Installation and operating instructions for AVID EaziCal IR Positioner
Contents
1. Figure 10 Optional mechanical switch assembly or proximity sensor Electro Pneumatic Positioner Transmitter Calibration Procedure 1 Calibrate the Positioner per the operating manual provided with the product 2 Stroke the valve to the fully clockwise extreme 3 Depress the main shaft gear disengaging it from its locking position take extreme care not to turn the main shaft gear as this will take the psoitioner out of calibration 4 With the main shaft gear depressed turn the transmitter gear to the fully counter clockwise position and note the reading mA of the transmitter Next turn the transmitter gear clockwise until the transmitter changes no more than 0 5 mA from previous reading 5 Turn the clockwise mA adjustment screw to adjust the transmitter reading to the desired output for this valve position typically this is 4 mA or 20 mA 6 Stroke the valve to the fully counter clockwise extreme 7 Turn the counter clockwise mA adjustment screw to adjust the transmitter reading to the desired output for this valve position 8 Stroke the valve between the full clockwise and counter clockwise positions checking and readjusting the mA output as necessary Only switches or retransmission is available They are not available together Main shaft O Main shaft gear J2 S nee O mA adjustment screw for clockwise position o c FAULT cau si2. fea Low CAL Hct E Transmitter output terminals 1 and 2 not polarity dependent mA adjustment screw for counter clockwise i position Output Transmitter gear Figure 11 Pentair reserves the right to change the contents without notice page 7 AVID EaziCal IR Positioner Installation amp Operating Instructions Technical data Operating Specifications Input Current 4 to 20 mA analogue Voltage Drop 9 volts Supply Air Pressure low 1 to 3 bar 15 to 45 psi high 2 6 to 7 8 bar 40 to 120 psi Resolution 0 5 of span Linearity 1 of span Hysteresis 0 4 of span Repeatability 0 4 of span Thermal Coefficient 3 100 C Output Flow Rate 458 l m at 6 2 bar Air Consumption 0 225 I m at 6 2 bar Operating Temp Range 40 C to 85 C 40 F to 185 F Gain Electrically Adjustable Air Connection Ports 1 4 NPT G1 4 ISO 228 Input Impedance 400 ohms Materials of Construction Housing Engineered Resin Nylon Cover Clear Engineered Resin Nylon Shaft Stainless Steel Fasteners Stainless Steel HiVue Copolyester ModMount Engineered Resin Nylon Manifold Anodized Aluminum V3 Mechanical Switches Electrical Version SPDT form C Electrical Rating 15 amps 125 250 VAC 6 amps 24 VDC 0 5 amps 125 VDC 0 25 amps 250 VDC Area Classification amp Approvals Weatherproof IP 66 General purpose Proximity Type Inductive Sensors e Proximity Type Inductive Sensors are available in 2 or 3 wir
3. gt PENTAIR AVID EaziCal IR Positioner Actuator Twist cover 45 then lift straight up Figure 2 Outlet Port 1 Gauge Outlet Supply Port 2 Inlet Port Outlet Thread Port 1 Identification Figure 3 www pentair com valves AVID EaziCal IR Positioner Installation amp Operating Instructions Installation and operating instructions for AVID EaziCal IR Positioner These devices require the provision of clean dry oil free instrument air via an Air Filter Regulator with a filter mesh size of 5 microns Drive insert must be provided with Keystone actuators for ModMount installations Mounting Instructions Note All AVID Products are factory equipped with Pentair direct mounting For standard Namur mounting see Appendix A Please ensure the Pentair Keystone actuator is provided with the standard 16 dia x 11 af drive Operate the actuator to full closed position 2 Fasten the EaziCal IR positioner to the actuator using 4 M5 x 12 mm hex head screws and 4 M5 washers while engaging its output shaft into the actuator s input figure 1 3 Loosen the 4 captive screws which fasten the EaziCal IR Positioner cover Twist cover approximately 45 and lift up figure 2 Wiring diagram inside EaziCal IR Positioner cover 4 Ensure the correct gland is installed to provide the appropriate rating Pneumatic Connection Single Acting Actuator
4. Instructions The IR Remote Control With The Positioner The positioner has the ability to be operated calibrated via an Infrared IR Remote Control The positioner can be calibrated by using the buttons on the positioner module however this requires the removal of the top cover With the IR Remote Control the positioner can be calibrated without the removal of the top cover If the 4 20 mA input current connected to the positioner is not available or the Position Sensor Initial Angle must be set then the removal of the top cover is required Although the positioner is configured for use with the remote the IR Remote Control is not provided with the positioner The IR Remote Control is an option and must be purchased separately The IR Remote Control Buttons PROGRAMMING BUTTON Used for the initial setup of the IR Remote BACKLIGHT BUTTON Turns the IR Remote backlight on and off RED LED Lights when IR signal is being sent MODE BUTTONS Enables one of the two modes which remains in effect until another one of these buttons is pressed P2 mode is the one used for the positioner HIGH CALIBRATE BUTTON Used to begin the high calibrate routine LOW CALIBRATE BUTTON Used to begin the low calibrate routine NUMERIC BUTTONS Used to select the 3 digit code for the positioner security address ENTER BUTTON Used to enter the 3 digit code for the positioner security address Programming The IR Remote Control The IR R
