Digital Positioner - Sense

Operation & Maintenance Instruction Manual

PFLEX PD Digital Positioner

Instruction Manual – PFLEX PD digital positioner LIT0014 rev.B

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1. GENERAL INFORMATION ....................................................................................................... 4

2. SPECIFICATIONS ................................................................................................................... 5

2.1 FUNCTIONAL SPECIFICATIONS ...................................................................................................... 5 2.2 PERFORMANCE SPECIFICATIONS ................................................................................................... 6 2.3 PHYSICAL SPECIFICATIONS ......................................................................................................... 6

3. DIMENSIONS ......................................................................................................................... 8

3.1 DIGITAL POSITIONER ................................................................................................................ 8 3.3 LINEAR MAGNET ..................................................................................................................... 9 3.3 ROTARY MAGNET ..................................................................................................................... 9

4. DESCRIPTION ...................................................................................................................... 10

5. INSTALLATION .................................................................................................................... 11

5.1 MAGNET ASSEMBLIES .............................................................................................................. 11 5.2 LOCAL INDICATOR .................................................................................................................. 11 5.3 STANDARD ROTARY MOUNTING .................................................................................................... 12 5.3 STANDARD LINEAR MOUNTING ..................................................................................................... 13 5.4 PRESSURE CONNECTIONS .......................................................................................................... 13 5.5 ELECTRICAL CONNECTIONS ........................................................................................................ 14 5.5 HAZARDOUS AREAS................................................................................................................. 16

6. CONFIGURATION ................................................................................................................. 16

6.1 CONFIGURATION RESOURCES ..................................................................................................... 17 6.2 IDENTIFICATION AND MANUFACTURING DATA ................................................................................... 18 6.3 MONITORING ........................................................................................................................ 18 6.4 DEVICE CONFIGURATION .......................................................................................................... 18 6.5 ADVANCED CONFIGURATION ....................................................................................................... 19 6.6 DEVICE MAINTENANCE ............................................................................................................. 19 6.7 TRIM ................................................................................................................................. 19 6.8 SETUP ................................................................................................................................ 19 6.9 MULTIDROP CONFIGURATION ...................................................................................................... 20 6.10 DIAGNOSTIC....................................................................................................................... 20 6.11 BACKUP ............................................................................................................................ 20 6.12 FACTORY ........................................................................................................................... 20

7. LOCAL PROGRAMMING ........................................................................................................ 20

7.1 LOCAL ADJUSTMENT ................................................................................................................ 20 7.2 MAGNET TOOL....................................................................................................................... 21 7.3 W1 AND W2 JUMPERS CONNECTION ............................................................................................. 21 7.4 LOCAL PROGRAMMING TREE........................................................................................................ 22 7.5 ADJUSTABLE PARAMETERS ......................................................................................................... 22

8. PARTS LIST ......................................................................................................................... 24

9. TROUBLESHOOTING ............................................................................................................ 27

10. MAINTENANCE .................................................................................................................. 29

10.1 RESTRICTION SCREW ............................................................................................................. 29 10.2 FILTER ............................................................................................................................. 29 10.3 TERMINAL BLOCK.................................................................................................................. 30 10.4 PRESSURE REGULATOR ........................................................................................................... 30 10.5 TRANSDUCER ...................................................................................................................... 31 10.6 MECHANICAL MODULE ............................................................................................................ 33 10.7 POSITIONER DIAPHRAGM ........................................................................................................ 33 10.8 SPOOL VALVE ...................................................................................................................... 34

11. WARRANTY ........................................................................................................................ 35

© COPYRIGHT 2014 BY SENSE

SPECIFICATIONS AND INFORMATION SUBJECT TO CHANGES WITHOUT NOTICE.

This technical documentation is protected by copyright. Translating, photocopying and disseminating it in any form whatsoever – even editing or excerpts thereof – specially reprint, photomechanical or electronic reproduction or storage on data processing systems or net-works is not allowed without permission of the copyright owner and non-compliance will lead to both civil and criminal prosecution.

Sense Eletrônica

TUIUTI, 1237

TATUAPÉ – SÃO PAULO - BRAZIL

ZIP CODE: 03081-012

TEL. +55 (11) 2145-0400


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1. General information This operation and maintenance instruction

manual provides installation, operating,

calibration, and maintenance information for the

PFLEX PD digital positioner.

The PFLEX PD digital positioner must only be installed operated and maintained by qualified personnel with adequate training. If you require

additional assistance or there is any question concerning the instructions, contact Sense.

Modifying this product, substituting non-factory

parts, or using maintenance procedures other than out-lined could affect performance and be hazardous to personnel and equipment.

WARNING

Use only procedures and new parts specifically referenced in this manual. Unauthorized procedures or parts can affect product performance.

The instruments are designated to operate with clean, dry, oil free. The requirements for a quality air supply can be found in the (ISA-S7.3) “Quality Standard for Instrument Air”.

WARNING

It is highly recommended to use a coalescent filter for the air supply meets this standard.

WARNING

The installation carried out in hazardous areas should follow the recommendations of the IEC60079-14 standard

The overall accuracy of measuring and control depends on several factors. In spite of the

excellent performance, the positioner must be

adequately installed so that it may work well.

Among all factors that may affect the positioner accuracy, environmental conditions are the most difficult to control. But there are ways to reduce the effects of temperature, humidity and

vibration.

Installing the positioner in areas protected from extreme environmental changes can minimize temperature fluctuation effects. In warm environments, the positioner should be installed

to avoid, as much as possible, direct exposure to the sun. Installation close to lines and vessels

subjected to high temperatures should also be avoided. If not possible to avoid it, consider using the remote position sensor version.

Use thermal isolation to protect the positioner from external heart sources, if necessary.

Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the O-rings

for the electronic housing covers must be correctly placed and the covers must be completely closed by tighten them by hand until you feel the O-rings being compressed. Do not use tools to tight the covers. Removal of the electronics cover in the field should be reduced to

the minimum necessary, since each time it is

removed; the circuits are exposed to the humidity.

The electronic circuit is protected by a humidity proof coating, but frequent exposures to humidity may affect the protection provided. It is also

important to keep the covers tightened in place. Every time they are removed, the threads are exposed to corrosion, since painting cannot protect these parts. Sealing methods should be employed on conduit entering of the positioner.

WARNING

Avoid to use thread sealant tapes on the air input and outputs connections, since small pieces of this

type of sealant may block the air flow inside the positioner, affecting the overall equipment performance.

Although the positioner is practically vibration resistant, it is not recommended to install it near pumps, turbines or other equipment producing too much vibration. If not possible to avoid it,

consider using of remote position sensor version.


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2. Specifications

2.1 Functional Specifications

Travel Linear Motion: 3 - 100 mm. Rotary Motion: 30° - 120° rotation angle.

Input and Communication Protocol

Two-wires, 4-20 mA, according to NAMUR NE43 specification, with super-imposed digital Hart® Protocol.

