DeZurik PMV P36C User manual

PMV P36C AND P41C

POSITIONERS

USED WITH DeZURIK PNEUMATIC

ACTUATORS

Instruction D10327

August 2012

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

Instructions

These instructions provide information about Models P36C and P41C PMV Positioners. They are for

use by personnel who are responsible for installation, operation and maintenance of Models P36C and

P41C PMV Positioners.

Safety Messages

All safety messages in the instructions are flagged with an exclamation symbol and the word Caution,

Warning or Danger. These messages indicate procedures that must be followed exactly to avoid

equipment damage, personal injury or death. Safety label(s) on the product indicate hazards that can

cause equipment damage, personal injury or death. If a safety label becomes difficult to see or read, or

if a label has been removed, please contact DeZURIK for replacement label(s).

Personnel involved in the installation or maintenance of valves should be constantly alert to

potential emission of pipeline material and take appropriate safety precautions. Always wear

suitable protection when dealing with hazardous pipeline materials. Handle valves that have

been removed from service with the assumption of pipeline material within the valve.

Inspection

Your positioner has been packaged to provide protection during shipment; however, it can be damaged

in transport. Carefully inspect the unit for damage upon arrival and file a claim with the carrier if damage

is apparent.

Parts

Order parts from your local DeZURIK sales representative, or directly from DeZURIK. When ordering

parts, please include the 7-digit part number and 4-digit revision number (example: 9999999R000)

located on the data plate attached to the valve assembly. Also include the part name, the assembly

drawing number, the balloon number and the quantity stated on the assembly drawing.

DeZURIK Service

DeZURIK service personnel are available to install, maintain and repair all DeZURIK products.

DeZURIK also offers customized training programs and consultation services.

For more information, contact your local DeZURIK sales representative or visit our website at

www.dezurik.com.

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

August 2012 Page 3 D10327

Table of Contents

Technical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Cam Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

Installation

Air Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Air Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

I/P Unit Electrical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Front Cover and Indicator Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Reversing the Positioner Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Cam Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Zero and Span Adjustment

Span Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Zero Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Resetting the Range Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Indicator Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Adjusting Travel Speed Dampers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

I/P Electric Control Unit, P41C

The I/P Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Installing I/P Unit On Positioner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Maintenance for Positioners

Pilot Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Diaphragm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Feedback Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Balance Arm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Lower Arm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

O-Ring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

D10327 Page 4 August 2012

Technical Specifications

Model P36C Both Models Model P41C

Input signal 20–100 kPa 3–15 psi

4–20mA

Linearity =<0,5% a=<0,75% a

Hysterisis =<0,75% a=<1%

Repeatability =<0,5% a=<0,5% a

Gain factor at 80%

load. (Supply: 87 psi)

1000 (kPa/kPa)

1000 (psi/psi)

Gain factor at 50%

load. (Supply: 87 psi)

1250 (kPa/kPa)

1250 (psi/psi)

Air consumption at

supply pressure: ±20% ±20%

0,2 MPa/29 psi 5,4 nl/min 0.19 SCFM

6,1 nl/min 0.22 SCFM

0,4 MPa/58 psi 12,3 nl/min 0.43 SCFM 13,6 nl/min 0.48 SCFM

0,6 MPa/87 psi 20 nl/min 0.71S CFM 22 nl/min 0.78 SCFM

0,8 MPa/116 psi 27,8 nl/min 0.98 SCFM 30,5 nl/min 1.08 SCFM

1 MPa/145 psi 35,7 nl/min 1.26 SCFM 39 nl/min 1.38 SCFM

Air delivery at

Supply pressure:

±20%

0,2 MPa/29 psi 135 nl/min 4.7 SCFM

0,4 MPa/58 psi 250 nl/min 8.7 SCFM

0,6 MPa/87 psi 360 nl/min 12.6 SCFM

0,8 MPa/116 psi 480 nl/min 16.8 SCFM

1 MPa/145 psi 590 nl/min 20.6 SCFM

Supply Pressure Max 1 MPa 145 psi 0,15–1 MPa 8–145 psi

Temperature Range

-15°C to +85°C

(5°F to 185°F)

Connector threads 1/4" NTP or G

Gauge threads 1/8" NTP or G

Weight std. 1,1 kg 2.4 lbs

1,6kg 3.5 lbs

Weight with gauges 1,3 kg 2.9 lbs 1,8 kg 4 lbs

Ingress Protection IP 65/NEMA 4

a. Percent of full scale.

