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Maintenance Instruction
Figure 1
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To engage handwheel drive, turn the Hand/Auto lever anticlockwise whilst turning the handwheel,
see Fig1.The lever can now be released upon which it will return to its original position. The handwheel
will remain engaged until the actuator is operated electrically when it will automatically disengage and
return to motor drive. If required the Hand/Auto lever can be locked in either position using a padlock
with a 6.5mm hasp.
3.2 Operating Electrically
Check that power supply voltage agrees with that stamped on the actuator nameplate. Switch on
power supply. It is not necessary to check phase rotation.
Do not operate the actuator electrically without first checking, using the infra-red Setting Tool,
that at least the primary settings have been made.
Selecting Local/ Stop/ Remote Operation
The red selector enables either Local or Remote control, lockable in each position using a padlock
with a 6.5mm hasp.
When the selector is locked in the Local or Remote positions the Stop facility is still available. The
selector can also be locked in the Stop position to prevent electrical operation by local or Remote
control.
Figure 2
Local control
With the red selector positioned at Local(anti-clockwise) the adjacent black knob can be turned to
select Open or Close. For stop turn red knob clockwise.
Remote control
Rotate the red selector to the Remote position(clockwise), this gives remote control only for Open
and Close but local Stop can still be used by turning the red knob anti-clockwise.
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The display consists of:
1. Red—position indication lamp
2. Yellow—position indication lamp
3. Green—position indication lamp
4. The upper LCD— showing percentage open
5. The lower LCD— human-machine interface
6. Infra-red signal confirmation indicator or alarm (red)
7. Infra-red Sensors
On power up the actuator’s LCDs are back-lit with a “soft amber” light and one of the indicator
lamps will be on, dependent on position. The upper LCD will show percentage open or an end of travel
symbol. The lower LCD will show the running state or the alarm information.
As standard, red lamp signifies valve open, yellow intermediate, and green lamp signifies valve
closed. Open and closed color functions can be reversed on request.
Open
Red indicator and open symbol displayed
Figure 4.1
Mid Travel
Yellow indicator and percentage open value displayed
Figure 4.2
Closed
Green indicator and closed symbol displayed
Figure 4.3
With the main supply switched off, the upper LCD is powered by a battery and display actuator
position for three seconds. However, the battery does not support screen back-lighting, or position
indicator lamps.
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3.3.2 Displays- Alarm Indication
Figure 5
The alarm information, figure 5, is displayed when a problem causes the actuator to “trip-off”.
Once the actuator has tripped off, electrical operation in the same direction is inhibited. The
information will remain displayed until operation in the opposite direction takes place.
2) Valve jammed
When motor is stalled, the valve alarm information will be displayed.
Control Alarm
ESD Active
When applied, an Emergency Shutdown Signal will override any existing local or remote control
signal, causing the actuator to respond in the direction selected for ESD.
The ESD function will be determined by the settings on Control Mode Configuration screens
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(refer to section 4.4.3.2.2).
The actuator will not respond to any local or remote control while an ESD signal is maintained.
2) Signal Loss
Control Alarm
Signal Loss
Failsafe action when signal lost , the actuator will move valve to position corresponding to
minimum set point, stayput on loss of set point, or move valve to position corresponding to maximum
set point.
Inner Connection
Error
“Panel Connection Error” will be displayed if control panel is disconnected to the actuator,
“Torque Connection Error” if torque switch connection error occurred, or “Inner Connection Error”
if both of the faults coexisted.
Motor OverHeat
Protection
2) Low battery
Actuator Alarm
Low Battery
Actuator will display “Low Battery” when the battery is no longer able to support actuator
functions under loss of power conditions.
The battery must be replaced (refer to section 4.4.2) and limit positions reset.
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3) Inner power down
Actuator Alarm
When the inner 24V power supply is abnormal, the “Inner power down” information will be
displayed.
4) Phase Loss
Actuator Alarm
Phase Loss
5) System Failure
Actuator Alarm
System Failure
Alarming will be displayed and electric operation will be inhibited if there is storage data failure
for control system of the actuator.
Alarming will be displayed and electric operation will be inhibited if the valve position signal
lost.
Figure 6
6
Loosen set screw and unscrew retainer using hammer and punch. Remove drive bush and machine
to suit valve stem or gearbox input shaft.
Allow apparently excessive clearance on screw thread for old rising stem valves.
Figure 7
If the actuator has a type A drive bush, this can be fitted in position 1 or 2 to suit the position of the
valve mounting flange.
If it has a type AZ drive bush, this can only be fitted below the actuator base to give the maximum
stem diameter acceptance.
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Figure 12 type A drive bush position3
Replacing drive bush
Having confirmed the position required, insert the machined drive bush, ensuring that the actuator
output shaft dogs are in full engagement with the bush.
