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C45 basic type intrinsically safe explosion-proof intelligent valve positioner

The TORLEO intelligent valve positioner with mechanical limit switch is used with pneumatic control valves (such as diaphragm control valves, ball valves, butterfly valves, etc.), and is widely used in the precise control of flow rate and other parameters in the production processes of industries such as petroleum, chemical engineering, metallurgy, power, and papermaking.

Classification:

Control Strategy of Membrane Control Valve

Ball valve control strategy

Butterfly valve control strategy

Diaphragm valve control strategy

Control Strategy of Damper Valve

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C45 basic type intrinsically safe explosion-proof intelligent valve positioner

Hall-effect intelligent valve positioner

　　The TORLEO intelligent valve positioner with mechanical limit switch is used with pneumatic control valves (such as diaphragm control valves, ball valves, butterfly valves, etc.), and is widely used in the precise control of flow rate in the production processes of the petroleum, chemical, metallurgical, power, and papermaking industries.

Hall-effect intelligent valve positioner

　　The technical principle of the TORLEO intelligent valve positioner is to use an electrical balance (digital balance) principle to replace the traditional force balance principle, converting the electrical control command into a pneumatic positioning increment to achieve valve position control; using digital on/off signals to drive the pneumatic actuator; the valve position feedback signal is directly transmitted through a high-precision position sensor to realize the electro/pneumatic conversion function. The microprocessor in the intelligent valve positioner receives a 4-20mA setpoint 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 electrical control instruction (PWM digital method) to the nozzle flapper I/P control unit according to the magnitude and direction of the deviation, thereby adjusting the air flow rate entering the actuator chamber, that is, the control valve converts the control instruction into a pneumatic displacement increment. When the deviation between the actual valve position and the setpoint is large (high-speed zone), the positioner outputs a continuous signal; if the deviation is not large (low-speed zone), the positioner will output a pulsed signal; when the deviation is very small (adaptive or adjustable dead zone state), there is no positioner output, at this time, the actual valve position reaches the setpoint, and the mechanism reaches a balanced state, i.e., a certain set current corresponds to a certain valve position.

Hall-effect intelligent valve positioner

Figure 1 TORLEO intelligent valve positioner principle diagram

Hall-effect intelligent valve positioner

　　TORLEO intelligent valve positioner, following German Samson, Swiss ABB, American Fisher, French Foxboro, Japanese Azbil, and South Korean YTC, has become the first domestic nozzle-flapper type intelligent valve positioner with independent intellectual property rights, featuring advanced technology and filling the gap in domestic products.

　　Product Technical Features:

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

　　■ The product has a built-in keyboard and a large LCD screen, making it easy for users to determine the working status of the positioner and view information on-site;

　　■ A HART communication module can be added, allowing users to obtain or modify the working information of the positioner and valve online;

　　■ A valve position output module can be added, making it easier for users to feedback the valve opening;

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

　　■ The self-invented patented rapid one-button self-tuning method meets the user's needs for quick installation and fool-proof debugging;

　　■ The innovative use of gray prediction-integral-differential PID composite control algorithm can achieve a control accuracy of 0.1-0.3%;

　　■ A special data backup function solves the problems of on-site application and online production maintenance and replacement for intelligent positioners.

　　Comparison with imported similar products:

