TVC Positioner - Paladon Systems
Contents
1. ANY KEY TO CONTINUE CURRENT OPEN TIMES ON 500mS OFF Q60s CURRENT CLOSE TIMES ON 500mS OFF Q60s H BACK MENU OPERATION The current on and off times are shown Pressing any key other than sets a flashing cursor on the OPEN TIME ON selection and further key presses will enter a value in the range 0 to 999mS Pressing any key other than then selects the OPEN TIME OFF and further key presses will enter a value in the range 0 to 999s note the different units from the ON time The OFF TIMES can be selected in a similar manner Repeated pressing of the Key will skip other entries and return the display to the Set up Menu saving any changes Set Deadzone and Band Edge Hysteresis The deadzone allows an area of control of the actuator position where no movement takes place Such a zone is required in systems that have on off control of the hydraulic control elements due to magnetic and mechanical delays inevitable with such components Control is enhanced by having two settings one for the open direction and one for the close direction solenoid operations The hysteresis value provides an additional suppressed band active only on entry into the deadzone to reduce instability due to conversion and arithmetical errors in the positioner The deadzone is expressed in percent of full stroke of the actuator whilst the hysteresis is a notional value SET DEADZONE AND HYST ANY KEY TO CONTINUE OPEN DEADZONE 00 7 CLOSE DEADZO2. Fault output 24Vdc open drain Hydraulic pump drive controlled by demand or external pressure sensors External fault contact monitoring Selectable interlock between ESD and fault outputs Low power normal operation less than 3W Direct mounting within Compact Ex d Enclosure System The TVC can be used in any positioning system relying on the on off control of the position driver including electro hydraulic actuators and reversing ac motors with the addition of suitable relays or contactors The TVC can accept positional feedback from a three wire potentiometer or a position transducer with a current output The TVC is mounted to a special chassis plate and fitted within an Exd enclosure All field and customer wiring is taken through a close coupled Exe enclosure Comprehensive power supply and signal isolation allows connection to any user DCS system without the need for further signal isolation This handbook describes the configuration and operation of the basic TVC Other hardware and firmware options will be described in additional sections published separately Doc Q068 Rev 1 Page 3 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Operation First Time Operation Please read this handbook before operating the TVC The instrument will have been set up during factory trials so please avoid changing any parameters until you have gained some familiarity with the operation of the positioner WARNING The actuator and assoc
3. NOT ENABLED CHECK INPUT 4 12 34 27 12 12 10 DEMAND ACTUAL 50 1 49 8 1 MANUAL 2 CONFIGURE Entering Manual Mode If the TVC input 4 is made and Key 1 is pressed on the IR900 then the following display is seen ENTER MANUAL MODE PASSCODE DISPLAY REVERTS IN 45 SECONDS If a correct 4 digit pass code is not entered by the IR900 within the time shown then the display will revert to the normal auto mode when the timer reaches zero Note that the actuator will remain stationary at the last auto position during the pass code entry sequence Doc Q068 Rev 1 Page 7 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Manual Mode After a successful pass code entry the following screen is displayed and LED 2 is illuminated MANUAL MODE 12 34 27 12 12 10 DEMAND ACTUAL 50 1 49 8 1 CLOSE 2 OPEN H BACK MENU OPERATION Keys 1 and 2 on the IR900 control the opening and closing of the actuator The actual solenoids operated will depend on the Solenoid Sense setting for the particular hydraulic circuit used in the actuator All system fault monitoring is disabled in manual mode thus enabling further diagnostics of a known faulty system Pressing the key starts the exit routine from manual mode Returning To Auto Mode Pressing the key does not immediately switch operation to auto An intermediate screen is displayed to warn if the actual position deviates more than the current dead zone setting from the current demand sig
4. adjustment procedure is as follows 1 Set the demand signal to the low end value usually 4mA 2 Use Key 1 close or Key 2 open to position the actuator to the desired position 3 Press Key to complete the operation Doc Q068 Rev 1 Page 12 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Instrument Set up Menu These sub menu allow the set up of the positioner to suit the hydraulic hardware the control signals and the process control required INSTRUMENT SETUP MENU SOLENOID SENSE INST FAIL MODE PUMP CONTROL SET STEPPING MODE SET DEADZONE HYST MORE CHOICES BACK MENU OPERATION A further selection appears if Key 6 is pressed SETUP MENU PAGE 2 1 SET I P O P SENSE 2 SET FAULT MATRIX 3 SET DEMAND DIR N H BACK MENU OPERATION Doc Q068 Rev 1 Page 13 of 29 TVC Positioner OJEEFEEN TOTAL VALVE CONTROL Solenoid Sense Selection This allows the matching of the solenoid control with the particular hydraulic circuit used and is normally a one off adjustment completed during factory tests The open and closed solenoids can be assigned to cause flow either when energised or when de energised This allows the three common hydraulic configurations stay put fail close or fail open under fault conditions The following screen is displayed SET SOLENOID SENSE CURRENT CHOICE IS 1 SIAY PUT 2 FAIL CLOSE 3 FAIL OPEN H BACK MENU OPERATION The current selection is shown a
