IOM SERIES 820-E/P Electro-Pneumatic Positioner

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1 FLUID CONTROL DIVISION Parker Hannifin Corporation 95 Edgewood Avenue New Britain, CT Telephone (860) IOM SERIES 820-E/P Electro-Pneumatic Positioner INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS 820 SERIES ANGLE BODY VALVES 2-WAY NORMALLY CLOSED CONTAINING INTEGRATED E/P POSITIONER! WARNING GENERAL SAFETY INSTRUCTIONS BEFORE INSTALLATION FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure, and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice. Carefully read installation, operation and maintenance procedures prior to installing or servicing valve. Do not use valve as a safety shut-off valve when making repairs. Do not install a valve before depressurizing system down to atmospheric pressure. Care must be taken to ensure that the valve materials selected are suitable for the media being handled. Parker assumes no liability for damage caused by improper material selection in the case of corrosion from aggressive media. Caution: Do not, at any time, make any alteration or modifications to any angle body valves without the express and written approval of Parker s Fluid Control Division. DESCRIPTION These valves are 2-way normally closed (N.C.) valves. The product line contains stainless construction. The valves can be actuated pneumatically. The pilot operated models require a minimum operating pressure differential to ensure valve operation. Pilot valves may be ordered with either NEMA 2, 4, 4X integrated coils for ordinary locations or NEMA 4, 4X, 7, and 9 for hazardous locations: Divisions I and II; Class I, Groups A, B, C, and D; Class II, Groups E, F, and G. PRINCIPLES OF OPERATION 2-way 820 SERIES - NORMALLY CLOSED VALVES The angle seat valve is kept closed by a spring which presses against a piston and piston rod forcing the seating seal tightly against the valve seat. When pressure is applied to the actuator pilot connection, the piston, piston rod and thus the seating seal are raised opening the valve. The valve tightly closes when pressure is removed from the pilot connection. The maximum permitted angle body valve pressure and pilot valve pressure and temperature ranges are described on the valve nameplate. CAUTION: A minimum pilot operating pressure differential is required for proper angle valve operation. Installation Instructions Mounting position and pressure limits: Valves can be mounted directly on piping and are designed to operate in any position. The valves may be installed in any line regardless of the direction in which the line runs. However, for optimum life and performance the valves should be mounted vertically upright so as to minimize wear and reduce the possibility of foreign matter accumulating inside the stem area. Pilot valve line pressure, voltage and frequency must conform to nameplate rating. Allow adequate clearance above valve for removal of coil. Page 1

