OMC RE20, Installation, Operation And Maintenance Manual

Page 1: ...OMC S p A Via G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468 INSTALLATION OPERATION AND MAINTENANCE MANUAL SMART POSITIONER RE20...

Page 2: ...s for installation 13 3 3 Linear positioner Installation 14 3 3 1 Linear positioner Installation of Standard lever type 14 3 3 2 Safety 14 3 3 3 Standard lever type positioner Installation Steps 15 3...

Page 3: ...8 8 8 2 Forward P parameter KP UP and reverse P parameter KP dN 39 8 8 3 Forward Integral time parameter TI UP and reverse Integral time parameter TI dN 39 8 8 4 Forward D parameter Kd UP and reverse...

Page 4: ...UNLOCK LOCK 53 8 11 4 Actual Position View Mode View Mode VI NORM REVS 54 8 11 5 Factory Reset dEFAULT oFF on 54 8 11 6 Positioner Self Test SELFTEST 55 8 12 Diagnosis Mode dIAGNd 56 8 12 1 Default A...

Page 5: ...o OMC Spa Positioner is an accessory of the control valve so please make sure to read the applicable instruction manual of the control valve prior to installation and operation 1 2 Manufacturer Warran...

Page 6: ...changes in supply pressure and or high vibration environment The method of Auto Calibration is very simple As an advantage of having very low air consumption It could greatly reduce operating costs in...

Page 7: ...RATING TEMP Indicates the allowable operating temperature SUPPLY PRESSURE Indicates the supply pressure range SERIAL NUMBER Indicates unique serial number YEAR MONTH Indicates manufactured year and mo...

Page 8: ...uator Rotary 2 Acting type S D Single Double 3 Lever Type Linear 0 1 2 10 40 mm Standard type 20 100 mm Standard type 90 150 mm Standard type Rotary 5 Namur 4 Conduit Air Connection Type 1 2 G 1 2 Rc...

Page 9: ...Pa 1 4 7 bar Stroke 10 150 mm 55 110 Impedance Max 500 20mA DC Air Connection Rc 1 4 or 1 4 NPT Gauge Connection Rc 1 8 or 1 8 NPT Conduit Entry G 1 2 Ingress Protection IP66 Operating Temperature 30...

Page 10: ...10 Installation Operation and Maintenance Manual ManRE20en Rev 06 2022 OMC S p A Via G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468...

Page 11: ...MC S p A Via G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468 2 6 Parts and Assembly Fig 2 1 exploded view 1 Base Cover 6 Pilot 2 PCB Cover 7 Pilot Block 3 Main PCB...

Page 12: ...lation Operation and Maintenance Manual ManRE20en Rev 06 2022 OMC S p A Via G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468 2 7 Product Dimension Fig 2 2 RE20L Fig...

Page 13: ...vices must be turned off Use bypass valve or other supportive equipment to avoid entire system shut down Ensure there is no remaining pressure in the actuator The positioner has a vent cover to exhaus...

Page 14: ...Feedback lever and lever spring M6 nut and spring washer fastening feedback lever to a main shaft Bracket bolts and washers for positioner or sensor not supplied with the positioner Connection bar no...

Page 15: ...oner Installation Steps 1 Assemble the positioner with the bracket made in previous step by fastening the bolts Fig 3 3 Linear Standard Lever Type 2 Attach the positioner with the bracket to the actua...

Page 16: ...valve stroke at 50 of the total stroke Fig 3 4 Linear Standard Lever Type 5 Insert the connection bar between the feedback lever and lever spring The connection bar must be located upward from the le...

Page 17: ...o make vertical Improper installation may cause poor linearity Fig 3 6 Linear feedback lever and valve stem 7 Check the valve stroke The stroke numbers are engraved on the feedback lever of the positi...

Page 18: ...y using direct air to the actuator On both 0 and 100 the feedback lever should not touch the lever stopper which is located on the backside of the positioner If the feedback lever touches the stopper...

Page 19: ...e or other type of actuators which its stem rotates 90 degrees Before proceeding with the installation ensure following components are available 3 4 1 Components Positioner Rotary bracket set 2 piece...

Page 20: ...wo components but the upper brackets of Fork lever type and Namur type are different The bracket is designed to fit onto the actuator with 20mm 30mm and 50mm stem height H according to VDI VDE 3845 st...

Page 21: ...3 Set rotation position of the actuator stem at 0 For single acting actuator it is easy to check 0 point by supplying no pressure to the actuator For double acting actuator check actuator stem s rotat...