5. control output ve switched Remote status output ve switched Pump control low press switch ve Pump control high press switch ve External fault input ve Operator enable input ve Doc Q068 Rev 1 Voltage 24Vdc 3 2V OV 3 2V 3 2V 3 2V OV 3 2V OV 3 2V 3 2V 3 2V 24V 3 2V OV 3 3V 3 3V OV 24Vdc OV 24Vdc 24Vdc 24Vdc 24Vdc 24Vdc 24Vdc 24Vdc 24Vdc 24Vdc 24Vdc Comment Not usually connected Common inst Supply Not usually connected Not usually connected For pump control and P S Connect to good signal ground Isolated analog input Not normally connected Not normally connected Not normally connected Can be sinking or Isolated output Connect to good signal ground Not usually connected Not usually connected Connect to good signal ground Solenoid ve to 24V Solenoid ve to 24V Output ve to 24Vdc Output ve to 24Vdc Output ve to 24Vdc Output ve to 24Vdc Switch to inst OV Switch to inst OV Switch to inst OV Switch to inst OV Page 28 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Spares Kit Ordering amp Additional Service Support When requesting service support or ordering spares kits please provide the following contract details Actuator Serial Number 6 or 7 digit number with a RFPL prefix Paladon Contract Number 5 digit number with an ACCP ACE ACP ACSP CCP CE CGH CP CPC or CSP prefix General Arrangement or Control Sch
6. main type hydraulic supply 2 On Demand this would be selected for systems with some local hydraulic accumulation and a low to moderate duty cycle The pump would start to operate when the actuator was caused to move either by a change in demand signal or in manual operation The control is sensitive to the particular solenoid sense set for the system thus the pump would not run for actuator closing if fail close was selected or fail open if fail open was selected Similarly the pump would not run if the system had detected a system fault as described above There is also an overrun time associated with mode that can be set if this pump control is selected 3 Pressure Switches external contact inputs 1 and 2 can be used as low pressure and high pressure controls respectively These switches fitted within the hydraulic system will stop the pump at high pressure and start it again at low pressure The sense of the inputs can be set in the Input and Output Sense Setting below 4 Pressure Transmitter the pressure switches mentioned above can be replaced with a pressure transmitter connected to Internal Analog Input 2 A further menu sets the low and high switching for this transmitter Choice 2 Set Pump On Demand Run On Time ON DEMAND PUMP RUN ON TIME ANY KEY TO CONTINUE RUN ON TIME 005 SECS H BACK MENU OPERATION Doc Q068 Rev 1 Page 16 of 29 GEED TVC Positioner TOTAL VALVE CONTROL The current run on time
7. move the actuator towards the set 4mA demand signal as it is possible to set the fully open position equivalent to 4mA DEMAND DIRECTION CURRENT CHOICE IS 4mA AT CLOSE 1 2 4mA AT OPEN BACK MENU OPERATION Keys 1 or 2 will change the choice and Key will return the display to the second page of the Set up Menu Doc Q068 Rev 1 Page 20 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Utilities Menu The final item in the Main Configuration Menu is the Instrument Utilities Settings Pressing Key 4 from the Configuration Menu enters the Utilities Menu UTILITIES MAIN MENU 1 SET DATE AND TIME 2 SET MISC TIMERS 3 SET MANUAL PASSCODE 4 SET CONFIG PASSCODE 5 FORCE RETRANS O P 6 MORE CHOICES BACK MENU OPERATION Pressing Keys 1 6 will access the listed choices and Key will return the display to the Main Configuration Manu Set Date and Time The TVC has a real time clock equipped with a short term back up in the event of power loss DATE AND TIME TIME 12 10 54 DATE 03 09 10 BACK MENU OPERATION Pressing Key returns the display to the Utilities Menu Pressing any other key starts the editing process by placing a flashing cursor on the hours display Key in the required time hh mm as prompted by the cursor A further press of the key will return to the Utilities Menu leaving the date unchanged but pressing any other key will start the editing process of the date dd mm yy The displa
