Power-Genex SS2L Series, Instructions And Operating Manual

Page 1: ...Instruction and Operating Manual Smart Valve Positioner SS2L SS2R Series SS2SL SS2SR Series SS316 Software Version 4 11 Power Genex Ltd ...

Page 2: ...rator 9 2 2 With Multi meter 9 3 Wiring Alarm Limits 9 4 HART Connection 9 5 Profibus PA Fieldbus Connection 9 6 Wiring SPDT Micro Switches 26 9 7 Setting SPDT Micro Switches 9 8 Earthing 9 9 Wiring for Intrinsic Safety 27 9 10 Cable Gland Blind Plug 28 10 Quick Auto Calibration 29 10 1 Quick Auto Calibration 10 2 Checking Ambient Temperature 11 Description of Parameters Flow 30 11 1 Parameters Fl...

Page 3: ...pen Control 48 11 5 11 C Setting of Output Signal 11 5 11 D Split Range Setting 11 5 11 E Chang of Decimal Display 11 5 11 F Setting of Alarm Limits 49 11 5 11 G Setting of Input Signal 51 11 5 11 H Setting of Output Signal 11 5 11 I HART Polling Address 52 11 5 11 J Partial Stroke Test 11 5 11 K ADDR Manual Setting of Profibus PA address 53 12 Maintenance Service 12 1 Preliminary Check Points 12 ...

Page 4: ...priate training should operate machinery and equipment The product specified here may become unsafe if handled incorrectly The assembly operation and maintenance of machines or equipment including our products must be performed by an operator who is appropriately trained and experienced 3 Do not service or attempt to remove product and machinery equipment until safety is confirmed 1 The inspection...

Page 5: ...lity a replacement product or necessary parts will be provided This limited warranty applies only to our product independently and not to any other damage incurred due to the failure of the product 3 Prior to using POWER GENEX products please read and understand the warranty terms and disclaimers noted in the specified catalogue for the particular products Note 2 Vacuum pads are excluded from this...

Page 6: ... pressure supply and always release the compressed air inside the positioner and actuator before performing this work 3 Always use with the body cover unit mounted Moreover the positioner may not meet degrees of protection IP66 depending on the body cover mounting conditions In order to meet degrees of protection IP66 tighten threads using the proper tightening torques 2 8 to 3 0 N m 4 Always flus...

Page 7: ...the positioner as this affects its characteristics Air Supply Caution 1 Use only dehumidified and dust extracted clean compressed air as the air supply 2 Use only dehumidified and dust extracted clean compressed clean air as the positioner contains extrafine orifices such as restrictor and nozzle Do not use a lubricator 3 Do not use compressed air containing chemicals organic solvents salinity or ...

Page 8: ...isk of ignition by impact or friction Care must be taken during installation and use to prevent impact or friction Particularly it must not be used for applications that specifically require EPL Ga equipment Caution 1 The insulation between an intrinsically safe circuit and a frame of the equipment is not capable of withstanding a 500V dielectric strength test as defined in CI 6 3 12 of EN 60079 1...

Page 9: ...nd LCD Potentiometer for position feedback Gauge block The followings are descriptions of internal parts without cover No Description 1 LCD 2 Board cover 3 Gauge block 4 Supply air gauge 5 Out 1 gauge 6 UP Up button 7 DN Down button 8 MO Mode button 9 ENT Enter button 10 Ground 11 Cable gland or blind plug 12 Blind plug or cable gland 13 Air venting hole 14 Body ...

Page 10: ...Hysteresis 0 2 F S Repeatability 0 2 F S Operating characteristic Linear EQ Quick open User set 17 points LCD display 4 digit Response speed 1 1000 Min 1 Max 1000 Scan time 2 ms Shut off value 0 10 Valve action Direct acting DA reverse acting RA Operating temperature 30 80 22 176 Pneumatic connections Rc 1 4 or NPT 1 4 NPT 1 4 Electrical connections G 1 2 NPT 1 2 or M20 x 1 5 NPT 1 2 Explosion pro...