Page 22: ...ressure range is 0 14 0 7 MPa 1 4 7 bar Set air filter regulator s pressure level 10 higher than actuator s spring range pressure 4 3 Piping Condition Ensure inside of pipe is clean of obstructions Do...

Page 23: ...18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468 Double acting type positioner is set to use OUT1 and OUT2 port As input signal increases the supply pressure will be supplied...

Page 24: ...r section are 1 25mm2 and that is suitable for 600V complying with the conductor table of NEC Article 310 The outer diameter of the cable should be between 6 35 10mm Use shield wire to protect against...

Page 25: ...68 6 Adjustments 6 1 Orifice Installment Hunting can be occurred when the actuator s volume is too small In order to prevent hunting orifice can be used 6 1 1 Plate type Orifice Installment By install...

Page 26: ...supports are supplied together with sub PCB 7 1 Installation steps 1 Mount 2ea of sub PCB support on sub PCB with 2ea of bolt 2 Open base cover PCB cover Separate the Main PCB from base body 3 Insert...

Page 27: ...he automatic calibration AutoCal to prevent any disruption of the process since this operation shall move the Valve and Actuator 8 2 LCD display and buttons 8 2 1 LCD display and symbols Fig 8 1 0BSym...

Page 28: ...o perform various functions Fig 8 2 Buttons Function UP Used to navigate to each menu at the same level or to increase the value of the selected parameter DOWN Used to navigate to each menu at the sam...

Page 29: ...Operation menu and move within Run Mode Monitor menu Press for more than 3 seconds in Run Mode to go to Configuration Operation Run Mode Monitor ESC Configuration and Operation RUN AP Actual Position...

Page 30: ...Deviation Value Deviation between target position and actual position RUN IV Integral Output Value Accumulated integral output value RUN MV Manipulator Value Digital input value applied to I P convert...

Page 31: ...Zero TVL ZERO Travel End TVL ENd Manual Operation MAN OPER Manual Operation by Set Position MAN SP Manual Operation by Manipulator Value MAN MV Control Parameters CTL PARM Dead Band dEAdbANd 0 1 10 0...

Page 32: ...ction PTM NORM REVS NORM Position Transmitter Zero PTM ZERO 0 100 00 Position Transmitter End PTM ENd 0 100 00 Back Calculation bAKCAL oFF on oFF Device Configuration dEV CFG Action Change ACT dIR REV...

Page 33: ...nt input between 4 and 20 mA is applied it takes approximately 2 3 minutes to complete the automatic calibration which may vary depending on the size of the actuator There are two types of Auto Calibr...

Page 34: ...ed when the origin and end points of the already calibrated positioner have changed slightly 3 seconds Press UP or DOWN button if the above is not displayed Press UP or DOWN button if the above is not...

Page 35: ...ustment of the zero point or endpoint of the valve after auto calibration Once you enter the TRAVEL ZERO or TRAVE END setting press the UP DOWN button to change the zero point or endpoint of the valve...

Page 36: ...n the positioner Use the Manual only when the operation is suspended or when no trouble is raised with the operation of Control Valve as the execution of Manual Mode may interfere with the currently o...

Page 37: ...V The input to I P converter is incremented or decremented by the UP and DOWN buttons based on the currently entered I P input value which moves the stem of the valve up and down Once out of the menu...

Page 38: ...se Integral time parameter TI dN 4 Forward D parameter Kd UP and reverse D parameter Kd dN 5 Auto Dead band Mode AUTO db 6 Performance Mode PER 8 8 1 Dead Band dEAdbANd Deadband indicates the size of...

Page 39: ...to oscillate it if set to high However smaller gains improve stability but make it slower to reach a target position 3 seconds Press UP or DOWN button if the above is not displayed Press UP or DOWN bu...

Page 40: ...ion of decreasing output air pressure A larger D value makes the valve hunting easier and a smaller value can lead to poor linearity or dynamic properties 3 seconds Press UP or DOWN button if the abov...

Page 41: ...ER This mode has three modes of operation Stable Normal and Fast that allow you to select the required responsiveness The performance modes in the order of Stable Normal and Fast indicates the respons...

Page 42: ...Characterization 21 Points U21 8 Tight Shut Open TSHUT OP 9 Tight Shut Close TSHUT CL 8 9 1 Signal Direction SIG NORM REVS This function changes the action type of the valve NORM or REV if NORM is se...

Page 43: ...or DOWN button if the above is not displayed UP DOWN ESC 3 times 4 20mA Control Initial condition 4 12mA Control 8 9 3 Custom Split Range Zero CST ZERO It is used to set the current corresponding to t...

