Stainless steel structure intelligent valve positioner
TORLEO stainless steel intelligent valve positioner adopts nozzle baffle technology, which is widely used in the precise control of flow in the production process of petroleum, chemical, metallurgy, electric power, papermaking and other industries. It is suitable for strong acid, strong alkali and corrosion-resistant environments.
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:
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 |
During the debugging process, possible problems and solutions are listed in chronological order as follows:
|
序号 |
问题 |
解决办法 |
|
1 |
给电流，液晶屏不亮 |
1）检查指令线是否接反 2）检查电流是否到板子的端子 3）拔掉和主板相连的插件,如仍不亮则主板坏,如恢复拔下的组件有故障 |
|
2 |
通气后定位器外部有漏气声 |
1）检查接头 2）检查气管 3）检查执行器 |
|
3 |
通气后定位器内部有明显漏气声 |
1）检查压力表组块和定位器本体之间，如是，则拧紧，还漏，则重装垫圈 2）检查IP的固定螺丝是否拧紧，检查IP底下的垫圈 3）IP可能漏气 |
|
4 |
给执行器充气时始终伴有排气 |
1）建议更换IP |
|
5 |
通气后不给指令但始终给OUT1充气 |
1）手动模式反复长按增和减 2）换IP |
|
6 |
手动时阀不动且压力上不来 |
1）检查外部是否漏气 2）恢复出厂设置试试 3）换定位器 |
|
7 |
手动阀动显示位置不变 |
1）检查反馈杆是否跟着动 2）电位器插件是否插好 3）电位器是否随齿轮转 |
|
8 |
CALC_ERR |
1）检查阀是否卡死 2）检查反馈杆是否跟着动 |
|
9 |
ZERO_ERR |
1）确定定位器的零位，此时反馈杆水平偏差是否太大 |
|
10 |
NO_SCALL |
1）检查上行时间和下行时间是否充足 2）检查反馈杆是否松动 |
|
11 |
整定在SD6不动 |
1）检查安装是否合理 2）反馈杆夹角是否小于60°，小于60°则加大 3）重新整定 |
|
12 |
控制效果不好 |
先判断是上行控制不好还是下行控制不好，分别修改相应的参数加以改善，一般充气对应P5_1、P5_3、 P5_5 排气对应P5_2、P5_4、P5_6 1）超调：如是充气超调，先减小P5_1，不能满足则适量减小P5_3，反之则修改另一组对应参数，每次修改50左右 2）欠调：是充气欠调，则适当增加P5_3，反之则修改另一组对应的参数 3）小幅振荡：将P5_5和P5_6各减小三分之一看看，如不行，减小P5_3和P5_4 4）还不能解决则重新整定试试 |
|
13 |
控制偏差 |
1）检查指令显示精度，如偏差大进入P8菜单重新校准 |
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
Phone:（86-27）8738-3559 Free hotline：400-878-5856
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