Foxboro SRP981 Pneumatic Positioner

Foxboro SRP981 Pneumatic Positioner
Master Instruction
04.99
MI EVE0101 A-(en)
SRP981 Pneumatic Positioner
The SRP981 Positioner is for operation of pneumatic valve actuators with pneumatic control signals. It is used to
reduce the adverse effects of valve friction, for higher thrust and shorter positioning time.
FEATURES
• Independent adjustment of stroke range and zero
• Adjustable amplification and damping
• Split range up to 4-fold possible
• Supply pressure up to 6 bar (90 psig)
• Low vibration effect in all directions
• Mounting according to IEC 534, part 6 (NAMUR)
• Rotation adapter for angles up to 120°
Repair and maintenance operations must be carried out by qualified personel!
• Certificate No. 90/20226(E2) Lloyd’s Register of
Shipping for use on vessels
• Modular system of additional equipment
- Electrical limit switches
- Electrical position transmitter
- Booster
- Connection manifold
2
SRP981
MI EVE0101 A-(en)
CONTENTS
CHP.
CONTENTS
1
1.1
1.2
1.3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of operation . . . . . . . . . . . . . . . . . . . . .
Additional equipment . . . . . . . . . . . . . . . . . . . .
2
2.1
2.1.1
2.1.2
2.2.1
2.2.2
2.2.3
2.3
2.3.1
2.3.2
2.3.3
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Built-in limit switch, Model Code R, T, U, V
Position transmitter, Model Code W
Additional parts . . . . . . . . . . . . . . . . . . . . . . . . . 7
Booster relays, Connection manifolds,
Connection manifolds with gauges
Attachment to diaphragm actuators
according to IEC 534-6 (NAMUR) . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Determining the mounting side. . . . . . . . . . . . . 9
Attachment to diaphragm actuators . . . . . . . . . 9
Attachment kit for rotary actuators . . . . . . . . . 10
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attachment to rotary actuators . . . . . . . . . . . . 11
Reversing the direction of rotation . . . . . . . . . 12
3
3.1
3.2
3.2.1
3.2.2
ELECTRICAL CONNECTIONS (of options)
Limit switches . . . . . . . . . . . . . . . . . . . . . . . . .
Position transmitter 4-20 mA . . . . . . . . . . . . .
Direct power supply . . . . . . . . . . . . . . . . . . . .
Supply with Power Supply Unit. . . . . . . . . . . .
13
13
13
13
13
4
4.1
4.2
4.3
4.4
4.5
4.6
4.6.1
4.6.2
4.7
COMMISSIONING . . . . . . . . . . . . . . . . . . . . .
Setting the amplification . . . . . . . . . . . . . . . . .
Setting of zero and stroke. . . . . . . . . . . . . . . .
Setting the damping . . . . . . . . . . . . . . . . . . . .
Subdivision of the input range (split range) . .
Determining of the rotation angle factor Uϕ . .
Determination of the stroke factor Ux . . . . . . .
Stroke factor ranges of the range springs . . .
Characteristics of the range springs . . . . . . . .
Manual bypass switch . . . . . . . . . . . . . . . . . .
14
14
14
15
15
15
16
16
17
17
5
5.1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .
Basic adjustment of the
single acting positioner . . . . . . . . . . . . . . . . .
Basic adjustment of the
double acting positioner . . . . . . . . . . . . . . . . .
Cleaning the throttle . . . . . . . . . . . . . . . . . . . .
18
2.1.3
2.2
5.2
5.3
6
6.1
6.2
6.3
PAGE
REPLACING SUBASSEMBLIES . . . . . . . . .
Replacing the amplifier . . . . . . . . . . . . . . . . . .
Replacing the amplifier diaphragm
in the single acting positioner . . . . . . . . . . . . .
Replacing the amplifier diaphragm
in the double acting positioner . . . . . . . . . . . .
3
3
4
5
18
19
20
20
20
21
22
CHP.
CONTENTS
PAGE
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
Option “Built-in limit switch” . . . . . . . . . . . . 23
Method of operation . . . . . . . . . . . . . . . . . . . . . 23
Electrical connections. . . . . . . . . . . . . . . . . . . . 23
Arrangement of connection . . . . . . . . . . . . . . . 23
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjusting the switching points . . . . . . . . . . . . . 24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety requirements . . . . . . . . . . . . . . . . . . . . . 24
Subsequent installation or exchange . . . . . . . . 25
8
8.1.
8.2
8.3
8.4
8.5
8.6
8.7
Option “El. Position transmitter” . . . . . . . . . 26
Method of operation . . . . . . . . . . . . . . . . . . . . . 26
Electrical connections. . . . . . . . . . . . . . . . . . . . 26
Arrangement of connection . . . . . . . . . . . . . . . 26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Adjusting the measuring range . . . . . . . . . . . . 27
Conversion from normal direction of action
in reverse direction of action . . . . . . . . . . . . . . 27
Subsequent installation or exchange . . . . . . . . 28
9
9.1
9.2
9.2.1
9.2.2
9.2.3
9.2.4
SAFETY REQUIREMENTS . . . . . . . . . . . . . . . 29
Accident prevention . . . . . . . . . . . . . . . . . . . . . 29
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . 29
General requirements. . . . . . . . . . . . . . . . . . . . 29
Connection requirements . . . . . . . . . . . . . . . . . 29
Explosion protection . . . . . . . . . . . . . . . . . . . . . 29
EMV and CE. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . 30
MI EVE0101 A-(en)
SRP981
3
1 GENERAL
The pneumatic positioner is used for the actuation of pneumatic actuators by means of pneumatic controllers with a
continuous output of 0.2 - 1 bar or 3 - 15 psi or split ranges.
In addition the positioning force of the actuator is increased
by means of an output pressure of max. 6 bar.
The pneumatic positioner can be mounted on both diaphragm actuators and rotary actuators.
The positioner and actuator form a control loop with the
command variable ws (output signal y of the master controller), the correcting variable ys and the linear position xs
of the actuator.
For actuators with spring resetting a single acting positioner
is used, for actuators without spring resetting a double acting positioner is used.
In this manner disturbances such as gland friction and medium forces are compensated.
The double acting positioner operates with two opposing
control pressures.
Master controller
Positioner
Actuator
max. 6 bar
w
ys
y
x
Stroke
xs
ws
0,2 ... 1 bar / 3 ... 15 psi
Transmitter
Valve
Fig. 1: Control circuit with single acting positioner
1.1 Identification
Nameplate
Example:
Single acting positioner
Example:
Double acting positioner
SRP981
SRP981
Pneumatischer Stellungsregler
Pneumatic Positioner
Pneumatischer Stellungsregler
Pneumatic Positioner
MADE IN FRANCE
ZULUFT max.6bar
SUPPLY AIR max.90PSI
STELLGRÖSSE 1
OUTPUT 1
FÜHRUNGSGRÖSSE W
INPUT W
Instr. specification, Model Code
No. for customized version
(01) CDS 514 370 061
ECEP
SER.No.
SRP981-CIDMS1G
ECEP
SER.No.
STELLGRÖSSE 2
OUTPUT 2
MADE IN FRANCE
ZULUFT max.6bar
SUPPLY AIR max.90PSI
STELLGRÖSSE 1
OUTPUT 1
FÜHRUNGSGRÖSSE W
INPUT W
Instr. specification, Model Code
No. for customized version
(01) CDS 514 370 052
A Siebe Group product
A Siebe Group product
SRP981-BIDLS1N
4
SRP981
MI EVE0101 A-(en)
1.2 Method of operation
OFF
AUS
w
51
52
w
ON
EIN
Supply air
Zuluft
y
70
35
45
y
50
31
y2
41
Supply air
Zuluft
9
34
36
37
y1
40
42
16
44
44
16
35
9
50
Supply air
Zuluft
42
32
34
36
33
37
31
32
33
Fig. 4: Single acting positioner with additional booster 52
Fig. 5: Double acting positioner
The positioner functions in accordance with the force balance principle:
The inputsignal w (0.2 ... 1 bar) acts on the input diaphragm
70 1). The stroke of the input diaphragm is transferred to the
flapper lever 35 . The resulting axial variation of the nozzle
36 and the flapper 37 varies the dynamic pressure at the
nozzle. In the single acting positioner, this pressure acts on
an amplifier 40, the output pressure y of which causes a linear movement in a diaphragm actuator without spring resetting 2).