Page 11: ...Block 2 DI Function Block 1 Transducer Block 1 Physical Block Physical layer In compliance with IEC 61158 2 Transmission rate 31 25 kbit s Supply voltage Bus powered 9 32 VDC Max permissible voltage 35 VDC Power consumption 15 mA Physical device tag SSPA PNO ID number 0x0E19 Bus address Between 0 and 126 default bus address 126 Certification No Z01802 Revision 1 0 SW FW 01 00 HW 01 00 GSD PWGX0E19...

Page 12: ...on 16 mA Certificate FF Conformance Test ITK 6 1 1 Device name PG SS Positioner Dev ID 0003460001_PG SS_XXXXXXXX Unit address Between 10 and 27 default address 247 Class LM profile 32L 31PS Factory default The PG SS Positioner is not delivered in an aligned state To adjust the operating range and control parameters an automatic configuration must be run on the unit Otherwise the transducer block r...

Page 13: ...rk lever F NAMUR shaft direct mounting N Pressure Gauge Not included 0 6 bar 90psi 1 10 bar 150psi 2 Position feedback Not included N Position transmitter 4 20mA output O 2 x alarm limit L 2 x micro switch SPDT S O L M O S Q Communication Not included N HART communication H Profibus PA communication P Foundation Fieldbus communication F Pneumatic Rc 1 4 G 1 2 standard 3 electrical NPT 1 4 NPT 1 2 ...

Page 14: ...escribed output Ui Ii Ri Pi Li Ci Intrinsic safety electrical parameters for output are described Limit Ui Ii Ri Pi Li Ci Intrinsic safety electrical parameters for alarm or switch are described ᆢ Protection class Explosion proof classifications approved are described ᆢ Certificate No Certification number is described 5 Principle of Operation If 4 20 mA input signal is supplied the micro processor...

Page 15: ... PARM Display mode ㆍ Selection of mA or in reverse way with values shown Ex Reverse 20 shown 80 shown HART communication ㆍ HART communication Up ㆍ UP button Down ㆍ DOWN button MO Mode ㆍ Selection of running mode ㆍ Selection of parameter group or parameter ENT Enter ㆍ Save of setting values Press Mode button for 5 seconds ㆍ Quick auto calibration Press Up button for 5 seconds ㆍ GROP gain adjustment...

Page 16: ...uired to move the valve 7 1 Mounting onto Linear Actuator 7 1 1 Installation of Follower Guide Follower guide Clamp plate Screws M6 Valve yoke Valve stem 7 1 2 Installation of Feedback Lever and Mounting Bracket Mounting bracket for SS2L positioner is designed to support IEC 60534 6 1 Mounting bracket Screws M8 Feedback lever SS2L positioner Feedback pin ...

Page 17: ...genex com 16 7 1 3 Mounting onto Cast Yoke or Pillar Yoke Cast yoke type Pillar yoke type Cast yoke Mounting bracket Screws M8 U bolts Pillar yoke 7 1 4 Mounting onto Other Kind of Cast Yoke Cast yoke Mounting bracket Screws M8 ...

Page 18: ...ies www powergenex com 17 7 1 5 Mounting on Diaphragm Actuator Feedback Levers A type 8 30mm stroke B type 8 70mm stroke C type 8 130mm stroke D type 80 200mm stroke 7 1 6 Installation of Feedback Pin Follower Guide ...

Page 19: ...ket up and down little by little so that it can be positioned horizontally Fix the mounting bracket with screws M8 Connect air lines between the SS2L positioner and the actuator and supply air to the positioner and perform auto calibration by pushing Mode button for 5 seconds The operating angle from 0 to 100 stroke should be within the range of 30 In case of the over range of 30 move the valve st...

Page 20: ...SS2L SS2R Series www powergenex com 19 Maximum operating ange 60 Indicator position at 50 Indicator position at 0 100 Indicator position at 100 0 ...

