 48.

Connections

Air:Port S Supply air, 2-7 barPort C+ Connection to actuatorPort C- Connection to actuator

(only for double action)

Electrical connectionSee page 12, 13.

DimensionsAir connections:1/4" NPT alt. G 1/4"Electrical connection:M20 x 1.5 alt. NPT 1/2"

Loctite 577 or equivalent is recommendedas a sealant.

Must be plugged when converting to single action function.

The D3 Ex positioner has an ISO F05footprint, A. The holes are used to attach itto the mounting bracket B, which is suitablefor most types of linear actuators.

The spindle adapter C can be changed tosuit the actuator in question, see previouspage.

A

B

C


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Single action positioner(Direct function)

Actuator with closing springWhen the control signal increases, the

pressure C+ to the actuator is increased. Thevalve spindle moves upward and rotates thepositioner spindle counter-clockwise. Whenthe control signal drops to zero, C+ is ventedand the valve closes.

Actuator with opening springWhen the control signal increases, the

pressure C+ to the actuator is reduced. Thesprings press the valve spindle upward andthe positioner spindle rotates counter-clockwise. When the control signal drops tozero, C+ is vented and the valve opens.

Double action positioner(Direct function)

Double action actuatorWhen the control signal increases, the

pressure C+ to the actuator is increased. Thevalve spindle is pressed upward and rotatesthe positioner spindle counter-clockwise.When the control signal is reduced, thepressure C- to the actuator increases and thevalve spindle is pressed downward. If thecontrol signal disappears, the pressure goesto C-, C+ vents, and the valve closes.

C–SC+

C–SC+

C–SC+


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Option

HART- connection

1 4-20 mA + input signal2 4-20 mA – input signal3 Switch 1 NO4 Switch 1 NC5 Switch 1 COM6 Switch 2 NO7 Switch 2 NC8 Switch 2 COM9 AUX input 4-20 mA +10 AUX input 4-20 mA –

11 4-20 mA + Feedback, 10-28 V DC12 4-20 mA – Feedback, 10-28 V DC13 Alarm output +14 Alarm output –

+ – + – + – + –

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Remote-unit

+ –

1 2 3 4 5 6

3 4 5

Shielded cables,grounded on the D3

Connecting a remote unit

D3The terminal block (below) for the posi-

tioner is accessible when the aluminium coverand inner cover is removed, see Section 8.

Warning! In a hazardousenvironment where there is arisk of explosion, electricalconnections must comply withthe relevant regulations.

Electrical connectionsThe diagrams show the terminal blocks

in D3 and D3 Ex.

Remote unitThe remote unit shall be connectedbetween terminals3, 4 and 5 in the D3 and 3,4 and 5 in the remote unit. Use a shieldedcable and ground it in the D3 only. Maxrecommended distance between D3 andremote unit: 5 m.

Note! When converting D3/D3 Ex for use

with remote unit, some changes have to bedone inside the positioner, see Section 8.

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


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1 4-20 mA + input signal

2 4-20 mA – input signal3 (Remote unit)4 (Remote unit)5 (Remote unit)9 AUX input 4-20 mA +10 AUX input 4-20 mA –11 4-20 mA + Feedback, 10-28 V DC12 4-20 mA – Feedback, 10-28 V DC13 Alarm output +, 8-28 V DC14 Alarm output –, 8-28 V DC

Optional

D3 ExThe terminal block (below) for the posi-

tioner is accessible when the terminal coveris removed, see Section 8.

Warning! In a hazardousenvironment where there is a

risk of explosion, electricalconnections must comply withthe relevant regulations.


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7. Control

Menus and pushbuttonsThe positioner is controlled using the five

pushbuttons and the display, which areaccessible when the aluminium cover isremoved.

For normal functioning, the displayshows the current value. Press the ESCbutton for two seconds to display the mainmenu.

Use the pushbuttons to browsethrough the main menu and the sub-menus.

The main menu is divided up into a basicmenu and a full menu, see page 16.

Other functionsESCExit the menu without making any changes(as long as any changes have not beenconfirmed with OK).

FUNCTo select function and change parameters.

OKTo confirm selection or change of para-meters.

MENU INDICATORDisplays the position of the current menurow in the menu.

ESC FUNC

OK

BASIC MENUMAN/AUTO

OUT OF SERVICE

MANUAL

UNPROTECTED

IN SERVICEThe positioner is following the input sig-

nal. This is the normal status when the posi-tioner is working.

OUT OF SERVICEThe positioner is not following the input

signal. Critical parameters can be changed.