Power Supply 4 to 20 mA loop-powered. No external supply required. Built-in circuit protection against overvoltage up to 60 Vdc. Built-in circuit protection against overcurrent up to 25 mA. Context saving in case of power failure. The critical variables used in the positioner are saved in the memory, avoiding the

startup being affected by missing data in the registers and positioner variables.

Input Impedance 550 ohms Minimum Current 3.8 mA

Configuration Local Adjustment with magnetic tool. No need to open the cover Remotely through: - CONF401 Windows Based configuration software

- HPC401 Palm OS Based Configurator

- Other configurations tools based on EDD

Protection against Reverse Polarity No damage occurs from reversal of normal supply current (4 - 20 mA) or from misapplication of up to 50 mA.

Output

Output from 0% to 100% pressure supply to the actuator. Single or double action.

Pressure Supply 40 - 150 psi Temperature Limits Operation: -20 to 70°C

Storage: -40 to 90°C

Display: -10 to 75°C Operation. -40 to 85°C Without damage. Remote Sensor: -40 to 105°C (-40 to 221°F)

Indication

4½ - numerical digits and 5-character alphanumerical digits Liquid Crystal Display indicator. Function and status icon. Humidity Limits 0 to 100% RH (Relative Humidity) Flow Characterization

Linear, equal percentage, quick opening and 16 freely selectable points by operator.


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Auto Setup It is an automatic adjustment of the positioner to the valve and actuator set, in others words, an auto-calibration procedure of the equipment. During this procedure, the positioner checks the 0%

and 100% of the valve stroke related to the magnet and also calculates the converter A/D gain for position readings. Proportional Gain, Integral and Derivative Rates Adjustable locally or by communication. Adjusted automatically during the Auto Tuning or Full Setup procedure.

Travel Time Adjustable locally or by communication. Position Sensor Non-contact Sensor by Hall effect. It is also available for the integral or remote assembling version.

2.2 Performance Specifications

Resolution 0.1 % F.S.

Repeatability 0.1 % F.S. Hysteresis 0.1 % F.S. Steady-state air consumption

0.31 SCFM @ 60 psi Output air capacity

11 SCFM @ 60 psi

Ambient Temperature Effect 0.05%/C F.S.

Pressure Supply Effect Negligible. Vibration Effect Negligible to 500 Hz at 2g Electromagnetic Interference Effect

Designed to comply with the IEC801 Standards and European EN50081 and EN50082 directives.

2.3 Physical Specifications

Electrical Connection ½” - 14 NPT ,Pg 13.5 and M20x1.5 Electrical housing IP66

Hazardous Area Certifications Explosion-proof INMETRO Exd IIB + H₂ T6 Gb


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Pneumatic Connections Supply pressure Two 1/4-18NPT female connection Output 1 and 2 Two 1/4-18NPT female connection

Gauges Two 1/8-27NPT female connection Construction material Case aluminum o´rings nitrile diaphragm nitrile

Weight Aluminum 3.5 kg Stainless Steel 6.5 kg Remote Sensor: 550 gr Cable 100 gr


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3. Dimensions

3.1 Digital positioner

Figure 1. Dimensions for digital positioner


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3.3 Linear Magnet

Figure 3. Dimensions for linear magnet

3.3 Rotary magnet

Figure 3. Dimensions for linear magnet


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4. Description

The block diagram Figure 4 describes PFLEX PD digital positioner. PFLEX PD digital positioner is Hall sensor feedback instrument. Positioning is based on a balance of two signals: a proportional one to the input signal and the other proportional one to the position of

the stem of the actuator.

Figure 4. Block diagram

The microprocessor compares the input signal from the control room and the feedback signal

from Hall sensor and determines how much

current to send to the electromagnetic coil based on a digital positioning algorithm. As the input signal increases, the current to the electromagnetic coil increases. This makes the magnetic attraction the nozzle and flapper

increase, causing flapper to restrict the nozzle, which increases the nozzle pressure. The nozzle pressure increases and causes a displacement of the diaphragm, pushing the feedback spring, causing the spool valve to open. This opens the

spool valve ports, supplying air to output pressure 1 and exhausting air from output pressure 2. The increased output pressure 1 causes the actuator stem to move. Stem position is sensed through the non-contact, linkage-less feedback

sensor which is electrically connected to analog board. The stem continues to move until the correct stem position is attained. At this point the main board stabilizes the current to electromagnet coil, and the spool is at its equilibrium position.

A decrease in the input signal reverts the actions above described, provoking a contrary movement, proportional the stem of the actuator.


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5. Installation

PFLEX PD digital positioner must only be installed operated and maintained by qualified personnel with adequate training. If you require additional assistance or there is any question concerning the instructions, contact a sales representative or Sense.

PFLEX PD digital positioner must be installed in accordance with local and national codes of practice. PFLEX PD digital positioner installation in hazardous area must be in accordance with the appropriate hazardous area installation codes.

WARNING In explosive atmospheres, remove the power to the PFLEX PD digital positioner before attempting to remove the terminal compartment cover or module cover.

PFLEX PD digital positioner mounting depends on the type of actuator, its actions, single (with

spring return) or double, and the movement characteristic (linear or rotary). It requires two parts: adapter for the magnet and mounting bracket for the positioner. Sense supplies both according to the specified ordering code.

Figure 5 shows mounting holes with M6 screws.

The face mounting enable mounting to standard rotary actuator to VDI/VDE 3845 (NAMUR) and standard linear actuator to IEC 534 (NAMUR). Additionally, a great variety of customized mounting brackets is available, covering several control valves models from different manufacturers.

Figure 5. Mounting holes

5.1 Magnet assemblies

The magnet has a valid travel range indicated by arrows molded into the piece. This means that the hall sensor, on the back of the PFLEX PD housing, has to remain within this range throughout the entire valve travel. Figure 6 shows magnet assemblies for rotary and linear actuators.

Figure 6. Magnets assemblies

5.2 Local indicator

The PFLEX PD digital positioner has LCD-Local indicator that is visible through a window in the main cover. The possible configuration and monitoring

operation are shown on Figure 7. The display simultaneously shows readout and some other information. Figure 7 shows the result of tool insertion in orifices Z and S, which inform, respectively, movement and actuation of the selected options.

Upon receiving power, the PFLEX PD initializes the position indication on the display, by showing model PFLEX and its software version (X.XX).


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Figure 7. Local indicator

During normal operation, PFLEX PD DIGITAL POSITIONER remains in the monitoring mode. Figure 8 shows the positioning in percentage.

Figure 8. Typical indication

5.3 Standard rotary mounting

Figure 9 shows mounting PLFEX PD on rotary actuator styles rack and pinion used in a typical

application for butterfly or ball valve. Mounting is accomplished using VDI/VDE 3845 standard (NAMUR).

Figure 9. Standard rotary mounting

1. Attach rotary magnet adapter to the valve

shaft with M6 x 20 mm screw.

