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CALIBRATION

TROUBLESHOOTING CALIBRATION ADJUSTMENTS

4 - 11

TROUBLESHOOTING CALIBRATION ADJUSTMENTS

The servo assemblies of the Type AV3/4 positioners come from
the factory completely calibrated.

Use the following procedures

only when operating difficulties occur

. The corrective action

column of Table

will prompt you to use the troubleshooting cal-

ibration.

Servo Assembly Adjustments (Type AV3 Positioner)

The purpose of this procedure is to adjust the servo so that the
four to 20-milliamp input signal will produce a 20.7 to 103-kilopas-
cals (three to 15 pounds per square inch gage) signal. Use the fol-
lowing procedure to adjust the servo assembly.

Instruments Required:

Digital voltmeter
0 to 30 psig instrument gage
Small screwdriver
Current source

1. If the positioner is mounted on an actuator and it is not desir-
able to have the actuator move during calibration, remove the air
lines from 01 and 02 ports. Plug the ports. If bench calibrating,
plug 01 and 02 ports to prevent excess air flow during calibration
(Fig.

Figure 4-7. Speed Adjustment Screw Locations

LO W E R A D JU S T M E N T
SC R EW

H IN G E S PR IN G

S IG N A L
D IA P H R A G M

TO P A D J U S TM EN T S C R E W

R A N G E S P R IN G

AL LE N W R E N C H

A C C E S S

T 00 77 8 A

WARNING

Type AV positioners are suitable for a maximum supply
pressure of 1034 kPa (150 psig). Do not exceed maximum
recommended final control element operating pressure.

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Summary of Contents for AV3

Page 1: ...INSTRUCTION MANUAL Characterizable Pneumatic Positioners Type AV3 and AV4 PN25058 ...

Page 2: ...ntrolled Some process upsets may cause injury or damage NOTICE The information contained in this document is subject to change without notice ABB Inc its affiliates employees and agents and the authors of and contributors to this publication specifi cally disclaim all liabilities and warranties express and implied including warranties of merchantability and fit ness for a particular purpose for th...

Page 3: ...4 POSITIONERS 3 2 CONNECTING TUBING TO TYPE AV POSITIONER 3 7 Filtering Supply Air 3 8 Recommended Supply Air Quality 3 8 Tubing Connections 3 8 WIRING TYPE AV POSITIONER 3 9 SECTION 4 CALIBRATION 4 1 INTRODUCTION 4 1 GENERAL CALIBRATION 4 1 AV3 Calibration 4 1 ZERO ADJUSTMENT AV3 4 2 SPAN ADJUSTMENT AV3 4 3 AV4 Calibration 4 3 ZERO ADJUSTMENT AV4 4 4 SPAN ADJUSTMENT AV4 4 4 SERVO MOTOR SPEED ADJU...

Page 4: ...BLY 8 8 Removing 8 8 Replacing 8 8 PILOT VALVE STROKE ADJUSTMENT 8 9 SECTION 9 SUPPORT SERVICES 9 1 INTRODUCTION 9 1 RECOMMENDED SPARE PARTS 9 1 ADDITIONAL SPARE PARTS KITS 9 2 APPENDIX A POSITION TRANSMITTERS A 1 INTRODUCTION A 1 DESCRIPTION AND OPERATION A 1 Potentiometric Position Transmitter A 1 Four to 20 mA Position Transmitter A 1 CALIBRATION A 2 Calibrating the Potentiometric Position Tran...

Page 5: ...gnment 4 3 4 3 Type AV4 Positioner Motor Speed Adjustments 4 6 4 4 Zero Adjustment Graph 4 7 4 5 Span Adjustment Graph 4 8 4 6 Pilot Valve Measurement for Maximum Speed 4 10 4 7 Speed Adjustment Screw Locations 4 11 4 8 Type AV3 Positioner EMI Electronics Housing 4 13 4 9 Servo Adjustments AV4 4 15 8 1 Type AV Positioner with Manifold 8 1 8 2 Manifold without Filter Cover 8 2 8 3 Manifold Rear Vie...

Page 6: ...ferring Data from the Graph to the Cam C 6 List of Tables No Title Page 1 1 Reference Documents 1 5 1 2 Type AV3 4 Nomenclature 1 5 1 3 Type AV 3 4 Positioner Specifications 1 6 1 4 Optional Potentiometric Position Transmitter Specifications 1 9 1 5 4 to 20 mA Position Transmitter Specifications 1 9 1 6 Agency Approvals 1 9 1 7 Positioner Accessories 1 10 1 8 Rotary Actuators Retrofitting Mounting...

Page 7: ...9 16 Type AV4 Positioner Parts List for Figures 9 4 9 5 and 9 6 9 8 9 17 Type AV4 Reference Table 9 10 9 18 Positioner Mounting Kit 9 12 9 19 Positioner Mounting Kit 9 12 9 20 Positioner Mounting Kit 9 13 9 21 Rotary Actuators Retrofitting Mounting Kits 9 13 A 1 Transmitter Assembly Parts List A 8 B 1 Type AV3 4 Nomenclature B 1 B 2 Calibration Procedures B 8 B 3 Motor Speed Adjustment AV4 Only B ...

Page 8: ... must be free of any hazardous materials acids alkalis solvents etc A Material Safety Data Sheet MSDS for all process liquids must accompany returned equipment Contact the factory for authorization prior to returning equipment Read these instructions before starting installation save these instructions for future reference Contacting the Factory Should assistance be required with any of the compan...