MANUALThe positioner can be adjusted manually

using the pushbuttons. See section ”Man/ Auto”, page 21”.

UNPROTECTEDMost of the parameters can be changed

when the positioner is in the ”Unprotected”position. However, critical parameters arelocked when the positioner is in the ”In ser-vice” position.


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Menu indicatorThere are indicators at both sides of the

display window and they indicate as follows:

Flashing in position Out of service

Flashing in position Manual

Displayed in position Unprotected

The indicators on the right-hand sideshow the position in the current menu.

MenusTo display the menus you can select:

- Basic menu , which means you can browsethrough four different steps

- Full menu , which comprises ten steps. Usethe Shift Menu to browse through the steps

Full Menu can be locked out using apasscode.

The main menus are shown on the nextpage and the sub-menus on the subsequentpages.

FULL MENU

CALIBRATE

FULL MENUMAN/AUTO

FULL MENUSHIFT MENU

Changing parameter valuesChange by pressing until the desiredfigure is flashing.

Press to step to the desired figure.Confirm by pressing OK.

A change can be undone by pressing the ESCbutton, which returns you to the previousmenu.


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BASIC MENUREAD

BASIC MENUMAN/AUTO

BASIC MENU CALIBRATE

BASIC MENUSHIFT MENU

FULL MENUREAD

FULL MENUMAN/AUTO

FULL MENU CALIBRATE

FULL MENUSHIFT MENU

FULL MENUPROTECTION

FULL MENUSTATUS

FULL MENUSETUP

FULL MENUTUNING

FULL MENU ALARMS

FULL MENUFACT SET

Menu system

The menus are describedon the following pages.


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BASIC MENUCALIBRATE

First startCalibrate in the basic menu is displayed

automatically the first time the positioner isconnected up, and can be selected from thebasic/main menu at any later time.

A complete calibration takes about 3minutes and includes end limit calibration,

auto-tuning, leak test, and a check on thespeed of movement. Start the automaticcalibration by selecting Auto-Cal and thenanswer the questions on the display by pres-sing OK or the respective arrow. The menuis described on the next page.

Calibration error messagesIf a fault occurs during calibration, one

of the following error messages can be dis-played:

Invalid movement/press ESC to abortNo movement because the air is

incorrectly connected, for example. After thefault is corrected, the calibration sequencemust be restarted.

Pot unaligned/press ESC to abortThe potentiometer has been set to an il-legal value. The potentiomenter is alignedusing the Calibrate - Expert cal - pot Menu.The calibration sequence must be restartedafter the fault is corrected.

C+(C–)

Clockwise = Increased damping/Less flowCCW = Decreased damping/More flow

3 revsCCW = Max flow

Note! To much increased damping (low flow)might cause irregular actuator function.

Air leak detected/ESC = abortOK = go on

An air leak has been detected. Thecalibration sequence should be restarted afterthe fault is corrected.

Increase C- damper/ESC = abortOK to retry

Increase C+ damper/ESC = abortOK to retry

Speed of movement is too fast. Adjustwith the damper screws (see page 5). PressOK. Repeat the adjustment and press OKuntil the speed is correct. If there is an abort,the calibration sequence must be restarted.

First start, ProfibusConnect the input signal at pos 1 and 2

on the terminal block. See Electricalconnections in the manual.

In the SETUP/Devicedata/Profibus:change the address from 126 to any numberbetween 1-125.

Do never use the same number to morethan 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


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The contents of the menu are shown on the next page. The various menutexts 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. withand 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 MENUCALIBRATE


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CALIBRATE AutoCal

AutoCalStart tune

Actuator?rotating

OK

TravelCalStart cal

Performnormal

LOSE PREVVALUE?OK?

OK

OK

OK

OK

OK

CALIBRATETravelCal

LOSE PREV

VALUE?OK?

IN SERVICE? Press OK

OK

OK

OK

OK

OK

OK

OK

OKDirection?direct

Direction?reverse

Calibration in progress

Calibration in progress

PerformFactory set

Perform50%

25%

12%

L

M

S

Actuator?linear

Actuator single act

Actuator single act

IN SERVICE? Press OK

OK

Set point LO: Use the calibrator set to 4 mA(or set another value on the display). Press OK.Set point HI: Use a calibrator of 20 mA(or set another value on the display). Press OK.Pressure read out only possible on D3 with builtin pressure sensor.

Pressure LO: Use a supply of 2 bar (30 psi)(or set another value on the display). Press OK.