Fit drive bush retainer securely, turning clockwise until fully tightened using hammer and punch.
Rotate by hand-wheel to align retainer set screw with hole in base and lock tight.
Figure 14
4.2.1 Rising stem valves, Top mounting
Lower the actuator on to the valve stem, engage ‘hand’ and wind the hand-wheel in the opening
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direction to engage the thread on the valve stem. Continue winding until the actuator is firmly down on
the valve yoke. Wind two further turns of the output shaft.
Fit securing screws or nuts and tighten fully.
4.2.2 Valve gearboxes, side mounting
Check that the valve mounting flange is at right angles to the input shaft, and that the drive bush fits
the shaft and keyway with adequate axial tolerance. Engage ‘hand’, offer up actuator to the input shaft
and turn hand-wheel to align keyway and key. Bolt up tight.
4.2.3 Non-rising stem valves, top mounting
Treat as for side mounting except that, when thrust is taken in the actuator, the thrust nut above the
drive bush must be securely tightened.
4.2.4 Hand-wheel sealing
Ensure that sealing plug in centre of h/w or spindle cover tube(depending on which is fitted) is
sealed with PTFE tape and fully tightened, ensuring that moisture does not pass down the centre column
of the actuator.
4.2.5 How to select torque values
Figure 15
Selectors A and B adjust the amount of torque which can be applied to the valve before the torque
switch cuts out the motor.
Ideally, only the minimum torque necessary to achieve tight shutoff should be applied. In practice
this value will vary from valve to valve and fluctuate with temperature, use, service etc.
We recommend that you dial selector A which controls closing torque to the first marked calibration
from the MIN position. But be prepared to remove the switch mechanism cover after start-up to increase
the torque value if tight shut-off is not being achieved with your original setting.
Selector B which controls opening torque should be dialed to MAX unless the valvemaker’s
specific instructions recommend against this.
Torque setting adjusters are fitted with locking tabs to discourage unauthorized tampering with
original settings. After adjusting ‘open’ and ‘close’ torque to require value, lock setting by bending up
appropriate tabs each side of pointer. If no open torque limit is required, turn open torque adjuster
pointer to boost position, where no locking is required.
4.3 Wiring up
Check that supply voltage agrees with that stamped on actuator nameplate.
4.3.1 Ground connections
A lug with 6mm diameter hole is cast adjacent to the conduit entries for attachment of an external
earthling strap by nut and bolt. An internal earthling terminal is also provided.
4.3.2 Removing terminal cover
Use two of the cover retaining screws in the jacking holes.
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Do not attempt to lever off with screwdriver as this will spoil ‘O’ ring seal and may damage the
flame path on a certified unit.
Figure 16
Note the wiring code card fixed inside the cover. This is particular to each actuator and must not be
interchanged with any other actuator. If in doubt check serial number on nameplate with that on code
card.
4.3.3 Sealing conduit entries
Conduit entries should be sealed in accordance with surrounding environment and with any
requirements of the regulatory authority.
Seal unused entries with threaded metal plugs. Do not use plastic plugs if supplied with actuator.
4.3.4 Connecting terminals
Refer to the wiring diagram inside the terminal cover to identify functions of terminals. Check that
supply voltage is the same as marked on the code card and actuator nameplate.
Remove power terminal screen, and begin wiring the power terminals.
4.3.5 Replacing terminal cover
Check that serial number on code card is the same as on the actuator nameplate before replacing
cover with its ‘O’ ring in position.
4.4 Commissioning
4.4.1 The setting procedure
All the commissioning functions are stored in non-volatile memory in the actuator. The Setting Tool
enables the user to view all the functions in turn via the actuator display window. As each function is
viewed its setting can be checked and ,if required, changed within the bounds of that function.
The setting procedure is divided into two stages:
1. Primary functions
Settings for end of travel limit action, torque values, limit positions etc.
2. Secondary functions:
Setting covering the control, indication and optional equipment functions.
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Name Instruction
1.↓ Display next function down
Decrease/change displayed function’s
value or option setting
2.↑ Display former function up
Increase/change displayed function’s
value or option setting
3.OK Enter displayed value or option setting
4. return to the upper level menu.
Infra-red local operation (when enabled)
5.Stop Stop actuator
6. Open actuator
7. Close actuator
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4.4.3 Entering the Actuator Setting Procedure
With the actuator securely mounted on the valve, the mains supply on and Local or Stop selected.
You can now commission the functions you need.
The layout of the various functions accessed with the Setting Tool are detailed in Fig.17.