2 WARNING: The actuator is spring loaded. Depressurize system and turn off electrical power to the pilot valve before attempting repair. The coil must not be energized unless it is installed on the valve. Otherwise, the coil will overheat and burn out. Failure to depressurize the system could result in injury. Dismantle the actuator circle clip exclusively with the appropriate tools provided in the repair kit only. Follow the instructions provided in the repair kit. CAUTION: The valve body need not be removed from the line. When dismantling the actuator assembly, it may be necessary to provide proper support to prevent the valve from rotating thereby causing damage to piping. Where the valve is to be removed from the piping system, the pipeline must be drained completely before removing the valve especially with hazadous or aggressive media that can be hazardous to health. Installation Steps Installation must be done according to all applicable Safety Codes and Standards and by qualified personnel. Inspect valve prior to installation. actuators must not be installed. Damaged valves or Ensure that the valves are installed whose pressure class, line pressure, type of connection and connection dimensions correspond to the usage conditions. WARNING: Do not install a valve whose permitted pressure / temperature ratings are inadequate to meet the operating conditions. Threaded connections are the most common. ANSI flanges, welded ends and tri-clamps are also available. Piping: Remove any protective enclosures from the body ports and connect line pressure to the inlet port of the valve. An arrow on the body indicates direction of flow. Use of Teflon tape, thread compound or sealant is permissible, but should be used sparingly to male pipe threads only. Connect outlet line to the opposite port. Ports should not be subjected to excessive torque by use of an oversized wrench, wrench extension or by impacting the wrench handle. Do not use the valve to stretch or align the pipe. Using the pipe to close a large gap can distort the valve or at least stress it unduly, and possibly cause it to malfunction, or the threaded ports may be damaged or stripped. Flanges: For flanged mounted valves, follow applicable ANSI, DIN, JIS specifications for bolting and torque recommendations. The bolt should pass first through the mounting flange before engaging the valve flange. Allow proper spacing for installing the valve. Do not use the valve to stretch or align the pipe. Using flange bolts to close a large gap can distort the valve or at least stress it unduly, and possibly cause it to malfunction, or the bolts may be damaged or stripped. The flange endings on the pipeline must align with the connection flanges on the valve and the faces must be parallel. Flanges which are out of alignment or not parallel may result in unacceptable stresses in the pipeline during installation and could thereby damage the valve. Welding: Care should be taken when soldering connections to avoid damage to synthetic internal parts. If pipeline welding is to be performed, care must be taken to ensure the cleanliness of both joints. It is recommended that the flame be directed away from the valve body. Cool body with a wet cloth or heat sink on the extensions at the body to prevent overheating while soldering. E/P POSITIONER Connections The original adjustment of the i/p positioner was performed with the positioner in the vertical position. When changing the original position, it is necessary to readjust the zero setpoint and end values. Connect the air supply with the corresponding connection P (G1/8). CAUTION: Supply air must be instrument quality free of water and oils. The pneumatic control signal is connected to connection W (G1/8). CAUTION: The control signal air pressure must NOT exceed 90 psi (6 bar). The i/p positioner is pre-set at 58 psi (4 bar) supply air pressure. Variations in supply air pressure from the pre-set value requires the i/p positioner to be adjusted. Input Signal Connection The connection of the input signal is provided bya 2m twoterminal clamp located in a side-mounted clamp adapter. The clamp adapter with the cable bushing is closed by a screwed cap. The polarity depends on the operating mode of the valve as follows: Standard Ordinary Location Operating Mode: Rising input signal brown + opens the valve Rising input signal closes the valve white or black brown white or black + Explosion Proof Operating Mode: Rising input signal 1 or brown + opens the valve 2 or black - Rising input signal 1 or brown + (works adjustment) closes the valve 2 or black - (works adjustment) The factory adjustment of the i/p positioner is stamped on the label. The electrical signal is converted to a signal pressure by the e/p converter. This pressure can be controlled by a gauge fitted into the G1/8 manometer connection port when the threaded stopper plug is removed. This eases adjustment and troubleshooting. E/P Positioner Adjustment Both zero set-point and end value (span) of the converter have to be adjusted: ZERO SET-POINT ADJUSTMENT: 1. Remove the zero set-point cap. 2. Turn the spur wheel with a screwdriver + increases converter pressure - decreases converter pressure Page 2

