DKJ and ZKJ Series Quarter-Turn Electric Actuator Operation Instructions

Transcription

1 ISO9001 Quality Authentication Enterprise The unit recommended by China Quality Wanlixing Member Unit of Tianjin Enterprise Union INSTRUMENT TECHNOLOGY TIANJIN BELL Specialized manufacture, excellent quality Specialized manufacturer of electric actuators and instrument valves DKJ and ZKJ Series Quarter-Turn Electric Actuator Operation Instructions TIANJIN BELL AUTOMATIC INSTRUMENT TECHNOLOGY CO.,LTD

2 0 10mA DKJ-210 ZKJ-210 DKJ-310 ZKJ-310 DKJ-410 ZKJ ma DKJ-2100 ZKJ-2100 ZKJ-210C DKJ-3100 ZKJ-3100 ZKJ-310C DKJ-4100 ZKJ-4100 ZKJ-410C I. Brief Introduction DKJ and ZKJ series quarter-turn electric actuator is terminal control set for survey of industrial process and control system. It can transfer control signals of system to the position of damming off element of angle displacement valve of output shaft or other adjusting mechanism, so that the medium under control can be operated under specified state of the system. Electric actuator can be divided into proportional type and integral type according to the control mode. Proportional actuator is consisted of servo amplifier and integral actuator. It can compare control signal of system with feedback signal concerning position of output shaft (closed loop control) to change stroke of output shaft and make it form proportional relations with output signal. Integral actuator is consisted of servo motor, speed reducer and position transmitter. It can cooperate with the electric operator to realize remote control of valves or other adjusting mechanisms. Automatic control system with electric actuator can realize non-disturbance switchover between automatic and manual if being equipped with DFD series electric operator. The electric actuator is safe and reliable with convenient installation, debugging, operation and maintenance. It can be widely used in energy, metallurgy, chemical industry, building materials and other industries, and plays very important role in survey of industrial process and control system. Specification for Specification II. Specification quarter-turn electric actuator is listed in the following table: Table 1 Rated load Nm Rated stroke Rated stroke time S 25 DKJ-510 ZKJ-510 DKJ-610A ZKJ-610A DKJ-5100 ZKJ-5100 ZKJ-510C DKJ-6100A ZKJ-6100A ZKJ-610CA DKJ-610 ZKJ-610 DKJ-6100 ZKJ-6100 ZKJ-610C DKJ-710 ZKJ-710 DKJ-810 ZKJ-810 DKJ-7100 ZKJ-7100 ZKJ-710C DKJ-8100 ZKJ-8100 ZKJ-810C Other specifications (M, W, C, B) are the same as above

3 1. Power Condition Single-phase AC Voltage: 2V III. Working Condition You must read this chapter carefully prior to use. +10% -15% Frequency: 50Hz ±1% 2. Environmental Condition 2.1 Temperature, relative humidity A. Electric servo amplifier and electric operator are instruments in the control room. Temperature: 0~50 Relative humidity: 10%~70% B. Electric actuator is instrument of in-house field installation. Temperature: -10~+55 Relative humidity: Not more than 95% 2.2 Atmospheric pressure: 86~106KPa 2.3 There is no media that may corrode in ambient air. IV. Main Technical Performance DKJ series quarter-turn electric actuator is manufactured according to the stipulations in Electric Actuators for Industrial Process Measurement and Control Systems (GB ), which is a national standard of the People's Republic of China; its main technical performances are as follows: 1. Rated load, rated stroke and rated stroke time of output shaft can be seen in table 1 and table Range of operating signals of electric actuator can be seen in table 1 and table 2. Input impedance of electric servo amplifier can be seen in table 2. Table 2 Range of Input Signals ma Input Impedance Ω 0~10 0 4~ Reference working performance Fundamental error limit: not exceeding±2.6% of rated stroke Return difference: not more than±1.5% of rated stroke Rated stroke time error: not exceeding±% of rated stroke time Proportional actuator Dead zone: Not more than 3% of input range Damping characteristic: not more than thrice half-cycle swinging Integral actuator Coasting operation range: not more than 1% of rated stroke (when rated stroke time is 10 ~ 25s); not more than 0.5% of rated stroke (when rated stroke time is 25 ~ 63s). 4. Insulation resistance: When temperature is at 15~, relative humidity is at 45%~75%, terminals for power supply casing not less than 50MΩ terminals for power supply input terminal not less than 50MΩ input terminal casing not less than MΩ 2