Serial Number	Performance Indicators	TORLEO (China)	ABB (Switzerland)	SAMSON (Germany)	Azbil (Japan)	Comparison Description
1	Pneumatic Component Characteristics	Digital I/P Converter Pneumatic 3/3 slide valve	Analog I/P Converter Pneumatic 3/3 slide valve	I/P Converter Pneumatic Amplifier	I/P Converter Pneumatic Amplifier	Superior to imported products
2	I/P Drive Method	Digital (PWM)	Analog (Voltage)	Analog (Voltage)	Analog (Voltage)	Superior to imported products
3	I/P Power Consumption	0.8mw	1.6mw	5mw	18mw	Superior to imported products
4	Vibration Resistance Index	20g	20g	10g	10g	Meets imported standards
5	Fault Lockout	Yes (built-in function)	Yes (built-in function)	Requires external accessories	Requires external accessories	Meets imported standards
6	Temperature Drift Compensation	With compensation technology	With compensation technology	With compensation technology	Without compensation technology	Meets imported standards
7	Air Source Pressure	1.4-6bar	1.4-6bar	1.4-6bar	1.4-7bar	Meets imported standards
8	Air Quality	ISO8573-1 particulate matter class 3, Oil content less than 1mg/m3, Dew point less than 10k	ISO8573-1 particulate matter class 3, Oil content less than 1mg/m3, Dew point less than 10k	ISO8573-1 particulate matter class 4, Oil content 3g, dew point 3g	ISO8573-1 particulate matter class 4, Oil content 3g, dew point 3g	Meets imported standards
9	Steady-state Air Consumption	0.056Nm3/h Irrelevant to air pressure	0.085Nm3/h Irrelevant to air pressure	0.11Nm3/h Irrelevant to air pressure	0.24Nm3/h(1.4bar) 0.3Nm3/h(5bar)	Superior to imported products
10	Control Precision	0.1%-0.3%	0.1%-0.3%	0.3%-0.5%	0.5%-1.0%	Meets imported standards
11	Auto-tuning	One-button foolproof setting 2-3 minutes	Multi-step menu setting 3-5 minutes	Multi-step menu setting 3-5 minutes	Toggle switch setting 8-15 minutes	Superior to imported products
12	Minimum operating current	3.4mA	3.4mA	3.5mA	3.8mA	Meets imported standards
13	Explosion-proof standard	Exia IIC T6	Exia IIC T6	Exia IIC T6	Exia IIC T6	Meets imported standards
14	Explosion-proof standard	Exd IIC T6	Exd IIC T6	Exd IIC T6	Exd IIC T6	Meets imported standards
15	Backup function	Yes	No	No	No	Superior to imported products
16	Price	Moderate	High	High	High	High cost performance

Hall-effect intelligent valve positioner

Serial Number	Project	Explosion-proof type	Explosion-proof type
1	Input signal	4-20mA, can be set as proportional control input The proportional range can be set between 20-100%
2	Input pressure	1.4-6kgf/cm²(0.14-0.6Mpa)
3	Stroke	10-150mm or 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 interface	PF 1/2 (G 1/2)
8	Repeatability	±0.2%F.S.
9	Operating temperature	-30℃∽85℃
10	Explosion-proof temperature	-40℃∽40℃
11	Linearity	±0.3%F.S.
12	Hysteresis	±0.2%F.S.
13	Sensitivity	±0.2%F.S.
14	Air consumption	Less than 0.03kg/h (irrespective of air source pressure)
15	Output characteristics	Linear, quick-opening, equal percentage, user-defined
16	Auto-tuning method	One-button auto-tuning
17	Material grade	Die-cast aluminum	Stainless steel 316
18	Explosion-proof grade	Exia IIC T4-T6
19	Explosion-proof grade	Exd IIC T4-T6
20	Weight	2kg	3.6kg

Hall-effect intelligent valve positioner

ØExternal dimensions

Top view

Hall-effect intelligent valve positioner

Bottom view

Hall-effect intelligent valve positioner

Figure 2 Positioner external installation dimensions

ØActuator introduction

Hall-effect intelligent valve positioner

Figure 3 Pneumatic diaphragm valve actuator

ØInstallation component introduction

Hall-effect intelligent valve positioner

Figure 4 Components for positioner installation

ØTools required

Fork wrench 8mm/10mm/12mm/13mm/14mm, hexagon wrench 4mm, adjustable wrench, sealant tape, signal source, flat-head screwdriver 3mm, Phillips screwdriver 3mm/6mm

ØInstallation and debugging steps

1. Install the follow-up guide rod on the actuator, as shown in Figure 5:

Hall-effect intelligent valve positioner

Figure 5 Follow-up guide rod installation diagram

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

Figure 6 Mounting plate installation diagram

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

Figure 7 Mounting plate installation diagram

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

Figure 8 Mounting diagram of the mounting plate

5. Circuit connection

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

6. Pneumatic connection

　　Wrap the pneumatic fitting with adhesive tape, and screw the fitting onto the IN and OUT1 ports of the positioner's air source. Note the winding method of the adhesive tape (wind 3-5 turns in the direction of the thread, so that the adhesive tape will not be squeezed out when tightening) Connect the air tube.