Page 9: ...ENDED USER The information in this publication is a guide for technical person nel responsible for installation calibration operation maintenance and repair of the Type AV3 4 positioner TYPE AV3 4 POSITIONER DESCRIPTION The Type AV3 and Type AV4 positioners are electro pneumatic control devices that satisfy a wide range of applications They pro vide fast sensitive and accurate positioning of pneum...

Page 10: ...wntime The Type AV3 positioner can be equipped with either an optional potentiometric or a four to 20 milliamp position transmitter The Type AV4 positioner comes standard with a four to 20 milliamp position transmitter TYPE AV3 4 POSITIONER APPLICATION The ABB Type AV3 and Type AV4 Characterizable Pneumatic Positioners control the position of a pneumatic actuator in a linear or nonlinear relation ...

Page 11: ...om the positioner at 483 kilopascals 70 pounds per square inch supply pressure See Figure 1 1 in SPECIFICATIONS Continuously Adjustable Span and Zero for Each Stroke Level Capable of 100 percent stroke for 50 percent signal span or 50 percent stroke for 100 percent signal span Low Air Consumption Enhanced pilot valve design and manufacturing technique allows the Type AV positioner maxi mum perform...

Page 12: ...nstructions for removing and replacing components of Type AV positioners Support Services Provides recommended and replacement parts lists Illustrations of both positioners provide part numbers for all major components Appendix A Provides calibration information about the four to 20 milliamp posi tion transmitter and potentiometric position transmitter Appendix B Contains quick start information f...

Page 13: ...sition 3 4 5 6 7 8 Type AV Characterizable Positioners Type 3 Characterizable 4 to 20 mA Input Positioner fail in place upon loss of signal 4 Characterizable Pulse Input Positioner fail in place upon loss of signal Input Signal 3 4 to 20 mA Type AV3 4 Contact closure open collector DDC Type AV4 Stroke Rotary Motion cam selection 1 12 7 50 8 mm 0 5 2 0 in or 45 rotary motion 2 25 4 101 6 mm 1 0 4 0...

Page 14: ...ulse widths Operation at colder temperatures may require longer minimum pulse widths Voltage Supply Type AV4 only Minimum 16 VDC Nominal 24 VDC Maximum 34 VDC NOTE Maximum 50 mA current draw Input Impedance1 1 66 kΩ at 4 mA 0 57 kΩ at 12 mA 0 35 kΩ at 20 mA Standard Stroke Range cam selection Type AV 1 positioner 12 7 to 50 8 mm 0 5 to 2 0 in linear rotary input 45 Type AV 2 positioner 25 4 to 101...

Page 15: ... 120 Hz at accelerations to 2 Gs RFI Effect Type AV3 Type AV4 1 5 maximum at 10 V per meter field strength 20 to 540 MHz 1 5 maximum at 10 V per meter field strength 20 to 450 MHz Pneumatic Connections NPT on supply signal and output connections NPT on pressure gages Materials of Construction Enclosure Pilot Valve Aluminum and 0 5 magnesium 303 Stainless Steel Enclosure Classification NEMA 3R clas...

Page 16: ... Figure 1 2 Air Consumption Data of Type AV3 4 Positioners FLOW SCFM SUPPLY PRESSURE PSIG 40 30 20 T00769A 10 0 0 20 30 40 10 50 60 70 80 SU PPLY CAPACITY EXHAUST C APACITY FLOW SCFM SU PPLY PRESSURE PSI 20 40 50 60 70 80 90 100 30 110 120 130 140 150 T00336A 0 90 0 80 0 70 0 60 0 50 0 40 0 30 0 20 0 10 0 ...

Page 17: ...span maximum Hysteresis 0 5 of span maximum Repeatability 0 4 of span maximum Ambient Tempera ture Effect 0 063 per C 0 035 per F EMI RFI Effect 1 5 maximum at 10 volts per meter field strength 20 to 450 MHz SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Table 1 6 Agency Approvals Nomenclature Approval Certification AV3 41 2 FM and CSA approval and certifications in the following categories Nonin...

Page 18: ...rt number 5400277_1 Regulator Refer to Table 1 11 Air Filters ABB recommends installing an air filter in the supply air line to prevent particles from entering the positioner which can lead to malfunction Refer to Table 1 12 for filter part numbers NOTE 1 For recommended spare parts and additional spare parts refer to Section 9 Table 1 8 Rotary Actuators Retrofitting Mounting Kits Retrofit Mountin...

Page 19: ...ges Part Number Max Outlet Pressure psi Max Inlet Pressure psi Inlet Outlet Connections 1951029_1 60 250 NPT 1951029_3 30 250 NPT 1951029_5 100 250 NPT 1951439_1 100 250 NPT Table 1 12 Supply Air Filters1 Part Number Max Inlet Pressure psi Maximum Temperature Inlet Outlet Connection Size C F 5328563_1 150 54 4 130 NPT 5328563_2 250 121 250 NPT NOTE 1 In line coalescing filter for removal of solid ...

Page 20: ...m Figure 2 1 Type AV3 4 Positioner Operation Diagram PILOT VALVE CAM SIGNAL DIAPHRAGM DIAPHRAGM FO RCE RANGE SPRING FO RCE RANGE SPRING 4 20 mA O R PU LSE SIG NAL T02000A GAIN HING E SPRING BALANCE BEAM SIGNAL PRESSURE 3 15 PSIG EM I ELECTRONICS AND SERVO ASSEMBLY SU PPLY PRESSURE TO ACTUATOR O2 S O1 TO ACTUATOR Figure 2 2 Block Diagram of a Typical Control System Utilizing a Positioner SET POINT ...

