Power-Genex SS3L Series, Instructions And Operating Manual

Page 1: ...Instruction and Operating Manual Smart Valve Positioner SS3L SS3R Series Software Version 6 06 Power Genex Ltd ...

Page 2: ...m Actuator 18 7 1 6 Installation of Feedback Pin Follower Guide 18 7 1 7 Standard Installation 19 7 2 Mounting onto Rotary Actuator 20 7 2 1 The SS3R positioner supports NAMUR mounting standard 20 7 2 2 Mounting with Fork Lever Type 22 7 2 3 Position of Fork Lever 22 7 2 4 Re assembling Multi size Bracket according to Rotary Actuator 23 8 Air Connections 24 8 1 SS3L linear type 24 8 2 SS3R rotary ...

Page 3: ...se Acting RA default RA 38 11 5 3 L EQ Selection of Linear E Q Quick Open or User Set default Linear 38 11 5 4 SPAN Span Adjustment default 100 40 11 5 5 ZERO Zero Adjustment default 0 40 11 5 6 PID Gain 41 11 5 7 CTRL Control Speed Adjustment 42 11 5 8 DEAD Setting of Dead Band default 0 5 43 11 5 9 SUB Parameter 44 12 Maintenance Service 51 12 1 Preliminary Check Points 51 12 1 1 Voltage 51 12 1...

Page 4: ...nery 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 and maintenance of machinery equipm...

Page 5: ...ility 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 thi...

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: ... position feedback Pilot valve Torque motor Pressure gauge and block The followings are descriptions of internal parts without cover 1 LCD 7 MO Mode button 13 Positioner body 2 Gauge block 8 ENT button 14 Positioner cover 3 Supply air gauge 9 Ground 15 Button cover 4 Out 1 gauge 10 Blind plug or cable gland 5 UP Up button 11 Cable gland or Blind plug 6 DN Down button 12 Air venting hole ...

Page 10: ...2 8 ℓ min 0 17 Nm3 h 0 1 scfm Sup 1 4 6 bar Characteristic Linearity 0 3 F S Sensitivity 0 2 F S 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 75 22 167 Pneumatic connections ...

Page 11: ...ication Profiles PROFIBUS Profile for Process Control Devices Version 3 02 Block types 1 AI Function Block 1 AO Function 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...

Page 12: ...the fieldbus 9 32 VDC Max permissible voltage 36 VDC Power consumption 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 co...

Page 13: ...oke C 80 200mm stroke D Rotary type Fork 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 communication P Pneumatic Rc 1 4 G 1 2 standard 3 electrical NPT 1 4 NPT 1 2 4...

Page 14: ...al number and a manufacturing date for tracking are described ᆢ Certificate No CE XXXX INERIS ATEX XXXX IECEx KTL 11 0020X 11 KB2BO XXXX ᆢ Code Ex d IIC T6 Gb Temp 30 to 75 ᆢ WARNING 1 Do not open when an explosive gas and dust atmosphere may be present 5 Principle of Operation If 4 20 mA input signal is supplied the micro processor compares input signal with position feedback and sends control si...

Page 15: ...ds ㆍ GROP gain adjustment Press Down button for 5 seconds ㆍ Span adjustment Press Enter button ㆍ Ambient temperature Display of input or output ㆍ mA Main parameters MODE RUN DISP MAN MON AUTO LOCK TEST 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 ...

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: ...g 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 type Pillar yoke type Cast yoke Mounting bracket Screws M8 U bolts Pillar yoke ...

Page 18: ...ies www powergenex com 18 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 SS3L 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: ...60 Indicator position at 50 Indicator position at 0 100 Indicator position at 100 0 7 2 Mounting onto Rotary Actuator 7 2 1 The SS3R positioner supports NAMUR mounting standard VDI VDE 3835 IEC 60534 6 2 SS3R positioner Multi size bracket Rotary pneumatic actuator ...

Page 21: ...oner onto the rotary pneumatic actuator with 4 pcs M5 screw ⓒ Connect air lines between the SS3R positioner and the rotary pneumatic actuator ⓓ Perform auto calibration by pushing MODE button for 5 seconds Make sure that the SS3R positioner works within the operating range indicated on the bottom See the below pictures Otherwise the error message of MONT appears on LCD and the auto calibration pro...