In the case of the double acting positioner this pressure
acts on a dual amplifier 41, the opposed output pressures
y1 and y2 of which cause a linear movement in a diaphragm actuator without spring resetting. This linear movement is picked up from the actuator spindle 16 by means
of the feedback lever 9 of the positioner and transferred to
the stroke factor lever 31 .
The stroke factor lever 31 is connected to the flapper lever
35 by means of a range spring 34 .
A force balance is created on the flapper lever 35 when the
torque generated at the input diaphragm 70 coincides with
the countertorque produced on the range spring 34 by the
linear position. This ensures that the actuating position is
always proportional to the input signal.
Dynamic matching of the actuator (sensitivity, stability) is
possible by means of the throtting screw 42 and the
damping throttles 44 , or 44 and 45 in the case of the
double acting positioner. The stroke range and zero are set
by means of the zero screw 32 and the stroke factor screw
33 .
The changeover plate 50 is used in the case of the single
acting positioner to set either an increasing or decreasing
control pressure for an increasing input signal.
1)
2)
If the single acting positioner is fitted with a bypass switch 51 , and if this
switch is set to the “OFF” position, the input signal w is supplied direct to
the actuator, in other words the positioner has no effect.
A booster 52 can be installed in order to increase the air output capacity
and reduce the positioning time.
MI EVE0101 A-(en)
SRP981
5
1.3 Additional equipment
Single acting pneumatic positioners can be supplied with
two built-in gauges for displaying the command variable 10
(input) and correcting variable 11 (output).
The air output capacity can be significantly increased by
means of additional single acting and double acting boosters 52; the positioning time is thereby shortened to between one quarter and one seventh.
A bypass switch 51 can only be installed with single acting
positioners.
The positioner can be matched to nearly all operating situations, such as a split range up to 4 ways, very long and
very short strokes and angles of rotation of special cams,
by means of a total of 5 range springs. The standard range
spring fitted is the 420 494 019. Other range springs are
available (Code FESG-FN, see page 16).
An attachment kit (Model Code EBZG-PN, -NN, -JN, -ZN or
-RN) for rotary movement is required for attachment to rotary actuators and rotary armatures.
10
11
51
52
Fig. 6: Single acting pneumatic positioner with built-in
gauges and booster
Fig. 9: Housing of the attachment kit for rotary movement
The Inductive limit switch 57 (Code R, T, U) and the limit
switch with two microswitches (Code V) in addition enables
end position signalling.
If 1/4-18NPT connections are desired, the connection manifolds Model Code LEXG-BN rsp. -CN must be used. The
connection manifold Model Code LEXG-CN is required for
10 mm piping. The connection manifold Model Code LEXG
-BN is required for piping up to 12 mm.
LEXG-BN
57
LEXG-CN
Fig. 10: Positioner with limit switches
Fig. 7: Connection manifolds
The position transmitter 4-20 mA 58 (Model Code W) signals the stroke or angle of rotation via a standard electrical
signal of 4 to 20 mA.
If a display of the control pressure, input signal or supply air
pressure is desired for single acting and double acting positioners, the connection manifold 53 with gauges (Model
Code LEXG-JN, -KN, -LN, -MN or -NN) can be used.
58
53
Fig. 11: Positioner with position transmitter 4-20 mA
Fig. 8: Connection manifold with gauges
6
SRP981
MI EVE0101 A-(en)
2 MOUNTING
2.1 Dimensions
2.1.1 Positioner
8,8
.35
58 (93*)
2.28 (3.66*)
105
4.13
mm
62,5
2.46
in
47,5
1.87
min.4˚
max.39˚
2.83
100
3.94
72
M6
17
.67
22
.87
22
.87
22
.87
1, 2, 3, 4
Front view
Code L
4
1
10
11
3
9
2
Code M, N
1
2
3
4
Female thread G 1/8 for supply air
Female thread G 1/8 for input (w)
Female thread G 1/8 for output I (y1)
Female thread G 1/8 for output II (y2)
(only on double acting positioner)
9 Feedback lever
10 Gauge for input
11 Gauge for output
* Dimension with built-in gauges
(optional, only on single acting positioner)
2.1.2 Options
“Built-in limit switch”,
Model Code R, T, U, V
“Position transmitter”,
Model Code W
96
3.78
MI EVE0101 A-(en)
SRP981
2.1.3 Additional parts
Connection manifold 1/4-18NPT
with connections same level, Code LEXG-CN
2
4 1 3
6
30
1.18
88
3.46
1
3
2
30
1.18
88
3.46
Booster relay single acting,
Code VKXG-FN
28,5
28,5
6
2
1.12
4 1 3
1.12
Connection manifold 1/4-18NPT
with staggered connections, Code LEXG-BN
Booster relay double acting,
Code VKXG-GN
6
4 1
3
2
85
3.35
65,5
2.58
6
88
91
3.46
3.58
104
4.09
Booster relay single acting
with doubled output capacity, Code VKXG-HN
5
2
6
Female thread 1/4-18 NPT for supply air
Female thread 1/4-18 NPT for input (w)
Female thread 1/4-18 NPT for output I (y1)
Female thread 1/4-18 NPT for output II (y2)
Female thread 1/2-14 NPT for output I (y1)
Fixing screws 17 mm A/F
87
3.43
1
1
2
3
4
5
6
104
108
4.09
4.25
mm
in
Connection manifold 1/4-18NPT with gauges Code LEXG-JN, -KN, -LN, -MN, -NN
Connection manifold 1/4-18NPT for gauges Code LEXG-RN, -SN, -TN
2.11
53,5
4 1 3 2
102
6
4.02
Connection
manifold
Code LEXG
75
2.95
60
60
61
62
Gauges
for
Gauges
for
Gauges
for
-JN (-RN*) without
Output (y)
Supply air
-KN (-RN*) Input (w)
without
Supply air
-LN (-RN*) Input (w)
Output (y)
Supply air
-MN (-SN*) Supply air
Output I (y1) Output II (y2)
-NN (-TN*) Input (w)
Output I (y1)
Output II (y2)
*) Connection manifold for gauges; without gauges
61
62
Version
of action
single
single
single
double
double
83
3.27
7
8
SRP981
MI EVE0101 A-(en)
2.2 ATTACHMENT KIT FOR DIAPHRAGM ACTUATORS FOR STROKE MOVEMENTS
2.2.1 Dimensions
Attachment to casting yoke
according to IEC 534-6 (NAMUR)
Code EBZG-GN
21
17
20 ... 35
.79 ... 1.38
17
54
2.13
2 pieces
8
.3
71
2.80
54
2.13
M8
71
2.80
20
43
1.69
20
Attachment to pillar yoke
according to IEC 534-6 (NAMUR)
Code EBZG-FN
9
9
49,5
1.95
2,5
.10
Feedback lever
Code EBZG-AN, -FN, -GN
Code EBZG-BN (extended version)
72
2.83
83
3.27
20
.78
9
91
3.58
14
Mounting bracket
according to IEC 534-6 (NAMUR)
for Code EBZG-GN, FN
4
.16
9
.35
52
2.05
116
4.57
21
.83
6,5
.26
11
.43
71
2.80
8
.31
72
2.83
80
3.15
15
8
.31
Corrier bolt
for attachment to valve stem
20
9
.35
30
43
1.69
43
1.69
10
.39
mm
in
M6
96
3.78
9
.35
14
.55
.31 +.01
7,9 +0,2
6
.24
16
65
2.56
10
.39
MI EVE0101 A-(en)
SRP981
2.2.2 Determining the mounting side
Single acting diaphragm actuators
Check whether the actuator is in the safety position required by the process (Does the actuator open or close with
spring force?). The mounting side is selected from the
table below in accordance with the direction of action and
the required direction of movement of the spindle for an increasing input signal.
Actuator closes Changeover Actuator opens Changeover
with spring force plate setting with spring force plate setting
The arrow indicates the direction of movement of the spindle for an increasing input signal.