Page 21: ...or coupling to the actuator Therefore range spring tension is a function of the actuator position A change in input signal a pulse or some value between four and 20 milliamp changes the force exerted by the signal diaphragm moving the balance beam in turn moving the pilot valve The pilot valve supplies and or exhausts air to the actuator which ultimately changes the position of the actuator The ch...

Page 22: ...positioner It is intended for control engineers having extensive experience in the use and application of pneumatic positioners The quick start guide highlights the major points of installation and calibration Detailed installation and calibration information is contained in Section 3 and Section 4 UNPACKING AND INSPECTION 1 Check for obvious damage to the shipping carton 2 Open carton and remove ...

Page 23: ...location for the positioner based on the following fac tors 1 Access to the internal positioner housing the mounting location should provide enough room to remove the cover in order to perform calibration and repair and replacement procedures inside the positioner Refer to Figure 3 1 for positioner dimen sions 2 Allow room for linkage to the actuator the mounting posi tion should be such that a pr...

Page 24: ... 93 0 1 44 36 5 0 64 16 2 2 80 71 1 2 50 63 5 1 13 28 6 90 1 03 26 3 0 50 0 002 O PTIONAL 12 7 0 05 SQ SHAFT 0 755 19 18 0 88 22 4 TYPE AV 1 ONLY 3 69 93 8 0 69 17 4 0 19 4 8 2 45 62 4 1 40 35 5 0 86 22 0 1 60 40 6 PRESSURE G AGES SEE N OTES 2 AND 6 3X 0 312 THRU MO UNTING HOLES PROVIDED FO R 0 250 FASTENER S FAR SIDE APPROX 45 MOTION FOR 1 2 TR AVEL C AM 2X 0 312 18UNC 2B THRU MOUN TING H OLES SE...

Page 25: ...AMP PLATE FRONT VIEW SIDE VIEW T00802A MO UNTING BRACKET ADJUSTABLE CO NNECTING LINK AD JUSTABLE STUD PAN HEAD MACHINE SCREW NOTE DRIVE A RM SHOULD BE PERPENDICULAR W ITH THE ACTUATO R AT MIDSTROKE G2 G1 Figure 3 3 Typical Positioner Mounting Using Direct Coupling AV 1 POSITIONER T00803A ROTARY ACTUATOR ACTUATOR SH AFT AV OUTPUT SH AFT COUPLING SET SC REW S ...

Page 26: ...s shipped from the factory The cams may be shaped to conform to special applications Refer to Appendix C for information about cam shaping NOTE If application is reverse acting the reverse acting cam red radial lines must be installed and ports 01 and 02 connec tions must be reversed WARNING Before mounting or installing positioner check nameplate data to make certain positioner is suitable for ap...

Page 27: ...spect to the cam This provides flexibility in arrangement so that the midpoint of the cam will corre spond to the mid stroke of the actuator 3 Adjust the connecting linkage so that the zero radial line on the cam intersects the center of the cam roller Fig 3 6 4 Lock all linkage components in place Figure 3 5 Positioning Cam Table 3 1 Positioner Cam Characteristics Positioning Cam Any Stroke Pisto...

Page 28: ...uare inch gage above operating pressure required by actuator Filtering Supply Air An outside filter is recommended for Type AV positioners for pri mary filtration of the supply air ABB provides supply air filters as accessories refer to Table 1 12 for part numbers NOTE Primary supply air filters are recommended for position ers with a manifold AV 1 and AV 2 or without a manifold AV 0 Figure 3 6 Ca...

Page 29: ...ine pressure should be 7 7ºC 18ºF below minimum expected operating tem perature 2 Supply air is required to be of instrument air quality and should conform to ISA S7 3 standard 3 Oil content of air supply should be as low as possible 1 0 parts per million is the recommended maximum 4 Particle size in the supply line should not exceed three microns Tubing Connections 1 Connect the required supply a...

Page 30: ...position transmitter ter minals TB1 1 and TB1 2 provide customer access to the 4 to 20 milliamp feedback signal If equipped with optional potentio metric position transmitter three leads are available for customer use at terminals TB1 1 TB1 2 and TB1 3 Refer to Appendix A for detailed information about position transmitters b Type AV44 positioner Connect DDC pulse or contact clo sure raise lower i...

Page 31: ...RECT ACTIN G CAM BLACK 2 CO UNTERCLOCKW ISE CAM ROTATION SEE NOTE 1 3 O 1 PO RT PLUGG ED 4 STEM M OVES UP W ITH SIGNAL FAILURE 5 STEM M OVES DOWN W ITH SUPPLY AIR FAILURE NOTES 1 REVERSE ACTING CAM RED 2 CLO CKW ISE CAM ROTATIO N SEE NOTE 1 3 O 2 PO RT PLUGG ED 4 STEM M OVES DOWN W ITH SIGNAL OR SUPPLY AIR FAILURE GENERAL N OTES 1 ROTATION OF CAM AS VIEW ED FROM FRONT OF POSITIO NER WITH COVER REM...