8. process as full stroke operation of the actuator is required It is usually best if the demand signal injection and the actual retransmitted position signal monitoring is done locally to the TVC and actuator Select Calibration by pressing key 1 MANUAL CALIBRATION KEY START NEXT STAGE H BACK MENU OPERATION Pressing key will return the display to the Configuration Menu Pressing key will start the calibration procedure at the low end i e the actuator stroke to be associated with the 4mA demand signal often the closed position MANUAL CALIBRATION KEY START NEXT STAGE LOW END DEMAND 0719 ACT 0738 RETRANS 0518 BACK MENU OPERATION The descriptions are in reverse contrast and the numeric values the internal bit conversion values are in normal contrast The low end calibration procedure is as follows Set the demand signal to the low end value usually 4mA Use Key 1 close or Key 2 open to position the actuator to the desired position Monitor the retransmitted actual position signal with a suitable DVM on current range Use Key 4 to reduce the retransmitted output or Key 5 to increase it Note that the last low end calibrated value for the retransmitted signal is used Press Key to complete the operation P IPR Doc Q068 Rev 1 Page 10 of 29 EEE TVC Positioner TOTAL VALVE CONTROL Press Key to continue to the high end calibration MANUAL CALIBRATION KEY START NEXT STAGE L
9. the actuator using the key pad This timer sets a short ON pulse followed by 5 times the pulse time OFF pulse The resulting pulse train can position the actuator more precisely than a continuous pulse 4 Pass Code Entry Timer this is the down count timer in seconds associated with Manual or Configuration pass code entry 5 Backlight Timer The display backlight is normally off but will light on any key press from IR900 key pad The display will stay lit for the duration of this timer Doc Q068 Rev 1 Page 22 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Manual Mode Pass Code Manual Mode entry is protected by a four digit pass code SET MANUAL PASSCODE ANY KEY TO CONTINUE CURRENT CODE 1234 H BACK MENU OPERATION Press Key to return to the Utilities Menu Press any other key to start editing the pass code The display returns to the Utilities Menu automatically after the entry is complete Configuration Mode Pass Code Configuration Mode entry is protected by a four digit pass code SET CONFIG PASSCODE ANY KEY TO CONTINUE CURRENT CODE 1234 H BACK MENU OPERATION Press Key to return to the Utilities Menu Press any other key to start editing the pass code The display returns to the Utilities Menu automatically after the entry is complete Doc Q068 Rev 1 Page 23 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Force Retransmitted Signal Output This option is included to acts as
10. NAL FAULT INPUT GO TO POSN ON FAULT Main Display LED Indicators There are 8 LED indicators above the main display and they have the functions running clockwise from top right CLOSE 8 1 _ OPEN FAULT 7 2 MANUAL ENABLED 6 3 _ STEP BE 4 _ ESD 1 OPEN lit when the open solenoid is energised 2 MANUAL lit when the TVC is in manual mode 3 STEP lit when stepping mode has been selected 4 ESD lit when the ESD output is energised this may be fail safe i e energised healthy 5 Future use 6 ENABLED lit when the enable contact has been made enabling access to manual and configuration 7 FAULT lit when there is a fault within the TVC system this may be fail safe i e energised healthy 8 CLOSE lit when the close solenoid is energised Doc Q068 Rev 1 Page 6 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Access To The Manual amp Configuration Systems An external volt free contact closure enables access to the manual and configuration modes of the TCV The contact should be MADE to enable The contact switches a 24Vdc input excited from the common bulk supply to the TVC LED 6 is lit if the TVC is enabled for manual operation or configuration If an attempt is made to access manual Key 1 or configuration Key 2 using the IR900 without the enable contact being made then the following display will be seen for 10 seconds The positioner will continue to operate in automatic mode ACCESS
11. NE 00 6 HYSTERESIS OPEN 005 HYSTERESIS CLOSE 005 H BACK MENU OPERATION The current deadzone and hysteresis values are shown Pressing any key other than sets a flashing cursor on the first value which can then be changed Subsequent presses of the Key pass through each value without change and eventually the display returns to the main Set up Menu Doc Q068 Rev 1 Page 18 of 29 TOTAL VALVE CONTROL EEE TVC Positioner Instrument Set up Menu Page 2 Options are on a second page accessed by pressing Key 6 Set Input and Output Sense The TVC has four digital inputs internally pulled high to the 24V instrument supply and four open drain Outputs acting as low side switches using the 24V instrument supply This setpoint allows the inactive state to be set for both inputs and outputs Pressing Key 1 sets a normal state inputs pulled high outputs not energised and Key 2 set the reverse condition If Key is pressed the display will return to the second page of the Set up Menu otherwise the key press is ignored but subsequent Key presses of 1 to select normal or 2 or any other key to select reverse will modify all four outputs and inputs sequentially Note that if editing is started then all values have to be re entered The display automatically returns to the second page of the Set up Menu when the final output is changed SET I P AND O P SENSE KEY 1 NORM KEY 2 REV PRES L NOR PRES H NOR EXT FL NOR ENABLE NO