4 V. Instructions for Structure and Operating Principle Proportional electric actuator is a position servo mechanism taking two-phase servo motor as power source; it is consisted of electric servo amplifier and integral electric actuator. Integral electric actuator is consisted of two-phase servo motor, speed reducer and position transmitter; system diagram can be seen in Fig.1. Propo rtiona l act uator Motor Speed reducer Valve Servo amplifier Position tran smitter Integral actuator A. Not coupled into electric operator Propo rtiona l act uator Motor Speed reducer Valve Servo amplifier Position tran smitter Integral actuator Electric operator B. Coupled into electric operator Input and forward control signal Feedback signal Machinery joining Fig. 1 Coupled into electric operator For proportional actuator (when electric operator is at automatic state or not being coupled into electric operator), when input terminal of servo amplifier has input of control signal, the signal will be compared repeatedly with the position feedback signal from the position transmitter, signal deviation will be enlarged after comparison, making power level switch into conduction of relevant loop to drive rotation of the two-phase servo motor, so that output shaft of speed reducer can rotate towards the direction of reducing the deviation (position transmitter constantly transfers actual position of output shaft to telecommunication signalposition feedback signal returns to servo amplifier) until signal deviation is smaller than the dead zone, at this point, output shaft will be stable at the position opposite to input signal. Stroke of output shaft shall form proportional relations with input signal. For integral actuator, electric operator is placed under manual state, after ON or OFF button of the electric operator is pressed, servo motor will be electrified and start rotating, the output shaft of speed reducer will rotate towards OFF or ON direction, position transmitter will constantly transfer actual position of the output shaft to telecommunication signalposition feedback signal will send back valve position opening scale of electric operator. When feedback signal of 3

5 valve position opening scale shows that the output shaft has rotated to the required position, the button of the electric operator will be released, the servo amplifier will be power off and stop rotating, and the output shaft will also stop rotating, rotating volume of output shaft shall form integral relations with electrified time. Motor is squirrel-cage two-phase AC servo motor. Rotor of the motor has large internal resistance, large starting torque and soft mechanical property. Brake gear is installed at the tail of the servo motor, it can brake rapidly at power failure of motor, can effectively restrict inertia idle running of output shaft and the effect of load reaction moment, so that the output shaft can stop at certain position accurately, thus can improve stability of system. Electric actuator adopts AC capacitor as split phase capacitance of two-phase servo motor, can improve reliability of the product. Speed reducer adopts first-grade cylindrical gear and first-grade involute planet gear with small tooth difference for rotation, has the features of large drive ratio, small volume, high efficiency, low noise, long serve life, etc. Handwheel device is setting on speed reducer for in-situ regulation and operation, rotating direction of handwheel is the same as the output shaft. Servo motor is installed on the speed reducer, there is a handle on its rear cover, which can switch over between electric and manual states, and can cut off power supply and pull out handwheel to manual position (handle of motor can also be turned to manual position) for in-situ operation if installation, debugging, system or circuit has any fault. Except for manual in-situ operation at power failure, handles of handwheel and motor must be placed at electric position. Two brake blocks fastened with T slotted screws and nuts are configured on end cap of the speed reducer, which are mechanical caging devices of the quarter-turn actuator. Position transmitter is consisted of transmission device, sensing element, power supply unit, amplified circuit, cam-sensitive switch, etc. Corner change of output shaft will drive rotation of cam and rotor shaft of conductive plastic potentiometer via gear wheels; resistance change of potentiometer will be transferred to position feedback current signal via amplification circuit as output of position transmitter; two potentiometers are installed on the printed wiring board of amplification circuit: 0% potentiometer and 100% potentiometer, which are used for adjusting upper limit and lower limit of position feedback current respectively. Two adjustable cams are installed on the shaft which drives the rotation of conductive plastic potentiometer, they can drive the motion of two sensitive switches respectively. One cam-sensitive switch near the conductive plastic potentiometer can cut off the motor loop that drives clockwise rotation of the output shaft (observe the output shaft face to face (note: all the below will follow this way)), the other cam-sensitive switch can cut off the loop that drives counterclockwise rotation of output shaft. The two groups of cam-sensitive switches constitute electric caging device of the actuator. There are two connectors on the position transmitter, in which the 14-wire rectangular connector -X1 connects power source, earth, control circuit of motor and transmits position feedback signal, and the 3-wire round connector -X2 connects servo motor (has been wired). Position feedback signal can be adjusted to two states: positive action or counter action. When output shaft of the actuator rotates in clockwise, position feedback current shall increase, which will be called positive action. When output shaft of the actuator rotates in reverse clockwise, position feedback current reduces, which will be called counter action. VI. Checking of Electric Actuator Each set of electric actuator has been tested strictly according to standard before leaving factory. In view of the effect of transportation and storage and to ensure safety in use, the user should make the following checks before installation and use: 1. Field kinetic conditions and ambient conditions should comply with the stipulations in Chapter III of the Operation Instructions. 4