Page 32: ...SED BY USING THE REVERSE ACTING CAM LOCATED IN POSITIONER COVER AND REVERSING THE O1 AND O2 CO NNECTIONS GAG E D ESIGNATIO NS G1 SIG NAL GAGE G2 OUTPUT GAGE O 1 PO RT G3 OUTPUT GAGE O 2 PO RT T00773A DIRECT ACTING BLACK CAM O1 O2 G3 G3 G2 G2 G1 G1 O1 O2 REVER SE ACTING RED CAM MOTION W ITH INCREASING SIGNAL MOTION W ITH INCREASING SIG NAL NOMENCLATURE AV23 Av33 AV44 AV 1 AV 2 1 2 3 TB1 CONNECTIONS...

Page 33: ...x C for detailed information about the cam GENERAL CALIBRATION A coarse calibration is performed during installation Section 3 that normally consists of adjusting the linkage between the posi tioner and actuator so that the positioning cam rotates through its full range for full actuator travel The general calibration procedure involves fine adjustments to the zero and span such that the input sig...

Page 34: ...nt nut clockwise moves actuator down range appropriately until the 0 radial line on the cam intersects with the center of the cam roller Fig 4 2 NOTE This adjustment may be biased i e turning the zero nut slightly counterclockwise to make sure a valve or damper is firmly seated at the minimum input signal 4 Tighten the zero adjustment set screw 3 32 Figure 4 1 Type AV Calibration Adjustment Locati...

Page 35: ...n until the actuator moves to align the 100 radial line with the center of the cam roller toward pilot valve increases span of actuator 4 Tighten the span adjustment screw AV4 Calibration The Type AV4 positioner uses voltage pulses from a controller to produce a proportional internal signal of 20 to 103 kilopascals three to 15 pounds per square inch Pulses to either the raise or lower terminal mov...

Page 36: ...rrive at the minimum internal signal of 20 0 1 4 kPa 3 0 0 2 psi The internal signal pressure may be measured at port I 2 Loosen the zero adjustment set screw Fig 4 1 using inch Allen wrench 3 Turn the zero adjustment nut clockwise moves actuator down range appropriately until the actuator moves so that the 0 radial line on the cam intersects with the center of the cam roller Fig 4 2 NOTE This adj...

Page 37: ...converter speed faster than the actuator can cause actuator overshoot However actuator stroking speed is typically not precisely known and is affected by temperature and load variations Therefore in applications that are not critical the P P converter should be set to a speed somewhat slower than the actuator speed Servo motor speed has coarse and fine adjustment provisions Coarse adjustment is ma...

Page 38: ...asure the time it takes the actuator to reach 100 by applying a constant increase signal 5 Having obtained an actuator speed value in Step 4 use Table 4 1 to determine the coarse speed adjustment setting which encompasses the actuator speed 6 Turn the FINE adjustment potentiometer counterclockwise Fig 4 3 by an estimated number of turns to achieve a motor speed that equals the speed of the actuato...

Page 39: ...p pression is useful when two or more actuators are to be operated in sequence where the actuator is equipped with a minimum stop or where the characteristics of the device that the actuator is mov ing must be matched with the characteristics of another regulated device Span Adjustment The span adjustment affords a variation of actuator motion for a given span of input signal For example the span ...

Page 40: ...in of the overall posi tioner The factory installed gain hinge spring 0 010 inch suits most applications This adjustment is not a mandatory part of cali bration Gain Adjustment Gain adjustment on the Type AV positioners is accomplished by changing the gain hinge spring item 7 Figures 9 3 through 9 6 connecting the beam assembly to the positioner housing Pro vided with each positioner are two diffe...

Page 41: ...040 inch speed control orifices part number 5327327_1 are available as an option from ABB These orifices are installed directly into the output ports 01 and 02 of the positioner and have NPT ports for connecting tubing from the actuator If these ori fices are too small causing the actuator to respond too slowly they may be drilled out to obtain desired speed control Blank ori fices part number 532...

Page 42: ...e same in both directions Be careful when accessing the lower adjust ment screw Insert the Allen wrench up through the bottom of the range spring Fig 4 7 This adjustment controls the amount of air going to port 02 NOTE A single acting application only requires one pilot valve screw adjustment depending on the port connection The top adjustment screw affects the 01 port The bottom adjustment screw ...

Page 43: ...inch gage signal Use the fol lowing procedure to adjust the servo assembly Instruments Required Digital voltmeter 0 to 30 psig instrument gage Small screwdriver Current source 1 If the positioner is mounted on an actuator and it is not desir able to have the actuator move during calibration remove the air lines from 01 and 02 ports Plug the ports If bench calibrating plug 01 and 02 ports to preven...

Page 44: ... 25 psig If the pressure equals this value proceed to Step 7 If the pressure does not equal this value proceed to Step 6 6 Adjust the zero and span of the servo as follows a a Disconnect the servo motor wires from the EMI elec tronics housing Fig 4 8 b Set the input current to 4 mA and record the setpoint volt age across P2 and P3 Fig 4 8 c Set the input current to 20 mA and record the setpoint vo...

Page 45: ...4 8 Then decrease gain another half turn NOTE If during operation any oscillation or overshoot of the servo assembly occurs the gain may be decreased further c After adjusting the gain Return to Step 5 NOTE This gain adjustment applies only to the servo assembly It is not used to adjust the gain of the overall positioner Refer to Gain Adjustment for information detailing overall positioner gain Fi...