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

August 2012 Page 5 D10327

Description

The positioner is a precision instrument which, when used in conjunction with a DeZURIK actuator, can

provide the exacting control necessary to satisfy the most demanding process requirements.

The model P36C will accept a 3-15psi, 3-9psi, or 9-15 psi input signal.

The model P41C will accept either a 0-20mA or a 4-20mA input signal.

The modular design allows for easy parts replacement, and quick access to Zero and Span

adjustments. The housing uses an O-ring seal that can be adjusted to a sealed or drained position.

Operation

P36C and P41C positioners operate on a force balance principal. Force is applied from a signal

pressure that is transmitted through a diaphragm (1) to the balance arm (2). The feedback spring (3)

provides the opposing force. This force is proportional to the level of the lower arm (4). The lower arm

level is determined by the position of the cam (5), which is secured to the spindle (6). The spindle is

connected to the actuator shaft thus providing the feedback from the actuator and valve. See Figure 1.

When the opposing forces are equal, the balance arm (2) and the spool in the pilot valve (7) are in

neutral position and the complete system is in a balanced condition.

Figure 1 –Internal Parts

Air is supplied through port S to the pilot valve, which controls air flow through ports C1 and C2.

Starting from a balanced condition, an increased control pressure will deflect the diaphragm (1) down,

compressing the feedback spring (3). The balance arm (2) moves the spool (7) in the pilot valve (8)

thus supplying air to the actuator. At the same time air is exhausted from the actuator and vented to

atmosphere through the pilot valve and the OUT port.

Air pressure to the actuator is increased, causing the actuator to move the valve and the positioner

spindle (6). The spindle and cam (5) rotate, forcing the lower arm upward, compressing the feedback

spring (3). This motion continues until the two forces are equal and the system returns to a balanced

condition.

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

D10327 Page 6 August 2012

Cam Selection

Each cam is designed to provide split range instrument signals. Standard cam characterization is linear;

however, other characterizations are available.

Installation

Positioners installed in hazardous areas can be ignition sources. Ensure positioners used in

hazardous areas have proper fire/explosion ratings.

Air Requirements

Maximum positioner supply pressure is 145 psi (1 MPa).

Supply air must be clean, dry and free from oil, water, moisture, dirt and debris. The air should be

freeze-dried or similar to a dew point of at least 18 degrees F (10°C) below lowest ambient

temperature.

A 30 micron (or finer) filter/regulator should be installed as close to the positioner as possible to ensure

proper supply air quality.

Air Connections

Air connections are for 1/4" NPT male connectors and are marked on the positioner. Gauge ports are

for 1/8" NPT.

DeZURIK recommends Loctite® 577 tape or similar for sealing.

Port I Input instrument pneumatic signal 3-15 psi (20-100kPa)

Port S Supply air, maximum 145 psi (1 MPa), minimum 21 psi

(0.15 MPa) for P41C

Port C1, C2 Actuator connections. C2 opening port

OUTLET Exhaust air port. Do not plug.

Port IpGauge port for pneumatic input signal (P36C).

Port IEInput electric signal (4–20 mA) (P41C)

Port P Gauge port for I/P unit output pressure (P41C)

Figure 2 - Connecting Block

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

August 2012 Page 7 D10327

Installation (Continued)

The outlet port is used for venting the positioner. All air from the positioner, actuator and I/P unit is

vented to atmosphere through this port. Do not plug this port. A high flow silencer or an exhaust pipe

can be connected to the outlet port to prevent foreign objects from entering and blocking the exhaust.

When using gas for supply, please contact. Port I should be plugged on the P41C. For single acting

operation, plug port C1 for increasing signal to OPEN, or C2 for increasing signal to CLOSE.

Note: See Figure 4 for proper cam position.

With the I/P unit mounted, the positioner is supplied with air from port S and does not need an external

air supply. See pages 8–11 for more information on the I/P unit.

I/P Unit Electrical Connections

Electrical connection on I/P unit accepts 1/2" NPT or PG 13,5 cable gland.