6 2. Contents marked on label plates of the actuator should comply with the requirements for normal operation of system and valve. 3. Checking of insulation resistance. Using 500E megohmmeter to measure insulation resistance between different groups of conductors and casings stated in Chapter IV of this Operation Instructions, which should comply with the stipulations. 4. Mechanical checking 4.1 Checking of fasteners All the fasteners should not have loosening phenomenon, if there is, it should be fastened with revolve tools. 4.2 Checking of movable components Manual and handle at the rear cover of motor (hereinafter referred to as motor handle) should be able to switch flexibly between manual and electric positions, and can be located reliably by internal steel ball at specified position (pressure of steel ball on handwheel shaft can be adjusted via the set screw), and handwheel can run idle flexibly at electric position. Handle of handwheel and motor must be reset to electric after completing the check. 5. Checking of connector assembly All the connectors should be mounted firmly and contacted reliably, after removal of connector, check if there is any defect such as corrosion or deformation and so on that may affect the contact. 6. Wire connection Wire connection should be made according to the connection diagram (Fig.2) in this Operation Instructions. Input signal I II III Electric servo amplifier -X N L Actuator -X Fig.2-A Connection Diagram of Proportional Actuator Not Being Coupled in Electric Operator 5

7 Electric servo amplifier -X N L Regulator DFD-05 Electric operator -X Actuator- X1 Fig. 2-B Connection Diagram of Proportional Actuator of Electric Operator in DFD-05 Electric Operator Electric servo amplifier -X0 DFD-09 electric operator -X L N 11 Regulator Actuator -X1 Fig. 2-C Connection Diagram of Proportional Actuator Being Coupled in DFD-09 Electric Operator 6

8 DFD-05 Electric operator -X Actuator- X Note: If electric operator is DFD-09, -X4:13 wire connection should be changed to -X4:12. L N Fig. 2-D Connection Diagram of Integral Actuator Being Coupled in DFD-05 Electric Operator Phase lines and neutral lines of power source should not be wrongly connected; earth connection must be firm and reliable. Shielded mounting wires must be used for channels of input signals and position feedback signals. 7.Checking of operating state of actuator 7.1 Checking of operating state of the proportional actuator a. Checking of servo amplifier Remove the wiring for position feedback signal, and switch on the power supply for servo amplifier, then indicating lamp of the amplifier is on. If output terminal of the amplifier does not have any external connected signal, adjust output voltage in preceding stage of the zero adjusting potentiometer to zero (measure on the measurement bar marked in the Installation and Operation Manual of Servo Amplifier), then add DC signal not less than 1.5% input range to any input channel (between 1-2, 3-4 terminals), output voltage in preceding stage should not less than 0.5V. b. Checking of working signal range Restore the position feedback signal channel and connect in series of DC ammeter of 0~ ma, then switch on power supply of the amplifier and the actuator, apply lower limit signal within the working signal range at the output terminal of the amplifier, servo motor will rotate, output shaft of actuator rotates in counterclockwise, position feedback signal changes towards the direction near output signal; when the output shaft rotates to lower limit of the rated stroke, the position feedback signal displayed on the ammeter will be lower limit of the working signal range; when motor stops rotation, the output shaft stops too. Change the input signal to upper limit value within the working signal, output shaft of the actuator rotates in clockwise; when the output shaft rotates to upper limit of the rated stroke, the position feedback signal displayed on the ammeter will be upper limit of working signal range, then motor stops rotation, the output shaft stops too. At this time, if rotate the 100% potentiometer on the position transmitter, position of the output shaft will change. 7