Pressure HI: Use a supply of 7 bar (105 psi)(or set another value on the display). Press OK.Temp: Calibrate using a known temperature.

Aux input LO: Use the calibratorand a power supply of 4 mA (or set anothervalue on the display). Press OK.

Aux input HI: Use a supply of 20 mA(or set another value on the display). Press OK.

Pot: Potentiometer setting, if its positionrelative to the gear segment has been changed.See Section 8.

Full reset: Resets all the set values.Allthesevaluesaresetatthe

factorybeforedeliveryand

shouldnotnormallybechanged.

CALIBRATEPerform

CALIBRATEExpertCal


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BASIC MENUREAD

Current values can be read using the Read Menu and some values can be reset.

Statisticsn cycles

Statisticsacc travel

Statisticsmean dev

Statisticsruntime

Statisticsextr. temp

Statisticshistogram

Pos Shows current position

Set&pos Set point and position

Set&dev Set point and deviation

Temp Shows current temperature

Aux Shows auxinput signal valve.External pot or similar

Statistics n cycles Shows number of movements

(turns)

Acc travel Shows accumulatedmovement

mean dev Shows accumulated deviationin %

runtime Shows accumulated runtimesince last reset

Extr temp Shows extreme min and maxtemperature

Histogram Shows position and time forPV

Alarms Displays tripped alarms

The menu contents are shown in the figures on the right and the texts are described below:

StatisticsReset stat

Reset statyes

Reset statno

READpos

READset&pos

READset&dev

READtemp

READaux

READStatistics

READ Alarms


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BASIC MENUMAN/AUTO

AUT, OK=MANPOS= 12,3% OK

MAN, OK=AUTPOS= 12,3%

The menu contents are shown in thefigures on the right and the various texts aredescribed below:

AUT, OK = MAN

Positioner in automatic mode

MAN, OK = AUTPositioner in manual mode

In the MAN mode, the value of POS canbe changed using . The push-buttons increase/decrease the value in steps.The value can also be changed in the sameway as for the other parameter values, asdescribed on page 15.

Other functionsC+ can be fully opened by pressingand then immediately OK simultaneously.

C- can be fully opened by pressingand OK simultaneously.

C+ and C- can be fully opened for blowingclean by pressing and OK simultaneously.

When changing betweenMAN and AUT mode, the OKbutton must be depressed for 3seconds.

The Man/Auto menu is used to change between manual and automatic modes.


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FULL MENUPROTECTION

PROTECTION

no OK

OKPROTECTIONyes

The Write Protect menu is used to protect all essential settings.

The menu contents are shown in the

figures on the right and the various texts aredescribed below:

No Entered values are not writeprotected. ”Unprotected” isdisplayed in the lower left-hand corner.

Yes Entered values are writeprotected. Passcod needed forchange to No (Applicablewhen a passcode has been setup in SETUP menu)..

When changing betweenYes and No mode, the OK

button must be depressedfor 3 seconds.

BASIC MENUSHIFT MENU

Full menuno

OK

Full menuyes

OK

The Shift Menu is used to choose between the basic menu and the full menu.

The menu contents are shown in thefigures on the right and the various texts aredescribed below:

No Full menu selected.

Yes Basic menu selected.

Full Menu can be locked with apasscode, see Setup menu.


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FULL MENUSTATUS

OK

OK

STATUSo o service

The Status Menu is used to select whether or not the positioner is in service.

The menu contents are shown inthe figures on the right and the varioustexts are described below:

o o service Not in service. Flashing

indicator in upper left-hand corner of display.

in service Positioner in service.Critical parameters cannot be changed.

When changing betweenIn service and Out of ser-vice , the OK button must bedepressed for 3 seconds.

STATUS

in service


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Actuator Type of actuator Size of actuator Time out

Rotating Rotating actuator. Small 10 s Linear Linear actuator. Medium 25 sLarge 60 sTexas 180 s

Lever Only for linear actuator. Lever stroke Stroke length to achieve correct display. Level cal Calibration of positions to achieve correct display.

Direction

Direct Direct function (signal increase opens). Indicator/spindle rotates counter-clockwise. Reverse Reverse function.

Character Curves that show position as a function of input signal. Linear Equal % See diagram. Quick open Sqr root Custom Create own curve.

Cust chr # of point Specify number of points (3, 5, 9,

17, or 33) Cust curve Enter values on X and Y axes.

Curr range

0%=4.0 mA 100%=20.0 mA Possibility of selecting which input signal values will correspond to0% and 100% movement respectively. Examples of settings:4 mA = 0%, 12 mA = 100%, 12 mA = 0%, 20 mA = 100%.