The direction of action of the input signal can be set on the
changeover plate 50 (see page 31):
N = normal direction of action
(increasing input signal produces increase
in control pressure to the actuator)
U = reverse direction of action
(increasing input signal produces decrease
in control pressure to the actuator)
Double acting diaphragm actuators
With double acting positioners the changeover plate 50
(see page 31) always stays in the “N” setting. The assignment of the input signal to the direction of movement of the
actuator spindle is determined by the selection of the mounting side for the positioner and the piping of the positioner
outputs to the actuator:
If the actuator spindle is to travel out with an increasing input signal, output y1 is connected on the top of the actuator
and output y2 is connected on the bottom.
The positioner is mounted on the right-hand side.
If the actuator spindle is to retract with an increasing input
signal, output y1 is connected on the bottom of the actuator
and output y2 is connected on the top.
The positioner is mounted on the left-hand side.
Changeover
plate setting
2.2.3 Attachment to diaphragm actuators
The positioner is attached using the attachment kit for diaphragm actuators according to DIN IEC 534-6 on the righthand or left-hand side of the actuator.
a) Screw carrier bolt 14 into the actuator coupling. (see
page 8).
b) Screw the attachment plate 20 to the positioner using
two M6 socket head screws.
c) Fasten the positioner with attachment plate 20 to the
diaphragm actuator.
For FOXBORO ECKARDT-diaphragm actuators with
casting yokes:
Fasten the attachment plate 20 using M8 screw to the
threaded hole of the casting yoke (see page 8).
This ensures that the feedback lever 9 is horizontal at a
50 % stroke.
For diaphragm actuators with pillars:
Fasten attachment plate 20 using two U-bolts 21 in
such a manner that the feedback lever 9 loosely attached on the shaft 17 of the positioner and the carrier
bolt 16 is horizontal at a 50 % stroke (see page 8).
d) Set the actuator to a linear position of 0 %.
Attach the feedback lever 9 on the shaft 17 of the
positioner and the carrier bolt 16 in such a manner that
the compensating spring 14 is above the carrier bolt
16, when the mounting side is on the right, and below
the carrier bolt 16 when the mounting side is on the left
(see Fig. 17).
e) Press the stroke factor lever 31 against the stop bolt 30,
and create a friction-type connection between the feedback lever 9 and the shaft of the positioner by tightening
the Allen screw 15 (A/F 10). See page 31.
f) With single acting diaphragm actuators connect positioner output y1 to the diaphragm actuator; with double acting diaphragm actuators connect outputs y1 and y2.
g) Connect command variable w (input).
h) Connect supply air of min. 1.4 bar to max. 6 bar, but do
not exceed the maximum permissible operating pressure of the diaphragm actuator.
i) Screw on the housing cover in such a way that the air
vent of the attached device faces downwards (see mark
‘M ‘ in Fig. 17).
9
16
14
Changeover
plate setting
The arrow indicates the direction of movement of the spindle with an increasing input signal.
9
M
Fig. 17: Pillar yoke, mounting side left
10
SRP981
MI EVE0101 A-(en)
2.3 ATTACHMENT KIT FOR ROTARY ACTUATORS
2.3.1 Dimensions
With shaft
(according to VDI/VDE 3845)
Code EBZG-ZN
Housing dimensions
Attachment kit with shaft
resp. without flange
Code EBZG-NN
8
.31
4,5
.18
4
.16
6
.53
99
3.90
64
2.52
12
.47
28 +0,5
1.10 +.02
14
.55
M6
50
1.97
M6 x 14 (2x)
DIN 912
30
1.18
Detail Z
95
3.74
16 H8
.63
88 (124*)
3.46 (4.88*)
43
1.69
167
6.57
13,5
.53
Without flange
Code EBZG-NN, -PN
88 (124*)
43
1.69
M6 x 14 (2x)
DIN 912
6,5
/
.26
95
3.74
45 0,2
1.77 .01
14 - 6 tief
.55 - .24 deep
M6
15 0,2
.59 .01
22
.87
12
99
3.90
12
.47
64
2.52
11
.43
1,2
.05
Detail Y
3.46 (4.88*)
Housing dimensions
Attachment kit without flange
Code EBZG-PN
0
12
.47
Adaption of the actuator drive shaft end
and correct axial location by client !
16
.63
M6
167
6.57
14 ... 15,5
.55 ... .61
*) with gauges (Option)
With flange
Code EBZG-JN
99
3.9
10
.39
12
.47
60 0,2
2.36 .01
75
2.95
0,2
.01
86
3.39
6
.24
50
1.97
6
.2 ,5
6
54
2.13
47
1.85
10
.39
mm
in
3
.12
5
.20
70
2.76
128 (164*)
5.04 (6.46*)
M6 x 14 (2x)
DIN 912
167
6.57
63
2.48
Rotation angle max 120˚; torque requirement 14 Nm
MI EVE0101 A-(en)
SRP981
Attachment kit for rotary actuators
11
24
For attachment of the positioner to rotary actuators or rotary
armatures an attachment kit is required. The linear cam enables sensing of rotation angles up to 120 °, whilst the
equal percentage and the invers equal percentage cams
sense rotation angles up to 90 ° (linear characteristic between 70 ° and 90 °).
y1
2.3.2 Attachment to rotary actuators
a) Remove the transparent cover plate from the housing of
the attachment kit 26 .
b) Mount the housing of the attachment kit on the rotary
actuatoror the armature; use the mounting hardware
supplied by the actuator manufacturer if necessary.
y2
Zuluft / Supply air
26
y1
y2
Zuluft / Supply air
Fig. 21: Rotary actuator with attachment kit for rotary movement and double acting positioner. For direction of
rotation see arrow on cam
e) Fasten the feedback lever 9 for the rotary actuator onto
the shaft of the positioner 17 as shown in Fig. 22.
17
Fig. 19: Rotary actuator with attachment kit for rotary
actuators
c) Move the actuator into the desired starting position
(rotation angle = 0 °).
d) Mount the cam 24 in accordance with the direction of
rotation of the actuator (see Fig. 20).
The linear cam is fastened to the actuator drive shaft in
such a manner that the dimension for x or y (Fig. 16) is
2 mm, whereas in the case of the inverse equal percentage cam the dimension x ≈ 17.5 mm and the dimension y ≈ 21.5 mm.
In the case of the inverse equal percentage cam the dimension x ≈ 18 mm and y ≈ 23 mm.
When employing the equal percentage and the inverse
equal percentage cams, the range spring 420 493 013
supplied in the accessory bag must be installed in the
positioner.
24
A = Mounting position
for actuator
rotation
A
B
B = Mounting position
for actuator
rotation
9
15
SW 5
Fig. 22: Attaching the feedback lever to the positioner
f) Mount the positioner on the housing of the attachment kit
26 . Attach the spring 18 to the feedback lever 9 and
the cam follower 19 against the cam (see Fig. 23).
9
18
26
19
25
linear
24
24
A
A
%
B
B
%
Fig. 23: Attachment of the positioner
19
equal percentage
25
invers equal percentage
Fig. 20: Mounting position of the cams
19
12
SRP981
Screw the positioner to the housing of the attachment kit
(see Fig. 25). With the linear cam and the inverse equal
percentage cam check whether the mark 25 points to
the centre of the cam follower 19 (see Fig. 20); adjust if
necessary.
With the equal percentage cam check whether the cam
follower lies directly ahead of the start of the cam lobe;
adjust if necessary.
g) Final mounting of the feedback lever 9 on the shaft of the
positioner is performed at a stroke of 0 %, i. e. a rotation
angle of 0 °. First loosen the 5 mm A/F Allen screw of
the feedback lever 9 through the hole 29 (see Fig. 24
and 25), then press the stroke factor lever 31 against
the stop screw 30 and tighten the Allen screw firmly.
h) With single acting actuators connect positioner output y1
with the actuator; with double acting actuators connect
y1 and y2 with the actuator. Connect the chamber in
which the pressure is to built up with an increasing input
signal to y1.
i)
MI EVE0101 A-(en)
Note !
If the actuator moves to an end position, the mounting position of the cam does not coincide with the direction of rotation of the actuator. In this case install the cam 24 in the
reverse position.
I) Affix the red pointer 27 on the headed screw 28 in such
a manner that 0 ° is indicated when the rotary actuator
is in its starting position (w = 0).
m) Attach the transparent cover plate.