Page 46: ...irements of the actuator 2 Apply the supply air to the positioner 3 Connect a calibrated pressure gage or some other accurate pressure measuring device to the I port This allows you to moni tor the signal pressure during calibration 4 Adjust the internal pressure to the minimum value 13 8 to 17 0 kPa 2 0 to 2 5 psig Do so by closing the lower contact until the pressure stops decreasing a If 13 8 t...

Page 47: ...k wise to decrease until the pressure is between 107 to 110 kPa 15 5 and 16 0 psig Verify that the hub screw is in contact with the tip of the maximum stop screw Fig 4 9 Tighten the maxi mum locknut and check the pressure 8 If unable to obtain the correct pressures in Steps 5 or 7 close the contact for the problem direction loosen the zero locknut screw With the appropriate stop screw positioned a...

Page 48: ...ware that if the actuator is not secured before transferring the valve handle of the manifold the actuator will move Transfer from Automatic to Manual Operation 1 Manually lock the actuator or final control element 2 If equipped with a manifold and equalizing valve push in the valve handle and turn it to the MAN position 3 If not equipped with a manifold and equalizing valve turn off the supply ai...

Page 49: ...osition a Depress valve handle and turn to AUTO position Actuator will oppose manual operator if drive position and input signal do not correspond b Manually operate the actuator until the load on manual operator decreases If output pressure gages are installed on the position gage reading should equalize NOTE If in Step 3 it is desired that the drive stay in its initial position the input signal ...

Page 50: ...ed movement of the actuator and bodily injury could result Table 6 1 Positioner Errors Error Probable Cause Corrective Action Oscillation of actuator Gain too high Change gain hinge spring to greater thickness Refer to GAIN HINGE SPRING in Section 8 Drive arm not securely attached to actuator Tighten or correct linkage as necessary Servo assembly unsta ble gain too high Adjust servo gain Refer to ...

Page 51: ...FOLD in Section 8 Pilot valve leaking Remove pilot valve body and check O rings Refer to PILOT VALVE BODY in Section 8 Tubing disconnected Check connection at pressure regulator and servo Slow response Pilot valve blocked Remove and clean Refer to PILOT VALVE BODY in Section 8 Full range cannot be obtained with mechanical zero and span adjustment Signal diaphragm leak ing Replace diaphragm Refer t...

Page 52: ...e solvent Refer to PILOT VALVE BODY in Section 8 5 If Type AV positioner is equipped with a manifold assembly AV 1 2 Annually replace filters refer to MANIFOLD in Section 8 6 Annually check adjustments and calibration of positioner and actuator Refer to GENERAL CALIBRATION in Section 4 7 Annually verify that the coupling between the positioner and the actuator is tight WARNING Permit only qualifie...

Page 53: ...nd set the cover screw and cover aside WARNING Make certain the positioner is disconnected from the supply pressure source and the signal source or is removed from service before attempting any repair or replacement proce dures Failure to do so could cause unexpected movement of the actuator and bodily injury could result WARNING Moving the equalizing valve to MAN or to AUTO will cause the actuato...

Page 54: ...g the lubricant supplied in the kit 5 Clean and place the cover over the filters and replace the cover screw Torque the cover screw to 2 Nm 18 in lbs 6 Transfer positioner back to automatic operation refer to Section 5 MANIFOLD Tools Required Screw driver inch Allen wrench 1 Secure lock the actuator and remove supply air 2 If equipped with equalizing valve push in on the valve handle and move it t...

Page 55: ...or clean them if they are in good condition Fig 8 3 7 Clean O ring grooves and apply Dow Corning No 4 or equiva lent lubricant to the O rings 8 Place the manifold in place on the positioner so it properly seats on the bosses 9 Insert the Allen screws and torque them to 3 5 Nm 31 in lbs NOTE Not all Allen screws are the same length 10 To replace the filters and filter cover refer to MANIFOLD FIL TE...

Page 56: ...y seats flush between the steps If the hinge spring hangs up remove and rotate hinge 90 Recheck for proper seating 7 Insert and torque hinge screws to 2 6 0 2 Nm 23 2 in lbs while holding the beam assembly steady item 6 8 Transfer the positioner back to automatic operation refer to Section 5 9 Perform the procedure outlined in PILOT VALVE STROKE ADJUSTMENT PILOT VALVE BODY Item numbers reference F...

Page 57: ...t number 6639917_1 or AV4 part number 6639473_1 from the EMI electronics housing Use this procedure if you are replacing either or both items Item numbers reference Figures 9 1 through 9 6 depending on positioner type Tools Required Flat tip screwdriver Philips screwdriver Pliers 1 Transfer the positioner from automatic to manual operation refer to Section 5 2 Remove positioner cover by removing t...

Page 58: ...onnector from the EMI electronics board 8 Remove the three screws securing the EMI electronics housing to the servo assembly NOTE When replacing do not over tighten the screws that secure the EMI electronics to the servo assembly Tighten these screws just until they become tight or snug 9 If replacing the servo assembly reverse the preceding steps If replacing the electronics circuit board perform...

Page 59: ...ner back to automatic operation refer to Section 5 CAM Item numbers reference Figures 9 1 through 9 6 Tools required Flat tip Screwdriver Adjustable Wrench Pliers 1 Transfer the positioner from automatic to manual operation refer to Section 5 2 Remove positioner cover by removing two cover screws 3 Remove indicator screw item 51 and indicator item 19 4 Hold and stop the cam shaft from rotating if ...