7. Debugging sequence

Give16mAinstructions, setMAN-SENSmode

↓

Air source: Adjust the air source to the required pressure (e.g., 0.4 MPa), and check the airtightness of the fitting

↓

Set actuator type: Set P1-1 to LINE, and 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 within-30degrees to+30degrees or so

↓

Check if the valve is stuck: In MAN-SENS mode, press and hold the increase or decrease key to see if the valve runs smoothly

↓

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

↓

One-button auto-tuning: In AUTO_RDT, press and hold the increase key for 5 seconds until the countdown ends, release the key to Enter auto-tuning, after the auto-tuning is completed, it will automatically Enter AUTO_RDT operation, the tuning time is about 2-3 minutes

↓

Check if the valve position and command are consistent: If opposite, change the value of P2_4 and save

↓

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

↓

Check if the feedback current and valve position are consistent, if opposite, change the value of P7_3 and save

↓

Check the control effect

↓

End

8. Common problem handling

Problems that may occur during debugging and their solutions are listed in chronological order:

Serial Number	Problem	Solution
1	Current is given, but the LCD screen does not light up	1) Check if the command line is reversed 2) Check if the current reaches the terminal of the board 3) Unplug the plug connected to the main board, if it still does not light up, the main board is broken, if the removed components are faulty
2	There is a leak sound outside the positioner after air is passed through	1) Check the joints 2) Check the air tube 3) Check the actuator
3	There is a clear leak sound inside the positioner after air is passed through	1) Check between the pressure gauge block and the positioner body, if so, tighten it, if it still leaks, reinstall the gasket 2) Check if the fixing screws of the IP are tightened, check the gasket under the IP 3) The IP may be leaking
4	Exhaust is always accompanied when the actuator is inflated	1) It is recommended to replaceIP
5	Air is always supplied after air is passed through without instructionsOUT1Inflation	1) Manually press and hold the increase and decrease keys repeatedly in manual mode 2) Change IP
6	The valve does not move in manual mode and the pressure does not increase	1) Check for external leaks 2) Try restoring factory settings 3) Change the positioner
7	The displayed position does not change when the manual valve moves	1) Check if the feedback rod is moving 2) Check if the potentiometer plug is inserted correctly 3) Check if the potentiometer rotates with the gear
8	CALC_ERR	1) Check if the valve is stuck 2) Check if the feedback rod is moving
9	ZERO_ERR	1) Determine the zero position of the positioner, is the horizontal deviation of the feedback rod too large at this time
10	NO_SCALL	1) Check if the up and down times are sufficient 2) Check if the feedback rod is loose
11	Tuning inSD6does not move	1) Check if the installation is reasonable 2) Check if the feedback rod angle is less than 60°, increase it if it is less than 60° 3) Retune
12	Poor control effect	First determine whether the upward control is poor or the downward control is poor, and modify the corresponding parameters to improve it. Generally, inflation corresponds to P5_1, P5_3, P5_5 Exhaust corresponds to P5_2, P5_4, P5_6 1) Overshoot: If it is inflation overshoot, first reduce P5_1, if it cannot be satisfied, then appropriately reduce P5_3, otherwise modify the other corresponding parameter group, modify about 50 each time 2) Undershoot: If it is inflation undershoot, then appropriately increase P5_3, otherwise modify the other corresponding parameter group 3) Small amplitude oscillation: Reduce P5_5 and P5_6 by one third each, if it doesn't work, reduce P5_3 and P5_4 4) If it still cannot be solved, try readjusting it
13	Control Deviation	1) Check the instruction display accuracy; if the deviation is large, EnterP8Menu Recalibration

For other uncommon problems, please refer to the instruction manual.

ØTORLEO Intelligent Valve Positioner Failure Lock (Three-Break Safety Position) Installation Guide

　　The implementation principle of the TORLEO intelligent valve positioner failure lock function is: the positioner receives the valve position specified signal sent by the DCS central control room, and completes the valve positioning control within 1-3 seconds. When the valve position enters the tolerance band (such as 0.3%), the output current of the positioner used to drive the I/P electrical conversion module is 0. At this time, the I/P electrical conversion module also works in the off state, which is equivalent to closing the valve's air inlet. At this time, in case of power failure (or signal interruption), the air passage is still closed, and the gas in the valve cylinder has no leakage channel, so the valve remains in the position before power failure. It realizes the two-break safety position function without adding power failure comparison and solenoid valve, easily. Special note: For two-wire intelligent valve positioners, power failure or signal interruption is the same concept.

　　The implementation method of air pressure retention is the same as the traditional method, using an air lock valve. The operating pressure of the air lock valve is adjustable (e.g., set to 3KG). When the air is cut off, the supply pressure will slowly decrease. When it drops to 3KG, the air lock valve switch will operate, closing the air inlet channel connected to the valve cylinder, thus achieving air pressure retention.

Figure 9 Single-acting failure lock installation diagram

Figure 10 Double-acting failure lock installation diagram

　　In some applications, in order to speed up the operation speed of the actuator, we need to add an air amplifier to the positioner output loop. The following figure shows an application example of a double-acting actuator air protection with an added air amplifier.

