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Nozzle baffle type intelligent valve positioner
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Nozzle baffle type intelligent valve positioner

TORLEO nozzle flapper type intelligent valve positioner is used in conjunction with pneumatic control valves (such as membrane control valves, ball valves, butterfly valves, etc.), and is widely used in precise control of flow in the production process of petroleum, chemical, metallurgy, electric power, papermaking and other industries.
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Exd IIC T4-T6Gb

 

霍尔式智能阀门定位器

  

TORLEO nozzle flapper type intelligent valve positioner is used in conjunction with pneumatic control valves (such as membrane control valves, ball valves, butterfly valves, etc.), and is widely used in precise control of flow in the production process of petroleum, chemical, metallurgy, electric power, papermaking and other industries.

 

霍尔式智能阀门定位器

 

The technical principle of the TORLEO intelligent valve positioner is to use the principle of electric balance (digital balance) instead of the traditional force balance principle, and convert electric control commands into pneumatic positioning increments to realize valve position control; use digital open, stop, and close signals To drive the pneumatic actuator; the valve position feedback signal directly passes through the high-precision position sensor to realize the electric/pneumatic conversion function. The microprocessor in the intelligent valve positioner receives the 4-20mA set value signal and compares it with the actual valve position value fed back by the valve position sensor. If a deviation is detected, it immediately outputs an electronic control command according to the magnitude and direction of the deviation ( PWM digital method) to the I/P control unit of the nozzle baffle, and then adjust the air flow into the air chamber of the actuator, that is to say, the control valve converts the control command into a pneumatic displacement increment. When the actual valve position deviates greatly from the set value (high-speed zone), the positioner outputs a continuous signal; if the deviation is not large (low-speed zone), the positioner will output a pulse signal; when the deviation is small (adaptive or adjustable) Dead zone state), there is no positioner output. At this time, the actual valve position reaches the set value, and the mechanism reaches a balanced state, that is, a certain set current corresponds to a certain valve position

 

霍尔式智能阀门定位器

 

Schematic diagram of TORLEO smart valve positioner

TORLEO nozzle flapper 3/3 spool valve IP working principle

 

Schematic diagram of nozzle baffle 3/3 spool valve IP principle

 

Nozzle baffle 3/3 spool valve type IP, independent intellectual property rights, technical adjustment to fill the domestic gap, its characteristics are as follows:

■ The site has a strong ability to resist dust, moisture, and oil pollution, and has low requirements for compressed air quality;

■ It is easy to realize single and double-acting control;

■ Low static air consumption and significant energy saving;

■ It can realize fault lockout (three-break protection position) without external power failure protector and solenoid valve, saving user investment;

■ Fast response speed and precise adjustment.

 

霍尔式智能阀门定位器

 

TORLEO intelligent valve positioner is the first nozzle baffle type intelligent valve positioner with independent intellectual property rights in China following Samson of Germany, ABB of Switzerland, Fisher of the United States, Foxboro of France, Azbil of Japan, and YTC of South Korea. Lack of blocks.

The technical characteristics of the product:

■ Nozzle baffle 3/3 spool type I/P, strong on-site resistance to dust, moisture, and oil, and low requirements for compressed air quality;

■ The product has a built-in keyboard and a large-size LCD screen, which is convenient for users to determine the working status of the locator and check information on site;

■ HART communication module can be added to facilitate users to obtain or modify the working information of positioners and valves online;

■ Valve position output module can be added to facilitate users to feedback valve opening;

■ The valve linearity, quick opening, equal percentage and user-defined flow characteristics can be set arbitrarily, which is convenient for valve control;

■ The self-invented and patented quick one-key auto-tuning method meets the needs of users for quick installation and fool-proof debugging;

■ Innovative use of gray prediction-integral split PID compound control algorithm, which can achieve control accuracy of 0.1-0.3%;

■ The special data backup function solves the problem of on-site application of intelligent positioners and maintenance and exchange in online production.

 
Performance comparison with imported similar products:
 
Serial number Index performance TORLEO (China) ABB (Switzerland) SAMSON (Germany) Azbil (Japan) Comparison description

1

Features of Pneumatic Parts

Digital I/P converter

Pneumatic 3/3 spool valve

Analog I/P converter

Pneumatic 3/3 spool valve

I/P converter

Pneumatic amplifier

I/P converter

Pneumatic amplifier

Better than imported

2

I/P drive mode

Digital (PWM) Analog (voltage)

Analog (voltage) 

Analog (voltage)  