5. Spring Return For single acting actuators Outlet Port 2 is to be plugged Outlet Port 1 is to be piped to the actuator inlet port that acts against the spring Increasing signal causes pressure to increase in Outlet Port 1 of the positioner Double Acting Actuator Double Return For double acting actuators Outlet Port 2 is piped to drive the actuator towards the fail position Outlet Port 1 is piped to drive the actuator away from the fail position Increasing signal causes pressure to increase in Outlet Port 1 of the positioner and pressure to decrease in Outlet Port 2 of the positioner Note Air supply to the positioner must be clean dry oil free instrument air 5 microns per ISA S7 3 and ISO 8573 1 Maximum supply pressure is 8 3 bar All pneumatic connections are 1 4 NPT or G1 4 ISO 228 See manifold for Identification of thread type Thread Identification B 1 4 BSP Without Marking 1 4 NPT AVDSB 0030 EN 1306 Pentair reserves the right to change the contents without notice AVID EaziCal IR Positioner Installation amp Operating Instructions Electrical Connectio 4 20 mA The electrical connection 4 20 mA Loop Input to the EaziCal positioner is polarity sensitive Input Connect the 4 20 mA Loop Input to terminal block J1 on the Connector Board as shown below Positive lead to terminal point 3 and negative lead to terminal point 2 The wire size can range from 20 to 14 AWG J1 is removable pl
6. ation Zero Position 1 Set the Input Current level to the value that drives the valve into the fully closed position typically 4 mA 2 Start the Low Calibration routine by pressing and holding the LOW CAL button on the EaziCal until the Yellow LED flashes or by pressing the LOW button on the IR Remote may require security code entry 3 Observe the flashing Yellow LED on the EaziCal which denotes the various stages of the calibration routine a Flashing 1 time indicates Coarse Gain routine b Flashing 2 times indicates Fine Gain routine c Flashing 3 times indicates Zero position set routine d Flashing 4 times indicates Low Drop Off routine 4 When the Green LED begins to flash the Calibration is completed If the Red LED flashes this is an indication that one of the Calibration routines could not be completed The number of Red LED flashes indicates the calibration routine that failed To Do a High Calibration Span Position 1 Set the Input Current level to the value that drives the valve into the fully open position typically 20 mA 2 Start the High Calibration routine by pressing and holding the HIGH CAL button on the EaziCal until Yellow LED flashes or by pressing the HIGH button on the IR Remote may require security code entry 3 Observe the flashing Yellow LED on the EaziCal which denotes the various stages of the calibration routine a Flashing 1 time indicates Coarse Gain routine b Flashing 2 times ind
7. bration functionality It should also be noted that this is to be used as a general guideline only The actuator valve package dynamics would dictate the success of the Auto calibration routine and could be compromised by the following instrument air supply volume capacity actuator sizing tubing size and actuator valve health Calibration complete For split range enter desired input values during low and high calibration AVID EaziCal IR Positioner Installation amp Operating Instructions Calibrating The EaziCal Positioner Once the EaziCal and actuator have been connected and the initial angle has been set Low and High Calibration can be performed on the EaziCal Low Calibration refers to the input current value that drives the valve into the fail position High Calibration refers to the input current value that drives the valve into the Span Position Calibration adjusts parameters internal to the EaziCal that are specific to the actuator and input current values The parameters that are adjusted are the Gain of the EaziCal servo loop The end position Zero Span of the valve travel and Drop Off point input current level at which the transducer is forced to the extreme position to insure that the valve is fully open or closed The calibration routine uses the input current value to set its internal adjustment so it is important that the input current does not change during the calibration routine To Do a Low Calibr