3 SPAN ADJUSTMENT: 1. Remove bleeder screw 2. Turn trimmer with a small screwdriver. counterclockwise increases converter pressure clockwise decreases converter pressure It may be necessary to repeatedly alternate the zero and span adjustments as they influence each other. Rising input signal opens the valve, springs closes valve, signal range 0-20 ma Connect the current source for the input signal (input resistance < 200 ohms for standard location) (input resistance < 420 ohms for explosion proof location) Input signal 0 ma Input signal 2 ma Input signal 20 ma valve is completely closed valve starts to open 4 ± 0.4 psi (0.3 ± 0.03 bar) (adjust with ZERO ) valve is completely opened 15 ± 0.4 psi (1.0 ± 0.03 bar) (adjust with SPAN ) Rising input signal opens the valve, springs closes valve, signal range 4-20 ma Connect the current source for the input signal (input resistance < 285 ohms for standard location) (input resistance < 460 ohms for explosion proof location) Input signal 4 ma Input signal 6 ma Input signal 20 ma valve is completely closed valve starts to open 4 ± 0.4 psi (0.3 ± 0.03 bar) (adjust with ZERO ) valve is completely opened 15 ± 0.4 psi (1.0 ± 0.03 bar) (adjust with SPAN ) Rising input signal closes the valve, springs closes valve, signal range 0-20 ma Connect the current source for the input signal (input resistance < 220 ohms for standard location) (input resistance < 420 ohms for explosion proof location) Input signal 0 ma valve is completely opened 15 ± 0.4 psi (1.0 ± 0.03 bar) (adjust with ZERO ) Input signal 18 ma valve starts to close 4 ± 0.4 psi (0.3 ± 0.03 bar) (adjust with SPAN ) Input signal 20 ma valve is completely closed Rising input signal closes the valve, springs closes valve, signal range 4-20 ma Connect the current source for the input signal (input resistance < 285 ohms for standard location) (input resistance < 460 ohms for explosion proof location) Input signal 4mA valve is completely opened 15 ± 0.4 psi (1.0 ± 0.03 bar) (adjust with ZERO ) Input signal 18 ma valve starts to close 4 ± 0.4 psi (0.3 ± 0.03 bar) (adjust with SPAN ) Input signal 20 ma valve is completely closed After the adjustments have been made, remove the control gauge and re-install the threaded stopper plug (with sealing). Replace the bleeder screw and the zero set-point caps. Air Supply Adjustment The adjustable nozzle screw controls the actuator air consumption and velocity. Turning the nozzle screw clockwise decreases the air supply thus slowing the opening of the valve or increasing valve response time. Caution: By turning the screw clockwise too far, the valve may not completely open. Turning the nozzle screw counterclockwise increases the air supply thus decreasing valve response time. Caution: By turning the screw counterclockwise too far, the valve may not completely close. Changing the E/P Positioner WARNING: Do not open the i/p positioner. If required, send the e/p positioner to Parker for repair. To change the i/p positioner, perform the following steps: 1. Disconnect the cable from the signal source. 2. Disconnect the air supply from port P. 3. Loosen the 3 screws at the ring fastener using a 2.5mm hexagon screwdriver. 4. Loosen the coupling nut from the tube. 5. Remove positioner. Pressure Testing and Valve Functioning It is recommended that newly installed pipeline systems first be flushed thoroughly to wash out all foreign matter. The test pressure of an open valve must not exceed 1.5 times the maximum rated pressure of the angle body valve. The test pressure of a closed valve must not exceed 1.1 times the maximum rated pressure of the angle body valve. Normal Operation and Maintenance The e/p positioner should be continuously connected to 58 psi (4 bar) air supply when being used with water or other fluids (e.g. when cleaning the installation). The angle body pneumatic valves are operated by pneumatic control signals. The valves do not require regular maintenance work. While the valves are design to operate over millions of cycles, it is recommended that valves be rebuild every 2 million cycles to ensure optimum quality performance. During routine system checks, no leakage should be found in the valve. If unacceptable leakage occurs, reference Troubleshooting section for recommended solutions. If a valve is to be removed from a pipeline carrying hazardous media, the parts of the valve in contact with the hazardous media must be properly cleaned and decontaminated before repairs are performed. Note: Depending on service conditions, fluid being used, filtration, and lubrication, it may be required to periodically clean and/or replace worn components. Page 3