Better than imported

3

I/P power consumption

0.8mw 

1.6mw 

5mw 

18mw 

Better than imported 

4

Vibration resistance index

20g 

20g 

10g 

10g 

Reach import

5

Fault lockout

Yes (built-in function) Yes (built-in function) Need external accessories

Need external accessories 

Reach import

6

Temperature drift compensation

Compensation technology 

Compensation technology  

Compensation technology 

No compensation technology  

Reach import 

7

Air pressure

1.4-6bar 

1.4-6bar 

1.4-6bar  

1.4-7bar  

Reach import 

8

air quality

ISO8573-1 particulate matter level 3, oil content is less than 1mg/m3, dew point is less than 10k

ISO8573-1 particulate matter level 3,

The oil content is less than 1mg/m3,

Dew point is less than 10k

ISO8573-1 particulate matter level 4,

3g oil, 3g dew point

ISO8573-1 particulate matter level 4,

3g oil, 3g dew point

Reach import 

9

Steady-state gas consumption

0.056Nm3/h

Has nothing to do with air pressure

0.085Nm3/h

Has nothing to do with air pressure

0.11Nm3/h

Has nothing to do with air pressure

0.24Nm3/h(1.4bar)

0.3Nm3/h(5bar)  

Better than imported

10

control precision

0.1%-0.3% 

0.1%-0.3% 

0.3%-0.5%  

0.5%-1.0%  

Reach import 

11

VDF

Fool-style one-key tuning

2-3 minutes

Multi-step menu setting

3-5 minutes

Multi-step menu setting

3-5 minutes

Toggle switch setting

8-15 minutes

Better than imported

12

Minimum working current

3.4mA 

3.4mA 

3.5mA  

3.8mA  

Reach import

13

Explosion-proof standard

Exia IIC T6 

Exia IIC T6 

Exia IIC T6  

Exia IIC T6  

Reach import

14

Explosion-proof standard

Exd IIC T6

Exd IIC T6

Exd IIC T6 

Exd IIC T6 

Reach import

15

Backup function

Have

without 

without without Better than imported

16

Selling price

Moderate high high high Cost-effective

 

霍尔式智能阀门定位器

 

Serial number project Explosion-proof Flameproof

1

input signal

4-20mA, can be set to separate program control input

Split range can be set between 20-100%

2

Input pressure

1.4-6kgf/cm²(0.14-0.6Mpa)

3

journey

10-150mm或0-120º

4

impedance

Maximum 460Ω/20mA(DC)

5

Air source interface

PT (NPT) 1/4

6

Pressure gauge interface

PT (NPT) 1/8

7

Power connector

PF 1/2 (G 1/2)

8

Repeatability

±0.2%F.S.

9

Operating temperature

-30℃∽85℃

10

Explosion-proof temperature

-40℃∽40℃

11

Linear

±0.3%F.S.

12

Hysteresis

±0.2%F.S.

13

Sensitivity

±0.2%F.S.

14

Air consumption

Less than 0.03kg/h (independent of air source pressure)

15

Output characteristics

Linear, quick opening, equal percentage, user-defined

16

Self-tuning method

One-key auto-tuning

17

Material grade

Die-cast aluminum

Stainless steel 316

18

Explosion-proof grade

Exia IIC T4-T6

19

Flameproof grade

Exd IIC T4-T6

20

weight

2kg

3.6kg


霍尔式智能阀门定位器

 

霍尔式智能阀门定位器

 

霍尔式智能阀门定位器

 

Øphysical dimension

Top view

 

霍尔式智能阀门定位器

 

Bottom view

 

霍尔式智能阀门定位器

 

Figure 2 Outline and installation dimensions of the positioner

 

ØIntroduction to Actuator

 

霍尔式智能阀门定位器

 

Figure 3 Pneumatic membrane control valve actuator

 

ØIntroduction to installation components

 

霍尔式智能阀门定位器

 

Figure 4 Components for installing the positioner

 

ØTools needed
Fork wrench 8mm/10mm/12mm/13mm/14mm, Allen wrench 4mm, adjustable wrench, raw tape, signal source, slotted screwdriver 3mm, Phillips screwdriver 3mm/6mm
ØInstallation and debugging steps
1. Install the follower guide rod on the actuator, as shown in Figure 5:
 
霍尔式智能阀门定位器
 

Figure 5 Follow-up guide rod installation diagram

2. Install the mounting plate on the actuator, as shown in Figure 6:

 
霍尔式智能阀门定位器
 

Figure 6 Installation diagram of the mounting plate

3. Connect the lever, feedback pin and positioner, as shown in Figure 7:

 
霍尔式智能阀门定位器
 

Figure 7 Installation diagram of the mounting plate

4. Fix the positioner to the mounting plate, as shown in Figure 8:

 
霍尔式智能阀门定位器
 

Figure 8 Installation diagram of the mounting plate

5. Circuit connection

Connect the 4-20mA command line and valve position feedback line as needed, and set the operation mode to manual.