2. Loosely attach rotary magnet to the rotary magnet adapter. Do not tighten the fasteners

because fine adjustment is required.

3. The PFLEX PD digital positioner can mount to the actuator in any one of two possible mounting positions. Determine the desired mounting position then proceed with the next

step.

4. Place four M5 x 10 mm screw and tighten mounting bracket against the actuator.

5. Place four M6 x 10 mm screw and tighten

positioner against the mounting bracket.

Proper alignment of Hall sensor housing to the rotary magnet is very important since improper alignment can cause excessive wear and friction to the positioner.

6. Rotate the valve shaft on the 50% of the

stroke. Check if the arrow molded into the


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magnet is align with the arrow of the positioner at 50% of stroke and tighten two M6 x 15 mm screws. See figure 10.

7. Check for actuator stroke. The Hall sensor housing has remain within throughout the

entire valve travel.

Figure 10. Rotary magnet alignment

5.3 Standard linear mounting

Figure 11 shows mounting digital positioner on

linear actuator styles diaphragm or piston used in

a typical application for globe valve. Mounting is

according IEC534-6 standard (NAMUR).

Figure 11. Standard mounting linear

1. Attach linear magnet adapter to the valve shaft with two M6 x 10 mm screws.

2. Attach linear magnet to linear magnet adapter

with two M6 x 10 mm screws.

3. Assemble mounting bracket on the actuator yoke using M8 x 25 mm screw and washer. Do not tighten the fastener because fine adjustment is required.

4. Place four M6 x 10 mm screw and tighten

positioner against the mounting bracket. Proper alignment of Hall sensor housing to the

linear magnet is very important since improper alignment can cause excessive wear and friction to the positioner.

5. Move the valve stem on the 50% of the

stroke. Check if the arrow magnet is align with the mark position at 50% of stroke and tighten M8 x 25 mm screw. See figure 12.

Figure 12. Linear magnet alignment

6. Check for actuator stroke. The Hall sensor

housing has remain within throughout the entire valve travel.

5.4 Pressure connections

The instruments are designated to operate with clean, dry, oil free. Dew point by least 10ºC (18ºF), filtered at five microns oil content must be not higher than 1 ppm. The requirements for a quality air supply can be


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found in the (ISA-S7.3) “Quality Standard for Instrument Air”.

WARNING

Inflammable, toxic or reactive gas must not be used as supply source. It can cause serious accident fire, patrimonial and personal damage.

WARNING

It is highly recommended to use a coalescent

filter for the air supply meets this standard.

WARNING Upon loss of input current, the control valve will open or close according its application. Check

for correct action (air-to-open or air-to-close) to match the control device.

Pressure connections are shown in figure 13.

Figure 13. Pneumatic connections

Connect the nearest suitable supply source to the 1/4 NPT IN connection on the filter regulator (if

furnished) or to the 1/4 NPT SUPPLY connection on the positioner. All pressure connections are 1/4 NPT internal. Use

3/8-inch tubing for all pressure connections. After making pressure connections, turn on the supply pressure.

WARNING

Do not mount the positioner in a location

where foreign material may clog the

exhaust port.

WARNING

When using single acting rotary actuator (spring return). Plug output 2.

Spool valve bleed air purges internal parts and

actuator housing for additional protection. Compartment is positively pressured to reduce external moisture. The exhaust opening at the back of the case should be left open to prevent pressure buildup inside the case and to provide a drain hole for any moisture that might collect

inside the case. Figure 14 shows exhaust port.

Figure 14. Exhaust port

Before installation of the positioner to a double acting rotary actuator, it is necessary to move the actuator stem to the end where the input signal

has its lower value. Upon loss input signal, the output 1 will decrease to 0 psi and output 2 will increase to near supply pressure.

5.5 Electrical connections

Figure 15 shows housing conduit connection for

PFLEX PD digital positioner.

1. Remove terminal cover from the housing.


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2. Bring the field wiring into the terminal housing. Conduit threads should be sealed by

means code-approved sealing methods.

3. Connect the positive signal lead to the positive

terminal, marked +. Connect the negative signal lead to the negative terminal, marked -.

WARNING Where condensate is common, use a conduit drip leg to help reduce liquid buildup in the terminal compartment and avoid shorting of the input signal.

The digital positioner is normally powered by a

control system output card. The use of shielded cable will ensure proper operation in electrically noisy environments. Wire size requirements are 14 AWG maximum, 26 AWG minimum.

Avoid routing signal wiring close to power cables or switching equipment.

It is also recommended to ground the shield of shielded cables at one end only. The non- grounded end must be carefully isolated.

WARNING Do not connect the instrument directly to a

voltage source; it will irreversibly damage to PCB. Only connect to a 4-20 mA current source.

PFLEX PD digital positioner has an equivalent

impedance of 550 Ohms. Make sure that the current supply or analog output of DCS, CLP or single loop controller powering the positioner is capable to handle a voltage drop of 11 V for each positioner (550 x 0.02 = 11 Volts).

WARNING

I/P converter has an equivalent impedance of 550 Ohms.

Figure 15. Electrical connections

The configurator can be connected to the communication terminals of the positioner or at

any point of the signal line by using the interface

HPI411-M5P with “alligator” clips. Figure 16 shows wiring diagram and Figure 17 shows wiring diagram with transmitter.

Figure 16. Wiring diagram


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Figure 17. Wiring diagram with transmitter

Connection of the PFLEX PD digital positioner in multidrop configuration should be done as in Figure 18. Note that a maximum of two positioners can be connected on the same line and that they should be connected in series.

Figure 18. Wiring diagram in multidrop

5.5 Hazardous areas

The PFLEX PD digital positioner must only be installed operated and maintained by qualified personnel with adequate training. If you require additional assistance or there is any question concerning the instructions, contact Sense.

Modifying this product, substituting non-factory

parts, or using maintenance procedures other than out-lined could affect performance and be hazardous to personnel and equipment.

Explosions could result in death or serious injury, besides financial damage. Installation of this instrument in an explosive environment must be in accordance with the national standards and according to the local environmental protection

method. Before proceeding with the installation check the certificate parameters according to the environmental classification. The electronic housing installed in hazardous areas must have a minimum of 6 fully engaged

threads. Tighten the cover with at least 8 turns to avoid the penetration of humidity or corrosive gases. Consult Sense for further information about certification.

Lock the housing using the locking screw Figure 19.

Figure 19. Locking screw

6. Configuration

The PFLEX PD positioner is a digital positioner with the most up-to-date features a controlling device can possibly have. The Hart® digital

communication protocol enables the instrument to be connected to a computer, in order to be configured in a very simple and complete way. Such computers connected to the positioners, are

called host computers. They can be either primary or secondary masters. Even though Hart® is a master-slave type of protocol, it is possible to work with up to two masters in a bus. Usually, the primary host, plays the supervisory role and the secondary host plays the configurator role.