2.3.3 Reversing the direction of rotation
Single acting actuator: Move the changeover plate 50 to
the “U” setting and reverse the cam 24 .
Double acting actuators: Exchange the positioner outputs
and reverse the cam (see Fig. 21). The changeover plate
50 remains in the “N” setting!
Connect command variable w (input).
k) Connect supply air of min. 1.4 bar to max. 6 bar, but do
not exceed the maximum permissible operating pressure of the actuator.
28
24
50
29
26 9
Fig. 24: Tightening the feedback lever
27
30
31
Fig. 25: Attachment kit for rotary movement and positioner
MI EVE0101 A-(en)
13
SRP981
3 ELECTRICAL CONNECTIONS
(of options)
3.2.1 Direct power supply
Electrical connections are available for pneumatic positioners with the auxiliary equipment limit switch or position
transmitter 4-20mA.
Upon installation, the installation requirements of DIN
VDE 0100 resp. DIN VDE 0800 as well as locally applicable requirements, must be observed.
In addition, the requirements of VDE 0165 must be observed for systems associated with hazardous areas.
Further important instructions are contained in page 29
(Safety requirements, Explosion protection).
IIf an earth connection or potential equalization is required,
the appropriate connections must be set up.
The unit must be operated in a fixed position.
The cable feeds in through a screwed gland Pg 13.5. This
is suitable for line diameters of 6 to 12 mm.
The electrical connections are suitable for wire crosssections of up to 2.5 mm².
US = 12 ... 36 V
1)
RB
12 ... 36 V
Positiontransmitter
Connected device
including
line resistance
(e. g. recorder,
indicator, etc.)
The max. load impedance RLmax is calculated per:
RBmax = (US – 12 V) / 0.02 A [Ohm]
Load characteristic for direct supply
RB
Ω
3.1 Option “Built-in limit switches”
1200
Connection terminals see page 23.
800
3.2 Option “Position transmitter”
400
Model Code W
US = 12 ... 36 V
0
11
12
K1
K2
12
K3
mA
K4
Position converter
20
36V
28
US
RB
Connected device
(e.g. recorder,
controller, etc.)
3.2.2 Supply with Power Supply Unit
For intrinsically safe applications, FOXBORO ECKARDTPower Supply Units are available.
Field
Control room
MUS
4 ... 20 mA
0 / 4 ... 20 mA
Us
RB
Connection terminals
K1 (+)
K3 (-)
K2 (+)
K3 (-)
} Power supply
} Test of the output signal without interruption.
K4
Earth connection
Position
converter
Power
supply
Connected device
(e. g. recorder,
controller, etc.)
RB max.
= 500 Ω
A low load ampere meter (Ri ≤ 10 Ω) can be
used.
1)
For explosionproof instruments observe the electrical limits,
see Product Specifications PSS EVE0101 A.
14
SRP981
MI EVE0101 A-(en)
4 COMMISSIONING
4.2 Setting of zero and stroke
Before commisioning pneumatic positioners must be matched to the stroke or rotation angle of the actuator and the
input signal range.
The supply air connected should be min. 1.4 bar and max.
6 bar, but should not exceed the maximum operating pressure of the diaphragm actuator.
4.1 Setting the amplification
The amplification and thus the sensitivity of the positioner
are set by means of the throttling screw 42. The throttling
screw is screwed in right in the factory, i. e. it is set to maximum amplification.
This amplification varies with the supply air pressure, as
shown in the following table:
Supply
air
Max. amplification
1.4 bar
Single acting
positioner
approx. 150
Double acting
positioner
approx. 100
4 bar
6 bar
approx. 90
approx. 60
approx. 150
approx. 180
The linear amplification is indicated. These values are
based on the built-in range spring FES 420 494 019.
From the basic setting the amplification can be matched to
the dynamic requirements of the control system (counterclockwise rotation of the throttling screw 42 results in less
amplification).
Note!
The zero must be reset following each change of amplification.
In order to ensure reliable pressure reduction in the actuator, the throttling screw 42 should not be opened beyond
the listed maximum values (with 6 bar max. ¼ ro). A limiting
screw 43 is therefor incorporated.
The basic setting at the factory permits a maximum opening of the throttling screw 42 of approx. 1 turn.
Before commencing settings press the flapper lever 35 several times alternately to the left and right in order to align
the flappers correctly.
a) Set the minimum value of command variable w (start of
stroke)
b) Turn the zero screw 39 until the actuator just begins to
move from its end position.
c) Set the maximum value of command variable w (end of
stroke).
d) Turn the stroke factor screw 40 until the actuator precisely reaches its end position.
Recheck the zero and stroke settings.
Note:
When the stop screw 20 is correctly positioned (see 5.1 or.
5.2) and the feedback lever is correctly mounted (see 2.2.3
d / e) there is no interaction between the adjustments of
zero and stroke.
If the stroke cannot be adjusted with the existing spring, the
correct spring can be approximately determined in accordance with the following criteria:
Upper end position requires softer spring with
higher number of turns (for large strokes and
“split-range”)
corresponds to 1b–5b (page 16)
Stroke range of the existing spring
corresponds to 1a–5a (page 16)
Lower end position requires harder spring
with fewer turns (for shorter strokes and equal
percentage cams)
There are 5 differently rated springs available for matching
to the stroke and input signal range. The particular spring
34 required can be determined precisely from the stroke
factor UX.
MI EVE0101 A-(en)
SRP981
15
4.3 Setting the damping
The air output capacity of the positioner can be reduced by
means of the damping throttle 44 (see page 31).
Double acting positioners are equiped with a damping
throttle 44 for output y1 and a damping throttle 45 for output y2.
In its normal setting the damping throttle is approximately
flush with the amplifier housing. The air output capacity is
reduced by a factor of approximately 2.5 when the damping
throttle is turned right in.
A reduction of the air output capacity should only be undertaken for very small actuator volumes, since the control
system would otherwise be too sluggish.
31
34
32
30
33
4.4 Subdivision of the input range
(split range)
If several actuators are to be controlled by the same command variable, and a complete stroke is to be made in only
one specific subrange of this command variable at a time,
each actuator must be provided with a positioner, on which
the zero and stroke range must be set to the desired subrange of the command variable.
In the case of positioners which are attached to FOXBORO
ECKARDT valves, 4-way subdivision is possible with subranges of 0.2 bar.
The range springs required can be selected on the basis of
the stroke factor range or the spring graph (see page 16).
If the zero point must be elevated to greater than 0.6 bar
as the result of the subdivision of the input range, the setting should be performed as follows:
a) Shut off supply air.
b) Remove tension from the range spring 34 by turning the
zero screw 32 .
c) Loosen the A/F 10 screw of the feedback lever and turn
the stroke factor lever 31 away from the stop screw 30.
This applies pretension to the range spring 34 (see Fig.
31). In this position retighten the screw of the feedback
lever.
d) Connect supply air.
e) Set the minimum value of command variable w (start of
stroke).
Fig. 31: Pretension of the range spring
f) Turn the zero screw 32 until the actuator begins to move
away from its end position. If this is not possible, the pretension of the range spring must be increased as described under c).
g) Set the maximum value of command variable w (end of
stroke).
h) Turn the stroke factor screw 33 until the actuator reaches its end position precisely.
Note!
At this setting the zero and stroke range are mutually dependent. Settings e) to h) should therefore be repeated as
often as necessary until both settings are correct.
Furthermore it should be noted that the deflection of the
stroke factor lever 31 from the starting position may not exceed a maximum of 39 degrees, since the stroke factor lever might otherwise touch the housing cover before reaching its end position.
4.5 Determining of the rotation angle factor Uϕ
In conjunction with the attachment kit for rotary actuators
(Code P, M, J, Z, R) the rotation angle factor Uϕ can be
determined as follows:
Uϕ =
Rotation angle ∠°
ϕ
=
∆w
Input signal range bar
The rotation angle factors Uϕ of the individual range springs
are given in the table on page 16. The rotation angles are
also taken into account in the graph of the range springs
(see page 16).