8. e DC 5 36 VDC PNP NPN NO NC or 2 wire AC DC 20 140 AC 10 140 DC configurations e Sensors are available in flush mount rectangular configurations Conduit entries 1x 1 2 NPT 1x M20 note 1 Note 1 2 x M20 when switches sensors are supplied Pentair reserves the right to change the contents without notice page 8 AVID EaziCal IR Positioner Installation amp Operating Instructions Dimensions mm EaziCal IR Positioner with Pentair Direct Mounting M20 190 gt 59da M PG 13 5 1 2 NPT t i pits ql 54 i y A j 151 y ModMount A l y Actuator 108 t mekan Ey ap Side View 11 ee Ls 11 0 Flat Figure 12 Standard Pentair Keystone output shaft Appendix A Instructions for EaziCal IR Positioner Mounting using standard Namur output 1 Remove Pentair direct mounting bracket assembly from the EaziCal IR Positioner Note The EaziCal IR Positioner are equipped with a standard Namur output shaft 2 Replace bracket assembly with a standard Namur mounting bracket Note Standard Namur mounting bracket is not included 33 _ 8 89 H 4 85 w 2 T 3 98 Namur shaft details Pentair reserves the right to change the contents without n
9. emote Control is programmed at the factory and should not need to be programed again unless the batteries are removed for an extended period of time greater than 10 minutes To program the IR Remote press the P1 button then press and hold the P button until the red LED blinks twice then press 0 0 8 1 after which the red LED on the IR Remote blinks twice to confirm the entry Press the P2 button then press and hold the P button until the red LED blinks twice then press 0 0 5 4 after which the red LED blinks twice to confirm the entry Using The IR Remote Control The positioner has two operating modes when using the IR Remote In the first mode the positioner will immediately act upon commands from the IR Remote this can be used when the positioner being calibrated is the only one that will be within range of the IR Remote signal such as one positioner in a closed room This mode is enabled by setting the positioner DIP switch position 2 the one closest to the Low Cal Button to the ON position away from the LED s In the second mode the positioner will not act upon commands from the IR Remote until a 3 digit security code is entered this can be used when there are multiple positioner s within range of the IR Remote signal This mode is enabled by setting the positioner DIP switch position 2 the one closest to the Low Cal button to the OFF
10. icates Fine Gain routine c Flashing 3 times indicates Span position set routine d Flashing 4 times indicates High Drop Off routine 4 When the Green LED begins to flash the Calibration is completed If the Red LED flashes this is an indication that one of the Calibration routines could not be completed The number of Red LED flashes indicates the calibration routine that failed Advanced Functions The EaziCal has the ability to change the calibration settings Gain Zero Span and Drop off manually This function was intended to make minor changes in the calibration values after doing the Low and High calibration Some examples where this might be used are decreasing the Gain if the valve still shows some overshoot on rapid position changes or increasing the High Drop off point so it will not be in effect at 20mA Exercise caution if using the manual calibration mis adjustment of these settings on the EaziCal positioner can result in erratic behavior or failure of operation and may require resetting the EEPROM before auto calibration can be performed again To Do a Manual Calibration Adjustment 1 Apply Input Current to the EaziCal typically 12 mA 2 Start the Manual Calibration routine by pressing and holding the Function centre button on the EaziCal until the Green and Yellow LED flashes 3 Observe the flashing Green and Yellow LEDs on the EaziCal The number of flashes denotes the various stages of the manual calibration rou
11. lish the setting of this initial angle using the S following steps 1 Apply loop current to the positioner and adjust to 12 mA O ir S E 2 Press amp hold both the high and low buttons until the yellow and green LED s begin to flash SSS 1B i VaN Release both buttons to remove air pressure from Outlet Port 1 f 3 If the valve fails clockwise and strokes counter clockwise then set switch SW1 to the CCW Pe position If the valve fails counter clockwise and strokes clockwise then set switch SW1 to the Ezel CW position see figure below 4 With no buttons pressed and the actuator in the fail position push the Main Shaft Gear larger of the two down until it disengages from its shaft locking position 5 Rotate the Main Shaft Gear both gears will turn until only the green LED is flashing Note If the LED is already green skip 5 and go to 6 6 Pull up the Main Shaft Gear allowing it to re engage on the shaft locking it into position 7 Press and hold the High Calibration button until the valve fully strokes away from the fail position S while watching the LED s The red or yellow LED s