The positioners may be connected in a point-to-


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point or multidrop type network. In a point-to-point connection, the equipment’s address must be "0". In a multidrop network, if the devices are recognized by their addresses, the positioners should be configured with a network address between "1" and "15”. In this case, the

positioners’ output current is kept constant, at 4 mA each if the acknowledgement is via Tag, the positioners addresses may be "0", and even in a multidrop configuration.

WARNING

In case of a multidrop network configuration for

classified areas, the entity parameters allowed for the area shall be strictly observed.

Therefore, the following shall be checked:

Ca Cij + Cc La Lij + Lc

Voc min [Vmaxj] Isc min [Imaxj]

Where: Ca, La = Allowed capacitance and inductance

on the bus

Cij, Lij = Non protected internal capacitance/Inductance of positioner j (j = up to 15)

Cc, Lc = Cable capacitance and inductance

Voc = Barrier open circuit voltage

Isc = Barrier short circuit current Vmaxj = Maximum allowable voltage to be

applied to the instrument j Imaxj = Maximum allowable current to be

applied to the instrument j

The PFLEX PD digital positioner includes a very encompassing set of Hart® command functions that make it possible to access the functionality of what has been implemented. Such commands according to the Hart® protocol specifications, and are grouped as universal commands, common

practice controls commands and specific commands. A detailed description of such commands may be found in the manual entitled Hart

® command

specification - PFLEX PD digital positioner.

Sense developed HPC401 configurator for Hart® PFLEX PD digital positioner. The HPC401 is the

most up-to-date technology in Palm platform handheld portable computers.

The operation and use characteristics of each one of the configurators are in their specific manual.

The figure 20 below show the front of the Palm based configurator and CONF401 screen with active advanced configuration.

a b c 1 2 3

HPC 301

CONTRAST ON/OFF

APPLICATIONS

BUTTON

HOME

MENU ACTIVE

ALFANUMERICAL KEYBOARD

CALCULATOR SEARCH

NUMERICAL KEYBOARD

NOTEBOOK

ADDRESS LIST

TEXT EDITOR

TASKS LIST

ROLLING BAR

GRAY

KEYBOARD

ALLIGATOR CLAMPSTO CONNECT TO THE TRANSMITTER

Figure 20. Handheld with HPC401

The TSO stands for "Tight Shut Off", which assure the valve is totally closed, avoiding leakage on the

valve seat. If the TSO value is 5% the valve will only start moving from the close position (for instance) on 5% of the controller signal. The TSO

D stands for "Tight Shut Off dead band". When the value is 1%, the valve will start to move from the close position on 6%. On 4% the valve shall close totally.

6.1 Configuration Resources

By means of the Hart® Configurator, the PFLEX PD

firmware allows the following configuration features to be accessed: Positioner’s Identification and Manufacturing Data;

Remote movement;

Special characterization function according to a 16-point configurable curve;

Flow characterization (Linear, equal percentage and quick opening);

Monitoring of all device variables: input, set

point, deviation and modulated output temperature;

Diagnostic (Preventive maintenance);

Positioner diagnostic and fail determination;

PID Controller Configuration;


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Device Configuration;

Device Maintenance.

The operations between the configurator and the positioner, do not interrupt the valve positioning, and do not disturb the positioner operation. The

configurator can be connected to the same pair of wires as the 4-20 mA signal, up to 2 kilometers away from the positioner.

6.2 Identification and Manufacturing Data

The following information about the PFLEX PD

manufacturing and identification data is available:

TAG - 8-character alphanumeric field for

identification of the positioner.

DESCRIPTION - 16-character alphanumeric

field for additional identification of the positioner. May be used to identify service or location.

MESSAGE - 32-character alphanumeric field

for any other information, such as the name of the person who made the last calibration, some special care to be taken, or if a ladder is needed for physical access to the positioner.

DATE - The date may be used to identify a

relevant date, such as the last calibration, the

next calibration or the installation. The date is presented in the American standard e.g.

(Example: Oct 30, 2003) is automatically assumed after the choice of these items.

UNIQUE ID - Used to identify the device and in construction of Hart® long address.

DEVICE INFORMATION - This button allows to read device identification and data recorded in the factory.

NOTE

These information items cannot be

modified. They are read directly from the

circuit memory

6.3 Monitoring

This function allows remote monitoring up to 4 different of positioner variables at the same time. The time to start the reading is around 5 seconds. The values are always updated. Altogether, 20 items could be monitored. These items are: valve actual position in percentage, input in percentage

of adjusted current range (before the limits and flow linearization), input current in mA or %, device temperature in Celsius and in Fahrenheit degrees, etc..

6.4 Device Configuration

This function allows remote monitoring up to 4 different of positioner variables at the same time. The time to start the reading is around 5 seconds. The values are always updated. Altogether, 20 items could be monitored. These items are: valve actual position in percentage, input in percentage

of adjusted current range (before the limits and

flow linearization), input current in mA or %, device temperature in Celsius and in Fahrenheit degrees, and etc..

Besides the configuration services for equipment

operation, the PFLEX PD allows self-configuration. Services from this group are related to: write protection, security position, flow characterization function, local indication and table configuration.

WRITE PROTECTION: The configurator only

shows that the writing is authorized if the W2 jumper from main board is connected to the pins under the word DOWN.

CHARACTERIZATION FUNCTION – It changes

the valve flow characteristics. For example, if

equal percentage flow characterization is applied to a valve with linear flow

characteristics, it will work as an equal percentage valve. Manufacturer documentation contains the valve inherent characteristic. The options for applied flow characterization are:

LOCAL INDICATIONS - The PFLEX PD local

indicator has three well-defined fields: information field with icons informing the active status of the configuration, 4 ½ numerical digit field to value indication and alphanumeric field with 5-digit for status

information and units.

The PFLEX PD accepts up to two local indicator

LINEAR UNALTERED

Equal percentage 1:25



Quick opening 1:25 (Hyperbolic)



Table 16 pairs (X, Y)


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configurations, showed with a 2 second pause between each one. The parameters that can be selected to visualization are showed below:

PARAMETERS DESCRIPTION

PV % Process variable in

percentage.

PV (mm) Process variable in mm.

SP % Setpoint in percentage.

SP(mm) Setpoint in mm.

TABLE CONFIGURATION - Through the Table button, a flow characterization curve with up to 16

points can be configured. This allows the construction of a special flow characterization curve, like linear combinations and equal percentage or other characterizations.

7

6

5Linear

Equal Percentage 1:25

1:33

1:50

Equal Percentage

Equal Percentage

Quick opening 1:25

1:33

1:50

Quick opening

Quick opening

2

1

3

4

OP

EN

ING

100

80

60

40

20

0

SP

100 20 30 40 50 60 70 80 90 100

7

6

5

1

23

4

Figure 21. Valve Characteristic Curve

6.5 Advanced configuration

This function affects valve advanced configurations. With advanced configuration is possible to configure the valve type, if it is air-to-open or air-to-close, valve action, setpoint limits and split-range.