4 CAUTION: Do not expose plastic or elastomeric materials to any type of commercial cleaning fluid. Parts should be cleaned with a mild soap and water solution. Replacement Parts: When ordering replacement parts kits, specify valve number and voltage from nameplate. Parts kits are available for each valve. Parts included in each kit are marked with an asterisk (*). See exploded views. REFERENCE CROSS SECTION DRAWINGS! Pilot Valve Installation Instructions Optional if pre-installed. These valves are 3-way, direct operated models. The brass versions are offered for multipurpose functionality for normally closed or normally open requirements. The stainless versions are offered in separate normally closed (N.C.), normally open (N.O.) versions. Valves may be ordered with either NEMA 2, 4, 4X integrated coils for ordinary locations or NEMA 4, 4X, 7, and 9 for hazardous locations: Divisions I and II; Class I, Groups A, B, C, and D; Class II, Groups E, F, and G. Media filtration: For protection of the pilot control valve, install a suitable strainer or filter in the inlet side as close to the valve as possible. Dirt or foreign material in the media may cause excessive leakage, wear, or in exceptional cases, malfunction. Clean periodically depending on service conditions. Lubrication: Lubrication is not required although air line lubrication will substantially increase valve life. Electrical connection: Electrical supply must conform to nameplate rating. Connect coil leads or terminals to the electrical circuit using standard electrical practices in compliance with local authorities and the National Electrical Code. Do not power coil until it has been fitted and the retaining washer and nut have been installed to prevent possible coil damage from overheating. WARNING: Turn off electrical power before connecting pilot control valve to the power source. WARNING: Valves to be installed in Hazardous Locations, must be outfitted with Hazardous Location coils only. Verify nameplate data and coil part number before installing the valve. Diagram of Normally Closed Valve WARNING: The actuator is spring loaded. Dismantle actuator with tools provided in repair kit. If the coil assembly is located in an inconvenient orientation, it may be reoriented to facilitate installation. Loosen coil assembly nut, rotate coil assembly to desired position, then retighten the nut with an input torque of in-lbs. MANUAL BYPASS OPTIONAL FEATURE Note: Pilot valve manual bypass is an option. The manual bypass operator allows manual operation when desired or during an electrical power outage. Page 4 COIL ASSEMBLY ASSEMBLY INSTRUCTIONS FOR ALL COIL TYPES Position coil (as described below) on the sleeve, install valve identification plate on top of coil, slide the wave washer over the sleeve and tighten coil assembly nut with an input torque of in-lbs. DIN Coil and various cable option terminations: Loosen cable screw and remove plastic housing from DIN coil. Do not remove the gasket from the DIN spades on the coil. Separate the plastic block from the housing with a small screwdriver to expose the electrical terminations. Feed the lead wires through the DIN connector housing and attach them to the appropriate screw terminal. Snap the plastic block back into place. Replace the plastic housing onto the

5 DIN spades and tighten the screws. To secure the housing and coil together, apply 20 to 30 in-lbs. Conduit Coil with 1/2 NPT connection: Conduit coils are available with either NEMA 2, 4, 4X integrated coils for ordinary locations or NEMA 4, 4X, 7, and 9 for hazardous locations: Divisions I and II; Class I, Groups A, B, C, and D; Class II, Groups E, F, and G. Use suitable electrical cabling and conduit materials and components meeting applicable NEMA recommendations. Coil/enclosure temperature: The pilot control valves are supplied with coils designed for continuous duty service. Normal free space must be provided for proper ventilation. When the coil is energized continuously for long periods of time, the coil assembly will become hot. The coil is designed to operate permanently under these conditions. Smoking and/or odor of burning coil insulation will indicate any excessive heating. For the maximum valve ambient conditions, as well as the fluid temperatures, check the valve part number on the nameplate and refer to the catalog to determine the maximum temperatures. Page 5

6 STAINLESS STEEL ANGLE BODIED CONTROL VALVE WITH PISTON ACTUATOR AND E/P POSITIONER zero set point screw Bleeder screw cap (range) adjustable nozzle screw coupling nut tube screws (3) Page 6