12. must not light as long as the High Cal button is being held down If the red or yellow LED lights while the High Cal button is being held down then the Position Sensor Orientation and Actuator air piping are out of phase Correct the phase f error by changing the position of SW1 and repeat this procedure starting from step 2 8 Release the High Calibration button and watch the red LED The red LED will flash until the valve reaches the fail position Press the Low Calibration button to exit the Position Sensor Setting Mode if no buttons are pushed then this mode will time out automatically in approx 2 minutes oO Pentair reserves the right to change the contents without notice page 2 Special note Flow Capacity EaziCal standard flow design is suitable for actuator swept volumes of a minimum 60 inch 0 98 liters to a maximum of 225 inch 3 7 liters for proper Auto Calibration functionality It should also be noted that this is to be used as a general guideline only The actuator valve package dynamics would dictate the success of the Auto calibration routine and could be compromised by the following instrument air supply volume capacity actuator sizing tubing size and actuator valve health EaziCal optional high flow design is suitable for actuator swept volumes of a minimum 200 inch 3 3 liters to a maximum of 600 inch 9 8 liters for proper Auto Cali
13. nput signal that the positioner drops output port 1 pressure by pressing the Low Cal button Decrease the mA input signal that the positioner drops output port 1 pressure by pressing the High cal button Continue to increase or decrease the drop off position by repeatedly pressing the buttons d Span Position To adjust the span position to a point other than the hard stop of the valve the High calibration of the positioner must have been performed at a current slightly higher than the span position HiVue Visual Indicator current Ex If the span position current is 20 0 mA the High calibration as described in the previous section needs to be performed at 20 1 mA Decrease the span position by pressing the High Cal button Increase the span position by pressing the Low Cal button Continue to increase ee or decrease the span position by repeatedly pressing the buttons C e High Drop Off Decrease the mA input signal that the positioner drops output port 2 pressure by pressing the J fi High Cal button Increase the mA Input signal that the positioner drops output port 2 pressure i m by pressing the Low Cal button Continue to increase or decrease the drop off position by repeatedly pressing the buttons Valve Open 5 The Input Current can be changed during the test to observe the adjustment effects on the EaziCal behavi
14. or 6 To save the adjustments and exit the Manual Calibration Mode the Function center button must be held for approximately 5 seconds green and yellow flashing LED s will change to flash just green when adjustments are saved This procedure to save and exit can be performed from any stage during the Manual Calibration 7 Pressing the Function Center button during the High Drop Off adjustment exits the Manual z AE te Calibration Mode without saving any adjustments made Valve Closed Figure 6 1 Replace cover and secure the 4 captive screws Confirm that you have noted the final position of the valve full open or full closed 2 Make sure the HiVue visual indicator coincides with the position of the valve figure 6 3 The inner HiVue indicator should show either Open or Closed If the position indicated is the opposite of the actuator position remove the 4 slot head screws that secure the HiVue Slot Head Screw indicator cover and rotate the indicator cover 90 so the proper symbol for the position of the HiV valve is displayed figure 7 T 4 Secure the visual indicator cover to the housing cover using the 4 slot head screws Indicator Cover Visual Indicator Housing Figure 7 Important Do not exceed 1 13 Nm of torque for each screw Pentair reserves the right to change the contents without notice page 4 Figure 8 AVID EaziCal IR Positioner Installation amp Operating
15. otice page 9
16. position toward the LED s Once the correct code is entered 3 digits followed by the ENTER button the positioner is enabled to act upon IR Remote commands for 5 minutes The IR Comand Enable time counts down to zero or is set to zero positioner no longer acts upon commands when the positioner gets an ENTER from the IR Remote that was not preceded by the correct 3 digit security code Pentair reserves the right to change the contents without notice AVID EaziCal IR Positioner Installation amp Operating Instructions Setting The Positioner Security Code The security code is initially set by entering a 3 digit code while the positioner is in the Position Sensor Initial Angle setup mode To set a security code enter Position Sensor Initial Angle setup mode by pressing and holding the High and Low Calibration buttons on the positioner until the Yellow and Green LED s flash Press the 3 digits for the security code on the IR Remote then press the ENTER button on the IR Remote entering the code too quickly may prevent the positioner from reading it correctly pause at least 1 2 second between each button pressed and hold each button down for at least 1 2 second on the IR Remote When the Low Calibration button on the positioner is pressed to exit the Position Sensor Initial Angle setup mode the 3 digit security code is stored in the EEPROM and will remain there even if power is removed Make sure that the security code