Page 60: ...ly 6 Remove diaphragm spacer item 22 7 Remove diaphragm ring item 24 8 Carefully remove small diaphragm Replacing 1 Place the small diaphragm item 20 in diaphragm housing with the concave side facing up Check for correct alignment of tabs rela tive to the diaphragm housing 2 Place diaphragm ring item 24 over small diaphragm item 20 Make sure the alignment pins on the diaphragm ring properly engage...

Page 61: ...ith the following procedures GAIN HINGE SPRING PILOT VALVE BODY DIAPHRAGM ASSEMBLY NOTE For internal speed adjustment refer to GAIN AND SPEED ADJUSTMENTS in Section 4 When the valve stem is in the balance position as shown in Figure 8 6 the stem is flush with both ends of the valve body There are two adjustment screws to adjust Use the following procedure to check and adjust the travel of the valv...

Page 62: ...for Type AV4 positioner 6 Use the long at least 5 inch inch Allen wrench to adjust the lower stroke adjustment screw Fig 8 5 Adjust the screw until the measurement matches the value shown in Figure 8 6 Figure 8 5 Stroke Adjustment Screw Locations Figure 8 6 Pilot Valve Measurement for Maximum Speed 3 32 LOW ER ADJUSTMENT SCREW HINGE SPRING SIGNAL DIAPHRAGM TOP ADJUSTM ENT SCREW RANGE SPRING ALLEN ...

Page 63: ...nearest ABB sales rep resentative supply the kit numbers or if the items are not of a kit sup ply the part numbers NOTE This is not a complete list of available parts refer also to ADDITIONAL SPARE PARTS KITS located in this section and ACCESSORIES in Section 1 Table 9 1 Pilot Valve Assembly Kit No 258488_1 Item Part Number Quantity Description 3 5400259_1 1 Valve stem 4 5400260_1 1 Valve body 5 5...

Page 64: ...ise cam 45 rotation 5400281_1 1 Forward acting full rise cam 90 rotation 5400281_2 1 Reverse acting full rise cam 90 rotation Table 9 6 Manifold Assembly Kit No 258491_1 Replaces 5400282_1 or 5400282_2 For replacement or field addition Type AV 1 2 Item Part Number Quantity Description 17 5400282_1 1 Manifold assembly 64 5311428_207 4 Manifold 0 rings 65 NTJHA09030 4 Manifold washers 66 NBAHA16020 ...

Page 65: ... 1 AV4 Table 9 10 Potentiometric Position Transmitter Part Number Quantity Description 6639540_1 1 Potentiometer assembly Table 9 11 Cover Assembly Kit No 258545_1 Replaces 5400258_1 Part Number Quantity Description 5400254_1 1 Cover 5400255_1 1 Window 5400256_1 1 Gasket 5400257_1 1 Cover 5400257_2 1 Cover insert 1964033_1 1 Styleplate Table 9 12 Cam Follower Arm Kit No 258544_1 Replaces 5400306_1...

Page 66: ..._1 1951569_8 Cable clip Large diaphragm Plug 25 26 27 5400295_1 5400296_1 193243_1 Diaphragm cover Exhaust mesh Large position trans gear1 75 76 77 1951655_1 6639300_2 NTJBC07030 Brass fitting 2 req Servo assembly Lock washer 28 29 30 1951652_1 1945803_1 197120_28 Barb fitting Plug button Cam nut 78 79 80 5400297_1 1951745_1 NHRAC13005 Regulator bracket Regulator assembly Threaded forming screw 31...

Page 67: ...Interior Wiring and Tubing Details T02007A 85 98 83 75 84 28 83 90 18 98 99 105 78 98 100 69 58 58 72 86 58 79 64 43 10 26 58 56 49 59 12 8 11 29 7 42 76 16 45 6 4 5 3 52 5 5 4 4 3 3 2 2 1 1 THIS SUPPORT BR ACKET O N SERVO ASSEMBLY VIEW W ITH COVER REMOVED WIRING AND TUBING DETAIL ...

Page 68: ...22 11 req 2 req AV33 0 Omit Omit Omit AV33 1 5400282_1 4 req 2 req AV33 2 5400282_2 4 req 2 req NOTES 1 5400289_1 or 5400281_1 direct acting black cam is shipped installed on the positioner 2 5400289_2 or 5400281_2 reverse acting red cam is shipped installed inside the front cover T02008A 51 19 30 55 13 90 27 80 31 32 31 62 14 35 50 2 1 44 48 15 39 38 44 31 43 61 9 74 46 18 58 89 20 24 22 73 23 54...

Page 69: ...0_2 1 req 2 req Omit 3 req 1 AV33 2 6639540_1 1 req 2 req 13 req 2 1 req AV331 0 5400287_1 1 req 5327445_2 AV332 0 5400287_1 1 req 5327445_1 AV33 1 5400278_1 Omit Omit NOTES 1 5400289_1 or 5400281_1 direct acting black cam is shipped installed on the positioner 2 5400289_2 or 5400281_2 reverse acting red cam is shipped installed inside the front cover T02006A 36 33 71 10 37 41 40 2 1 65 65 65 65 6...

Page 70: ...agm ring 72 73 74 1943187_1 5400288_1 1951569_8 Cable clip Large diaphragm Plug 25 26 27 5400295_1 5400296_1 193243_1 Diaphragm cover Exhaust mesh Large position trans gear 75 76 77 1951655_1 6639300_1 NTJBC07030 Brass fitting 2 req Servo assembly Lock washer 28 29 30 1951652_1 1945803_1 197120_28 Barb fitting Plug button Cam nut 78 79 80 5400297_1 1951745_1 5400317_1 Regulator bracket Regulator a...