FULL MENUSETUP

The Setup Menu is used for various settings .

The menu contents are shown in the chart on the next page and the various texts aredescribed below:

QoSqr

Lin Eq%

Signal

M o v e m e n t

x

y


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Lever Stroke

Lever Lever cal

SETUP Actuator

SETUPLever

SETUPDirection

SETUPCharacter

SETUPCust chr

SETUPcurr range

Directiondirect

Directionreverse

Character linear

Character equal %

Character quick open

Character custom

Character sqr root

OK

Stroke

LEN= XX,Xmm

Set lever at max...

Set lever at center...

Set lever at min...

OK

OK

OK

Set lever at center...

OK

Lever cal

Done

OK

OK

OK

OK

OK

OK

OK

Seetext!

OK

OK

OK

OK

OK

OK

OK

OK

OK

Actuator type

Actuator function

Actuator size

Typelinear

Typerotating

SizeMedium

SizeSmall

SizeLarge

SizeTexas size

Cust chr # of point

Cust chr Cust curve

Curr range

0%=4,0 mACurr range100%=20 mA

Functionsingle act

FunctionDouble act

OK

OK


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TRVL range Setting end positions 0%=0.0% Select Out of Service.

Set percentage valuefor desired end posi-tion (e.g. 3%).

Set 0% Select In Service.Connect calibrator.Move forward to desiredend position (0%) andpress OK.

100%=100.0% Select Out of Service.Set percentage value fordesired end position (e.g.97%).

Set 100% Select In Service.Connect calibrator. Moveforward to desired endposition (100%) andpress OK.

Trvl ctrl Behaviour at set endposition

Set low Choose between Free (go

to mechanical stop),Limit (stop at set endposition), and Cut off (godirectly to mechanicalstop at set end position).

Set high Similar to Set low. Values Select position for Cut off

and Limit at therespective end positions.

Passcodes Setting passcodes forvarious functions

Full menu Passcode for access tofull menu.

Write prot Passcode for removingwrite protect.

Expert Passcode for access toExpert menu (TUNING).

Fact set Passcode to return todefault values applicablewhen positioner wasdelivered.

Numbers between 0000 and 9999 can be used aspasscodes. 0 = no passcode required.

Appearance On display Language Select menu language. Units Select units. Def. Display Select value(s) to be

displayed during service.The display reverts tothis value 10 minutesafter any change is made.

Start menu Start in Basic menu orFull menu.

Contrast Adjust display contrast. Orient Orientation of text ondisplay.

Par mode Display of control parameters such as P, I, D orK, Ti, Td.

Devicedata HW rew

SW rew General parameters. Capability HART Menu with HART para-

meters. Only amendablewith HART communi-cator. It is possible to readfrom display.

Profibus Status Indicates present status Device ID Serial number Address 1-126 Tag Allotted ID Descriptor ID description Date N/A Failsafe Value = preset pos

Time = Set time +10sec=time before movementValve act = failsafe (preset pos) or lastvalue(present pos)Alarm out= On/Off


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SETUPTrvl range

SETUPTrvl ctrl

SETUPPasscodes

SETUP Appearance

SETUPDevicedata

Trvl range0%= 0,0%

Trvl rangeSet 0%

Trvl range100%=100,0%

Trvl rangeSet 100%

Trvl ctrlSet low

Trvl ctrlSet high

Trvl ctrlValues

Passcodesfull menu

Passcodesprotection

Passcodesexpert

Passcodesfact set

Seetext!

Seetext!

Seetext!

Seetex

t!

Seetext!

OK

OK

OK

OK

AppearanceLanguage

AppearanceUnits

AppearanceDef. Displ

AppearanceStart menu

AppearanceContrast

AppearanceOrient.

AppearancePar mode

DevicedataHW rew

Devicedata

SW rew

DevicedataCapability

DevicedataHart

Devicedata

Profibus


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FULL MENUTUNING

Close time Minimum time from fully open to closed.Open time Minimum time from closed to fully open.Deadband Setting deadband. Min. 0.2%.

Expert Advanced settings.Togglestep Test tool for checking functions. Overlays a square wave on the

set value.K, Ti, Td Setting K, Ti, and Td parameters.

Self test Test of processor, potentiometer, etc.

Leakage Air leakage detected can be either connections, positionertubing or actuator.

UndoYou can read last 20 changes.