Figure 11 Single-acting straight-stroke actuator installation example

Figure 12 Double-acting straight-stroke actuator installation example

　　Appendix: Working principle of air lock valve

　　Generally, air lock valves can be divided into single-acting and double-acting types. The following figure shows a double-acting air lock valve with two air inlets, two air outlets, and one main air source interface.

　　The air lock valve uses the main air source as the signal pressure. When the signal pressure is lower than the set pressure of the air lock valve, it cuts off the internal air passage of the lock valve to prevent the air from flowing. The main application is to install it on the control valve. When the main air source pressure of the factory drops below the set pressure due to power failure, leakage, etc., it automatically closes the air passage from the positioner to the actuator, maintaining the current valve opening. Its working principle is that when the signal pressure is greater than the set pressure, the signal pressure pushes the upper diaphragm upwards, and finally the inlet pressure.

Figure 13 Schematic diagram of the working principle of the air lock valve

　　The air is discharged from the outlet through the inside of the air lock valve, that is, the inlet and outlet are connected. Conversely, if the signal pressure is lower than the set pressure, the upper diaphragm moves downwards, the passage to the lower diaphragm is cut off, a gap is created between the steel ball and the upper diaphragm, and the air pressure in the upper air chamber of the lower diaphragm is discharged through the gap. As the pressure in the upper air chamber of the lower diaphragm decreases, the push rod connected to the lower diaphragm will also rise, eventually cutting off the passage between the inlet and outlet. The general set pressure is 3kgf/cm?. Adjust according to the actual needs of the site. If the set pressure is too high, please reduce the set pressure.

1. Flexible and fast ordering service

All customers can obtain the company's product samples free of charge to understand the product performance and make a satisfactory selection;

All customers can order through a 400 toll-free hotline, telex, email, etc. For products with special technical requirements, the company will provide product selection and technical support solutions in the shortest possible time.

2. Timely and efficient in-sales service

The company uses standardized packaging and convenient transportation methods to deliver goods to the user's designated location;

If the user needs, the company has professional personnel to guide the installation and commissioning on site.

3. Lifetime warranty after-sales service

Free three guarantees within the warranty period;

Paid service is provided for life outside the warranty period. The main board, feedback board, HART board, and pneumatic IP module of the product can be repaired or replaced separately to reduce the user's maintenance cost.

4. Regular and careful return visit system

Customers are always God, always the company's friends;

Customer satisfaction is the company's highest interest.

Figure 14 Guodian Shenneng Sichuan Huayingshan Power Generation Co., Ltd. 32# unit denitrification project

　　Guodian Shenneng Sichuan Huayingshan Power Generation Co., Ltd. is located in Linba Town, Quxian County, Dazhou City, Sichuan Province. It is a new power generation enterprise organization jointly established by Guodian Sichuan Power Generation Co., Ltd. (73.75% holding) and Shenzhen Energy Group Co., Ltd. (26.25% participation).

　　In March 2014, the Huayingshan Company's No. 32 unit denitrification project started, lasting 9 months, and was fully put into trial operation in December 2014. During this period, in May 2014, 60 TORLEO split-type double-acting intelligent valve positioners were ordered and applied to the boiler secondary air valve system renovation. During the period of use, the operation was stable, the control and positioning accuracy was accurate, and it fully met the requirements of the power plant's secondary air valve control, obtaining unanimous recognition from the client. It also successfully passed the acceptance monitoring of the Sichuan Provincial Environmental Monitoring Station for the denitrification project of Unit 32 in March 2015. The expert review group unanimously agreed that all indicators of the denitrification project of Unit 32 of Sichuan Huayingshan met the environmental protection acceptance standards, and the project effect was excellent.

　　Given the excellent performance of the TORLEO split double-acting intelligent valve positioner in the denitrification project of Unit 32, 60 units of the same model of intelligent valve positioner were ordered again from our company for the subsequent denitrification project of Unit 31. It is understood that this project successfully passed the 168-hour trial run in June 2015.

　　Based on the good operation of the TORLEO split double-acting intelligent valve positioner in the denitrification projects of Units 32 and 31, and the positive and effective cooperation during installation and commissioning, Guodian Shenneng Sichuan Huayingshan Company gave full affirmation and recognition to our company's independently developed TORLEO intelligent valve positioner, regarding our company as a superior supplier and will prioritize the TORLEO series of intelligent valve positioners in future projects.

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