Page 71: ...Interior Wiring and Tubing Details T02004A 81 98 85 75 84 28 85 83 18 98 99 101 78 98 100 69 58 58 72 86 58 79 64 43 10 26 58 56 49 59 12 8 11 70 29 42 7 76 16 45 6 4 5 3 52 5 5 4 4 3 3 2 2 1 1 THIS SUPPORT BRACKET ON SERVO ASSEMBLY VIEW W ITH COVER REMOVED WIRING AND TUBING DETAIL ...

Page 72: ... 5400282_1 4 req 2 req AV44 2 5400282_2 4 req 2 req AV44 0 5400287_1 1 req AV44 1 5400278_1 Omit AV441 0 5327445_2 AV442 0 5327445_1 AV442 1 Omit NOTES 1 5400289_1 or 5400281_1 direct acting black cam is shipped installed on the positioner 2 5400289_2 or 5400281_2 reverse acting red cam is shipped installed inside the front cover T02003A 36 33 71 10 37 41 40 2 1 65 65 65 65 67 67 66 66 17 O2 O2 O1...

Page 73: ...AL SPARE PARTS KITS 9 11 Figure 9 6 Type AV4 Positioner Exploded View T02005A 48 15 39 38 44 31 32 63 34 43 74 9 46 18 58 88 89 20 24 22 73 23 54 53 25 47 68 77 70 60 58 80 81 76 93 51 19 30 55 13 32 31 62 14 35 50 2 1 44 81 61 ...

Page 74: ...er mounting bracket assembly part number 5313138_1 Minimum yoke diameter is 2 25 inches This mounting bracket assembly is not included in the positioner mounting kits Table 9 19 Positioner Mounting Kit Number 5327321_131 Valve Stem Diameter 0 750 to 1 00 inches Item Part Number Description Item Part Number Description 1 5400266_1 Positioner mounting bracket 12 197120_5 Elastic stop nut 2 req 2 250...

Page 75: ...mp plate 0 375 0 750 in diameter 19 1218 00 Shkproof lock washer 2 req 27 375 16x1 50 Hex soc head cap screw 2 req 20 5319524_1 Star lock washer 28 375 16 Hex jam nut 2 req 21 375 Med sprg lock washer 3 req 29 125 dia x 750 Type 1 groove pin NOTES 1 Positioner mounting kits for direct or reverse acting diaphragm actuators and single or double acting piston actuators with linear recip rocating moti...

Page 76: ...meter to the positioner cam shaft The position of the potentiometer shaft indicates the position of the actuator The relationship between the potentiometer and the cam shaft results in one degree of rotation of the cam shaft corresponding to approxi mately 9 9 ohms of resistive change at the potentiometer wiper Three leads from the potentiometer are for customer use and are available at terminals ...

Page 77: ...connections of Figure A 1 are described as follows AV23 The positive and negative connections at position TB1 4 and TB1 5 refer to the four to 20 milliamp signal to the I P converter AV33 The positive and negative connections at position TB1 4 and TB1 5 refer to the four to 20 milliamp signal to the servo assembly AV44 The positive and negative connections at position TB1 1 and TB1 2 refer to the ...

Page 78: ...Type AV positioner output is 80 percent 1 Determine the angular rotation of 80 of 90 degrees 0 80 x 90 degrees 72 degrees The 72 degrees of cam rotation is 80 of 90 degrees 2 Determine the resistive change of the potentiometer through 72 degrees of rotation For every degree of rotation the resistive change is 9 9 ohms nominally 72 degrees x 9 9 ohms 712 8 ohms The change of resistance for this rot...

Page 79: ...ample 1 Move the actuator to the 0 output position 2 Remove the field wiring from TB1 1 TB1 2 and TB1 3 Using an ohmmeter measure the resistance between TB1 1 and TB1 2 If the reading is 200 20 ohms remove the ohmmeter and proceed to Step 3 Otherwise continue with Step 2 Figure A 2 Schematic for Potentiometric Position Transmitter Example 24 VDC 10 96 VDC 5 48 mA 2380Ω TB1 2000 20 Ω 2380 NOMINAL A...

Page 80: ...djusting the resistance hold the gears and cam shaft stationary so rotation does not occur Only the potentiometer shaft should move while adjusting the resistance 1 16 Figure A 3 Potentiometric Position Transmitter Assembly Exploded View NOTES 1 SOM E HARDWARE ITEM S HAVE BEEN OM ITTED FOR CLARITY 2 IDENTIFIED ITEM S PERTAIN TO THE POSITION TRANSM ITTER OPTIO N ONLY T00788A TERM INAL BLOCK TB1 21 ...

Page 81: ... reads 5 VDC 5 Move the actuator to the 0 position to verify that the voltmeter reads less than 5 VDC 6 Move the actuator to the 100 position to verify that the voltme ter reads greater than 5 VDC 7 Potentiometric calibration complete Calibrating the Four to 20 mA Position Transmitter Labels located inside the positioner cover show the location of jump ers test points calibration pots and field co...