16
SRP981
MI EVE0101 A-(en)
4.6 Determination of the stroke factor Ux
The stroke factor Ux is the ratio of the entire range of the
output variable (stroke x) to the entire range of the input
variable (command variable w).
For FOXBORO ECKARDT diaphragm actuators PA200 to
PA700 / 702 :
Ux =
The stroke factor can be used to determine for each application whether or with which spring the desired setting can
be made.
Five different range springs are available for matching to
the stroke and input signal range.
x
Stroke in mm
=
∆w
Input signal range in bar
For FOXBORO ECKARDT diaphragm actuator (1500 cm²)
and other manufacturers (I0 = 117.5 mm):
4.6.1 Stroke factor ranges of the range springs
The stroke factor Ux determined as described in 4.6 should
lie within the ranges of the respective range springs indicated in the following table, as close as possible to the lower
value.
l
x
Ux =
× 0
∆w
ls
Is = Feedback lever length in mm (for FOXBORO ECKARDT-actuator 1500
cm²: Is = 122.5 mm)
Io = Standard feedback effective length
Cam 1)
Equal perc.
linear
and inverse
equal perc.
Range spring
Ident No.
old ID
Colour
1 420 493 013
FES 627/1
yellow
2 420 494 019
FES 628/1
green
3 502 558 017
FES 612/1
- without -
4 420 496 011
FES 715/1
gray
5 420 495 014
FES 629/1
blue
1)
2)
3)
4)
max. 120°
max. 90°
1.7 ... 4.7
(max. 7)
3.5 ... 9.5
(max. 14)
5.8 ... 14.5
(max. 21.75)
8.4 ... 21.5
(max. 32.75)
11.5 ... 27.5
(max. 41.5)
2.4 ... 8
(max. 10)
5 ... 15
(max. 20)
8.2 ... 24
(max. 28)
12 ... 35
(max. 43)
-
Stroke factor ranges
Stroke factor
Stroke
Ux
range2)
mm
bar
Remarks
mm
10 ... 30
(max. 42)
22 ... 60
(max. 84)
35 ... 90
(max. 130)
50 ... 140
(max. 190)
70 ... 180
(max. 250)
8 ... 34
3)
17 ... 68
built-in
28 ... 105
3)
40 ... 158 4)
3)
55 ... 200 4)
3)
For equal percentage and inverse equal percentage cams the rotation angle factors are a function of their corresponding rotation angles.
For feedback effective length Is = 117.5 mm and ∆ w = 0.8 bar
Included in FESG-FN (Id No. 407 083 013)
Theoretically value
x0
ϕ
%
2b
5a
S2
40
4a
30
3a
5a
20
90
70
30
2a
10
1a
10
0
1b
S1
90
30
3b
50
120
60
4b
[mm]
[∠°]
lin
5b
Stroke
0
Setpoint
0
0
0.2
0.4
Zero elevation
0.6
0.8
1
w [bar]
1a ... 5a = minimum stroke range of each spring
1b ... 5b = maximum available strokes
MI EVE0101 A-(en)
SRP981
4.6.2 Characteristics of the range springs
The stroke xo is based on the FOXBORO ECKARDT- standard
feedback lever effective length Io = 117.5 mm.
Is min. =
72
2.83
Is max. =
142
5.59
Io =
117,5
4.62
Fig. 33: Feedback lever
If another length (Is) is used, the actual stroke xs must be
converted to the stroke x0:
x0 =
117,5 × x s
mm
ls
Selection of measuring spring and setting of span
Determination of suitable spring for split range:
a) Enter desired setpoint value w for travel start in the diagram field.
b) Determine xo if Is unequal 117.5 mm.
c) Enter intersection w/xo .
d) Connect points determined at a) and c). This results in a
straight line.
e) If the straight line does not run through the origin, move
this parallel here.
f) Use the spring the characteristic line (a) of which is located directly below the presently determined characteristic line.
4.7 Manual bypass switch
The single acting pneumatic positioner can also be supplied with a bypass switch 51 (see page 31) if it is intendet
for use with actuators with a signal range of 0.2 ... 1 bar.
In the “ON” position the actuating signal of the master controller is supplied via the positioner; in the “OFF” position it
is connected direct to the actuator.
Note!
The bypass switch may only be operated in the normal
direction of a action (changeover plate 50 in position N,
see page 31), i. e. when the “OFF” position is set.
It should also be noted that the stored pressure in the actuator chamber may have a feedback effect on the preceding controllers when the “OFF” position is set, and could
overload them. The pressure in the actuator chamber
should therefore be reduced accordingly before the changeover. The spring range of the actuator should not exceed
the maximum signal value of the master controller, in order
to ensure that the valve can open and close fully.
w
x
51
EIN
ON
Fig. 34: Bypass circuit
Example: Split-range-operation
(shown in graph)
Valve 1:
w = 0.2 ... 0.6 bar
xs = 30 mm (stroke range)
Is = 140 mm
x0 =
117,5 × 30
= 25,2 mm
140
Intersection w = 0.6 bar with xo = 25.2 mm → S1
Selected: spring 4 (FES 420 496 011, grey), because the
characteristic curve, based on the begin of the determined
straight line, lies directly beneath of them.
Valve 2:
w = 0.6 ... 1.0 bar
xs = 50 mm (stroke range)
Is = 140 mm
x0 =
117,5 × 50
= 42 mm
140
Intersection w = 1.0 bar with xo = 42 mm → S2
Selected: spring 5 (FES 420 495 014, blue), because the
characteristic curve, based on the begin of the determined
straight line, lies directly beneath of them.
17
w
x
51
AUS
OFF
18
SRP981
MI EVE0101 A-(en)
5 MAINTENANCE
5.1 Basic adjustment of the single acting
positioner
A basic adjustment is only required when the device has
been disassembled or subassemblies have been exchanged. All settings performed in order to match the positioner
to the actuator are described in chapter 4 Commissioning,
page 14.
i)
The following tools are required for the basic adjustment:
1 screw driver
1 set spanner A/F 7
1 feeler gauge 0.6 mm
2 pressure test gauges 1.6 bar
1 signal generator 0.6 bar
If adjustments are made with the device attached, the feedback lever on the shaft of the positioner must be loosened.
k)
a) Set the changeover plate 50 to “N”.
b) Turn the throttling screw 42 clockwise as far as its stops
(maximum amplification).
c) Unhook the range spring 34 from the flapper lever 35 .
d) Check that the flappers 37 are aligned concentrically with
the nozzles 36. If necessary loosen the mounting bolts
of the amplifier on the rear of the positioner and align
the amplifier accordingly.
e) Press the flapper lever 35 several times alternately to
the left and right, so that the ball-guided flappers are
parallel to the nozzles.
f) Press the flapper lever 35 to the left. Set the clearance
between the right-hand nozzle and the right-hand flapper to 0.6 mm with the aid of a feeler gauge by turning
the hexagonal nut 56 A/F 7. Then secure the nut
against further turning.
g) Connect the positioner as shown in the test circuit in Fig.
35. Connect supply air of 1.4 bar.
h) Press the flapper lever 38 to the left. If the output y does
not rise to the level of the supply air pressure, either
leaks are present or the flapper is not correctly aligned
(repeat e)).
I)
m)
n)
o)
p)
Hook the range spring 34 onto the flapper lever 35 and
connect w ≈ 0.6 bar.
The following procedure must be observed in order to
achieve a no-feedback adjustment of the zero and
stroke settings:
Press the stroke factor lever 31 against the stop screw
30 .
Set the stroke factor screw 33 to a high stroke factor
(approx. 2 mm before the upper stop).
Turn the zero screw 32 until the output pressure
y ≈ 0.6 bar, and make a note of this value.
Set the stroke factor screw 33 to a low stroke factor
(approx. 2 mm before the lower stop).
The output pressure y may not vary by more than
± 150 mbar as compared with the setting described in
m).
In case of excessive deviations the stop screw 30 should
be adjusted.
Whenever the stop screw 30 is adjusted, the settings
described in l) to n) should be repeated until the deviation is less than ± 150 mbar.
Secure the stop screw 30 with sealing paint.