Page 22: ...wergenex com 22 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: ...SS3L linear type 8 2 SS3R 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: ...valve positioner SS3 positioner is certified to ATEX IECEx explosion proof Exd IIC T6 Take extra care when handling the positioner as explosion proof equipment To use as Ex d IIC T6 A Pressure proof packing As shown below in the chart use Cable gland B Metal Piping Attach the sealant fitting bracket near the cable port 1 4 20mA Input signal 2 4 20mA Input 3 Ground 4 4 20mA Output signal 5 4 20mA O...

Page 26: ... auto calibration process 9 3 Earthing The SS3 positioner provides the internal earthing and the external earthing as shown below Note that the SS3 positioner should be earthed for a safe usage and operation Position Transmitter Specifications Output signal 4 20mA 2 wire Power supply 12 30 VDC Output current limit 30mA DC Linearity 0 75 F S Operating temperature 20 80 Internal earthing External ea...

Page 27: ...larm limits 9 5 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 6 Profibus PA Fieldbus Connection Make sure of and when connecting wires ...

Page 28: ... code 10 1A 250 VAC Operating temperature 25 85 9 8 Setting Micro Switches a Push the red cam down and move b Turn the red cam until it touches the limit switch And push up c Do the same procedure with the blue cam But push the blue cam up to move Upper switch 1 terminals 11 12 13 Lower switch 2 terminals 14 15 16 ...

Page 29: ...positioner 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 the 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 ...

Page 30: ...S3L SS3R Series www powergenex com 30 11 Description of Parameters Flow 11 1 Diagram of Parameters Note that the PST function Partial Stroke Testing is loaded at the factory on demand only when requested ...

Page 31: ...NITOR checks the current status of the positioner CHEK ERROR CHEK checks the errors occurred to the positioner MILE Runtime checks the total valve runtime Ref Parameter Description Function 11 4 5 AUTO AUTO SET performs auto calibration and return to the factory settings TUNE Auto calibration performs auto calibration REST RESET returns to the factory settings STEN START END re sets the position o...

Page 32: ...UTO 11 5 7 C KISP AUTO 11 5 7 D GNLT GAP LIMIT AUTO 11 5 7 E CNLT CONTROL LIMIT AUTO 11 5 7 F HDGP HARD GRAPHITE OFF 11 3 3 SUB Parameter Ref Parameter Description Function Default 11 5 9 A SHUT Shut off 0 9 9 0 3 11 5 9 B FOPN Full open 0 9 9 0 3 11 5 9 C OUT Output signal 4 20mA or 20 4mA 4 20mA 11 5 9 D SPLT Split range 4 12mA or 12 20mA 4 20mA 11 5 9 E LCD Change of display position FOR REV FO...

Page 33: ...alue SV is displayed with mA or Setting value stands for 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 wit...

Page 34: ...T 11 4 4 Monitor Mode MON CHEK OK 0 ㆍㆍㆍOK 12 MILE 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 in MILE corresponds to 10 hour For example if 1156 appears it means that this valve has been working for 11 560 hours ...

Page 35: ...an is re set without changing other values set after auto calibration 11 4 5 D COLD Re booting Restarts the program without changing any settings 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 ...

Page 36: ...NT button one time and the valve will be fully open or closed and also the actual valve position angle will be shown Step 3 Push the ENT button one time and the actual valve middle position angle will be shown It shows the middle position angle between two ends fully open and closed measured through the above procedures of Step 1 and Step 2 Move the positioner upwards or downwards so that the valv...

Page 37: ...SS3L SS3R 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 ...

Page 38: ...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 Selection 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 39: ... 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 40: ...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 5 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 41: ...ation 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 11 5 6 B I Gain Integral Gain I GN Auto Set As I Gain is set automatically during auto calibration process it is not necessary to change manually 11 5 6 C D Gain Differential G...

