Operation and Maintenance Instructions Manual BOOSTER. Volume amplifier

Transcription

1 Operation and Maintenance Instructions Manual BOOSTER Volume amplifier

2 1. GENERAL INFORMATION TECHNICAL SPECIFICATIONS DIMENSIONAL DESIGN BOOSTER WITHOUT SIGNAL ADAPTER BOOSTER WITH SIGNAL ADAPTER OPERATION INSTALLATION CALIBRATION DEFECT LOCATION PARTS LIST MAINTENANCE DIAPHRAGM GUARANTEE COPYRIGHT 2011 SENSE Subject to change without notice. This technical documentation is protected by copyright. Translation, photocopies and reproductions of any kind or editing parts, especially mechanical photo reprint or electronic reproduction, storage systems or networks, is not permitted without permission of the copyright owner, the noncompliance will be subject to civil and criminal proceedings. Sense Eletrônica Ltda. Address: Rua Tuiutí, Tatuapé City: São Paulo - SP Post Code: Phone / Fax: (11) vendas@sense.com.br website: 2 / 12

3 1. General Information This manual provides operating instructions, calibration and maintenance of booster - volume amplifier. The booster should only be installed, operated and serviced by qualified personnel with adequate training. For further information, please contact a sales representative or directly to Sense. Modification of this product, the replacement of non-original parts and the use of maintenance procedures outside the given pattern may affect the operation of the equipment and endanger people and equipment. Use only original parts and consistent procedures described in this manual. Unauthorized procedures or non-original parts can affect product operation. The instruments are designed to operate with clean, dry, oil-free air. The requirements for quality of supply air can be found in ISA-S7.3 "Quality Standard for Instrument Air". Pressure Ratio (output and input) 1:1 1:2 1:3 1:4 1:6 Supply pressure 30 to 150 psi Output flow psi Dead zone % of the supply pressure 60 psi (zero for maximum pressure). Temperature limits Ambient -40 a 85 C Pneumatic connections Air supply Output Signal female 1/4-18NPT female 1/4-18NPT female 1/8-27NPT Construction material housing aluminum electrostatic paint o rings nitrile rubber diaphragms nitrile rubber It is highly recommended the use of coalescing air filter to achieve certain standards of air supply. Weight without signal adapter with signal adapter Mounting options 0.6 Kg 0.7 Kg 2. Technical specifications Input signal (maximum) 150 psi (1:1 ratio) 75 psi (1:2 ratio) 50 psi (1:3 ratio) 37,5 psi (1:4 ratio) 25 psi (1:6 ratio) The booster is designed for direct mounting on I/P EDGE signal converter, and may also be mounted on a 2" wall or pipe through the option with signal adapter. 3 / 12

4 3. Dimensional design 3.1 Booster without signal adapter Output input thread clamp - supply Figure 1. Dimensional booster without signal adapter 4 / 12

5 3.2 Booster with signal adapter Signal clamp output - supply Figure 2. Dimensional booster with signal adapter 5 / 12