9 c. Adjustment of the dead zone Dead zone of the product has been adjusted properly before leaving factory, it has no need to be readjusted in general. If oscillation appears, it indicates that the dead zone is too small, it can be enlarged by adjusting the stabilizing or dead zone adjusting potentiometer of the servo amplifier to stabilize the mechanism, but it should not be overenlarged to avoid reducing of sensitivity. d. Positive action changes to counter action Generally, the actuator will be connected and adjusted as per positive action before leaving factory; if user requires actuator with counter action, the following adjustments can be made: (1) Change the wire connection of motor between servo amplifier and integral actuator. Change the original wire connection between the amplifier terminal -X0 and the actuator terminal -X1, the original connections of -X0:12 to -X1:8, -X0:10 to -X1:3 shall be changed into connecting -X0:10 to -X1:8, connecting -X0:12 to -X1:3 according to the connection diagram 2-A. Change the original wire connection between the amplifier terminal -X0 and the operator terminal -X4, the original connections of -X0:10 to -X4:1, -X0:12 to -X4:2 shall be changed into connecting -X0:10 to -X4:2, connecting -X0:12 to -X4:1 according to the connection diagram 2-B. (2) Change the changing direction of the position feedback signal Adjust and reweld the conductor pair at 1, 3 on the welded joints of the conductive plastic potentiometer. e. Gradually increase or decrease DC signal at the input terminal of the amplifier, the output shaft will rotate accordingly, input signal and corner should comply with the input-output characteristic curve, see Fig Checking of operating state of the integral actuator a. Checking of rotating direction of the output shaft Switch on power supply and press ON button of the electric operator, the output shaft will rotate in clockwise, position feedback signal will increase; press OFF button of the electric operator, the output shaft will rotate in counterclockwise, displacement feedback signal will reduce. If need to realize counter action, please change wire connection of the actuator terminal - X1 and terminal -X4 of DFD-05 electric operator, i.e. change the original connections of -X1:3~5 to -X4:11, -X1:8~10 to -X4:13 into connecting -X1:3~5 to -X4:13, and connecting -X8~10 to -X4:11. b. Change the changing direction of the position feedback signal As per the method 7.1d (2) in this Chapter. c. Corner of the output shaft and the position feedback signal should comply with the outputfeedback characteristic curve, see the Fig.4. Rated stroke% Working signal range% Position feed back signal Corner of output shaft 0 Input 0 range% Input signal Corner of output shaft Fig. 3 Fig. 4 Rated stroke % 8