12. OW END DEMAND 0719 ACT 0738 RETRANS 0518 HIGH END DEMAND 3615 ACT 3702 RETRANS 2565 H BACK MENU OPERATION The descriptions are in reverse contrast and the numeric values the internal bit conversion values are in normal contrast The high end calibration procedure is as follows 7 Set the demand signal to the high end value usually 20mA 8 Use Key 1 close or Key 2 open to position the actuator to the desired position 9 Monitor the retransmitted actual position signal with a suitable DVM on current range 10 Use Key 4 to reduce the retransmitted output or Key 5 to increase it 11 Note that the last high end calibrated value for the retransmitted signal is used 12 Press Key to complete the operation Press the Key to continue to the calibration confirmation procedure MANUAL CALIBRATION KEY TO CONFIRM CALIBRATION KEY LEAVE WITHOUT SAVING CALIBRATION If the calibration is confirmed then scaling factors are calculated and all are saved to EEPROM Doc Q068 Rev 1 Page 11 of 29 EEE TVC Positioner TOTAL VALVE CONTROL Calibration Trim This facility allows the calibration at the low demand end normally valve closed to be finely adjusted typically for seating of valves without having to go through a full calibration CALIBRATION TRIM SET DEMAND AT LOW 4mA KEY1 CLOSE KEY2 OPEN LOW END DEMAND 0719 ACT 0738 RETRANS 0518 KEY LEAVE WITHOUT SAVING CALIBRATION The trim
13. PALADON SYSTEMS LIMITED paladon VAT No GB 336 4172 64 Ferro Fields Brixworth Northampton NN6 9UA UK TOTAL VALVE CONTROL Tel No 44 0 1604 880700 Fax No 44 0 1604 882424 Email info paladonsystems com www paladonsystems com OPERATING amp MAINTENANCE MANUAL TVC Positioner Doc Q068 Rev 0 TVC Positioner OJEEFEEN TOTAL VALVE CONTROL Contents 6 A a a aia 2 Sl rf oe A 3 A UA SAA 4 ATTE A 4 MERA PA A 4 A A H 4 Normal Positioner Operation sss eee eee 5 ANECA 5 A AA A 6 UE o LED INOIGA OFS occcooocococoocococcocncocononanocononccncnonncocnnncenononcrnnnannnernnnnrenenannrrrnannrerenanennns 6 Access To The Manual 8 Configuration Systems cccccsesssseeeeseeensseeeeeeenseeeeeeeenseeeeeeeenseeeseoeenseessoes 7 ey MEAN A 7 Je po A 8 EOS AA 8 Entering Configuration MOE ccoo RR eenn 9 O A A AAA 10 a AS A A 12 Msiriheaibet U E 13 Solenoid Sense SEE 14 mstrument Fall MEORE ec cence cceeececccenccecceeseeccenececceseccesceeteesceeseeccasececcceneessceaseesouseeescseeeescceneeess 14 AAA A 16 ooo AA AA 16 Set Stepping MOE a 17 Set Deadzone and Band Edge Hysteresis e 18 Lelie MEME Page 2 cccccccssscessseeceeeecssccssseeeeeeeseccesseneeeeesseceseeeeeeeessecceseneeeseesssceesens 19 ele Ifet i CRON i Sn csccescerccsscsseerscsscsssersesscsseersesscssearsentousearsessenusarsenssuearsensesuearsentensearss 19 elz fe AEW 0 e 19 Setting Aetuator A 20 RI
14. Paladon Systems logo is displayed over the first three lines The first text line shows the time as hrs mins secs 24 hour clock followed by the date as dd mm yy The main display shows the current demand signal as a percentage of the full range normally 4 20mA followed by the actuator stroke as a percentage of the full stroke In normal operation the display will reflect changes in the demand signal and the position of the actuator Alternative Displays Pressing key on the IR900 keypad removes the Paladon Systems logo and displays the current dead zone and band edge hysteresis data and the current fail mode setting DZ Up 0 5 DZ Down 0 7 HYS In 0 2 HYS Out 0 1 FAIL CLOSE ON FAULT 12 34 27 12 12 10 DEMAND ACTUAL 50 1 49 2 1 MANUAL 2 CONFIGURE The display toggles back to the Paladon Systems logo with a further press of the key on the IR900 Doc Q068 Rev 1 Page 5 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Faults In the event of a positioning fault the first three lines will detail the fault and the response of the actuator Note The failed system information will be reset to a normal display when the fault condition has been resolved SYSTEM FAILURE LOSS OF DEMAND SIGNAL FAILED CLOSE 12 34 27 DEMAND 50 1 1 MANUAL 2 CONFIGUR Descriptions Line Can Include Positioner Fault Line LOSS OF DEMAND SIGNAL FAILED CLOSE LOSS OF F B SIGNAL FAILED OPEN FAILURE TO POSITION FAILED STAY PUT EXTER
15. R ESD OP NOR FLT OP NOR PUMP NOR STATUS NOR BACK MENU OPERATION Setting the Fault Matrix The TVC has four main fault conditions divided between positioning faults and external faults and four possible reactions to a fault condition Positioning Faults 1 Demand signal out of range normally a break 2 Actual position feedback out of range normally a break 3 Failure to position within a preset time External Faults 1 External fault contact Possible Actions Change actuator position or control stay put fail up down or to position Change state of Emergency Shutdown Output Change state of Fault Output Alert operator with a display message and LED changes YN E Doc Q068 Rev 1 Page 19 of 29 EEE TVC Positioner TOTAL VALVE CONTROL This option can associate Positioning Faults and External Faults with any of these four actions FAULT ACTION MATRIX SEL 1 4 CNG 1 2 NXT ACTION POSN EXT 1 POS NER ON OFF 2 ESD O P ON OFF 3 FLT O P OFF ON 4 DISPLAY ON ON H BACK MENU OPERATION The matrix can be inspected without change by just pressing the Key to exit to the second page of the Set up Menu Keys 1 4 select the positioner action followed by Keys 1 or 2 to change the choice The selections for Positioner and External Faults have to be completed for each action Key terminates the entry for each choice Setting Actuator Direction The positioner needs to know what solenoid operates to
