.IM-P343-16 3.568.5275.226 CH Issue 7 - 2016 EP5 and ISP5 Series Electropneumatic Positioners Installation and Maintenance Instructions Attention: Additional instructions are required when a ATEX intrisically safety instrument ISP5 is used in an explosion risk area. Safety information 2.
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Introduction 3.Consider: explosion risk areas, lack of oxygen (e.g. Tanks, pits), dangerous gases, extremes of temperature,hotsurfaces,firehazard(e.g.duringwelding),excessivenoise,movingmachinery. 1.6 The system Considertheeffectonthecompletesystemoftheworkproposed.Willanyproposedaction(e.g. Dangersmightincludeisolationofventsorprotectivedevicesortherenderingineffectiveofcontrols oralarms.Ensureisolationvalvesareturnedonandoffinagradualwaytoavoidsystemshocks.
1.7 Pressure systems Ensurethatanypressureisisolatedandsafelyventedtoatmosphericpressure.Considerdouble isolation(doubleblockandbleed)andthelockingorlabellingofclosedvalves.Donotassumethat thesystemhasdepressurisedevenwhenthepressuregaugeindicateszero. 1.8 Temperature Allowtimefortemperaturetonormaliseafterisolationtoavoiddangerofburns. 1.9 Tools and consumables Beforestartingworkensurethatyouhavesuitabletoolsand/orconsumablesavailable.Useonly genuine Spirax Sarco replacement parts. 3.568.5275.226.1.10 Protective clothing Considerwhetheryouand/orothersinthevicinityrequireanyprotectiveclothingtoprotectagainst thehazardsof,forexample,chemicals,high/lowtemperature,radiation,noise,fallingobjects,and dangers to eyes and face. 1.11 Permits to work Allworkmustbecarriedoutorbesupervisedbyasuitablycompetentperson. Installation and operating personnel should be trained in the correct use of the product according to the Installation and Maintenance Instructions.
Whereaformal'permittowork'systemisinforceitmustbecompliedwith.Wherethereisnosuch system,itisrecommendedthataresponsiblepersonshouldknowwhatworkisgoingonand,where necessary,arrangetohaveanassistantwhoseprimaryresponsibilityissafety. 1.12 Handling Manualhandlingoflargeand/orheavyproductsmaypresentariskofinjury.Lifting,pushing,pulling, carryingorsupportingaloadbybodilyforcecancauseinjuryparticularlytotheback.Youareadvised.2. Introduction Introduction TheEP5isa2wirelooppoweredpositionerrequiringa4-20mAcontrolsignal,andisdesigned forusewithlinearpneumaticvalveactuators.Thepositionercomparestheelectricalsignalfrom a controller with the actual valve position and varies a pneumatic output signal to the actuator accordingly.Thedesiredvalvepositionisthereforemaintainedforanycontrolsignalandtheeffects ofvaryingdifferentialpressure,stemfrictionandhysterisisareovercome.Amountingkitissupplied tosuitallNAMURstandardcolumnsoryokes. Operating principle TheEP5operatesonaforcebalanceprinciplebymeansofanozzle/flappermechanismanda feedbackspring(refertoFigure1). The electrical control signal (A) is converted into a proportional air pressure (I). This pressure is appliedtotheflapper(5) via the receiver (1),causingadeflectionoftheflapperrelativetothenozzles U1/U2.Step 1 Identify actuator type Forcorrectoperationitisimportanttoknowtwofactorswhichwillaffectoptimummovementofthe positioner feedback mechanism: Thedistancebetweentheaxesofthevalve/actuatorstemandthepositionerslidepin.
The travel of the valve actuator. To ensure these are set correctly, please note the following: WhenattachinganEP5toanySpiraxSarcovalveactuator,ignoreStep3. For non-Spirax Sarco actuators, ignore Step 2. 3.568.5275.226.Step 2 For attachment to Spirax Sarco actuators Usingthe2offM6panheadscrews,securelyattachthe'T'shapedslidingpinholdertothevalve actuatorcouplingblock(Figure2).ApplyLoctitetotheslidingpinandscrewintohole'Y'(asshown) on the sliding pin holder and tighten. Valve actuator coupling block 'T'shaped sliding pin holder Fig.