Page 21: ... have other size bracket see 7 2 4 Re assembling Multi size Bracket according to Rotary Actuator ⓑ Mount the SS2R positioner onto the rotary pneumatic actuator with 4 pcs M5 screw ⓒ Connect air lines between the SS2R positioner and the rotary pneumatic actuator ⓓ Perform auto calibration by pushing MODE button for 5 seconds Make sure that the SS2R positioner works within the operating range indica...

Page 22: ...ition at 0 or 100 Indicator position at 100 0 7 2 2 Mounting with Fork Lever Type SS2R positioner Multi size bracket Rotary pneumatic actuator Fork lever Positioner feedback lever 7 2 3 Position of Fork Lever Clockwise movement Counter clockwise Movement ...

Page 23: ... 2 4 Re assembling Multi size Bracket according to Rotary Actuator L mm H mm L mm H mm 80 20 130 20 80 30 130 30 80 50 130 50 Check L and H on the actuator and re assemble the multi size bracket to fit your actuator mounting configuration L H ...

Page 24: ...SS2L linear type 8 2 SS2R rotary type Be sure to install the air filter regulator before the positioner Supply air should not contain water oil or moisture It is recommended to set a supply air pressure 10 higher than the actual operating pressure of the actuator ...

Page 25: ...id place more attention is required It may cause a serious damage or malfunctions 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 F NO NC COM NO NC COM Input Communication Ground Alarm limit 1 Switch 1 Switch 2 Output Alarm limit 2 1 4 20mA input signal HART Profibus PA Fieldbus 9 Alarm limit 2 2 4 20mA input signal 3 Ground 11 Switch 1 NO 4 4 20mA output signal 12 Switch 1 NC 5 4 20mA output signal 13 Switch...

Page 26: ...supplied for alarm limits 9 4 HART Connection Note that wires for HART communication should be connected to terminals No 1 and No 2 together with wires for input signals For reference there is no distinction in and between HART wires 9 5 Profibus PA Fieldbus Connection Make sure of and when connecting wires Position Transmitter Specifications Output signal 4 20mA 2 wire Power supply 12 30 VDC Outp...

Page 27: ...the micro switch cams clockwise slowly and check the contact points After checking the contact points of the micro switches at a desired position fix with screws For reference upper switch 1 No 11 12 13 lower switch 2 No 14 15 16 9 8 Earthing Micro Switch Specifications Type SPDT Rating code 10 1A 250 VAC Operating temperature 25 85 ...

Page 28: ...all the proper safety device to block the static or electromagnetism 3 If possible minimize inductance and capacitance of wires If the operating conditions are specified try to keep inductance and capacitance as low as possible 4 Protect wires from the external damage 5 Ground in order to meet the operating regulations of the installation area 1 The electronic card and the internal coils can be da...

Page 29: ...cable gland and the blind plug for installation on other side 2 Turn the cover of the cable gland counter clockwise to open and insert wires 3 Connect wires to terminals and tighten the cable gland 1 Use the cable with diameter of Max Ø 12 5 to Min Ø 9 2 Be sure to disconnect a power supply before the above process 9 10 2 Blind Plug 1 Use the blind plug for the cable entry not used 2 Install or di...

Page 30: ...sitioner VALP POSP is shown as below Please choose either VALP or POSP within 6 seconds by pushing the UP DN button Otherwise VALP is set as standard 10 2 Checking Ambient Temperature In case of a reverse acting actuator RA is displayed and a countdown begins RA 5 4 3 2 1 END RUN auto calibration is completed DA In case of a direct acting actuator DA is displayed and a countdown begins VALP VALVE ...

Page 31: ...ONT FDGN Normal RUN Mode Push MODE RUN DISP MAN MON AUTO PVPR MSET CHEK TUNE T S E R E L I M PARA R DA SVMA mA PV R TEST PARM INPU SPAN ZERO L EQ PID DEAD C MD CTRL SUB DIGN OUT SHUT FOPN SPLT SUB Parameter grop CTRL Parameter grop F F O LOCK ON FCAL ICAL PST POLL ALRM ANGL SENT COLD CNLT SWST GCNL SPED SRPS ...