6. Gas connection

Wrap raw tape on the air circuit adapter, and screw the connector on the air source port IN and the exhaust port OUT1 of the positioner. Pay attention to the winding method of the raw tape (wind 3-5 times in the direction of the thread so that the raw tape will not be squeezed out when screwing) and connect it to the trachea.

7. Debugging sequence

 

Give 16mA instruction, set MAN-SENS mode

Ventilation source: adjust the air source to the required pressure (such as 0.4MPa), and check the air tightness of the joint

Set the actuator type: set P1-1 to LINE, select YES in P1_6SAVE to save

Move the valve up and down to see if the angle between the lever and the horizontal is about -30 degrees to +30 degrees

Check if the valve is stuck: long press the increase or decrease button in MAN-SENS mode to see if the valve runs smoothly

Set the upper and lower limit of the valve: this valve only needs to set the upper limit in P3_2

One-key auto-tuning: In AUTO_RDT, long press the up key for 5 seconds to count down and release the key to enter auto-tuning. After auto-tuning, it will automatically enter AUTO_RDT operation, and the setting time is about 2-3 minutes

Check whether the valve position is consistent with the command: if it is opposite, change the value of P2_4 and save

Check whether the display and position are consistent: if the opposite is the case, change the value of P4_3 and save

Check whether the feedback current is consistent with the valve position, if the opposite is the case, change the value of P7_3 and save

Check the control effect

Finish

 

8. Handling of common problems
During the debugging process, possible problems and solutions are listed in chronological order as follows:
 
Serial number Problem Solution

1

When the current is supplied, the LCD screen does not light up

1) Check whether the command line is connected reversely

2) Check whether the current reaches the terminals of the board

3) Unplug the plug-in connected to the motherboard. If it still doesn’t light up, the motherboard will be broken.

2

 There is a sound of air leakage outside the positioner after ventilation

1) Check the connectors

2) Check the trachea

3) Check the actuator

3

There is obvious air leakage inside the positioner after ventilation

1) Check between the pressure gauge block and the positioner body, if yes, tighten it, and if it leaks, reinstall the gasket

2) Check whether the fixing screws of the IP are tightened, check the washer under the IP

3) IP may leak

4

Exhaust is always accompanied when the actuator is inflated 1) It is recommended to change the IP

5

 Do not give instructions after ventilation but always inflate OUT1

1) In manual mode, press and hold repeatedly to increase and decrease

2) Change IP

6

The valve does not move and the pressure does not come up during manual operation

1) Check for air leakage from the outside

2) Try to restore factory settings

3) Change the positioner

7

Manual valve movement display position remains unchanged

1) Check whether the feedback lever is moving

2) Is the potentiometer plug-in properly inserted?

3) Whether the potentiometer rotates with the gear

8

 CALC_ERR

1) Check whether the valve is stuck

2) Check whether the feedback lever is moving

9

 ZERO_ERR

1) Determine the zero position of the positioner, at this time whether the horizontal deviation of the feedback lever is too large

10

 NO_SCALL

1) Check whether the upstream time and downstream time are sufficient

2) Check whether the feedback lever is loose

11

Tuning in SD6 does not move

1) Check whether the installation is reasonable

2) Whether the included angle of the feedback lever is less than 60°, and if it is less than 60°, increase it

3) Re-tuning

12

Poor control effect

First judge whether the upstream control is not good or the downstream control is not good. Modify the corresponding parameters to improve it. Generally, the inflation corresponds to P5_1, P5_3, P5_5 and the exhaust corresponds to P5_2, P5_4, P5_6.

1) Overshoot: If it is overshoot for inflation, first reduce P5_1, if it cannot be satisfied, reduce P5_3 by an appropriate amount, otherwise, modify another set of corresponding parameters, modify about 50 each time

2) Under-adjustment: if it is under-adjustment of inflation, increase P5_3 appropriately, otherwise, modify another set of corresponding parameters

3) Small oscillation: reduce P5_5 and P5_6 by one third each, if not, reduce P5_3 and P5_4

4) If you still can't solve it, try setting again

13

 Control deviation

1) Check the display accuracy of the command, if the deviation is large, enter the P8 menu to recalibrate

 

For other uncommon problems, please refer to the instruction manual.
  
ØTORLEO Intelligent Valve Positioner Fault Lockout (Three Break Position) Installation Guide

The realization principle of the fault blocking function of the TORLEO intelligent valve positioner is: the positioner receives the valve position designation signal from the DCS control room, and completes the valve positioning control in 1-3 seconds. When the valve position enters the tolerance band (such as 0.3%), The positioner is used to drive the output current of the I/P electrical conversion module to 0. At this time, the I/P electrical conversion module is also working in the closed state, which is equivalent to closing the air inlet of the valve. Signal), the gas circuit is still closed, the gas in the valve cylinder has no leakage channel, and the valve is in the position before the power failure. There is no need to increase the power loss comparison and solenoid valve, and it can easily realize the function of two-off position retention. In particular, for the two-wire intelligent valve positioner, power failure or signal failure is a concept.