6 4. Operation The Figure 3 block diagram describes the booster with the power options of the input signal through an adapter or I/P signal converter. The pneumatic input signal can be sent to a signal converter I/P positioner for or through an adapter booster signal, or via an I/P converter mounted directly on the booster. The pneumatic signal on the upper diaphragm force its movement down, sealing the exhaust port seat and the seat opening for the passage of the supply pressure. The output pressure is applied to the lower diaphragm. It increases until the force that moves the diaphragm upward force is equal to the pneumatic signal that moves down. When the forces are equal, the pin will be in equilibrium diaphragm, sealing the exhaust port seat and the seat of the passage of supply pressure. 5. Installation The booster should only be operated or serviced by qualified personnel with adequate training. If you need additional assistance or other issues or concerns regarding the instructions, contact a sales representative or directly to Sense arise. The booster must be installed in accordance with local and national codes in effect. In installations in hazardous areas shall be in accordance with their installation codes. Figure 4 shows the adapter coupled to the signal booster using two ¼ UNC x ½ " screws. The signal adapter enables receiving the pneumatic signal, e.g. from an I/P positioner or signal converter. The 1:1 ratio between outlet pressure and inlet pressure is equal to areas between the upper and lower diaphragm. Other relationships are obtained by the proportional change between the areas of the diaphragms. The booster - amplifier volume has screw constraint to eliminate saturated and ensuring the stability of the system. The adjustment screw restriction allows the pneumatic actuator to respond to small changes in the signal from the signal converter or controller, without compromising accuracy and balance. Figure 4. Booster and signal adapter Figure 5 shows the signal converter I / P coupled to the booster through two ¼ UNC x 1 1/2 ". The converter receives the signal 4 to 20 ma, which in turn converts the signal to proportionally 3 to 15 psi, as shown in figure 5. SIGNAL ADAPTER VERSION SIGNAL CONVERTER VERSION PNEUMATIC SIGNAL SIGNAL ADAPTER 4 TO 20 Ma SIGNAL SIGNAL CONVERTER 3 TO 15 PSI SIGNAL EXHAUST PORT SUPPLY PRESSURE UPPER DIAPHRAGM RESTRICTION SCREW LOWER DIAPHRAGM DIAPHRAGM PIN OUTPUT PRESSURE SPRING PNEUMATIC ACTUATOR Figure 3. Block Diagram 6 / 12

7 OUTPUT SIGNAL INPUT Figure 7. Pneumatic Connections SCREW - SIGNAL CONVERTER If flammable or toxic or reactive gases are used as a means to supply food, personal injury or property damage may result from fire, explosion or gas accumulation, or by contact with toxic or reactive gases. 9 Figure 8 shows the location of the two exhaust ports which must not be blocked during field assembly. To achieve this standard, the use of coalescing filter for the supply air is highly recommended. If you are using an external filter regulator connect the inlet hose to the inlet connection of the filter and connect the tubing connecting regulator output filter to the IN connection on the booster. Figure 7 shows the connections of the pressure booster. All connections are threaded 1/4-18 NPT females. For applications requiring large volumes of air, use at least a 3/8 inch piping (10 mm). EXHAUST PORT Figure 8. Exhaust location The exhaust ports should always be free of obstruction to ensure perfect operation of the booster. 6. Calibration Figure 9 shows the adjustment screw booster and the locking screw. The only necessary requirement for operation is booster adjustment screw. Prior to operation, turn the bypass restriction adjusting screw (figure 3) four or five turns counterclockwise from the fully closed position. With the actuator in operation, slowly turn the restriction clockwise until the booster operates in 7 / 12

8 response to large changes in the input signal, yet allows small changes to move the actuator without initiating booster operation. If the actuator is to be used for on/off control, the restriction should be closed (turned fully clockwise). Verify that the capacity of the regulator meets the stroking capacity requirements. ADJUSTMENT SCREW LOCK SCREW Figure 9. Booster adjustment screw 8 / 12

9 7. Defect Location PROBLEM POSSIBLE CAUSE ACTION SUGGESTED Instrument does not respond to the input signal Insufficient air supply to move the actuator Diaphragm damaged or leaking Check the work supply pressure of the pneumatic actuator. Replace diaphragm Spool valve is stuck Clean or replace valve spool Incorrect installation of the piping between positioner and actuator Check the pneumatic connection between the actuator and positioner Installation of the wrong cam Correct the position of the cam. Reverse polarity signal 4 to 20 ma Correct the position of the wires on the terminal block The actuator reaches the 100% position with a small variation of the input signal Installation of the wrong cam Zero and Span adjustment remains to be done For the linear positioner check the position of the guide arm to the feedback arm Correct the position of the cam. Adjust zero and span Check the maximum stroke of the valve and correct the position of the guide arm. Imprecise Positioning Dirt on the spool valve Diaphragm damaged or leaking Clean the spool valve Replace diaphragm Insufficient air supply to move the actuator Check the work supply pressure of the pneumatic actuator. Valve motion with great difficulty, "gripping Increase work supply pressure to the maximum allowed for the actuator (positioner up to 150 psi) or replace the valve Slack in the mechanism of feedback arm Eliminate the feedback arm slack Slack between the rotary cam shaft and the actuator shaft Eliminate slack between shafts. Overshooting or reaching the position very slowly Dirt on the spool valve Supply air piping incorrect or clogged filter regulator Clean the spool valve Replace the air pipe specified by the regulator or replace filter Spool valve is stuck Replace the spool valve Improper adjustment of the flow screws of outputs 1 and 2 Adjusting flow screws 9 / 12