7 E/P Positioner With Clamp Adapter Page 7

8 PROBLEM Angle Body Valve fails to operate. Angle Body Valve fails to close (normally closed valve). Angle Body Valve fails to close (normally open valve). External leakage at sleeve flange. Internal Seating Seal Leakage TROUBLE SHOOTING PROCEDURE 1. Check that pilot air supply is properly connected. 2. Verify that pilot air supply meets the minimum pressure required to actuate the specific angle valve model number. 3. Check pilot control valve functionality. Make sure that pressure complies with pilot control valve nameplate rating and pressure is supplied to actuator head through the output port of the pilot valve. 4. Check pilot control valve electrical supply with voltmeter. Voltage must agree with nameplate rating. 5. If supply voltage is too low, locate and correct cause of low voltage. Should exceed 85% of rated voltage. 6. Check coil with ohmmeter for shorted or open coil. 1. Check pilot control valve functionality. Make sure pilot valve closes eliminating pressure to the actuator head. 2. Verify that pilot valve is vented from valve actuator. 3. Check pilot control valve functionality. Make sure pilot valve closes eliminating pressure to the actuator head. 4. If the pilot control valve works properly, it will be necessary to disassemble angle body valve. WARNING: following all caution and safety precautions prior to Disassembly. 1. Check Angle Body Valve for functionality. 2. Check that pilot air supply is properly connected. 3. Verify that pilot air supply meets the minimum pressure required to actuate the specific valve model number. 4. Disassemble valve as per the Disassembly Instructions. Clean out extraneous matter. The plunger must be free to move without binding. 5. With coil energized, check power at coil wires. Power should be on. If power is present, correct faulty contacts or wiring. 1. Check that sleeve is torqued to in-lbs. 2. If leakage persists, it will be necessary to disassemble angle body valve. WARNING: following all caution and safety precautions prior to Disassembly. Remove sleeve and check O-ring seal for damage. Replace if defective. 1. Check if the actuator has closed the valve 100 percent. Debris or contamination can prevent full closure. 2. Disassemble valve as per the Repair Kit Disassembly Instructions. WARNING: following all caution and safety precautions prior to Disassembly. It is recommended that all components included in the repair kit be installed to prevent future problems. 3. Examine orifice in body for nicks. Damage may require a new replacement valve. 4. Inspect the seat sealing material for foreign matter or dirt accumulation. Worn sealing material requires replacement. Pilot Valve Troubleshooting Valve coil burn-out Valve is sluggish or inoperative electrical supply and pressure check out. External leakage at manual bypass stem (where available). 1. Continuous high voltage greater than 10% of rated voltage could result in coil failure. Locate and correct cause of high voltage. 2. Disassemble valve as per the Disassembly Instructions. Check for foreign material lodged in valve. Clean out extraneous matter. The plunger must be free to move without binding. 3. Check electrical wiring installation. 4. Valve located in high ambient temperature. Ventilate or isolate area from high temperatures. May require valve relocation to lower temperature area. 1. Disassemble valve as per the Disassembly Instructions. Clean out extraneous matter. The plunger must be free to move without binding. 2. Check all springs, if broken, replace. 1. Disassemble manual stem in valve per the Disassembly Instructions. Inspect components for damage. Replace o-ring if necessary. Page 8

9 DECLARATION Parker s Fluid Control Division certifies its valve appliance products complies with the essential requirements of the applicable European Community Directives. We hereby confirm that the appliance has been manufactured in compliance with the applicable standards and is intended for installation in a machine or application where commissioning is prohibited until evidence has been provided that the machine or application is also in compliance with EC directives. The data supplied in the Parker catalogs and general Installation, Operating & Maintenance Instructions are to be consulted and pertinent accident prevention regulations followed during product installation and use. Any unauthorized work performed on the product by the purchaser or by third parties can impair its function and relieves Parker Hannifin of all warranty claims and liability for any misuse and resulting damage. The angle body valve family complies with European Directive 97/23/EC in accordance with Annex II, category II, Group 2, module A1. A separate Declaration of Conformity or Manufacturer s declaration is available upon request. Please provide valve identification numbers and order serial numbers of products concerned. Page 9

OPERATING and MAINTENANCE MANUAL SERIES 2700A CONTROL VALVE CONTENTS. INTRODUCTION...1 Scope...1 Description...1 Valve Identification...

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