The way to realize the air-off and position-preservation is the same as the traditional method, which is realized by the air-lock valve. The operating pressure of the air lock valve can be adjusted (for example, set to 3KG). When the air is cut off, the air supply pressure will slowly drop. When it drops to 3KG, the air lock valve switch will act and connect the air intake of the valve cylinder. The channel is closed, so as to realize the air cut and keep in place.

 
霍尔式智能阀门定位器
 
Figure 9 Schematic diagram of single-acting fault lockout installation
 
霍尔式智能阀门定位器
 
Figure 10 Schematic diagram of double-acting fault lockout installation
 
 
  
In some applications, in order to speed up the action of the actuator, we need to add an air circuit amplifier to the positioner output circuit. The following figure shows an application example of adding the double action of the air circuit amplifier to realize the air cut protection of the actuator.
 
霍尔式智能阀门定位器
 
Figure 11 Installation example diagram of single-acting linear actuator
 
 
霍尔式智能阀门定位器
 
Figure 12 Installation example diagram of double-acting linear actuator
  

Working principle of air lock valve

General air lock valves can be divided into two types: single-acting and double-acting. As shown in the figure below, the double-acting air-locking valve has two air inlets, two air outlets and one main air source interface.

Air lock valve is a device that uses the main air source as the signal pressure and cuts off the internal air circuit of the lock valve to prevent air flow when the signal pressure is lower than the set pressure of the air lock valve. The main purpose is to install on the control valve, when the main air source pressure of the factory drops below the set pressure due to power failure, etc., it will automatically close the air path from the positioner to the actuator to maintain the current valve position opening. The principle of action is that the signal pressure is greater than the set pressure, then the signal pressure pushes up the final inlet pressure of the upper diaphragm.

 
霍尔式智能阀门定位器
 
图13 气锁阀工作原理示意图
  
It is discharged from the air outlet through the inside of the air lock valve, that is, the air inlet and the air outlet are connected. On the contrary, if the signal pressure is lower than the set pressure, the upper diaphragm moves downwards and the path to the lower diaphragm is cut off. A gap is created between the steel ball and the upper diaphragm to press the air pressure in the upper air chamber of the lower diaphragm to discharge through the gap. . As the pressure of the air chamber above the lower diaphragm decreases, the push shaft connected to the lower diaphragm will also rise together and finally cut off the passage of the air inlet and the air outlet. The general setting pressure is 3kgf/cm?. Adjust according to the actual needs of the site. If the set pressure is too large, please reduce the set pressure.
 
霍尔式智能阀门定位器
 

1. Flexible and fast ordering service

All customers can get the company's product samples free of charge for you to understand the product performance and make a satisfactory choice;

All customers can order through 400 toll-free hotline, telex, e-mail, etc., and order products with special technical requirements. The company provides product selection programs and technical support programs in the shortest time.

2. Timely in-sale service

The company delivers goods at the location designated by the user with standardized packaging and convenient transportation;

If the user needs, the company has professionals to guide the installation and commissioning on the customer site.

3. After-sales service with lifetime warranty

During the warranty period, free three packs;

After the warranty period, paid services are provided for life, and the main board, feedback board, HART board, and pneumatic IP module of the product can be repaired or replaced item by item, reducing the user's maintenance cost.

4. Regular and serious return visit system

Customers will always be God and will always be friends of the company;

Customer satisfaction is the highest interest of the company.

 
霍尔式智能阀门定位器
 
 
Figure 15 The use site of Xingfu Electronics of Xingfa Group
  

Hubei Xingfa Chemical Group Co., Ltd. was established in 1994 and is located in Xingshan County, Yichang City, Hubei Province. Main business listed company. The company was listed on the Shanghai Stock Exchange in 1999 with the stock code: "600141". After nearly two decades of development, the company has become China's largest fine phosphate producer.

Xingfu Electronics and Silicone Factory located in Yichang Industrial Park, the first-phase equipment production line is equipped with intelligent valve positioners such as Yamatake, ABB, SAMON and Siemens. Some equipment has begun to age. In July 2013, we began to order a batch of TORLEO smart valve positioners to replace the aging Japanese Yamatake smart valve positioners, and achieved good operating results. We plan to use our TORLEO series in a large area in the next transformation or new projects. Smart valve positioner products and provide practical use reports.

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