16. T lt a C TA A A 21 SIDE IA AA 21 Set Miscellaneous a 22 Manual Mode PSOE eee e eee 23 Configuration Mode Pass Code sss sss see 23 Force Retransmitted Signal Output sss eee eee 24 Normal Operation Fault Detection and Logging ss ssssssssssssssssssss essen 24 Maintenance and Fault FiNding ccoooccnccconnnccconnnnoconcnnoconnnnnnnannnnononcnnononnononnnnnnnonannnnonanrnnennnnnnennaneness 24 SAA ic E A E E E A E A E E 26 Te LST A 27 STELE a E a oo s secnnccccecccccessnnccccesccccssseneeeeecsccusseneeeeenseccassenneeeesesccasseneeeeessscgssseseeeessssas 27 TVC Terminal Descriptions s nsnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn mnnn 28 Spares Kit Ordering amp Additional Service Support sssssssssssssssssssssssessssss esse e ennenen eenn 29 Doc Q068 Rev 1 Page 2 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Features Large backlit liquid crystal display Communication via infra red keypad Simple two step calibration Calibration trim for fine adjustment 4 20mA current command signals and current or potentiometer feedback signal Actual position 4 20ma calibrated output Three way isolation for command and actual position signals MANUAL mode Stepping mode with adjustable ON and OFF times Selectable solenoid drive sense for failsafe operation Selectable default operation on command signal feedback signal break ESD solenoid output on fault 24Vdc open drain
17. TVC from the EX2010 housing and unplug the free sockets d package the unit in anti static bubble wrap and a good solid outer box and return to the supplier Doc Q068 Rev 1 Page 25 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL TVC Appearance 101112 Company Logo 12 34 27 12 12 10 DEMAND ACTUAL 90 1 49 8 1 MANUAL 2 CONFI GURE LEDs USB 2 Processor Analog Board 1 Display Board 800 a _ TOP BOTTOM fo e 2 Cl DIT A B 3 F E links er 2 4 L Comms Board TE not always fitted gt H G 5 Power and Digital I O board All boards are shown in upper view connectors are underneath Note elevation is rotated by 90 Doc Q068 Rev 1 Page 26 of 29 850 a OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Physical Description Size with chassis plate 80mm wide 80mm high 85mm deep Weight with chassis plate 0 25kg Specification COMMAND SIGNAL INPUT 4 20mA nominal 160R input impedance fully isolated ANALOGUE POSITION O
18. UTPUT SIGNAL 0 5 22mA can be calibrated anywhere in this range normally 4 20mA fully isolated Sourcing 750R load Sinking max excitation 30V FEEDBACK SIGNAL INPUT Potentiometer 3 wire any value greater than 200R 4 20mA nominal 160R input impedance signal common with instrument supply SOLENOID OUTPUTS x 2 Maximum 2A for each output PWM with 12 bit resolution 24Vdc common with instrument supply SWITCHED OUTPUTS x 4 Maximum 1A for each output low side switched 24Vdc common with instrument supply CONTACT CLOSURE INPUTS X 4 Internally pulled high to instrument power supply INSTRUMENT AND SOLENOID SUPPLY 24V de nominal 15 28V absolute maximum range 2 8W excluding solenoids 100mA maximum current drawn in normal use USER ADJUSTMENTS All adjustments via IR900 Infra Red Keypad INTERNAL LINKS Retransmitted actual position excitation Link 1 and 3 sourcing internal excitation from isolated 24Vdc supply Link 2 and 4 sinking external excitation maximum 30Vdc ENVIRONMENT Operating temperature 40 C to 59 C ambient Storage temperature 40 C to 115 C PERFORMANCE the following applies to the TVC only characteristics of the feedback element and actuator system response will have additional effects Conversion 12 bit max normal conversion range 4 20mA 1 in 4000 O P switch res 1 bit theoretically modified to up to 5 of span by dead band Doc Q068 Rev 1 Page 27 of 29 TVC Positio
19. a check for the outgoing signal loop from the positioner This can be useful in checking problems in the signal interface on the process DSC FORCE RETRANS OUTPUT ENTER O P IN mA 12 0 H BACK MENU OPERATION Entering a value in mA will cause that current to be output by the suitably calibrated TVC Key returns the display to the Utilities Menu Normal Operation Fault Detection and Logging In normal operation the TVC positioner will cause the actuator to position to the demand signal within the dead zone set and output an actual position signal The system will detect faults in demand and feedback signals and changes to the external fault input and take preset actions in event of these faults None of the fault conditions are latched within the TVC and any fault action will clear automatically the fault is rectified Any faults power up events and entry into the Manual or Configuration modes will be logged in a simple log of 255 events The log can be inspected in the Utilities Menu Maintenance and Fault Finding 1 The vast majority of first time use failures are a result of incorrect electrical connections or compatibility problems in control signals Remember the positioner and actuator system will have been tested before shipment so double check all electrical connections and signal excitation sense against drawings and descriptions specific to the particular installation before any power is applied 2 In fault finding the s