Return the changeover plate 50 to its original position. Reattach the positioner or fasten the feedback lever back onto
the shaft of the positioner see chapter 4, page 14.
y
w
w
Fig. 35: Test circuit
Supply air
Supply air 1,4 bar
MI EVE0101 A-(en)
SRP981
19
5.2 Basic adjustment of the double acting
positioner
A basic adjustment is only required when the device has
been disassembled or subassemblies have been exchanged. All settings performed in order to match the positioner
to the actuator are described in chapter 4 Commissioning,
page 14.
The following tools are required for the basic adjustment:
1 screw driver
1 set spanner A/F 7
1 feeler gauge 0.6 mm
3 pressure test gauge (2 x 6 bar, 1 x 1.6 bar)
1 signal generator 0.6 bar
If adjustments are made with the device attached, the feedback lever on the shaft of the positioner must be loosened.
a) Set the changeover plate 50 to “N”.
b) Turn the throttling screw 42 clockwise as far as its stops
(maximum amplification).
c) Unhook the range spring 34 from the flapper lever 35 .
d) Check that the flappers 37 are aligned concentrically with
the nozzles 36. If necessary loosen the mounting bolts
of the amplifier on the rear of the positioner and align
the amplifier accordingly.
e) Press the flapper lever 35 several times alternately to
the left and right, so that the ball-guided flappers are
parallel to the nozzles.
f) Press the flapper lever 35 to the left. Set the clearance
between the right-hand nozzle and the right-hand flapper to 0.6 mm with the aid of a feeler gauge by turning
the hexagonal nut 56 A/F 7. Then secure the nut
against further turning.
g) Connect the positioner as shown in the test circuit in Fig.
36. Connect supply air of 1.4 bar.
h) Press the flapper lever 35 to the left and the right. The
pressures y1 and y2 should vary in opposite directions
between 0 bar and the supply air pressure.
i) Hook the range spring 34 onto the flapper lever 35 and
connect w ≈ 0.6 bar.
k) Set the zero screw 32 until the pressures y1 and y2 are
equal.
I) Set the adjusting screw 47 so that the pressures y1 and
y2 are approx. 4.2 bar (70 % of the supply air pressure).
If necessary repeat the settings described in k) and l)
alternately.
m) Connect supply air of 1.4 bar. Set the zero screw 32 so
that the pressures y1 and 2 are equal. They should be
approximately 0.7 bar (50 % of the supply air pressure).
(Check measurement only.)
The following procedure must be observed in order to
achieve a no-feedback adjustment of the zero and
stroke settings:
n) Press the stroke factor lever 31 against the stop screw
30 .
o) Set the stroke factor screw 33 to a high stroke factor
(approx. 2 mm before the upper stop).
p) Turn the zero screw 32 until the output pressures y1 and
y2 are equal.
r) Set the stroke factor screw 33 to a low stroke factor
(approx. 2 mm before the lower stop).
The output pressures y1 and y2 may not vary by more
than ± 150 mbar as compared with the setting described in p).
s) In case of excessive deviations the stop screw 30 should
be adjusted.
Whenever the stop screw 30 is adjusted, the settings
described in o) to r) should be repeated until the deviation is less than ± 150 mbar.
t) Secure the stop screw 30 with sealing paint.
Reattach the positioner or fasten the feedback lever back
onto the shaft of the positioner see chapter 4, page 14.
w
y1 Supply air y2
w
Fig. 36: Test circuit
Supply air 6 bar
20
SRP981
MI EVE0101 A-(en)
6 REPLACING SUBASSEMBLIES
5.3 Cleaning the throttle
6.1 Replacing the amplifier
a) Remove the limiting screw 43 .
b) Pull the throttling screw 42 down out of the limiting screw.
c) Place the throttling screw 42 in a solvent (e. g. benzene)
and blow through it carefully. It is better still to clean it in
an ultrasonic bath.
d) Turn the throttling screw 42 right in again as far as its
stop (clockwise).
e) Turn the limiting screw 43 right in clockwise as far as its
stop, then back again counterclockwise by about half a
turn.
f) Secure the limiting screw 43 with sealing paint.
a) Remove the housing cover.
b) Unhook the range spring 34 from the flapper lever 35 .
c) Unscrew and remove the amplifier 40 or dual amplifier
41. The two mounting bolts are accessible from the rear
of the positioner.
d) Install a new amplifier. Do not forget the O-rings between
the amplifier and the base plate (air baffle).
Before tightening the mounting bolts align the amplifier
in such a way that the flappers 37 are concentrically
aligned with the nozzles 36 .
e) Hook the range spring 34 onto the flapper lever 35 .
f) Perform a basic adjustment (see 5.1 or 5.2).
MI EVE0101 A-(en)
SRP981
6.2 Replacing the amplifier diaphragm
in the single acting positioner
c) Reassemble the amplifier:
Reassemble the components and subassemblies in the
correct position in the sequence specified. Replace
faulty parts.
Put housing block A 64 with the open side facing upwards. Insert pipe 65 in the hole in the housing block A.
Place spring 66 in position in the diaphragm disk subassembly 67. Insert diaphragm disk subassembly 67 in
housing block 64 so that the pipe 65 passes through
the holes in the diaphragm disk subassembly 67. Place
amplifier diaphragm 68 on the diaphragm disk subassembly 67 (with the projection facing downwards), pipe
65 should be inserted in the hole of the amplifier diaphragm 68.
Place housing block B 69 in its correct position, so that
the pipe 65 is inserted in the relevant hole in housing
block B 69. Press housing block B 69 against housing
block A 64.
Note:
When these two components are pressed together
housing block B 69 should be planeparallel with housing block A 64.
If not, why are they misaligned?
(Is pipe 65 in its correct position in the holes of housing block A 64 and housing block B 69 ?)
Insert input diaphragm subassembly 70 in housing block
B 69. Install cover 71 in the right way round (threaded
holes on the amplifier setting side), and screw the amplifier together.
Tighten the four screws 63 uniformly.
d) Screw on the flapper lever 35 again.
e) Install the amplifier (see 6.1)
f) Perform a basic adjustment (see 5.1)
a) Remove the amplifier (see 6.1)
b) Dismantle the amplifier.
Remove the screw 54 . Remove the two screws 56.
Remove the strip 55 and flapper lever 35 .
56
40
55
54
35
Fig. 37: Amplifier
When the four screws 63 are removed, the amplifier can be
dismantled into the following components and subassemblies:
64 housing block A
65 pipe
66 spring
67 diaphragm disk subassembly
68 amplifier diaphragm
69 housing block B
70 input diaphragm subassembly
71 cover
A
66
B
64
65
67
68
63
69
70
71
21
Fig. 38: Amplifier dismantled
22
SRP981
MI EVE0101 A-(en)
6.3 Replacing the amplifier diaphragm
in the double acting positioner
Remove the dual amplifier 54 (see 6.1)
Replace the input diaphragm
a) Remove screw 54 .
b) Remove two screws 56, the strip 55 and the flapper lever
35.
41
56
54
55
35
Fig. 39: Dual amplifier
c) Remove four screws 72 and the cover 71.
d) Remove and replace the input diaphragm subassembly
70.
e) Reassemble the input diaphragm in the reverse order.
d) Insert the new diaphragm assembly 77 in its correct
position in housing block B 78.
Important note:
The pipe 79 passes through the first disk 80 and is inserted in a hole in the second disk 81.
If the two disks 80 and 81 are not absolutely flush
when the diaphragm assembly is pressed together by
hand, the pipe is not in its correct position in the hole.
In this case disk 81 should be turned until the pipe is
correctly inserted in the hole.
e) Install housing block A 74 in its correct position and
screw on with the four screws 73.
f) Measure the gap between the housing blocks 74 and 78
with the aid of a feeler gauge.
g) The spring washer 75 selected should have a wire diameter which corresponds to the gap measured as described in f), or which is no more than 0.1 mm smaller in
diameter.
h) Remove the four screws 73 again and remove housing
block A 74.
Install the spring washer 75 selected, replace housing
block A 74 in its correct position, and tighten the screws
73 firmly and unformly. Align the spring washer so that
it does not project over the edges of the housing blocks
74 and 78 .
Reinstall the amplifier (see 6.1) and perform basic adjustment (see 5.2).