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TUNINGClose time

TUNINGOpen time

TUNINGDeadband

TUNINGExpert

OK

OK

OK

ExpertK,Ti,Td

ExpertSelf test

ExpertLeakage

ExpertUndo

Close timeMin= 0,05

Open timeMin= 0.05

DeadbandD= 0,2%

ExpertTogglestep

TogglestepRuntimetime

TogglestepCycletime

Togglestepsize

Togglestepstart

Togglestep Abort step


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FULL MENU ALARMS

Deviation Alarm generated when deviation occursOn/Off Alarm on/off.Distance Allowed distance before alarm is generated.Time Total deviation time before alarm is generated.Alarm out Select ON/OFF offers output on terminals 13 and 14.

Valve act Behaviour of valve when alarm is generated.

Limit 1 Alarm above/below a certain level.On/Off Alarm on/off.Minipos Setting of desired min. position.Maxpos Setting of desired max. position. See diagram below!Hysteresis Desired hysteresis.Alarm on Select ON/OFF offers output on terminals 13 and 14.Valve act Behaviour of valve when alarm is generated.

Limit 2 See Limit 1.

The menu contents are shown in the chart on the next page and the various texts are

described below:

Limit 1, max Hysteresis

Limit 2, max Hysteresis

Hysteresis Limit 2, min

Hysteresis Limit 1, min

0%

100%

Alarm Limit 1 on

Alarm Limit 2 on

Alarm Limit 1 off

Alarm Limit 2 off

Alarm Limit 2 on

Alarm Limit 1 on Alarm Limit 1 off

alarm Limit 2 off

T r a v

e l

Set alarm and hysteresis values


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DistanceD = 10.0%

TimeT=0.00s

Alarm outOFF

Alarm outON

ALARMSDeviation

ALARMSLimit 1

ALARMSLimit 2

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

SeeLimit 1 Limit 1

Valve act

OK

OK

OK

OK

Alarm Outon

Alarm Outoff

OK

OK

DeviationOn/off

DeviationDistance

DeviationTime

Deviation Alarm Out

DeviationValve act

On/off on

On/off off

Limit 1On/off

Limit 1Minpos

Limit 1Maxpos

Limit 1

Hysteresis

Limit 1 Alarm

On/off on

On/off off

MiniposP= 0,0%

MaxposP= 0,0%

Hysteresis

H= 0,0%

Valve actno action

Valve actgoto open

Valve actgoto close

Valve actmanual

Valve actno action

Valve actgoto open

Valve act

goto close

Valve actmanual


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Pos=aux External potentiometer

On/Off Function on/off.

Max diff Max. allowed deviation between internal and external potentiometer.

Alarm out Select ON/OFF offers output on terminals 13 and 14.


Aux input External input signal 4-20 mA.

On/Off Alarm on/off.

Minipos Setting of desired min. position.

Maxpos Setting of desired max. position.

Hysteresis Desired hysteresis.


Function similar to Limit 1 and 2.See chart on previous page.


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ALARMSPos=aux

ALARM Aux input

On/off on

On/off off

MiniposP= 0,0%

MaxposP= 0,0%

Hysteresis

H= 0,0%

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

Alarm outOFF

Alarm outON

Aux inputValve act

Pos=auxOn/off

Pos=auxMax diff

Pos=aux Alarm out

Pos=auxValve act

Aux inputOn/off

Aux inputMinpos

Aux inputMaxpos

Aux input

Hysteresis

Aux input Alarm out

Valve actdo nothing

Valve actgoto open

Valve act

goto close

Valve actmanual

On/off on

On/off off

Max diff P= 0,0%

Alarm outOFF

Alarm outON

Valve actdo nothing

Valve actgoto open

Valve actgoto close

Valve actmanual


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Temp Alarm based on temperature On/Off Temperature alarm on/off. Low temp Temperature setting. High temp Temperature setting. Hysteresis Allowed hysteresis. Alarm out Select ON/OFF offers output on terminals 13 and 14. Valve act Behaviour of valve when alarm is generated.

FULL MENUFACT SET

Valve act

No action Alarm generated only. Operations not affected.

Goto open C+ gives full pressure and valve moves to fullyopen position. Positioner changes to positionManual.

Goto close C- gives full pressure and valve moves to fullyclosed position. Positioner changes to positionManual.

Manual Valve stays in unchanged position. Positionermoves to position Manual.


The default values that were set on delivery can be reset using the Fact Set menu. Valuesfrom calibration and from other settings will then be lost.


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OK

OK

Alarm outOFF

Alarm outON

ALARMStemp

OK

OK

OK

OK

OKOK

OK

OK

OK

FACT SETno

FACT SETyes

OK

OK Press OKfor 3 sek

OK OKDiscardsettings?