Page 44: ...gin point and the endpoint must be greater than 4 mA 3 seconds Press UP or DOWN button if the above is not displayed Press UP or DOWN button if the above is not displayed UP DOWN ESC 3 times This func...

Page 45: ...tial positions are P0 4mA 0 P1 8mA 25 P2 12mA 50 P3 16mA 75 and P4 20mA 100 User can change all 5 points or only change partially and exit the menu by pressing ESC button 3 seconds Press UP or DOWN bu...

Page 46: ...A 95 and P20 20 mA 100 For example a characteristic curve below can be made through the settings of P1 to P20 User can change all 21 points or only change partially and exit the menu by pressing ESC b...

Page 47: ...he valve If the input current of 4 mA is 0 of valve position and 20 mA is 100 of valve position and the Tight Shut Open value is set to any position less than 100 e g 95 then the valve stroke will be...

Page 48: ...100 of valve position and the Tight Shut Close value is set to any position larger than 0 e g 5 then the valve stroke will be 0 immediately when the input signal goes below the set value e g 5 The air...

Page 49: ...ition Transmitter Direction PTM NORM REVS 2 Position Transmitter Zero End PTM ZERO ENd 3 Back Calculation bACKCAL oFF on 8 10 1 Position Transmitter Direction PTM NORM REVS The analog feedback signal...

Page 50: ...usts the zero point of the position transmitter 4mA feedback and ENd adjusts the end point of the transmitter 20mA feedback This is used when the analog output signal needs to be feedbacked differentl...

Page 51: ...to end point Fit the feedback signal to 20mA 8 10 3 Back Calculation bACKCAL oFF on This function recalculates the output RUN AP value changed by the flow characteristics setting mode to display it l...

Page 52: ...on 6 Positioner Self Test SELFTEST 8 11 1 Action Setting ACT Reverse Action REVS or Direct Action dIR are automatically set by performing AUTO 2 within the Auto Calibration function However this func...

Page 53: ...20 but it is set to OFF when this angle is less than 20 or rotary positioner is used The settings below are the process of manually changing the ITP oFF to the ITP on 3 seconds Press UP or DOWN butto...

Page 54: ...layed Press UP or DOWN button if the above is not displayed UP DOWN ESC 3 times 8 11 5 Factory Reset dEFAULT oFF on This function initializes all parameters stored in the positioner to initial factory...

Page 55: ...ayed after FINISH is displayed and if abnormalities are detected the message SEt NVMW is displayed 3 seconds Press UP or DOWN button if the above is not displayed Press UP or DOWN button if the above...

Page 56: ...f NE107 signal So the corresponding NE107 signal is displayed especially when particular alarm occurs As shown in the table below the status alarms that can be manually reset are Auto Calibration Runn...

Page 57: ...Abbreviation Function None dS GOOd Good dS FAIL Failure dS FUNC Functional Check dS OUTS Out of Specification dS MNTR Maintenance Required Alarms generated by each process are assigned to one of the f...

Page 58: ...is automatically released when internal temperature drops below the Temperature High Limit However if the Partial Stroke Test fails or Auto Calibration fails use this function to release the alarm Bel...

Page 59: ...l as the content of the event EVT INFO See 8 14 Status and Alarm Codes for an abbreviation and description of the event details 3 seconds Press UP or DOWN button if the above is not displayed Press UP...

Page 60: ...G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468 8 13 Position information INFO The diverse Positioner information is provided in the INFO Mode 3 seconds DOWN Press...

Page 61: ...e time of the product Upper 4 18 indicates 4 hours and 18 minutes Lower 0d indicates days used Interval to store time is one minute 3 12 FULL OP Upward Full Stroke Time FULL OP This value is stored au...

Page 62: ...entative 7 NVMW Non Critical NVM Defect 15 dVTO Deviation Time Out It is active when actual deviation greater than the preset Deviation persists longer than the preset Deviation Time Check if the sett...

Page 63: ...umatic leaks lever position and others Alarm Code Abbreviation Status Alarm name Description or proposed actions 32 STAK Stack Overflow Replace the electronics board by contacting the manufacturer or...

Page 64: ...64 Installation Operation and Maintenance Manual ManRE20en Rev 06 2022 OMC S p A Via G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468 9 Main Software Map...

Page 65: ...65 Installation Operation and Maintenance Manual ManRE20en Rev 06 2022 OMC S p A Via G Galilei 18 20060 Cassina de Pecchi MI ITALY www omcvalves com Tel 39 02 95 28 468...