Replace the diaphragm assembly
a) Remove four screws 73 and housing block A 74.
b) Remove spring washer 75.
c) Through the holes 76 ,the diaphragm assembly 77 can
be pressed out of the housing block B 78, for example
by means of a small screwdriver. The diaphragm
assembly is a self-contained component,
and should not be dismantled further.
74
73
77
75
78
70
71
A
72
80
81
79
76
B
Fig. 39: Dual amplifier dismantled
MI EVE0101 A-(en)
23
SRP981
7 Option “Limit switch”
7.2 Electrical connection
The limit switches are additonal equipment either installed
in the factory or updated. They are constructed either with
inductive switches or micro switches and signal exceeding
or deceeding of a stroke or rotating movement of actuators.
Grounding conductor connection following installation in the
SRP981 - see page 13.
7.1 Method of operation
Stroke or rotation angles of the actuators are transferred to
the control vanes via a deviating mechanism to the control
vanes which either dampen an oscillator circuit or switch a
mechanical contact depending on the version.
The inductive limit switches are supplied with power via a
separately mounted switch amplifier. The current signal is
transferred into a switch output.
In the three-wire version an integrated switch amplifier
supplies a switch signal; direction of reaction PNP closing
function.
7.3 Arrangement of connection
The connection cable is guided through the cable gland
Pg 13.5 (cable diameter 6...12 mm) and connected to the
terminal bar (see page 24).
The terminals are tied up as follows:
2-wire technique
Code T, U
A
3-wire technique
Code R
AB
B
42 41 52 51
1 2
41
A
Actuator
Control vanes
and probes
electronic
relay
Signaling
device
Fig. 41: Functional schematic (acc. to DIN 19324 / NAMUR)
We recommend the following switch amplifiers:
Separating switch amplifier with relay output
Pepperl+Fuchs GmbH type numbers:
Normal version
WE 77/Ex2
Safety version
WE 77/Ex-SH-03
For further information see above documentation.
A
3 4
41
1
DC
2-wire technique: if control vane is immersed the initiator
power circuit becomes high-ohmic.
3-wire technique: if control vane is immersed the contact is
closed against plus.
Micro switch: Contact opens during passing of the control
vanes.
A
DC
2
51
3
42
51
A
B
DC
B
4
52
52
The terminals are suited for cable cross-sections of up to
2.5 mm² (fine-strand).
7.4 Start-up
The switching functions may be freely selected and set.
The control vanes may be adjusted as desired in order to
reach the wanted switching behavior. The illustration here
shows the four basic settings and adjacent the respective
switch behavior (gray=immersed vane).
The examples are based on the following setting:
Mounting left = feedback lever right; transmission is selected so that at stroke x from 0 to 100% the guidance shaft
travels through a rotary angle of 180°.
Illustrated in resting position x = 0%.
B
42 41 52 51
42
B
micro switch
Code V
x=100 %
x=0 %
X 0%
100 %
A
B
X 0%
100 %
A
B
X 0%
100 %
A
B
X 0%
A
B
100 %
24
SRP981
MI EVE0101 A-(en)
7.5 Setting Limit Values
The switching points are dependent on the setting of the
control vanes 83 , on the settings of the probes A and B
and on the ratio setting.
To set the control vanes loosen the screw 82 on the drive
shaft and align the control vanes in accordance with the
illustrations on page 23.
During loosening and/or tightening this screw hold control
vanes tightly to avoid damaging pinion and tooth segment.
83
82
Adjust the probes as follows:
a) Move the actuator to the position to be signalled
b) Loosen locking screw 86 and adjust the switching points
by turning adjustment screws 87 .
c) Then retighten locking screws.
To set the transformation the ratio of the rotation angle of
the control vanes can be set continuously by turning the
spindle screw 85 of the adapter. Turn clockwise to increase
the ratio and counter-clockwide to reduce it.
Screw on housing cover with the air vent facing downwards
when the device is mounted.
7.6 Maintenance
No maintenance is required.
106
7.7 Safety requirements
see page 29.
112
86
87
85
86
87
MI EVE0101 A-(en)
SRP981
25
7.8 Subsequent installation or exchange
For subsequent installation there are kits available in appropriate versions - see PSS EVE0101A. Safety requirements
indicated on page 29 are to be absolutely observed!
111
The kit includes the following parts:
108 Adapter for transferring the rotary movement to
the control vane
107 Hexagonal bolts for mounting plate
119 Mounting plate with probes, adjusting devices,
terminals
111 Bolts for housing cover
112 Cable gland
112a Screw plug
117 Frame with sealing
107
111
119
110
104
117
31
102
118
107
108
110
Installation:
a) Screw on adapter 108 :
Unscrew bottom screw 102.
Fit adapter 108, then screw in the
screw again and tighten slightly. Hold
adjusting device 31 firmly in position and
unscrew top screw 104. Install adapter 108
and tighten the screw again. Tighten screws 102
and 104 .
b) Insert two hexagonal bolts 107 (8 mm A/F): Release
screw 121 , attach gasket to long hexagonal bolt and
insert instead of screw 121.
In case of single-acting positioners release screw 122 ,
transfer gasket to short hexagonal post and insert instead of screw 122 .
In case of double-acting positioners release screw 123 ,
transfer gasket to medium length hexagonal post and
insert instead of screw 123 .
122
121
123
121
single acting
double acting
112a
112
c) Screw mounting plate 119 to the two hexagonal bolts
107 with the two screws 110 (if necessary, adjust the
adjusting devices so that the right-hand mounting hole
is accessible). Be careful to ensure that the driving pin
of the adapter engages in the slot in the gear segment.
d) Screw the two bolts 111 into the female threads to secure the housing cover. When the positioner is installed,
these will be the female threads in the top left-hand corner and in the bottom right-hand corner.
e) Secure cable gland 112 and screw plug 112a to frame
117 with the enclosed nuts.
Fit the frame with the rubber seal facing the positioner
and cable gland 112 at the terminals .
f) Screw on the housing cover with the air vent facing
downwards when the device is mounted.
26
SRP981
MI EVE0101 A-(en)
8 Option “El. Position Transmitter”
The electrical position transmitter is additonal equipment
either installed in the factory or up-dated. It converts the
stroke or rotary movement of an actuator into an electrical
standard signal 4...20 mA.
106
8.1 Function
The stroke or rotary angle of an actuator are transmitted to
the position controller with a built-in electrical position converter via control lever. The angle setting is converted proportionately into a voltage with a potentiometer. This voltage is then converted into the electric standard signal 4 ... 20
mA. Adaption to the stroke of the actuator takes place internally. The start and end of the measuring range are set
with trim potentiometers.
8.2 Electrical Connections
Grounding cable connection following installation in the
SRP981 - see page 13.
8.3 Arrangement of connection
The cable is inserted through the Pg 13.5 cable gland 112
(suitable for lead diameters 6...12 mm) and is connected at
the terminal block 106 .
The terminals are suitable for wire cross-sections of up to
2.5 mm².
Cable gland 112 and screw plug 112a are interchangeable.
112a
112
The terminals are connected as follows:
K1 Auxiliary energy (+)
K2 Uninterrupted signal current measurement with
a low resistance ampmeter (Ri ≤ 10 Ohm)
K3 Auxiliary energy (–)
K4 Protective earth connection
The power supply (Us = DC 12...36 V) originates from the
signal circuit in two wire connection.
The maximum permissible load impedance RBmax is
calculated with the following equation:
RBmax = (Us - 12 V) / 0,02 A [Ohm]
Us = Supply voltage in V
8.4 Maintenance
No maintenance is required.
8.5 Start-up (countinued on next page)
9
P4
P3
17
115
116
Fig. 49: Adjusting the start and end of the measuring range
113 114
MI EVE0101 A-(en)
SRP981
27
8.5 Adjusting the measuring range
Start of measuring range
Bring the actuator to the starting position. With potentiometer P4 , adjust the measuring range start 4 mA.
End of measuring range
Bring the actuator to the end position and set potentiometer
P3 to the measuring range end value 20 mA.
If you wish to make a greater adjustment to P3 , check the
setting of P4 again and correct if necessary. Next adjust
P3 again.
Attachment side, left:
rising
output signal
with retracting
drive spindle.
20 mA
Adjusting the mechanical zero
(Only necessary if adjustment is not possible as described
above.)