6.6 Device maintenance

This group includes maintenance services, related to obtainment of necessary information to the device maintenance and performance test. Some of the available services are: position adjustment and valve performance test, general information about the actuator and the valve, operations count, password level, code number model and performance.

6.7 Trim

There are two trim operations: Current trim and

Temperature trim. Current trim allows to calibrate the positioner input current reading and Temperature trim is the temperature reference to the positioner temperature sensor. There are two current trims available:

4 mA TRIM: is used to adjust the input current

reading correspondent to 0%.

20 mA TRIM: is used to adjust the input

current reading correspondent to 100%.

6.8 Setup

This function allows to calibrate the valve travel automatically (Auto Setup and Auto Tuning), the

points of the totally opened or totally closed

stroke with higher precision (lower and higher position), to adjust the opening and closing times and the proportional, integral, and derivative actions of the PID (Proportional, integral, derivative) control, the state of air supply, the magnet conditions, the position sensor, setup and the coil current conditions. Setup Stages for

PFLEX PD (Full Setup, Auto Setup, Auto Tuning) HALL

Sends the valve to the end of travel, open or closed, depending on mounting. - Full setup 10% - Auto setup 20% - Auto tuning N/A GAIN

Verifies if the valve movements up to the other extremity and finds the A/D gain. - Full setup 15% - Auto setup 40% - Auto tuning N/A SPAN

Calibrates the valve travel, with limit values for the position sensor. - Full setup 20% - Auto setup 60% - Auto tuning N/A TIME

Finds opening and closing times for the valve. - Full setup 40% - Auto setup 100% - Auto tuning N/A CNTRL

Starts Auto tuning in 50% position - Full setup 45% - Auto setup N/A - Auto tuning 0% TUNE1

Oscillates the system for PID parameters calculation. - Full setup 55% - Auto setup N/A


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- Auto tuning 30% TUNE2

Oscillation values acquisition. - Full setup 60% - Auto setup N/A - Auto tuning 35% CALCULATION

Beginning of PID parameters calculation. - Full setup 65% - Auto setup N/A - Auto tuning 40% SAVE

Saves the calculated parameters and returns to the control at the setup end (calibration). - Full setup 98% - Auto setup N/A - Auto tuning 98%

6.9 Multidrop configuration

ADDRESSING – The PFLEX PD contains a

variable that define the device address in a Hart®

network. Hart® addresses assume values from "0" to "15", the addresses "1" to "15" are specific addresses to multidrop connection. When PFLEX PD is configured to multidrop , it means that the local indicator is showing “MD” and the address is

an value from "1" to "15".

PFLEX PD is factory configured with address "0".

6.10 Diagnostic

This function allows engineering unit configuration, the parameters for diagnostic purposes and shows positioner general conditions. See parameters:

Dead zone (0 to 100%)

Odometer Curse (mm/rad)

Odometer Value Maximun (mm/rad)

Engineering Unit (mm/rad or %)

Dead zone Reversal (%)

Reversal Limit (uni)

6.11 Backup

Data transference from transducer to main board must be done immediately after the assembly when there is a transducer or main board

substitution.

This process is automatically done when the positioner is powered. If necessary, the user could

force transference using the option Read from Sensor.

The option Write on Sensor could be used to record changes previously made, for example, in Kp, Tr, etc., in transducer memory. The previous

values for Kp, Tr, etc. will be lost.

6.12 Factory

This option is used only in the factory, and the user cannot access it.

7. LOCAL PROGRAMMING

7.1 Local Adjustment

The PFLEX PD digital positioner has LCD-Local indicator that is visible through a window in the main cover.

During normal operation, the PFLEX PD remains in the monitoring mode and the display indicates the valve position, either as a percentage or as a current readout. Normal displaying is interrupted when the

magnetic tool is placed in orifice “Z” (Local

Adjustment), entering the programming mode local adjustment. The magnetic tool activates the local programming mode, by inserting it in orifice “Z” on the local adjustment plate. Figure 22.

ORIFICE ACTION

Z Moves between the functions.

S Selects the display function.


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Figure 22. Local adjustment

The holes identified with Z (Zero) and S (Span)

will be indicated by (Z) and (S). The table shows the action accomplished by the magnetic tool when inserted in (Z) and (S) according to the adjustment selected. The digital display is necessary to visualize the programming tree via local adjustment.

7.2 Magnet tool

With the magnetic tool, it is possible to configure PFLEX PD locally, eliminating the need of additional configurators in many basic applications.

7.3 W1 and W2 jumpers connection

Write Protection

W1 Jumper connected in OFF

If the W1 jumper is connected in OFF, the write protection is disabled.

W1 Jumper connected in ON

If the W1 jumper is connected in ON, the write protection is enabled.

Local Adjustment

W2 Jumper connected in OFF

If the W2 jumper is connected in OFF and the local adjustment is disabled, the programming tree parameters cannot be modified.

W2 Jumper connected in ON

If the W2 jumper in ON and the local adjustment

is enabled, the programming tree parameters can be modified.


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7.4 Local programming tree

The programming tree is structured with menus of the main software functions.

Figure 22. Local programming tree

With local adjustment enabled, it is possible to travel through all the configuration options maintaining the magnetic tool in the hole marked with "Z". To select the option, after choosing the option by the previous way, place the tool in the

hole marked with "S".

NOTE

Do all changes and configurations very carefully

since all modifications in the parameters are

recorded automatically and do not need user

confirmation to save the configuration.

By keeping the tool in “S” hole it is possible to continuously operate the selected parameter,

since this is a numeric value. Incrementing

actions are performed by repeatedly placing and removing the magnetic tool until reaching the

desired value.

7.5 Adjustable parameters

FULL SETUP Executes the AUTO SETUP and the AUTOTUNING for full valve adjustment, including the PID control parameters.

AUTO SETUP During this adjustment, the positioner checks the

0% and 100% valve travel in relation to the magnet and then calculates the AD converter gain for position readings.


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AUTOTUNING Performs the PID control tuning through automatic selection of the Kp, Tr and Td values.

MANUAL SETUP Executes the AUTO SETUP steps but it needs user

confirmation between steps.

The user must confirm the current step conclusion only when the valve is not active. The steps are described below: Step 1: Valve closing to check the 0% position.

Step 2: Valve opening to check the 100% position. Step 3: Valve closing to begin calculating the AD converter gain.

Step 4: Valve opening to end the calculation of the AD converter gain

NOTE

The MANUAL SETUP is recommended in

cases where it is not possible to activate

the AUTO SETUP due to very unstable

environment

NOTE

Do not touch the moving parts of the

valve/positioner/actuator, because they

may unexpectedly move automatically.

TYPE – Valve Type Through this parameter, the user configures the valve type and the type of action associated to valve.

See valve type options:

Sind: Single action and Direct;

Sinr: Single action and Reverse;

Doud: Double action and Direct;

Dour: Double action and Reverse.