Inputaccepted

OK

FACT SETDone

OK

TempOn/off

TempLow temp

TempHigh temp

TempHysteresis

Temp Alarm out

TempValve act

On/off on

On/off

off

Low tempMin=0,0 °C

High tempMax=100,0 °C

Hysteresis

H=

Valve actno action

Valve actgoto open

Valve actgoto close

Valve actmanual


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8. Maintenance/service

Disassembling PMVD3

Removing cover and inner cover• Unscrew the screws A and remove thecover.

• Pull off the arrow pointer, B.

• Unscrew the screws C, pull the inner coverslightly in the direction of the arrow, andremove the cover.

When carrying out service, replacing a circuit board, etc., it may be necessary to removeand refit various parts of the positioner. This is described on the following pages.

Read the Safety Instructions on page 3 before starting work on the positioner.

Cleanliness is essential when working with the positioner. Contamination in theair ducts will infallible lead to operational disturbances. Do not disassemble theunit more than that described here.

Do not take the valve block apart because its function will be impaired.

When working with the D3 positioner, the work place must be equipped with

ESD protection before the work is started.

Always turn off the air and electrical supplies before starting any work.

A

B C

➜


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Circuit boards (pcb)

Disconnect or switch off the electricpower supply before starting anywork.

• Lift off the display pcb.

• Unscrew the spacers E, release the cableconnections F and G, and lift up the proces-sor pcb.

• Remove the terminal board by unscrewingthe spacers H.

F E

H

G

D


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Valve block

Turn off the air and electric powersupply before starting any work.

• R elease the connector F from the proces-sor pcb.

¥ Remove the four screws I .

¥ L ift out the valve block

N.B. Do not disassemble the valve block

¥ When installing the valve block Ñ torque

the four screws to 1,4 Nm and sealwithLocktite 222.

SilencerA silencer, L (option) can be mounted underthe plate M on the D3. Contact PMV .

Spindle adapterThe spindle adapter can be changed to suitthe actuator in question, see page 9.

I F

M L


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Transmitter boardsThe equipment for transmitter feedback consists of a circuit board A, cam assemblyB and screws.

The circuit board exists in four:- with mecanical switches, SPDT- with namur sensors, DIN 19234- with proximity switches- with feedback transmitter only

A

B

K

Potentiometer

90° and 270 ° spring loaded potentiometerThe spring-loaded potentiometer K can be

removed from the gearwheel for calibrationor replacement.

If the potentiometer is replaced or the set-ting is changed, it must be calibrated.

• Select the menu Calibrate - Expert - Calpot. The display shows Set gear (1).

• Turn the spindle shaft (2) cw to end posi-tion and press OK. Turn ccw to the end andpress OK.

• Unmesh the potentiometer (3) and turn itaccording to display until OK is shown. PressOK.

OK

1

2

3


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B

Transmitter board installation

Caution! Turn off the power and air supply starting the installation.

Important for D3 Intrinsically safe units:Transmitter boards NOT for on sitemounting by customer. FM, CSA andATEX certificate only valid when trans-mitter board is mounted by manufacturer.

• Remove the cover, indicator and inner

cover according to the description on page37.

• Check that both spacers C are installed.

• Carefully mount the circuit board in itsposition. The pins D should fit in theconnector and the positioners motherboard.Make sure that the feed back PC board isproperly connected.

• Secure the circuit board with the enclosedscrews E.

• Install the cam asssembly B on the shaftand push it down to its position. If the boardhas microswitches, be careful not to damage

the levers.

C

D

E

C


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• Tighten the screws F , on the cam assembly.Do not tighten the screws to hard. The camsshould be able to move in relation to eachother.

• Install the inner cover with the two screws,

G .

• Connect the wiring for the transmitter feed-back on the terminal block, according to thedrawing on next page.

• Adjust the position where the switches/ sensors should be affected, by turning thecams with a screwdriver.

• Tighten the cam assembly screws F whenthe cams are correctly adjusted.

• Install the indicator and cover.To calibrate the feedback transmitter, seedrawing on next page.

F

G

F


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.


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Disassembling PMV D3 Ex

• Loosen the screws A and B and removethe caps C och D.

• Remove the inner display cover E byloosening the four screws F .

• Carefully remove the display board and

loosen the connections H and I.

• Release the wide cable from the connectorJ on the terminal board.

• Loosen the three screws K .

• Remove the circuit board package L, con-sisting of terminal and processor board.