Turn potentiometer P4 counterclockwise to the lowest
value and set potentiometer P3 to the highest value.
Bring the actuator to the starting position.
Undo screw 115 . Set the mechanical zero point by turning
the hexagon screw 116 with an set spanner A/F 4 to a
starting value of between 3.5 and 3.8 mA.
Tighten screw 115 again.
Adjust start and end of measuring range as described
above.
4 mA
Attachment side, right:
rising
output signal
with extending
drive spindle.
4 mA
8.6 Conversion from normal direction of action
in reverse direction of action
20 mA
Set potentiometer P4 to the lowest value by turning it
counterclockwise and set potentiometer P3 to the maximum value.
Swap around connections 113 and 114 .
Start of measuring range
Bring the actuator to its end position.
Undo screw 115 . Set the machanical zero point to a starting value of between 3.5 and 3.8 mA by turning the hexagon screw 116 with an set spanner A/F 4.
Tighten screw 115 again.
With potentiometer P4 , adjust the measuring range start
4 mA.
End of measuring range
Bring the actuator to the starting position.
Set potentiometer P3 to the measuring range end value
20 mA.
In the event of a greater adjustment to P3, check the setting
of P4 again and correct it if necessary, then check the setting of P3 again.
Important in the case of Ex version:
The conversion from “normal” to “reverse” must be certified
by a recognized expert or carried out by the manufacturer.
Attachment side, left:
Falling
output signal
with retracting
drive spindle.
4 mA
20 mA
Attachment side, right:
Falling
output signal
with extending
drive spindle.
20 mA
4 mA
28
SRP981
MI EVE0101 A-(en)
8.7 Subsequent installation or exchange
Adjusting the measuring ranges (see Fig. 49)
For subsequent installation there are kits available, see
PSS EVE0101A. Safety requirements indicated in page 29
are to be absolutely observed!
Kit components:
101 Driver plate for transmitting the rotary motion
105 Support Ø 7 mm for converter plate
109 Converter plate with 2 fillister head screws 110
and one lock washer 120
111 Support for cover
112 Cable screw connection
112a Screw plug
117 Frame with rubber seal
–
–
–
–
–
Bring actuator to starting position.
Connect control lever 9 non-positively with position
controller shaft 17 .
Unscrew cover 118 and frame 117 .
Turn potentiometer P4 counterclockwise to the lowest
value and set potentiometer P3 to the maximum value.
Remove screw 115 .
Set the mechanical zero point to a starting value of
between 3.5 and 3.8 mA by turning the hexagon screw
116 with an open-end spanner A/F 4.
Re-tighten screw 115 .
Adjusting the start and end of measuring range see page
27.
110
111
109
105
111
104
110
120
117
31
102
118
105
101
Installation:
a) Unscrew lower screw 102 of
stroke factor adjustment facility 31.
b) Position driver plate 101, turning screw
102 again and tighten gently.
c) Hold the stroke factor adjustment unit together manually and remove upper screw 104 . Swivel in driver
plate and return screw. Tighten screws 102 and 104 .
d) Screw in the 2 supports 105 Ø 7 mm as follows: Longer
support left, shorter support right.
e) Secure converter plate 109 with screws 110 and a
lockwasher 120 (left screw) to the two supports so that
the pin on the driver plate 101 engages into the slot on
the tooth segment.
f) Screw two supports 111 into the female thread for securing the cover. In installation position, these are the
female threads in the top left corner and in the bottom
right corner.
112a
112
g) Secure cable screw connection 112 and screw plug
112a to frame 117 using the nuts supplied. Position
the frame so that the rubber seal faces towards the
position controller and so that the cable screw connection 112 is next to the terminals.
h) Screw on cover 118 so that the ventilation slot is at the
bottom when the unit is attached.
MI EVE0101 A-(en)
SRP981
29
9 SAFETY REQUIREMENTS
9.1 Accident prevention
This device complies with the regulations for the prevention
of accidents Power-Driven Work Aids (VBG 5)
of 1st October 1985.
9.2 Electrical safety
9.2.1 General requirements
This device with the equipment Inductive limit switches,
Model Code R, T, U or Position transmitter 4-20 mA,
Model Code W satisfies the conditions for safety class III
according to EN 61010-1 (IEC 1010-1).
With the equipment Two micro switches, Model Code V
it satisfies the conditions for safety class II, pollution degree
2, overvoltage category II according to EN 61010-1 (IEC
1010-1).
Any work on electrical parts must be done by qualified personnel if any power supply is connected to the instrument.
9.2.2 Connection requirements
The device has to be used for its designated purpose, it has
to be connected in accordance with the electrical connection (see page 13). The national requirements need to be
considered (for Germany DIN VDE 0100 and DIN VDE
0800).
.
The device has to be operated with safety extra-low voltage
SELV or SELV-E.
Internal safety precautions may be rendered ineffectual if
the instrument is not operated in accordance with the Master Instruction.
Limitation of power supplies for fire protection have to be
observed due to EN 61010-1, appendix F (rsp. IEC 1010-1).
Devices with position transmitter 4 ... 20 mA: For electromagnetic compatibility EMV, the ground connection must
be made (CE).
9.2.3 Explosion protection
Only if ordered accordingly, with Inductive limit switches,
Model Code T or U or with Position transmitter 4-20 mA,
Model Code W,
Technical data for explosion protection see Product Specification PSS EVE0101 A.
For installations in contact with explosive atmospheres, all
relevant national regulations and installation conditions
must be observed, e. g. in the Federal Republic of Germany
ElexV and DIN VDE 0165.
Attention:
When repairing explosion-proof equipment, observe the
national regulations.
Use only original spare parts when making repairs.
The following applies to the Federal Republic of Germany:
Repairs involving parts required for explosion protection
must either be carried out by the manufacturer or by authorized personnel and confirmed by certificate.
9.2.4 EMC and CE
Remarks according Electromagnetic compatibility EMC and
CE marking see Product Specification PSS EVE0101 A.
30
SRP981
MI EVE0101 A-(en)
10 TROUBLE SHOOTING
Fault
Actuator does not react to the
applied input signal nor to a
change in the input signal
Possible cause
pneumatic connections switched
feedback lever loose
positioner mounted on the wrong side
changeover plate in the wrong position
amplifier defective
Output pressure does not attain supply pressure too low
the full value
flappers not parallel to nozzles
pre-throttle in amplifier blocked
filter in supply connection blocked
Actuator runs to the end position positioner mounted on the wrong side
Unstable behaviour positioner circuit oscillates
Stroke range cannot be set
feedback lever loose
pneumatic connections switched
(double-acting version)
amplification too high
gland friction on valve too great
for piston actuators:
static friction on cylinder too great
range spring unsuitable
positioner does not exhaust pressure
completely
Remedy
check connections
tighten feedback lever (see 2.2.3)
check mounting side with the table in chapter
2.2.2
check position with table insection 2.2.2
change amplifier (see 6.1)
check supply air
align flappers (see 5.1 d, e or 5.2 d, e)
clean pre-throttle (see 5.3)
change filter
check mounting side with table in chapter
2.2.2
tighten feedback lever (see 2.2.3)
check connections
(see 2.2.2 and 2.2.3)
reduce amplification (see 4.1)
loosen gland slightly or renew
reduce amplification (see 4.1)
change range spring (see 4.5 and 4.6)
check supply air (max. 6 bar)
check amplification (see 4.1)
adjust distance between nozzle and flapper
(see 5.1 e, f and 5.2 e, f)
Detail: Nozzles / flappers system
36 37
35
38
37
36
MI EVE0101 A-(en)
SRP981
31
Single acting positioner SRP981
56 40 44 42 43
50
35
38
34
51
32
31
30
33
Double acting positioner SRP981
42 43
44
41
45
47
32
SRP981
MI EVE0101 A-(en)
Subject to alterations - reprinting, copying and translation prohibited. Products and publications are normally
quoted here without reference to existing patents, registered utility models or trademarks. The lack of any such
reference does not justify the assumption that a product or symbol is free.
FOXBORO ECKARDT GmbH
Postfach 50 03 47
D-70333 Stuttgart
Tel. # 49(0)711 502-0
Fax # 49(0)711 502-597
DOKT 535 781 027
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