20. e external DSC d Replace the TVC in the enclosure before re applying power 6 Problems in instability and precision of positioning can be address by adjustment of the dead zone and hysteresis bands or more directly by adjusting the speed of the actuator via hydraulic flow regulation Positional overshoot is caused by a failure of the control solenoids to act quickly enough to stop the actuator where required Slowing down the actuator stroke speed is the ONLY way of improving positional accuracy 7 Reversed demand signal loops or incorrect connection of external fault devices can cause a failure to operate in automatic mode when there is apparently no fault seen in manual mode Check the fault display input and output sense setting and the fault matrix setting against the required fault environment 8 Inthe event of losing the manual and configuration mode pass codes there is a back door a Set the demand signal to OmA or temporarily disconnect b Enter the Configuration Mode and use the pass code 8765 c Goto the Utilities Menu and reset the pass code as required d Reconnect and reset the demand signal 9 The TVC is not user serviceable In the event of suspected failure a check all the advice above to eliminate external system faults b produce a full a failure report as possible with times dates photographs logs etc anything to help us to understand the environment surrounding the failure c carefully remove the
21. ematic Drawing Number Full Actuator Model Number s and Descriptions Tag Number s Please contact your nearest Paladon representative as detailed below Paladon Systems Ltd Ferro Fields Brixworth Northampton NN6 9UA England Tel 44 0 1604 880700 Fax 44 0 1604 882424 info paladonsystems com Paladon Systems Ltd Howemoss Drive Kirkhill Industrial Estate Dyce Aberdeen AB21 OGL Scotland Tel 44 0 1224 772442 Fax 44 0 1224 772868 info scotland paladonsystems com Paladon Italia Via Barbieri 24 27040 Pinarolo Po PV Italy Tel 39 0383 878524 Fax 39 0383 878042 info italia Wpaladonsystems com Paladon SDT 121352 Davydkovskaya Str 12 3 Moscow The Russian Federation Tel Fax 7 495 735 28 07 08 09 info russianfederation paladonsystems com Paladon Systems Ltd Asia Pacific Region Lot 3 4 Jalan Tanjung Keramat 26 35 Seksyen 26 40400 Shah Alam Selangor Malaysia Tel 603 5102 5063 Fax 603 5102 5100 Mobile 6012 311 3247 info asiapacific paladonsystems com www paladonsystems com Doc Q068 Rev 1 Page 29 of 29
22. iated mechanical equipment connected to it could possibly move in an unpredictable manner during initial calibration Ensure that all personnel take appropriate precautions 1 Ensure that any end of travel limit switches and mechanical stops are correctly adjusted before operation 2 Apply power and provide the 4 20mA command signal G lt Use the IR900 to enter Manual Mode 4 Operate the actuator in manual and confirm that the actuator moves as required En Return to automatic mode and confirm that the actuator follows the demand signal and that a suitable actual position retransmitted signal is produced 6 At this stage the accuracy of the calibration and the response of the system can be assessed and recalibration and modification to the control parameters can be considered The instrument compares two analogue signals one representing the desired position command signal and the other representing the actual position feedback signal of the actuator A difference between these two signals will cause one of the TVC outputs to operate driving the actuator to the desired position A positional dead zone may be adjusted to overcome hunting problems associated with mechanical overrun of the actuator and further band edge hysteresis adjustments refine this setting The speed of transit of the actuator can be reduced by selecting the stepping mode that provides independently adjustable on and off times for the open and close sole
23. is displayed Press any key to start and enter the required time in the range 0 to 999 seconds The entry can be changed by repeating the procedure and the operation can be finished and the values saved by pressing Key Choice 4 Pump Control Pressure Transmitter Set Points PRESSURE TRANSMITTER PUMP CONTROL ANY KEY TO CONTINUE LOW PRESS 170 BAR HIGH PRESS 210 BAR H BACK MENU OPERATION The current pressure set points are displayed Press any key to start and enter the required low and high pressure set points in the range O to 999 Bar The entries can be changed by repeating the procedure and the operation can be finished and the values saved by pressing Key Set Stepping Mode The TVC can operate its control solenoids intermittently in order to slow down the actuator speed in situations where the process cannot tolerate sudden changes in flow This stepping mode applies preset on and off times to both the close and open solenoids giving the option for different soeed operation for opening and closing STEPPING MODES CURRENT CHOICE IS 1 STEPPING ON 2 STEPPING OFF 3 SET STEP TIMES BACK MENU OPERATION The current stepping mode is displayed Press Keys 1 3 to select the required option Pressing the Key saves the selection and returns the display to the main Set up Menu Selecting 3 opens a new menu Doc Q068 Rev 1 Page 17 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL SOLENOID STEP TIMES
