Die-cast aluminum structure intelligent valve positioner
TORLEO die-cast aluminum intelligent valve positioner adopts nozzle baffle technology and is used in conjunction with valves with safety requirements in the production process of petroleum, chemical, metallurgy, electric power, papermaking and other industries. It currently has basic, explosion-proof, explosion-proof, and Series products such as body type remote transmission type.
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
Figure 1 Schematic diagram of TORLEO intelligent valve positioner
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.
| 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 |
| 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 |
Øphysical dimension
Top view
Bottom view
Figure 2 Outline and installation dimensions of the positioner
ØIntroduction to Actuator
Figure 3 Pneumatic membrane control valve actuator
ØIntroduction to installation components
Figure 4 Components for installing the positioner
Fork wrench 8mm/10mm/12mm/13mm/14mm, Allen wrench 4mm, adjustable wrench, raw tape, signal source, slotted screwdriver 3mm, Phillips screwdriver 3mm/6mm
1. Install the follower guide rod on the actuator, as shown in Figure 5:
Figure 6 Installation diagram of the mounting plate
3. Connect the lever, feedback pin and positioner, as shown in Figure 7:
Figure 7 Installation diagram of the mounting plate
4. Fix the positioner to the mounting plate, as shown in Figure 8:
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 |
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.
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.
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.
CONTACT INFORMATION
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