Page 32: ...he errors occurred to the positioner MILE Runtime checks the total valve runtime PARA Registry memory values checks the registry records in memory ANGL Operating angle displays the operating angle of the positioner shaft and feedback lever Ref Parameter Description Function 11 4 5 P 33 AUTO AUTO SET performs auto calibration and return to the factory settings TUNE Auto calibration performs auto ca...

Page 33: ...11 3 2 CTRL Parameters control speed adjustment Ref Parameter Description Function Default 11 5 7 A P 41 SPED Response speed 1 1000 1000 11 5 7 B P 41 SWST Slow start Smooth operation Auto set 11 5 7 C P 42 CNTL Control limit 50 1250 Auto set 11 5 7 D P 42 GCNL Gap Control limit 100 650 Auto set 11 5 7 E SRPS Control status Auto set 11 3 3 SUB Parameter Ref Parameter Description Function Default 1...

Page 34: ... input signal If a control valve is a direct acting type and it is necessary to see the feedback values in a reverse way select PV R LOCK ON Saves all setting values LOCK OFF Be sure to LOCK OFF when it is necessary to read or change the selected parameters and the saved setting values Quick auto calibration Span P Gain can be carried out without LOCK Off see 10 Quick Auto calibration LOCK is on u...

Page 35: ... P51 ANGL You can check the error codes and a total valve runtime 11 4 1 MON blinks Select CHEK Select PARA Select MILE Total valve runtime Select ANGL Number 1 corresponds to 10 hour For example if 1156 appears it means that this valve has been working for 11 560 hours P01 to P61 are just for a factory setting and only for reference ANGL is a factory setting just for reference ...

Page 36: ...Span STEN Only Zero and Span is re set without changing other values set after auto calibration 11 4 5 D Re booting COLD Reverse acting RA is a standard factory setting Even if air lines are connected wrongly by mistake the SS2 positioner detects automatically and performs auto calibration for direct acting DA If the actuator doesn t work with 4 20mA input signal properly change air lines of OUT1 ...

Page 37: ...valve will be fully open or closed and also the actual valve position will be shown as If the valve doesn t move any longer push the ENT button Step 3 If the ENT button is pushed on Step 2 the actual valve position is shown as in case of the 12mA input signal 50 by using the actual valve positions got on the above Step 1 and Step 2 The positioner can get the best linearity at the actual valve posi...

Page 38: ...2L SS2R Series www powergenex com 37 11 5 Parameters Flow Diagram The colored cells stand for the standard factory settings All setting values return to the standard factory settings if RESET begins HEVY ...

Page 39: ...o 20 4mA input signals optionally even though 4 20mA input signals are supplied 11 5 2 R DA Selection of Direct Acting DA or Reverse Acting RA default RA R DA R A D A 11 5 3 L EQ Change of Linear E Q Quick Open or User Set default Linear L EQ LIN E25 E50 QOPN USER The valve characteristic can be changed to Linear 1 25 EQ 1 50 EQ Quick Open or User Set ...

Page 40: ... 2 Point Parameter Input Signal mA Valve Opening set value 1 4MA 4mA 0 50 2 5MA 5mA 20 30 3 6MA 6mA 29 20 4 7MA 7mA 35 15 5 8MA 8mA 40 10 6 9MA 9mA 45 6 7 10MA 10mA 48 4 8 11MA 11mA 49 2 9 12MA 12mA 50 0 10 13MA 13mA 51 3 11 14MA 14mA 52 7 12 15MA 15mA 55 11 13 16MA 16mA 60 20 14 17MA 17mA 65 30 15 18MA 18mA 71 43 16 19MA 19mA 80 60 17 20MA 20mA 100 100 ...

Page 41: ...er set value after interval of the Shut Off setting value 0 3 is the default value of Shut Off As Shut Off is set to 5 in Example 2 the curve maintains by 50 from 4 to 4 8mA and moves forward according to the user set 11 5 4 SPAN Span Adjustment default 100 SPAN 100 0 100 11 5 3 ZERO Zero Adjustment default 0 ZERO 0 0 99 Zero can be adjusted to 0 99 Be sure to supply 20mA input signal before adjus...