CHAR - Characterization Curves

Through this parameter, the user configures the

characterization curve of the valve. See the existing options:

Linear: linear

EP25; EP33; EP50: equal percentage

QO25; QO33; QO50: hyperbolic (quick

opening)

Tab: table of 16 points (configurable)

Allows choosing the mode in operation. When activating the positioner, it will be always in automatic mode.

Operation Mode options: Auto - Automatic Mode In the automatic mode, the position is adjusted according to the 4 to 20 mA current signal input. This mode does not allow the local access to the

SP% parameter. Man - Manual Mode In the manual mode, the position is adjusted according to the SP% parameter value, independently of the input current. Only this mode allows the operation in the SP% parameter.

SP % - Set Point This parameter represents the desired position value. In the “Manual” mode, this parameter may

be operated remotely, independently from the input current. The desired value from the input current level is calculated in the “Auto” mode.

LOPOS - Lower Position adjustment This parameter allows the user to calibrate the desired lower position, associated to the input current. This is also useful to calibrate the lower Split Range position.

UPPOS - Upper Position Adjustment This parameter allows the user to calibrate the desired upper position, associated to the input current. This is also useful to calibrate the upper Split Range position.

TIME - Setpoint Variation Time

Allows to configure the Setpoint variation rate by selecting the desired time for the valve open or close. The unit is shown in seconds.

Kp - Proportional Gain Allows to adjust the proportional gain of the

digital PID control.

Tr - Integral Time Allows to adjust the integral time of the digital PID control.

Td - Derivative Time Allows to adjust the derivative time of the digital PID control.

DISP – POS, SP or CRTL

During the normal operation, the display shows position in percentage (POS%). This parameter allows to select setpoint in percentage (SP%) or current to coil in percentage (CRTL%).

AIRTO - Air to Open or Air to Close

This option allows adjustment of the positioner according to the valve actuation. If the actuator works with "air to open" or "air to close", the positioner should be configured for AirTo OPEN or AirTo CLOSE, respectively.


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8. Parts list

Figure 23. Parts list


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Item Qty Description 1 2 captive screw 2 1 cover 3 2 M5 screw 4 1 feedback spring

5 1 feedback spring setscrew 6 1 feedback spring base 7 1 M8 nut 8 2 M5 screw 9 3 O-ring 10 1 spool valve 11 2 M5 screw

12 1 O-ring 13 2 pressure gauge scale to 160 psi 14 1 gasket

15 3 screen cup 16 1 base 17 2 O-ring

18 1 exhaust cover 19 1 sealing plug 20 1 connector cover 21 1 ensor board 22 1 sensor cover 23 1 sensor Base 24

25

1

1

M5 screw

tubing 26 1 conector 27 28 29 30

2 2 1 4

¼” – 20 screw M3 screw balance spring M4 screw

31 1 diaphragm flange

32 1 diaphragm base 33 1 lower diaphragm washer 34 1 positioner diaphragm 35 36 37

38 39 40 41 42 43 44

45 46

47 48 49 50 51

52 53 54 55 56 57

58 59

1 1 2

1 1 1 3 1 3 1

1 3

3 1 1 2 1

1 1 2 1 2 1

1 1

upper diaphragm washer M4 screw M3 screw

main board actuator setscrew actuator setscrew locknut M3 screw spacer M4 screw analog board cover

analog board M2 screw

M4 screw analog board housing spring diaphragm M3 screw O-ring

coil flange O-ring flame arrestor O-ring M4 screw housing

O-ring O-ring

60 61 62 63 64 65

66 67 68 69 70 71 72

73 74

75 76 77 78 79

80 81 82 83 84 85

86 87 88 89 90

91 92

93 94 95 96 97 98 99

100 101 102 103

1 1 1 1 1 1

4 1 1 1 1 1 1

1 1

1 1 1 1 1

1 1 1 1 1 1

1 1 1 1 1

1 1

1 1 1 1 1 1 1

1 1 1 1

restriction screw filter O-ring filter cover vent cover vent element

M4 screw regulator setscrew regulator cover regulator spring button regulator spring regulator poppet guide screw O-ring

regulator poppet poppet spring

ground screw M4 spring washer ground washer ground base pressure gauge scale to 30 psi

feed thru negative pole feed thru connector feed thru positive pole identification tag negative pole identification tag positive pole terminal block

M3 spring washer M3 screw O-ring terminal cover terminal label

M4 nut upper diaphragm washer

diaphragm lower diaphragm washer coil housing coil nozzle coil cover retaining ring

conical compression spring window O-ring housing cover


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9. Troubleshooting

SYMPTOM POSSIBLE CAUSE ACTION

Instrument will not

communicate

Controller output providing less

than 4 mA to loop

Check signal input current. Minimum current for

positioner operation is 3.8 mA.

Improper field wiring Check polarity of wiring and integrity of connections.

Make sure cable shield is grounded only at the control

system

Insufficient voltage available Voltage should be greater than or equal to 11 Vdc

Controller output impedance too

low

Install a HART filter

Polling address incorrect Use the HART communicator to set the polling address.

Set the polling address to 0

Cable impedance too high Review maximum cable capacitance limits

Instrument will not

calibrate

Oscillating, slow response or fast

respone

Select full setup to automatically calibrate the

instrument travel and performance

I/P converter minimum pressure

out of specification

Check I/P converter minimum pressure. The minimum

pressure should be 4 to 5 psi

I/P converter coil current out of

specification

Check I/P converter coil current. The coil current %

should be 45% to 55%

I/P converter

damage/corroded/clogged

Check for contamination or dirty air supply. Check for

open coil, resistance should be between 1050 – 1150

ohms. Check for bent flapper or restriction clogged

9.1 Error Messages

The error messages inform the diagnostic through the self-diagnostic of errors and malfunctioning. When the configurator is communicating with the positioner, the user is informed on any problem found, through the self-diagnostic. At the PFLEX PD digital positioner, the error messages always alternate with the information on the top line of the configurator’s display. Errors messages

and more details on corrective action are showing below.


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ERROR MESSAGES POTENTIAL SOURCE OF PROBLEM

PARITY ERROR - The line resistance is not according to the technical characteristics.

- Excessive noise or ripple.

- Low level signal.

- Interface damaged.

- Power supply or battery voltage of the configurator lower than 9 V.

OVERRUN ERROR

CHECK SUM ERROR

FRAMING ERROR

NO RESPONSE

- Positioner line resistance is not according to technical characteristics.

- Positioner not powered.

- Positioner not connected or damaged.

- Positioner configured in multidrop mode being accessed by ON LINE SINGLE UNIT.

- Positioner reversibly powered (polarity is reversed).

- Interface damaged.

- Power supply or battery voltage of the configurator lower than 11 V.

LINE BUSY - Other device using the line.

CMD NOT IMPLEMENTED - Software version not compatible between configurator and positioner.