24. nal This protection will protect the process from a step change in flow and allow a smooth transfer to auto WARNING DEMAND AND ACTUAL ARE NOT EQUAL KEY 1 BACK TO MANUAL H BACK MENU OPERATION Key 1 will return to manual mode and key will show the auto mode display LED will extinguish and the positioner will go into automatic operation with fault monitoring re established Doc Q068 Rev 1 Page 8 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Entering Configuration Mode ENTER CONFIG MODES PASSCODE DISPLAY REVERTS IN 45 SECONDS If the TVC is not enabled then the same warning message as described for manual mode entry above will be shown If enabled automatic positioning is suspended and the actuator is left in its stay put position and the pass code entry display above will be shown Entry of the correct pass code within the time indicated will allow entry to the main configuration menu CONFIGURATION MENU CALIBRATION CALIBRATION TRIM INST SET UP MENU UTILITIES MENU BACK MENU OPERATION Key 1 to 4 selects one of the options shown and key returns the display and operation to automatic mode Doc Q068 Rev 1 Page 9 of 29 EEE TVC Positioner TOTAL VALVE CONTROL Calibration Calibration is a two stage procedure requiring control of the demand signal to the TVC and a means of measuring the retransmitted signal from the unit The actuator and valve may need to be isolated from the
25. nd pressing Keys 1 3 will select a new setting Pressing Key will return to the main Set up Menu and save any changes Instrument Fail Mode The TVC can detect failures in the systems connected The demand or actual position feedback signals are monitored and an alarm is set if they stray outside the normal 4 20mA range the detection points are less than 1mA or greater than 21mA The time taken to position is monitored and an alarm set if position has not been attained An external contact input possibly monitoring hydraulic pressure unit operation is also monitored Any or all of these points can cause the positioner to fail to a predetermined position see Fault Matrix Selection below for further details This menu sets the fail position Doc Q068 Rev 1 POSITIONER FAIL MODE CURRENT CHOICE IS STAY PUT FAIL CLOSE FAIL OPEN FAIL TO POSITION H BACK MENU OPERATION Page 14 of 29 TOTAL VALVE CONTROL GEED TVC Positioner The current selection is shown and pressing Keys 1 4 will select a new setting Pressing Key will return to the main Set up Menu and save any changes In most cases the fail mode will be associated with the state of the hydraulic flow with the solenoids de energised 1 Stay put normal for a double acting system where both solenoids are de energised when the actuator is at the required position 2 Fail close normal for an actuator with a mechanical spring or hydraulic accumulator to close
26. ner TVC Terminal Descriptions Note Always use specific drawings and hook up diagrams supplied with the job for site wiring The descriptions below are for information only OJEEFEEN TOTAL VALVE CONTROL Connections are made via up to nine 3 and 4 way polarised 0 1 free sockets The free sockets are marked A to as are the printed circuit board pin headers Double check all connections when removing or replacing the TVC from the enclosure No 2 3 Oot O 0 N Conn Description A A A Nm mm m UUU OOO www TITTI Gap a 0 24V dc instrument supply feedback excitation Feedback signal ve 4 20mA into 160R Feedback signal ve instrument OV Uncommitted analog internal input 4 160R Uncommitted analog internal input 3 160R Pressure TX ve 4 20mA into 160R External analog inputs EMC ground Demand signal ve 4 20mA into 160R Demand signal ve Uncommitted analog isolated input 1 160R Uncommitted analog isolated input 2 160R Uncommitted analog isolated input 3 160R Retrans actual position signal ve 4 20mA sourcing Retrans actual position signal ve Retrans Signal EMC ground Foundation Fieldbus data ve Foundation Fieldbus data ve Fieldbus Signal EMC ground Instrument and solenoid supply ve Instrument and solenoid supply ve Close solenoid ve switched Open Solenoid ve switched ESD solenoid output ve switched Fault output ve switched Pump