Page 42: ...PID values 11 5 7 C KISP kI Gain Speed default 100 KISP AUTO 0 30 As KSIP is set automatically during auto calibration process it is not necessary to change manually 11 5 7 D GNLT Gap Control Limit default automatically set GNLT AUTO 100 650 GNLT is to control a whole operating range If the valve comes within 3 of input signal GNLT works with 1 2 value of CNLT for a safer control In case that a hu...

Page 43: ... a hunting problem can happen If CNLT is decreased as shown in Graph 4 a control speed can become slower but the positioner works more stably CNTL can be adjusted by 100 11 5 7 F HDGP In case of a hard packing friction default Off HDGP OFF ON HDPG is helpful to eliminate a hunting problem with a hard packing friction 11 5 8 DEAD Setting of Dead Band default 0 5 DEAD 0 5 0 9 99 If there is a differ...

Page 44: ...ting to 4 20mA input signal Factory setting 11 5 9 H FB4M FB20 sets to values relating to 4 20mA output signal Factory setting 11 5 9 I HART polling address 0 15 0 11 5 9 J Partial stroke testing checks a valve status OFF 11 5 9 A SHUT Valve Shut off Control default 0 3 SHUT 0 3 0 9 9 It is a safety function to close a valve completely And it is possible to change 0 to 9 9 For reference 0 1 means ...

Page 45: ...ns that a valve is fully open at 19 952mA 11 5 9 C OUT Setting of Output Signal default 4 20mA OUT 4 20 20 4 4 20mA is a standard factory setting It s available to change to 20 4mA reversely 11 5 9 D SPLT Split 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 9 E LCD Change of Display Position on LCD LCD FOR REV LCD is to change the display position ...

Page 46: ...05 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 47: ...SS3R Series www powergenex com 47 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 48: ...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 9 H FCAL Setting of Output Signal default factory setting FCAL FB4M FB20 This is to re set the 4 20mA output sign...

Page 49: ...g 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 too low Adjust RESP to show that there is no proble...

Page 50: ...3L SS3R Series www powergenex com 50 11 5 9 K ADDR PROFIBUS Communication Address default 126 ADDR 0 0 126 This is to select one of PROFIBUS communication address 0 125 on site The default address is 126 ...

Page 51: ...oil in conformance with IEC 770 and ISA 7 0 01 12 2 Module Parts RTQ Coil Assembly spare part No 12 Pilot Valve Assembly spare part No 5 PCB Control Board Assembly spare part No 3 12 3 Re setting of Potentiometer spare part No 14a 14b It is necessary to adjust a setting of potentiometer as below when a gear position is moved due to user s carelessness For reference 0 10kΩ potentiometer is installe...

Page 52: ...2 How to Exchange SS3L SS3R RTQ Disassemble the pilot valve cover Disassemble the fixing bolts 4 pcs fastened on airline body after removing the pilot valve cover Detach airline body from the positioner body Disassemble the bolt 1 pc after removing the seal on RTQ cover bolts Disassemble the fixing bolt 2 pcs after removing the RTQ cover Disassemble the RTQ Re assemble using new RTQ by following a...

Page 53: ... 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 54: ...SS3L SS3R Series www powergenex com 54 14 Spare Parts 14 1 SS3 Parts ...

Page 55: ... 14 PG SS3 08 Airline body 4 16 PG SS3 09 Vent Unit 4 17 PG SS3 10 Airline Oring 5 PG SS3 11 Shaft ass y 6 PG SS3 12 SS3 Main body 7 PG SS3 13 SS3 Cover ass y 7 4 PG SS3 14 PG logo 7 5 PG SS3 15 SS3 Main board 7 7 PG SS3 16 Botton cover 7 8 PG SS3 17 Glass 7 9 PG SS3 18 Glass fix plate 7 13 PG SS3 19 SS3 botton spring 7 14 PG SS3 20 SS3 main cover 7 15 PG SS3 21 Cover pin 7 16 PG SS3 22 Botton 8 P...

Page 56: ...SS3L SS3R Series www powergenex com 56 15 Dimensions 15 1 SS3L linear type ...

Page 57: ...SS3L SS3R Series www powergenex com 57 15 2 SS3R rotary type ...

Page 58: ...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...