10 VII. Installation, Adjustment, Operation and Maintenance of Electric Actuator 1.Installation 1.1 Installation of servo amplifier Servo amplifier is the instrument for installation and use in the control room. It has two kinds of installation modes: Wall hanging structure can be mounted vertically on post of metal holder inside the control cabinet; rack mounting structure can be mounted onto stand inside the control cabinet. External forms and mounting dimensions of servo amplifier should comply with the stipulations in the Installation Manual of the servo amplifier. 1.2 Installation of integral actuator Actuator should be installed onto base of concrete or metal framework and be fastened with ground bolts. The output arm of the actuator can be connected with adjusting mechanism via connecting rod and special joint. The actuator is not applied lubricating oil when leaving factory, before it is put into use officially, the lifting eye bolt on the speed reducer should be taken off, and machine oil should be filled in from the bolthole; filling quantity of the machine oil can be observed from oil window, oil level should be between the two oil holes. External forms and mounting dimensions of the integral type actuator can be seen in Fig.5, connection terminals can be seen in Fig.6. 2.Adjustment 2.1 Adjustment of working positions Loosen the nuts for fastening the brake blocks, dismantle the motor plugs, remove shroud of the position transmitter, place the handwheel and motor handle at manual position, sway the handwheel and rotate the output shaft to the position opposite to the lower limit of the position feedback current (hereinafter referred to as lower limit position). Cling a brake block tightly to output arm and fasten the nuts according to positive action or counter action of working state, sway the handwheel (rotate clockwise for positive action, counterclockwise for counter action) to make the output shaft rotate 90 (this position and below is called upper limit position for short). Cling another brake block tightly to the other side of the output arm and fasten the nuts. Adjust cam according to the instructions for cam-sensitive switch in Chapter V, so that relevant sensitive switch action can be used when the output shaft is between two limit positions, fasten the round nut on the camshaft. Connect the motor plug, place handwheel and motor handle at electric position, switch on power supply, make the output shaft rotate back and forth, and observe correctness of adjustment. Rotate the output shaft to the lower limit position, loosen screws for fastening set plate of conductive plastic potentiometer, hold the potentiometer and make it rotate slowly up to the lower limit of the working signal range for position feedback current, and fasten screws on the set plate. If there is any deviation, adjust the 0% potentiometer on the printed circuit board, switch on motor and make the output shaft rotate towards the upper limit direction, position feedback current shall increase (if position feedback current increase abruptly and reduces when it reduces to certain point, then exchanges the 1, 3 connection joints on the conductive plastic potentiometer and readjust the lower limit of the position feedback current. When the output shaft reaches upper limit, adjust the 100% potentiometer on the printed wiring board, making the position feedback signal as upper limit of working signal range. For proportional actuator, couple in servo amplifier, making output signal lower limit of working signal range, the output shaft should rotate to lower limit position, if there is any deviation, the 0% potentiometer on the conductive plastic potentiometer or printed circuit board can be adjusted. After adjustment, cover of the position transmitter should be mounted well. 3.Operation Please check whether wire connection is correct and handwheel and motor handle are at electric position before being electrified. 9

11 The electric actuator has three operation modes: a. Automatic operation-receive control signal of system and automatic operation. b. Manual operation (remote control)-manmade single to make actuator realize electric operation. c. In-situ operation-cut off current, operator can rotate handwheel to realize local operation of actuator. Automatic operation: for proportional actuator, when being coupled in electric operator, handle of the changeover switch of the operator should be transferred to automatic position, thus can realize automatic operation. Manual operation: rotate the operator to manual position. In-situ operation: it is mainly used for installation, debugging, or, when there is any failure with system or lines, handwheel can be used for in-situ operation, at this point, the electric operator should be rotated to the middle point, then plug of the motor should be pulled out, and motor handle and handwheel should be placed at manual position. After in-situl operation is completed, the handwheel and motor must be reset to manual position, and motor plug should be plugged in. 4. Maintenance The actuator should be maintained regularly. For locations with large vibration, fasteners should be checked often to see if there is any loose or whether contact of connectors is good and locking is reliable, if not, they should be repaired timely. Actuators for frequent use should be overhauled once every one and a half year. Before dismantling the position transmitter and speed reducer, screws for oil discharge holes should be screwed down, and lubricant oil in the speed reducer should be emptied. Components should be cleaned carefully, all fasteners and torn up components should be replaced. All lubricating grease should be removed, and new lubricating grease should be refilled. Speed reducer of actuator with rated load not less than 600Nm has two planet gears. Number on wheel spoke of the planet gears should be found out and corrected first, then the 8-hole gear teeth of the two gears should be coincided strictly, then rotate 180 of one blade wheel and mount onto bearing of eccentric sleeve. When checking the motor, rear cover should be dismantled first to clean out the scraps between brake disc and brake wheel, then adjust space and braking force between the brake disc and brake wheel. When checking the electric device, damaged elements and aged conductors should be replaced, all sensitive switches should also be replaced. When the position transmitter is installed at the speed reducer, sealing elements must be under effective operation. Insulation resistance between different groups of conductors and casings should be checked with 500V megohmmeter. Machine oil should be filled into speed reducer. Wire connection, adjustment and installation of the actuator should be done according to this Operation Instructions. key d2 A d1 2φ C F δ E d3 D B K B' C' L D' H Fig. 5 R H' 10