• Remove he four screws M and lift the block N.

A D

F

E

G

B C H

I

J

L

M

N

K


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Filter change, D3 and D3 Ex

Turn off the compressed airsupply before starting any work.Otherwise the filter can beuncontrollably blown out of thepositioner by the air pressure,which can be dangerous.

• Remove the filter cap using a coin of

suitable size.

Note! Do not use a screwdriver. The fil-ter cap might crack and cause air leakage.


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Converting for remote control

Disconnect or switch off the electricpower supply before starting anywork.

• Remove cover and inner cover, see page37.

• Lift off the display pcb, D.

• Disconnect and secure the pot cable.

• Install transmitter board D3-AS38T , F .

• Install the enclosured wire between G andO on the transmiter board.

• Connect the wiring between terminals 3, 4,

5 in the D3 unit and 3, 4, 5 in the remoteunit.

Use a shielded wire and ground it in the D3unit only.

Avoid longer distance than 5 m between D3unit and remote unit.

F

G

D

O

3 45

3 4 5


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9. Trouble shooting

Fault symptom

Change in input signal to positioner doesnot affect actuator position.

Change in input signal to positioner ma-kes actuator move to its end position.

Inaccurate regulation.

Slow movements, unstable regulation.

Action

• Check air supply pressure, aircleanliness, and connection between po-sitioner and actuator.

• Check input signal to positioner.

• Check mounting and connections of po-sitioner and actuator.

•Check input signal.

•Check mounting and connections of po-sitioner and actuator.

• Implement auto-tuning. Check for anyleaks.• Uneven air supply pressure.• Uneven input signal.• Wrong size of actuator being used.• High friction in actuator/valve package.• Excess play in actuator/valve package.• Excess play in mounting of positioneron actuator.• Dirty/humid supply air.

• Implement auto-tuning.• Adjust the pressure adjusting screws.• Increase the deadband (Tuning menu).• Adjust Performance (Calibrate menu).


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10. Technical dataRotation angle min. 30 ° max 100 °Stroke 5 - 130 mm (0.2” to 5.1”)Input signal 4 - 20 mAAir supply 2 - 7 bar (30 - 87 psi) Free from oil, water

and moisture. Filtered to min. 30 micronAir delivery 400 nl/min (13.8 scfm)Air consumption


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Mechanical switchesType SPDTSize Sub Sub miniatureRating 3 A/125 V AC

2 A/30 V DCNamur sensorsType Proximity DIN 19234 NAMURLoad current " 1 mA " 3 mAVoltage range 5 - 25 VDCHysteresis 0.2 %Temp –20 °C to 85 °C (–4 °F to 185 °F)

Proximity switchesType SPDTRating 5 W/250 mA/30 V DC/125 V ACOperating time 0.7 msBreakdown voltage 200 VDCContact resistance 0.1 !Mechanical/electrical life >50 x 10 6 operations

4 - 20 mA transmitterSupply 9 - 28 VDCOutput 4 - 20 mAResolution 0.1 %Linearity full span +/–0.5 %