2 Close-up of sliding pin holder fitted to valve coupling. Usingthe2offM8x15hexheadscrewsand8mmspringwashers,attachthemountingplatetothe backofthepositioner,utilisingholesNo.2inthebracket(Figure3).Takecarenottoover-tighten thesescrewsandstripthethreads. Positioner Mounting plate Fig.Actuatorpillar Actuator or yoke spindle 100% Fig. 4 Pillar/yoke spacing, showing 50% travel. Table 2 Hole to be used Upto125mm 125to150mm 150to175mm above 175 mm Step 4 Temporarily apply adequate air pressure directly into the actuator so that the valve is at50%oftravel(Figure5).Step 6 Fittheangledprotectionplatetotherearofthepositionerusingthe2offcaptiveM3pan headscrews.Accesstothesecaptivescrewsisfrominsidethepositioner.
Step 7 Adjusttheairsupplypressuretostroketheactuatorfrom0%to100%andensurethe positioner lever rotates freely. Remove the temporary air supply from the actuator. Step 8 Fitting a gauge block (optional) ToaidcommissioningitisrecommendedtofitagaugeblockandpressuregaugestoallEP5s.Please note that gauges and gauge block can be supplied as spare parts if required. FitgaugestotheblockbeforeattachingtheblocktotheEP5.Usethreadsealanttoensureairtight connections.TheuppergaugedisplaystheoutputoftheI/Pconverter,andisnormally0-2barg.The lowergaugedisplaysthepositioneroutputpressure,sothegaugerangewilldependontheactuator.3.3.2 Electrical connections CablingshouldbeinstalledinaccordancewithBS6739-InstrumentationinProcessControlSy- stems: Installation design and practice or local equivalent. TheEP5onlyrequiresa4-20mA(standard)or2-10Vdc(ifrequested)signal.Removethefront coverandlocatetheterminalblockandearthterminalpost(Figure6). ConnectiontotheunitisthroughthePg13.5cablegland(assupplied),whichwhenusedwithsuitable cablewillensuretheIP54protectionrating.Appropriateconduitconnectionsmaybeusedinstead. Connectconductors(0.5to2mm²)totheterminalblockandearthpost(3mm²)notingthepolarity +/-showninFigure6.
InhazardousareasusemodelISP5withintrinsicprotection(typeEExiallCT6,T5,T4)ensuringthe powersupplyfromadjoiningequipmentiscertifiedinaccordancewithEN50.014andEN50.020 standards,inrespectofthelimitsofelectricfeaturesshownatapprovalstage.Refertoapproval certificatesuppliedwitheachISP5product. Earth terminal Cable post gland Terminal block Fig. 6 3.568.5275.226.4. Commissioning Once the positioner has been mounted and connected up, proceeed as follows. Step 1 Set the valve action Establishingthecorrectactionofthevalveisdoneby: a.
ConnectiontoeitherU1orU2nozzles(seeFigure7)and b. Connection tonozzleU2 Connection tonozzleU1 Fig.
7 U1 = Increase action = Withincreasingelectricalcontrolsignaltheairpressuretotheactuator willincrease. U2 = Decreaseaction = Withincreasingelectricalcontrolsignaltheairpressuretotheactuator willdecrease.To change the slider location: RefertoFigure8todeterminethecorrectportion.Tochangethesliderslackenthescrewandslide it into the correct portion of the arm. 8a Increase action and spring extend Upper sector U1nozzle Fig.
8b Increase action and spring retract U1nozzle Lower sector Fig. 8c Decrease action and spring extend U2nozzle Lower sector.Step 2 Set sensitivity Thepositionersensitivityisadjustedusingthesensitivityscrew(Xp%,seeFigure10).Itissetde- pending on air supply pressure. Before the commissioning stage it is essential to set the sensitivity withinaproportionalbandof(3%to6%).UseFigure10toadjustthesensitivityscrewbyfirstlyfully closingthescrew(clockwise),thenreopenthescrew:- ¾ Supply pressure (S) 1.4 bar - Screwopen of a turn ¼ 4.0bar - Screwopen of a turn 6.0bar - Screwopen of a turn 1.4 bar.Step 3 Set damping The final adjustment of damping screw should be performed with plant in operation, in order to limit,ifnecessary,theactuationspeed.Duringthecommissioningsetthedampscrewflushwith the body see Figure 11. Dampscrew Fig.
11 Thereductionofairflowratecapacitytotheactuatorwillslowdownthevalvemovementtolimitthe effectofcyclinghunting.Closingthescrew(clockwise)increasesdamping,andviceversa. Step 4 Set zero point Check all air and electrical connections are in place.
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