12 Model DKJ-2100 DKJ-3100 DKJ-4100 DKJ-5100 DKJ-6100A DKJ-6100 DKJ-7100 A B C D E F d d d H R K H L δ 30 B C D Φ Key * 10*50 12*60 18*80 18*80 *80 *80 L N Motor Motor Position transmitter Output current Fig. 6 VIII. Troubleshooting Fault Cause Solution No action of actuator No action of actuator after removing the above faults 1 Wrong wire connection 2 Fuse tube of the amplifier is blown out. 3Disconnection or bad contact of circuit 4 Fault of servo amplifier 5 Burning down of motor 6 Breakdown or failure of split phase capacitance Remove working signal, short circuit anode and cathode of thyristor with conductors 1If motor rotates, it indicates that the thyristor is short circuit. 2If motor does not rotate, it indicates that, a. motor is burnt down. b. breakdown of split phase capacitance. Connect again Replace the fuse tube after finding out reason Check whether welded points of different parts are sealing off; contacts between printed wiring board and sockets, plug-in unit and plugs are good; repair or replace. Handle as per Operation Manual of servo amplifier Replace motor Replace split phase capacitance Replace thyristor Replace the motor Replace split capacitance 11

13 Fault Cause Solution Starting rotation when switching on output shaft of power supply Output shaft of actuator can rotate towards only one direction Number of oscillations of proportional actuator exceeds semiperiod for three times Input signal and output shaft corner of proportional actuator are not matched No position feedback signal Decrease of output torque Abnormal operation of potentiometer unit Abnormal running, has abnormal noise 1Voltage between output testing bars is not zero when servo amplifier has no input signal 2Screws for fastening the set plate of the conductive plastic potentiometer loose and cause zero drift 3Breakdown of one thyristor or diode 1One conductor led to motor is disconnected 2Fault of servo amplifier 3Conductor led to control circuit of motor is connected in reverse 1Too small dead zone 2Small braking moment of servo motor 1Position feedback unit is not adjusted correctly 2Disconnection of wires, damage of elements (damage of conductive plastic potentiometer) 1Wrong wire connection 2Damage of elements for position transmitter 1Fault of motor brake 2Insulation layer of motor is aged or broken down 3Mechanical components wear and tear, reducing efficiency 1Damage of sensitive switch, adhesion of contacts (cannot be sprung) 2Wrong wire connection 3Bad contact of lead wire Wearing of driving parts like bearing, gearwheel, etc. Adjust zero adjustment potentiometer Fasten screws, readjust upper and lower limits of feedback signal range Replace Repair Handle as per Operation Manual of servo amplifier Exchange welding of the wire connection of 14-wire terminals 3~5 with 8~10 Adjust stabilizing or dead zone adjusting potentiometer of servo amplifier Adjust braking moment of servo motor Readjust Check wire connection and replace elements Correct Replace Replace worn parts and readjust Repair or replace motor Replace or repair Replace Correct Reweld Replace IX. Storage The product shall be stored in ventilating rooms of -10~+40 and with relative humidity not larger than 80%, and ambient air should not contain any medium that may cause corrosion or other damage to the product. Actuators stored more than 18 months should be replaced lubricant in speed reducer before use. X. Contents of Guaranty Under normal circumstance, our company shall be liable for maintenance free of charge within 12 months from the date of delivery of the product. For any damage of the product arisen from error in installation or operation due to uncomplying with the Operation Instructions, our company can repair according to the user's requirements, but shall collect relevant expenses. 12

14 Address:13Yingsheng Road, Daming Road,Xiqing District,Tianjin,P.R.China Postcode: Telephone: , Fax: Website: Thank you for purchasing Bell Company product,we welcome your valuable opinions regarding our product and service.