17. tine Pressing the Function centre button again advances to the next stage Flashing twice indicates Manual Gain adjustment Flashing 3 times indicates Zero position adjustment Flashing 4 times indicates Low Drop off adjustment Flashing 5 times indicates Span position adjustment Flashing 6 times indicates High Drop off adjustment Pentair reserves the right to change the contents without notice page 3 fe tao g AVID EaziCal IR Positioner Installation amp Operating Instructions 4 To alter any characteristics of the positioner follow the following steps a Manual gain Increase the positioner gain by pressing the High Cal button Decrease the positioner gain by pressing the Low Cal button Continue to increase or decrease the gain by repeatedly pressing the buttons The maximum adjustment has been achieved when the red LED lights b Zero position To adjust the zero position to a point other than the hard stop of the valve the Low calibration of the positioner must have been performed at a current slightly lower than the zero position current Ex If the zero position current is 4 0 mA the Low Calibration as described in the previous section needs to be performed at 3 9 mA Increase the zero position by pressing the Low Cal button Decrease the zero position by pressing the High Cal button Continue to increase or decrease the zero position by repeatedly pressing the buttons c Low Drop Off Increase the mA i
18. ugs into a pin header soldered to the PCB for ease of wiring Oy st Conduit Opening 9 and service 4 20 mA J O Input CHAN ano Dip Switches OESS Dip switch 1 CD Off Position Factory Setting Normal Acting 4 mA represents zero Fail Dip Switch 1 S bs o o position and 20 mA represents Span position O On Position Reverse Acting 20 mA represents zero Fail position and 4 mA represents Span position non A0 Dip switch 2 Off Position JA rs Enables the security code requirement for IR a Remote operation Dip Switch 2 On Position Factory Setting Disables the security code requirement Dip Switches shown in factory set Infrared remote can be used without security positions code Figure 4 Switch za FA A Position Sensor SW1 Position Sensor Initial Angle Setting Mode Gear Main Shaft The EaziCal s Position Sensor which measures the absolute position of the valve has a limited Gear operating angle for proper position measurement The Position Sensor must remain within the operating angle in both the open and fail valve positions This is accomplished by initially setting the Position Sensor angle while the valve is in the fail position The EaziCal has a mode of operation to accomp
19. witch position 1 to the ON position away from the LED s The positioner should be calibrated again every time the switch position is changed Setting of the Switches 1 Operate the actuator to one extreme Choose the switch you would like to signal this position upper or lower switch Disengage the appropriate switch cam from the spline by pushing or pulling against the spring push down for the upper switch lift up for the lower switch 2 Turn the cam until the switch is activated Activation of the switch can be monitored using a continuity tester or equivalent means 3 Release the cam allowing it to re engage with the spline 4 Operate the actuator to the opposite extreme and repeat steps 1 through 3 for the other switch Wiring Schematic T BROWN SWITCH lt a Y UPPER Noo ne SWITCH T m 2 LOWER yoo RED GND Pentair reserves the right to change the contents without notice page 6 Top Cam Push down turn amp release Figure 9 Bottom Cam Lift up turn amp release AVID EaziCal IR Positioner Installation amp Operating Instructions EaziCal parts description Item Qty Description Housing Assembly Shaft Assembly Cover Assembly ModMount Manifold Assembly Electronic Assembly Connector Board Assembly Motor Assembly Mechanical Switch Assembly Output Transmitter Gear OANODOABWN gt sy ese a ey se
20. you assign is different for each of the positioner s in the area Resetting the EEPROM Back to Factory Default Values The positioner has an internal Electrically Erasable Programmable Read Only Memory EEPROM that is used to store the calibration values and the IR Remote security code These values remain in the EEPROM memory even if power is removed from the positioner During normal operation of the positioner the EEPROM will not have to be reset The memory may become corrupted if power to the positioner is lost while the positioner is writing to the EEPROM which only happens at the very end of the calibration cycle or at the end of the Position Sensor Initial Angle setup This memory can be reset back to factory default values by holding down the HIgh Cal button while the positioner is being powered up After the EEPROM is reset the positioner will have to be calibrated again and the IR Remote security code will have to be set again Reversing the 4mA and 20mA Positions Reverse Acting Normally 4mA of input current represents the closed valve position and 20mA represents the open valve position The positioner has the option to switch this so 20mA represents the closed valve position and 4mA represents the open valve position The normal mode is chosen by setting the positioner DIP Switch position 1 the one closest to the LED s to the OFF position toward the LED s The reverse acting mode is chosen by setting the positioner DIP s
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