27. noid operation Physical The TVC is mounted on a chassis plate and housed within an Exd enclosure The circuit boards are coated with a resist layer that protects the track from moderate condensation and mould growth problems Connections within the EXd enclosure are by factory assembled 0 1 connectors and must not be disturbed or re wired The only internal hardware configuration adjustment is the jumper link selection of either sinking or sourcing excitation of the retransmitted actual position signal and is usually set to customer requirements on order The TVC requires the Intrinsically Safe Exia IR900 keypad for calibration configuration and manual operation Wiring Wiring to the Exe enclosure terminals should be completed by suitably trained personnel taking into account the following notes e To ensure RFI compliance the analogue signals should be routed in copper braided screened cables with a fill factor density of at least 0 7 e The screens should be terminated to the metal of the actuator housing ideally at a suitable metal cable gland e Signal cables should be routed separately from power and switching conductors Doc Q068 Rev 1 Page 4 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Normal Positioner Operation When the TVC is first switched on the display will show the normal running status paladon TOTAL VALVE CONTROL 12 34 27 12 12 19 DEMAND ACTUAL D0 1 49 8 1 MANUAL 2 CONFIGURE The
28. with the solenoids de energised 3 Fail open normal for an actuator with a mechanical spring or hydraulic accumulator to open with the solenoids de energised 4 Fail to position would normally be used on a double acting system where the process required a particular fail position Choice 4 Fail To Position The final choice requires the setting of the stroke position that the actuator would drive to on fault SIGNAL FAIL TO POSITION ANY KEY TO CONTINUE ENTER POSITION 55 5 PERCENT H BACK MENU OPERATION The current fail position is displayed Pressing any key will place a flashing cursor on the value waiting for a position to be entered in the range 00 0 to 99 9 The value can be changed by repeating the process and the operation can be finished and the valued saved by pressing Key Doc Q068 Rev 1 Page 15 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Pump Control The TVC can oversee the control of the hydraulic power unit pump supplying the hydraulic circuit to the actuator system This menu lists the choices available for that control and the associated settings PUMP CONTROL MODES CURRENT CHOICE IS NO PUMP CONTROL ON DEMAND PRESSURE SWITCHES PRESSURE TX H BACK MENU OPERATION The current selection is shown and pressing Keys 1 4 will select a new setting Pressing Key will return to the main Set up Menu and save any changes 1 No Pump Control this is selected for systems with a ring
29. y returns automatically to the Utilities Menu on completion of editing the date Doc Q068 Rev 1 Page 21 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL Set Miscellaneous Timers The TVC has a number of utility timers that can be reset if desired These are normally set during factory testing and should only be adjusted after fully understanding the function of the timer and any consequences of the change SET MISC TIMERS 1 POSN TIME S 030 2 ENABLE WARN S 010 3 TRIM PULSE 1S 003 4 P CODE WAIT S 050 5 B LIGHT TIME S 010 BACK MENU OPERATION Pressing Key returns the display to the Utilities Menu Pressing Keys 1 5 selects the timer to be edited and places a flashing cursor on the first digit 1 Time To Position this is the time in seconds allowed for the actuator to move to the desired position before a positioning fault is set This should be set to at least 50 more than the full stroke time of the actuator to avoid spurious alarms This timer will be suspended if the positioner is in stepping mode due to the very long potential stroking times 2 Operator Entry Enable Warning Time this is the time in seconds that a warning will show on the display if an attempt is made to enter Manual or Configuration modes without the external enable contact being made 3 Trim Pulse this is the on time pulse length in 100mS increments During the Calibration operation it may be necessary to finely position
30. ystem always work from the known towards the unknown Operating the system in Manual Mode confirms a large part of the system as being ok hydraulics power to the positioner general TVC operation If the manual mode display shows correct variations of the demand and actual position signals then these signals are also proved similarly for the retransmitted actual position signal 3 At the most basic level disconnect the actuator solenoids ALWAYS with the TVC power OFF and operate the solenoids directly with 24Vdc This will isolate hydraulic problems from electrical control ones 4 The current loops in and out of the TVC are isolated from each other and the instrument supply so there will be no problems with crossed grounds and no need for external isolators 5 There is a need to check on the excitation of the retransmitted signal form the TVC This is the only hardware adjustment on the instrument and comprises of a set of jumper links on the third board down from the display board The instrument will have to be removed from the enclosure Doc Q068 Rev 1 Page 24 of 29 OJEEFEEN TVC Positioner TOTAL VALVE CONTROL a Unscrew the two captive fixings at the top and bottom of the instrument b Carefully pull out the instrument part way until the jumper links are visible on the lower edge of the board c From the left the link positions are Sourcing 1 and 3 excitation from the TVC Sinking 2 and 4 excitation from th
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