DEVICE BUSY - Positioner carrying out an important task, e.g., local adjustment.

POSITIONER MALFUNCTION - current to pressure coil disconnected.

- current to I/P converter failure.

COLD START - Start-up or reset due to power supply failure.

OUTPUT FIXED - Operating in local mode with fix position.

- Connected in burnout.

OUTPUT SATURATED - Position out of calibrated span or in fail-safe (Output current in 3.9 or 21

mA).

2 OUT OF LIMITS - Temperature out of operating limits.

- Temperature sensor damaged.

1 OUT OF LIMITS

- Position out of operation valve range.

- Voltage to pressure transducer damaged or not connected.

- Positioner with error configuration.

LOWER RANGE VALUE TOO HIGH - The lower range value > (Upper limit of minimum span range).

LOWER RANGE VALUE TOO LOW - The lower range value < (Upper limit of range).

UPPER RANGE VALUE TOO HIGH - The upper range value > 110 % x (Upper limit of range).

UPPER RANGE VALUE TOO LOW - The upper range value < - 10 % (Lower limit of range).

UPPER AND LOWER RANGE VALUES OUT

OF LIMITS

- Both the upper and lower points are outside the positioner range limit.

SPAN TOO SMALL - The difference, between the upper and lower points, is less than the allowed

by the positioner.

ACTUAL POSITION - The actual valve position was above of the upper range limit.

ACTUAL POSITION - The actual valve position was below of the lower range limit.

PASSED PARAMETER TOO LARGE - Parameter above operating limits.

PASSED PARAMETER TOO SMALL - Parameter below operating limits.

CONTROL LOOP SHOULD BE IN MANUAL - Indicates that the operation could affect the output.

CONTROL LOOP MAY BE RETURNED TO AUTO

- After the operation is complete, you are reminded to return the loop to automatic control.


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10. Maintenance

This section provides preventive maintenance procedure and troubleshooting procedures for the PFLEX PD digital positioner. Modifying this product, substituting non-factory parts, or using

maintenance procedures other than out-lined could affect performance and be hazardous to personnel and equipment.

WARNING Use only procedures and new parts specifically

referenced in this manual. Unauthorized

procedures or parts can affect product performance.

10.1 Restriction screw

Figure 24 shows the restriction screw. Use the following steps to confirm that the restriction is not clogged: 1. Shut off the air supply.

2. Remove the restriction from the housing. Check

if the O-rings missing or hard and flattened losing seal. Replace if necessary and make sure the O-rings are lightly lubricated with silicone grease and properly seated in the groove.

2. If they show a buildup of contaminants, clean the restriction by gently inserting a wire with a maximum diameter of 0.015 inches (0.38 mm). Do not enlarge the hole.

3. Reassemble and check operation.

4. If after cleaning the PD digital positioner does

not function, replace the restriction with a new

one.

Figure 24. Restriction screw

10.2 Filter

Figure 25 shows the filter used to prevent

performance degradation of pneumatic equipment. The water and oil that collect at the bottom of the filter must periodically be checked. It is recommended to establish a maintenance cycle to monitor the degree of pollution of the coalescent filter. Use the following steps to

confirm that the coalescent filter is not damaged

or clogged: 1. Shut off the air supply. 2. Remove the filter cover from the housing. Inspect the O-ring for wear and replace as necessary. Make sure the O-rings are lightly

lubricated with silicone grease and properly seated in the groove. 3. Remove the filter. Check for contamination, staining, or dirt air supply. Replace if necessary.



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Figure 25. Filter

10.3 Terminal block

Figure 26 shows the terminal block assembly. Use the following steps to remove and replace the terminal block:

WARNING In explosive atmospheres, remove the power to the EDGE I/P Converter before attempting

to remove the terminal compartment cover or module cover.

1. Remove the terminal compartment cover (see Warning above). 2. After removing the cover, note the location of field wiring connections and disconnect the field

wiring from the terminal block. 2. Check for contamination, damaged, corroded terminal block. Replace if necessary.


Figure 26. Terminal block

10.4 Pressure regulator

Figure 27 shows the pressure regulator assembly. Use the following steps to remove the pressure regulator assembly: 1. Shut off the air supply.

2. Remove the set screw from the pressure regulator cover. 3. Remove the four pan head screws that attached the pressure regulator cover.

4. Remove the pressure regulator cover. 5. Remove the spring. 6. Remove the diaphragm assembly. 7. Use a 1/2-inch socket wrench to remove the

poppet guide. 8. Remove the poppet and the spring.

Figure 27. Pressure regulator


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Use the following steps to replace the pressure regulator assembly:

WARNING

Do not use chlorinated solvents for cleaning the diaphragm assembly. The chlorinated solvents will deteriorate the rubber diaphragm.

1. Install the spring of poppet. 2. Check if the surface of poppet is free of dust, dirt, scratches, and contamination. Install the poppet.

3. To avoid affecting performance of the instrument, inspect the surface on the seating area in the housing before installing the guide plunger. These surfaces must be free of dust, dirt, scratches, and contamination. Ensure the O-ring is in good condition. Do not reuse a damaged or

worn O-ring. 4. Check diaphragm assembly for closed up holes, excessive deformation due to over tightening or “oozing”. Insert the diaphragm assembly. (see Warning above).

5. Insert the spring.

6. Apply a small amount of thread locking compound (Loctite 222 or equivalent) on the pan head screws.

7. Install four screws in the pressure regulator cover into the housing and evenly tighten them in a crisscross pattern. 8. Apply a small amount of thread locking compound (Loctite 222 or equivalent) on the set

screws. 9. Install and tighten the set screw according the adjusting pressure regulator procedure.

Use the following steps for adjusting the pressure

regulator assembly:

1. The housing cover should be tightened firmly.

Check for air leak and repair.

2. Plug the exhaust port with a 1/8-27 NPT plug.

Check for air leak and repair.

3. Connect air supply to the positioner. The

instrument must be calibrated at a supply

pressure of 80 psig (5.6 bar).

4. Remove the regulator set screw and apply a small amount of thread locking compound (Loctite 222 or equivalent) on the set screw. 5. Install the regulator set screw and observe

pressure indicated by the pressure gauge on the I/P converter to adjust the output pressure to obtain a measured pressure of 22 ± 1 psi.

6. Shut off the air supply and remove the 1/8-27 NPT plug from the exhaust port and reinstall the

muffler and check operation.

10.5 Transducer

Figure 28 shows the transducer module.

Remove the transducer module

WARNING In explosive atmospheres, remove the power to the EDGE I/P Converter before attempting to remove the terminal compartment cover or module cover.

1. Shut off the air supply.

2. Disconnect power from the positioner.

3. Remove the transducer compartment cover (see Warning above).

4. Remove the two M3 screws that attached the

main board to spacer.

5. Disconnect the wiring and the ribbon cable from

main board. Each cable has its own unique

connector to prevent mistakes in reconnecting.