Local Control
Target:
XXXX%
Press“↓”
Press“OK”
Changing Setting
Viewing Setting
CHINESE
更换设置
Machine Code
查看设置
XX
ENGLISH
Input Code
50
Press “OK”
Figure 17
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4.4.3.1 Primary System Settings
Press “OK”
Direction To Close Clockwise To Close Press‘↑↓’to select
Press “OK”
Set Closing Limit Current Valve Press‘↑↓’to select
Press “OK”
Set Opening Limit Current Valve Press‘↑↓’to select
*Manually operate actuator and valve to establish correct closing direction. If the handwheel labeling is
found to be incorrect please apply to us for conversion labels.
Indication Contact
Configuration
Press‘OK’to sub menu refer to 4.4.3.2.1
Control Mode
Configuration Press‘OK’to sub menu refer to 4.4.3.2.2
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4.4.3.2.1 Indication Contacts
Indication contacts S1,S2,S3 and S4 may each be set to trip for any one of the following functions:
S2 On Opening Close
Intermediate For Contact
Close Interlock
Control Alarm
ESD Active
Valve Alarm
Torque Trip In
Mid Travel
Valve Jammed
Hand Operation
Actuator Alarm
Phase loss
Low Battery
System Failure
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4.4.3.2.2 Control Mode Configuration
The control mode configuration affects how the actuator will respond under conditions of
emergency shut down, local control, remote control interlocks, and 2-wire remote control.
2 Wire
Press‘OK’to sub menu Refer to J
Remote Control
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A Self Maintained Local Control
Self Maintained
Local Control Press ‘↑↓’ to select
Press ‘OK’ to accept
Push To Run
Press to return
Local Control
B ESD Action
An active ESD signal applied to the actuator to the actuator will override any existing or applied
local or remote control signal. ESD can be configured to override the transformer thermostat, active
interlocks or local stop selection.
Normal Open
For ESD Close Press‘↑↓’to select
Press ‘OK’ to accept
Normal Close
Press to return
For ESD Contact
Overheat protection
Override ESD Press‘↑↓’to select
Press ‘OK’ to accept
ESD Override
Press to return
Overheat Protection
Interlock
Press‘↑↓’to select
Override ESD
Press ‘OK’ to accept
ESD Override Press to return
Interlock
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F ESD override Local stop
Local Stop
Override ESD Press‘↑↓’to select
Press ‘OK’ to accept
ESD Override
Press to return
Local Stop
Interrupter Timer
Override ESD Press‘↑↓’to select
Press ‘OK’ to accept
ESD Override
Press to return
Interrupter Timer
H External Interlocks
Disable
External Interlock Press‘↑↓’to select
Press ‘OK’ to accept
Enable
Press to return
External Interlock
I Conditional Control
Disable
Conditional Control Press‘↑↓’to select
Press ‘OK’ to accept
Enable
Press to return
Conditional Control
Where a high level of safety integrity is required, Conditional control can be configured. In this
mode two discreet signals are required for remote operation. Remote control will be conditional on both
a control signal (open or close) and the appropriate interlock signal being applied simultaneously. Failure
of either or a spurious signal will not cause operation.
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K OverTorq Protection Bypass
Disable OverTorque
Protection Bypass
Press‘↑↓’to select
Enable OverTorque
Press‘OK’to accept
Protection Bypass
Press to return
Disable OverTorque
Protection
20mA Stands
For Fully Open Press‘↑↓’to select
Press ‘OK’ to accept
4mA Stands
Press to return
For Fully Open
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L Input Signal Mode
StayPut On
Loss Of Set Point
Press‘↑↓’to select
Valve Fully Open On Press‘OK’to accept
Loss Of Set Point Press to return
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P Dead-band For Valve Position Control
(Do not change the value, which is for Factory Setting Only.)
Standard Hardwired
Press‘↑↓’to select
Remote Control
Press‘OK’to accept
Press to return
Analog Remote
Control
Password:
50
Press‘↑↓’to change the value
New Password: Press ‘OK’ to accept
XX Press to return
Restore
Default Settings Press‘↑↓’to select
Press ‘OK’ to accept
Replace With Press to return
New Settings
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All the function are configured to a set of ShangYi default (standard) settings before dispatch.
When requested, alternative settings specified with the order will be used. When site commissioning
takes place, entered settings overwrite ShangYi defaults and these “current” settings are used for
operation along with the remaining unadjusted defaults.
Should difficulty be encountered during commissioning the default settings can be reinstated,
returning the actuator configuration to its original manufactured state. Site commission must then begin
again.
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2.7 Optional indication contact configure
2.7.1 Optional indication contact S5 normally open
2.7.2 Optional indication contact S6 normally open
2.7.3 Optional indication contact S7 normally close
2.7.4 Optional indication contact S8 normally close
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