Output current limit 30 mA DCLoad impedance 800 ! @ 24 VDC


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Certificates


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4-20mA input signalPin 1;2

AUX input 4-20 mAPin 9;10

4-20 mA OutputPin 11;12

AlarmPin 13;14

NAMUR switchesPin 3;4 : Switch 1Pin 6;7 : Switch 2

NON HAZARDEOUS AREAHAZARDEOUS AREA

3

5Isolator

D3Ui : 10,6VIi : 29,7mAPi : 79mWCi : 1 nFLi : 1 µH


6

8Isolator


Mechanical or Proximity switchesPin 3;5 : Switch 1Pin 6;8 : Switch 2


4+

3-Isolator



7+

6-Isolator

D3Ui : 10,6V

Ii : 29,7mAPi : 79mWCi : 35 nFLi : 50 µH

HART-connection

Mechanical or Proximity switches

Pin 3;5 : Switch 1Pin 6;8 :Switch 2

Normally Open


3

5Safety Barrier

/PA /PA


6

8Safety Barrier

/PA /PA


9+

10-Safety Barrier

/PA /PA


4

5Safety Barrier

/PA /PA


7

8Safety Barrier

/PA /PA

Mechanical or Proximity switches

Pin 4;5 : Switch 1Pin 7;8 : Switch 2

Normally Closed


1+

2-Safety Barrier

D3Ui : 28VIi : 93mA

Pi : 653mWCi : 4 nFLi : 5 µH

/PA /PA


13+

14-Safety Barrier

/PA /PA


11+

12-Safety Barrier

/PA /PA

1. Input signal

2. Input signal

3. Switch 1 NO

4. Switch 1 NC

5. Switch 1 COM

6. Switch 2 NO

7. Switch 2 NC

8. Switch 2 NC

9. AUX 4-20 mA + Input

10. AUX 4-20 mA - Input

11. 4-20 mA +

12. 4-20 mA -

13. Alarm Output +

14. Alarm Output -

71 2 3 5 148 9 10 11 12 134 6

+ - + - - -+ +

Option Option

D3

Li : 1 µHCi : 1 nF

Pi : 315mWIi : 45mAUi : 28V

D3

Li : 1 µHCi : 1 nF


D3

Li : 1 µHCi : 1 nF


D3

Li : 1 µHCi : 1 nF


D3

Li : 5 µHCi : 5,7 nF


D3



D3



Profibus PA input signalPin 1;2


Ui : 15VIi : 208mAPi : 1,93WCi : 4 nFLi : 5 µH

D3

2

1

Safety Barrier

/PA /PA

Pin 1: IsrcPin 2: Irtn


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4 3 31 17 11 12 13 14 15 16 2 1

9 10 5 7 8

6 19 18

20

23 24 25 26

27 28 21 22


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Pos Par t no. Descr iption1 D3-SP6 Cover incl.screws

2 D3-SP11 Internal cover incl.screws3 P3-SP13 Cover plate incl. screws4 P5-Sxx Spindle adapter5 D3-SP1 Block compl incl. cable, rubber seal, filter-plug6 D3-SP9 Filter-plug incl. O-ring, filter7 D3-SP8 Potentiometer compl incl. spring, holder, cable8 D3-SP8-270 Potentiometer compl incl. spring, holder, cable, 270deg

9 D3-SP20 Shaft compl incl. gearwheel, friction clutch10 D3-SP20-270 Shaft compl.incl. gearwheel, friction clutch, 270deg11 D3-SP37 Pcb display assy12 D3-SP35X PCBs (terminal and processor)13 D3-SP35H PCBs (terminal and processor) HART14 D3-SP35I PC Bs (terminal and processor) intrinsically safe15 D3-SP35IH PCBs (terminal and processor)intrinsically safe, HART

16 D3-SP35P PCB s (terminal and processor) Profibus17 P48A Arrow pointer18 D3-SP/SCREW K it, bag with screws19 D3-SP/SEAL K it, bag with O-rings, seals20 D3-SP42 Cables and PC boards to pneumatic block 21 D3-SP34G Gaugeblock G, complete22 D3-SP34N Gaugeblock N, complete

23 D3-AS38M Transmitter board, Mechanical switches, assy24 D3-A S38N Transmitter board, Namur sensors, assy25 D3-A S38P Transmitter board, Proximity switches, assy26 D3-AS38T Transmitter board 4-20, assy27 D3-SP46G Dumpvalve valve assy ÓGÓ for single acting28 D3-SP46N Dumpvalve valve assy ÓNÓ for single acting30 D3-SP6WC Cover incl. screws, Worcester

31 D3-67 Silencer


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Pos Part no. Description

1 D3E-SP2 Front cover incl. screw

2 D3E-SP3 Terminal cover incl. screw

3 D3E-SP4 Internal cover incl. screws

4 P5-Sxx Spindle adapter

5 D3-SP1 Block compl. incl. cable, rubber seal, filter-plug6 D3-SP9 Filter plug incl.O-ring, filter

7 D3E-SP8 Potentiometer compl. incl. spring, holder, cable

8 D3E-SP8-270 Potentiometer compl. incl. spring, holder, cable

9 D3E-SP20 Shaft compl. incl. gearwheel, friction clutch

10 D3E-SP20-270 Shaft compl. incl. gearwheel, friction clutch

11 D3-SP37 Display pcb

12 D3E-SP35X All PCB´s, (processor, mother, terminal)13 D3E-SP35H All PCB´s, HART, (processor, mother, terminal)

14 D3E-SP40 Terminal PCB

15 D3E-SP/Screw Kit with screws D3E

16 D3E-SP/Seal Kit with O-rings

17 D3E-SP42 Cable for pneumatic block, incl. 2 x PCB

18 D3E-SP46G Dump valve G assy for D3E

19 D3E-SP46N Dump valve NPT assy for D3E20 D3E-SP18 Adapter complete for dump valv assy


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PMW PN22549/02

Documents

FlowServe PMV D3