WARNING To avoid damaging any components, exercise caution by gently raising the locking tab to release the ribbon cable

6. Remove the three M4 screws that attached the

transducer to housing.

7. Pull the transducer module straight out of the housing. Be careful not to damage the electrical

leads that come out of the housing. 8. Loosen actuator setscrew locknut and remove actuator set screw. 9. Disconnect the wiring to analog board.


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10. Pull the mechanical module straight out of the electronic module.

Figure 28. Transducer module Replace the transducer module 1. To avoid affecting performance of the instrument, inspect the surface on the transducer

module and the corresponding seating area in the housing before installing the transducer module assembly. These surfaces must be free of dust, dirt, scratches, and contamination. 2. Ensure the O-ring is in good condition. Do not reuse a damaged or worn O-ring.

3. Insert the transducer module into the housing. Ensure that the module is aligned properly on the housing. 4. Connect the cable from the housing to the transducer module. Orientation of the connector is

required. 5. Apply a small amount of thread locking compound (Loctite 222 or equivalent) on the screws.

6. Install three screws in the transducer module into the housing.

7. Tighten the three screws. 8. Reconnect the ribbon cable and wiring to the main board. 9. Insert two M3 screws into main board.

10. Tighten all two screws and check operation. Adjusting the transducer module Figure 29 shows the transducer module adjustment.

1. Although the transducer minimum pressure can

be adjusted using the standard output pressure

gauge on the I/P converter, its accuracy is ± 3%.

It is recommended that the standard gauge be

removed for calibration and more accurate

calibration instrument of ± 0.1% of span be used.

6. Once the pressure regulator is set to 22 psi.

Install the hexagon set screw and adjust the

output pressure to obtain a measured pressure of

4 to 5 psi.

7. Cycle the positioner air supply several times

and recheck the minimum pressure and readjust,

if necessary, to ensure that the pressure has

settled within the range specified.

8. Replace the main board and reconnect wiring to

the main board.

Figure 29. Transducer module adjustment

Checking the adjusting the transducer module

To ensure instrument accuracy, check calibration

of transducer module after to procedure full setup

calibration.


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The minimum and maximum pressure registering

on the pressure gauge scale 30 psi should be according below table.

Adjusting the feedback spring Figure 30 shows the feedback spring adjustment.

1. Once the pressure regulator is set to 22 psi and

transducer is set to 4 psi. Loosen the M8 locknut.

2. Through DISP parameter, configure the CRTL. The current to coil will be showed in percentage. 3. Adjust the feedback spring setscrew by turning

the setscrew with a small flat screwdriver. The current coil percentage showed at the display should be set to 48 to 52%.

4. Cycle the input current several times and

recheck the current coil and readjust, if

necessary, to ensure that the percentage has

settled within the range specified.

Figure 30. Feedback spring

10.6 Mechanical module

Figure 31 shows the mechanical module. Use the following steps to confirm that the orifice is not clogged: 1. Shut off the air supply.

2. Remove the restriction from the housing. Check if the O-rings missing or hard and flattened losing seal. Replace if necessary and make sure the O-

rings are lightly lubricated with silicone grease and properly seated in the groove. 2. If they show a buildup of contaminants, clean the orifice by blow off accumulated dust or dirt with dry, low velocity air. Any dust or dirt that remains should be removed with a soft brush or a

cloth dampened with a mild detergent and water solution.

3. Make sure the spring diaphragm is properly seated in the groove into analog board housing. Follow the orientation showed at figure 33.


5. If after cleaning the PD digital positioner does

not function, replace the mechanical module with a new one.

Figure 31. Mechanical module

10.7 Positioner Diaphragm

Figure 32 shows diaphragm. Removing the diaphragm. 1. Disconnect air supply to the unit. 2. Remove the cover of the positioner and the

feedback spring.

POSITION PRESSURE GAUGE SCALE 30 PSI

0% 4 to 5 psi

50% 8 a 9 psi

100% 12 a 15 psi


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2. Unscrew the two screws and remove the

diaphragm from the positioner.

Figure 32. Diaphragm

WARNING

Avoid the use of chemical cleaning agents which might damage the nitrile compound of

the diaphragm

Replacing the diaphragm:

1. Remove the four screws holding the flange. Carefully push the diaphragm assembly through the capsule base. 2. Examine the diaphragm assembly for wear or failure and replace if necessary.

2. To avoid affecting performance of the instrument, inspect the surface on the diaphragm and corresponding seating area in the base before installing the diaphragm. These surfaces must be

free of dust, dirt, scratches, and contamination.

2. Ensure the O-ring is in good condition. Do not reuse a damaged or worn O-ring. 3. Insert the diaphragm into the base. Carefully engage the notched end of spool with the beam spring. Before to fasten securely with to screws, check if spool slides freely. Figure 33.

4. Compress the feedback spring and flex into the housing, securing the spring socket onto the stud

on the balance arm. Be sure that the ends of the

feedback spring lies flat with their respective contact surfaces.

Figure 33. Diaphragm and spool assembly

10.8 Spool valve

Figure 34 shows spool valve. Removing the spool

valve. 1. Disconnect air supply to the unit. 2. Unscrew the two screws and remove the spool valve from the positioner. Be careful not to

damage the spool valve.

WARNING

Do not apply oil or grease to the spool. It must be free of dust, dirt, scratches, and contamination.


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Figure 34. Spool valve

WARNING

Each spool valve body has an individual matching spool which cannot be replaced with any other spool part.

Replacing the spool valve: 1. To avoid affecting performance of the instrument, inspect the surface on the spool valve

and corresponding seating area in the base before installing the spool valve. These surfaces must be free of dust, dirt, scratches, and contamination.

2. Ensure the O-ring is in good condition. Do not reuse a damaged or worn O-ring.

3. Slide the spool from the spool valve body and check it for dirt build-up or sticking. To operate properly, the spool should slide very freely and fall through by its own weight when held vertically. Clean both the spool and spool valve body with degreasing solvent. Insert the spool into the body and check it slides freely for proper operation.

Reclean if is necessary. 4. Insert the spool valve into the base. 4. Install two spool valve screws and tighten

securely.

11. Warranty

Sense warrants all equipment manufactured by it and bearing its nameplate, and all repairs made by it, to be free from defects in material and workmanship under normal use and service:

1. Sense guarantees its products for a period of

12 months, starting on the day of issuance of the invoice.

2. Sense guarantees its products for a period of 6 months for service of warranty or non-warranty repair. 3. In cases of repairs under warranty, recall or outside warranty, the client is responsible for the correct packaging and packing and Sense shall not

cover any damage caused during transportation. 4. Sense does not guarantee wrong handling or lack of basic maintenance compliant to the equipment manual provisions.

5. In order to expedite analysis and solution of the problem, the defective item should be returned with a description of the failure observed, with as many details as possible. Other information concerning to the instrument operation, such as service and process conditions, is also helpful.

6. For warranty or non-warranty repair, please contact Sense.

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