Page 42: ...value during auto calibration process in consideration of sizes of the valve and the actuator If a hunting problem happens decrease P Gain value If an oscillation problem happens increase P Gain value P Gain values are different according to the working conditions In case of a small actuator increase or decrease 5 to 10 In case of a big actuator increase or decrease by 20 to 30 ...

Page 43: ... LOW Most hunting or oscillation problems can be solved by selecting HARD in Control Mode But if it is necessary to adjust PID values MIDD HIGH LOW can be selected without a full understanding of PID control Parameter Status Description Standard parameter Hunting is happening Change to Hard mode in case of a hunting problem by rapid under or overshooting Oscillation is happening Change to Low mode...

Page 44: ... Max 1000 11 5 7 B SWST Slow Start default automatically set SWST ON OFF This is to make a valve work slowly In case of a small actuator a hunting problem can happen due to a fast movement This hunting problem can be solved with SWST parameter SWST is set automatically during an auto calibration process if it takes a valve below 1 second to move from 0 to 100 11 5 7 C CNLT Control Limit default au...

Page 45: ...nal GCNL works with 1 2 value of CNLT for a safer control In case that a hunting or oscillation problem happens around the position related to the input signal a safer control can be accomplished by lowering GCNL 11 5 7 E SRPS default automatically set SRPS AUTO 1BST 8B SRPS is the fast and easy setting to make the positioner work smoothly according to the working condition of the valve For a stab...

Page 46: ...matically during auto calibration The user can re set the FDGN value manually More power pneumatic torque is required to move a valve with a strong friction packing and it can cause a hunting or overshooting problem by inertia By way of prevention when the positioner reaches to a desired position air is charged or discharged momentarily for a more stable valve control The FDGN value stands for the...

Page 47: ...riction UP DN UP DN UP DN ENT UP DN MO T EN T EN UP DN See 11 5 Repleat Move to other Sub Parameter Push ENTER button one time and read or change by moving to other parameter Push ENTER button two time and move to Run and Setting is locked Select C MD Push one time move to Main Parameter Push two times move to RUN 1 Please carry out auto calibration again in case that it is changed to HDGP from NO...

Page 48: ...4M IN20 Set to values relating to 4 20mA input signal Factory setting 11 5 11 H FB4M FB20 Set to values relating to 4 20mA output signal Factory setting 11 5 11 I HART Polling Address 0 15 0 11 5 11 J Partial Stroke Test Checks a valve status OFF 11 5 11 K Profibus address Changes the Profibus address 126 11 5 11 A SHUT Valve Shut off Control default 0 3 SHUT 0 3 0 9 9 It is a safety function to c...

Page 49: ...ans that a valve is fully open at 19 952mA 11 5 11 C OUT Setting of Output Signal default 4 20mA OUT 4 20 20 4 4 20mA is set as a standard factory setting It is possible to change to 20 4mA 11 5 11 D SPLT Spilt Range Setting default 4 20 SPLT 4 20 4 12 12 20 Split range can be set to 4 12mA or 12 20mA 11 5 11 E LCD Change of Display Position on LCD LCD FOR REV LCD is to change the display position...

Page 50: ...105 ALRM AL1L AL1H AL2L AL2H 0000 0010 0090 0105 You can set an opening point or a closing point of a control valve AL1 L H is set to 0 10 and AL2 L H is set to 90 105 from the factory as standard For example see the below in order to re set AL1 to 20 40 AL1L 20 AL1H 40 AL1L Setting AL1H Setting ...

Page 51: ...SS2R Series www powergenex com 50 For example see the below in order to re set AL2 to 80 100 AL2L 80 AL2H 100 AL2L Setting AL2H Setting How to wire the Alarm Limits 24VDC should be supplied for alarm limits ...