10 8. Parts List EXPLODED VIEW SIGNAL ADAPTER - EXPLODED VIEW I/P CONVERTER Figure 10. Parts List 10 / 12

11 Analogue Positioner Manual LIT0010 EA Rev_B Item Qt Description 1 1 U clamp and nut 2 2 Screw 3 6 Lock washer 4 1 Support for U clamp 5 4 Screw 6 1 Booster label 1:1 7 1 Booster label 1:2 8 1 Booster label 1:3 9 1 Booster label 1: Booster lid 11 1 Upper diaphragm booster 12 1 Intermediary booster 1: Intermediary booster 1: Intermediary booster 1: Intermediary booster 1: Nut 17 1 Intermediary washer booster 1: Intermediary washer booster 1: Intermediary washer booster 1: Intermediary washer booster 1: Lower diaphragm booster 22 1 Lower washer booster 23 1 Bino nut booster 24 1 O ring 25 1 Pin 26 1 Spring 27 1 Adjustment screw booster 28 1 O ring 29 1 Screw 30 2 O ring 31 1 Label no. of series 32 1 Base do booster 33 1 Screw 34 1 I/P converter 35 2 Screw 36 1 Signal adapter 37 2 Manometre 0 30 psi 9. Maintenance 9.1 Diaphragm Figure 11 shows the diaphragm. Use the following steps to remove the diaphragm: 1. Disconnect the air supply. 2. Remove the two screws holding the diaphragm. 3. Remove the diaphragm assembly. SCREW Figure 11. Diaphragm Do not use solvents to clean the diaphragm. It is a composite of rubber and may deteriorate. This section describes the main components, assembly and disassembly of the positioner. Modifications, substitutions per non-original parts or using maintenance procedures not described herein may affect performance and cause risks to people and equipment. Use only original parts and procedures referenced in this manual. Unauthorized procedures and non-original parts can affect product performance. Use the following steps to replace the diaphragm: 1. To prevent performance degradation of the instrument, check the surface of the diaphragm and the corresponding area of the seat base before installing the diaphragm. This surface should be free of dirt, dust, scratches and contamination. 2. Ensure that the gasket is in good condition. Do not reuse damaged, old or damaged rings. 3. Place the diaphragm in the base. Make sure it is aligned properly with the holes. Note the mounting between the spool and the flat spring Figure / 12

12 Analogue Positioner Manual LIT0010 EA Rev_B 4. Put the two fixing screws at the base of the diaphragm. 5. Tighten the screws and check the operation. 10. Guarantee Sense guarantees the equipment and repairs performed by it and sold under its brand as free from defects in materials and manufacturing under normal operating conditions and proper use in accordance with: 1. Guarantee of new products is 12 months from date of shipment from the Sense factory and applies to any part of the equipment described herein and sold by Sense. 2. The guarantee for products reviewed is 6 months after the repairs performed on the Sense factory or its authorized factory. 3. Equipment should be returned to Sense factory with freight prepaid. 4. The Sense factory assumes no liability for misuse by the purchaser, his employees or others. 5. If possible, please state the reasons for return (e.g.: the failure symptom, installation environment etc.). 6. Warranty is void if the repair is performed by personnel authorized by the Sense. 12 / 12