See Figure 10E for wiring connections. Maximum recommended wire size is 16 AWG.

Front Cover and Indicator Cover

The front cover is secured to the pneumatic positioner with four captive screws and sealed with an O-

ring (1). This sealing system allows for complete sealing or draining of the positioner by changing the

position of the O-ring. The O-ring system is common to the Pneumatic positioner, I/P unit and

Feedback unit in the Valve Control System.

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. See Figure 3.

Figure 3 –Front Cover and Indicator Cover

The indicator cover (3) is 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. Once loosened, the

identification cover and O-ring (5) can be removed. When installing the indicator cover and identification

cover ensure the O-ring is properly sealed.

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

D10327 Page 8 August 2012

Reversing the Positioner Action

To change the positioner action from increasing signal to OPEN to increasing signal to CLOSE, or vice

versa, follow the steps below.

Moving parts from accidental operation of power actuator can cause personal injury or

equipment damage. Disconnect and lock out power to the actuator before servicing.

1. Shut off the supply air pressure and the input signal pressure.

2. On double-acting cylinders, disconnect and reverse the two connections to positioner ports C1

and C2. For spring-return cylinders, proceed to step 3.

3. Remove the positioner cover and dial indicator.

4. Loosen the cam locking nut screw and remove the cam locking nut.

5. Turn the cam over and position the cam so the cam roller is about 1/32" from the stop on the

cam. See Figure 4.

Figure 4 –Cam Positions

6. Tighten the locking screw — allow room for movement of the cam as the cam locking nut is

tightened.

7. Turn on the supply and input pressures and operate the valve.

8. Adjust the zero and span adjustments, if necessary.

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

August 2012 Page 9 D10327

Cam Adjustment

Figure 5 –Cam Adjustment

1. With the cover and indicator removed, loosen the screw (1) and turn the cam locking nut (2)

counterclockwise until the cam loosens. See Figure 5.

2. Adjust the cam (3) as desired, making sure the ball bearing (4) is always riding on an active lobe

on the cam.

3. Finger tighten the locking nut and tighten the screw (1).

Note: Ensure screw (1) is loose from the cam before tightening locking nut (2).

4. Install and adjust the indicator, and install cover.

Zero and Span Adjustment

Span Adjustment

Span is adjusted with the yellow (upper) thumb wheel (1)

located on the feedback spring. See Figure 6. To adjust

the span, loosen the locking screw (2) and turn the yellow

thumb wheel. Do not allow the top of the spring to contact

the spring guide (3). When span is set, tighten the locking

screw. Always check Zero after adjusting Span.

Zero Adjustment

Zero is adjusted by turning the silver (lower) thumb wheel

(4) located on the lower arm (5). It can also be adjusted

externally with a screwdriver (7), through the zero adjust

opening. Remember to re-install the zero adjust cover (6)

to keep the unit clean.

Figure 6 –Zero and Span Adjustment

DeZURIK

PMV P36C and P41C Positioners

used with DeZURIK Pneumatic Actuators

D10327 Page 10 August 2012

Resetting the Range Spring

If the correct span cannot be obtained after 2 or 3 zero/span adjustments, reset the range spring as

follows:

1. Disconnect air supply and remove the range spring from the positioner.

2. Loosen screws (1 and 2).

3. Adjust the collar so it is 3/16" or 9/32"* below the flange face.

*Depending on spring style—see Figure 7

Figure 7 –Spring Styles

4. Adjust the spring end to 1/32" clearance.

5. Tighten screws (1 and 2).

6. Adjust the lower zero screw so that 1 or 3 threads are showing (depending on spring style).

7. Reinstall the range spring assembly.

Indicator Adjustment

To adjust the indicator, remove front cover and pull the

indicator upward until it comes off the Allen screw. Before

installing the indicator make sure the Allen screw is

tightened. Press the indicator on the screw and adjust it

by rotating clockwise into position.

Adjusting Travel Speed Dampers

The dampers (5) located on the connecting block provide

a simple means of adjusting the actuator travel speed.

See Figure 8.

For double acting actuators, set the damper marked

Supply to fully open and adjust only the damper marked

Outlet.

For single acting actuators, adjust both the Supply and

Outlet dampers for operation.

Figure 8 –Speed Dampers

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