Page 52: ...9 8mA with a signal calibrator on site 4 2mA can be recognized as 0 and 19 8mA as 100 by re setting with ICAL If ICAL is set at 4mA and 20mA the middle output signals between 4mA and 20mA are set automatically See 11 5 3 L EQ if it is necessary to change other characteristic curve 11 5 11 H FCAL Setting of Output Signal default factory setting FCAL FB4M FB20 This is to re set the 4 20mA output sig...

Page 53: ...ng direction Valve position 50 move to the increasing direction to adjust a moving range per second default 1 0 sec One of 1 0 0 5 0 25 0 12 or 0 06 sec can be selected to adjust a waiting time that the valve follows after the test signal default 10 seconds Even though Good is shown if RESP is set too long the judgment point will not be good for the next comparison Also if Bad is shown RESP is set...

Page 54: ...ART 8 7VDC 435Ω 20mA With HART 9 4VDC 470Ω 20mA 12 1 2 Electrical Connections Check polarities of 4 20mA input signal definitely and make the electrical connections 12 1 3 Pneumatic Connections see 8 1 8 2 12 1 4 Supply Air Quality A supply air should be definitely clean and compressed free of water moisture or oil in conformance with IEC 770 and ISA 7 0 01 12 2 Module Parts RTQ Coil Assembly spar...

Page 55: ... due to user s carelessness For reference 0 10kΩ potentiometer is installed into the SS2 positioner Dis install the electronic card from the SS2 positioner and make the markings on two gears match with each other Move the feedback lever to 50 position and adjust a potentiometer so that it can reach nearly 5kΩ Re install the SS2 positioner onto the valve and re perform auto calibration ...

Page 56: ... of range MONT is shown during step 4 and an auto calibration process is finished without completion Re install the SS2L SS2R positioner LOTT Bias Low The valve is not closed or moves slowly Loosen a valve packing HITT Bias High The valve is not open or moves slowly FBFT Feedback error 0 1 PM00 is shown at step 4 and an auto calibration is finished without completion Defectiveness of potentiometer...

Page 57: ...try to set in Control Mode and change to other valve working condition again Note that it is necessary to perform auto calibration again in case of change of Normal Hard or Small Hard Status Action An actuator is small and responds fast And a hunting problem happens SWST ON SPED Adjust 11 5 12 11 5 11 A valve doesn t move smoothly even in HARD mode due to a very strong packing FDGN Re adjust 11 5 ...

Page 58: ...SS2L SS2R Series www powergenex com 57 14 Spare Parts 14 1 SS2L Spare Parts 1 2 3 4 5 6 7 8 10 11 17L 16L 19 18 13 14L 15 9 12 SS2L LINEAR TYPE ...

Page 59: ...SS2L SS2R Series www powergenex com 58 14 2 SS2R Spare Parts 1 2 3 4 5 6 7 8 10 11 19 18 13 14R 15 9 12 17R 16R SS2R ROTARY TYPE ...

Page 60: ...dy air line cover 7 S2BO 07 Air line O ring 8 S2BO 01 SS2 body 9 RUB 52 Gauge block O ring P10 10 S2BO 02 SS2 gauge block G 11 S2BO 02N SS2 block N 12 TQ SS2 3 RTQ coil module 13 S2TQ 02 RTQ coil cover 14 S2BO 09 SS2 potentiometer bracket 15 GEAR 11 SH 36 SS2 main shaft gear 16L LEVER 05 08 SS2 feedback lever 16R SH 38 SS2 3 rotary feedback joint 17L BR 12 SS2 3 linear bracket 17R BR 13 14 SS2 3 r...

Page 61: ...SS2L SS2R Series www powergenex com 60 15 Dimensions 15 1 SS2L linear type ...

Page 62: ...SS2L SS2R Series www powergenex com 61 15 2 SS2R rotary type ...

Page 63: ...SS2L SS2R Series www powergenex com 62 15 3 SS2R with 2 x SPDT micro switch ...

Page 64: ...that customers retro fit the products improperly without any instructions from Power Genex In case that the products are damaged by a bad delivery storage or handling beyond design conditions In case that the products are used beyond specifications In case that the products are damaged by an improper installation In case that the products are damaged by fire earthquake storm flood thunder lighting...