Page 82: ... ohmmeter from TB1 1 and TB1 2 Install the cam screw flag nut and washer Fig A 5 4 Place the CAL OPER jumpers into the operate OPER position Fig A 4 If a direct acting cam is being used place the FOR REV jumpers in the FOR position For a reverse action cam place these jumpers in the REV position Fig A 4 5 Move the actuator to the 0 position Insert ammeter leads into TP2 and TP1 If the position of ...

Page 83: ... Threaded forming screws 60 5400317_1 1 Gear adapter 91 6639479_1 1 4 20 mA position transmitter assembly 92 NDPAC13012 2 Threaded forming screws 95 5400268_1 1 Potentiometer mounting bracket 96 193242_1 1 Small position transmitter gear 21 91 58 95 96 31 60 27 92 POTENTIOMETER 2000 Ω SET SCR EW CAM FLAG MOUNTING BR ACKET SM ALL GEAR LARGE GEAR NOTES 1 SOM E HARDWARE ITEMS HAVE BEEN O MITTED FOR C...

Page 84: ...zable Pulse Input Positioner fail in place upon loss of signal Input Signal 3 4 to 20 mA Type AV3 4 Contact closure open collector DDC Type AV4 Stroke Rotary Motion cam selection 1 12 7 50 8 mm 0 5 2 0 in or 45 rotary motion 2 25 4 101 6 mm 1 0 4 0 in or 90 rotary motion Manifold includes filters 0 None 1 Manifold with equalizing valve 2 Manifold without equalizing valve Position Transmitter1 0 No...

Page 85: ...r each drive arm hole 2 Install the cam black direct acting or red reverse acting that will provide the required direction of rotation NOTE Cams have three mounting holes A square root B lin ear C square Each mounting hole is star shaped so the cam can be rotated in 45 increments to suit the application 3 With the actuator in the closed position adjust the connecting linkage so that the zero radia...

Page 86: ... ACTUATOR ACTUATOR SH AFT AV O UTPUT SHAFT CO UPLING SET SCREW S STROKE 45 OR HALF CAM STROKE 90 OR FULL CAM 0 193 200 4 9 5 1 7X T00804A TYPE AV 0 DIMENSIO NS INCHES M ILLIMETERS 0 65 16 5 0 33 8 4 0 35 8 9 4 00 101 6 2 00 50 8 3 00 76 2 1 50 38 1 3 50 88 9 1 75 44 5 2 50 63 5 1 25 31 8 1 50 38 1 0 75 19 1 2 00 50 8 1 00 25 4 1 00 25 4 0 50 12 7 TYP TYP 0 71 18 0 ...

Page 87: ...tub ing example and B 7 shows a double acting tubing examples NOTE The piping arrangements shown in Figures B 6 and B 7 are general examples and may not reflect exactly the arrange ment required for your application 3 Install 1 8 inch NPT permanent instrument gages to the gage ports if desired or for calibration requirements EXTERNAL WIRING CONNECTIONS Connect the signal wiring using inch NPT cond...

Page 88: ...ters refer to Appendix A 2 Type AV44 positioner Connect DDC pulse or contact clo sure raise lower input signal wires to terminals TB1 4 and TB1 5 Connect the 24 VDC to terminal TB1 3 and the position trans mitter feed back connection to terminals TB1 1 and TB1 2 Fig B 8 NOTE Route the wiring inside the positioner so it does not become entangled with moving parts A cable clip Fig B 9 is provided in...

Page 89: ...GNAL FAILURE 5 STEM M OVES DOW N W ITH SUPPLY AIR FAILURE NOTES 1 REVERSE ACTING CAM RED 2 CLO CKW IS E CAM ROTATIO N S EE NOTE 1 3 O 2 PO RT PLUGG ED 4 STEM M OVES DOWN W ITH S IGNAL OR S UPPLY AIR FAILURE GENERAL N OTE S 1 ROTAT ION OF CAM AS VIEW ED FROM FRONT OF POSITIO NER W ITH COVER REM OVED FOR AN INCREASING SIG NAL 2 G AGE DESIG NAT IONS G1 SIGNAL GAGE G2 OUTPUT GAGE O 1 PO RT G3 OUTPUT G...

Page 90: ...REVERSED BY USING THE REVERSE ACTING CAM LOCATED IN POSITIONER COVER AND REVERSING THE O1 AND O2 CO NNECTIONS GAG E D ESIGNATIO NS G1 SIG NAL GAGE G2 OUTPUT GAGE O 1 PO RT G3 OUTPUT GAGE O 2 PO RT T00773A DIRECT ACTING BLACK CAM O1 O2 G3 G3 G2 G2 G1 G1 O1 O2 REVERSE ACTING RED CAM MOTION W ITH INCREASING SIGNAL MOTION W ITH INCREASING SIG NAL ...

Page 91: ... 1 AV 2 1 2 3 TB1 CONNECTIONS T00807A 4 5 24 Figure B 9 Type AV Calibration Adjustment Locations T02002A PILOT VALVE SPAN ADJUSTMENT ASSEMBLY SPAN ADJUSTMENT SCREW TERM INAL BLOCK TB1 CABLE CLAMP ZERO ADJUSTMENT NUT SERVO ASSEMBLY CONDUIT HOLE ZERO ADJUSTMENT SET SCREW OPTIONAL MANIFOLD 5 4 3 2 1 ...

Page 92: ...2 Loosen the span adjustment screw Fig B 9 using a inch Allen wrench 2 Loosen the span adjustment screw Fig B 9 using a inch Allen wrench 3 Slide the span adjustment assem bly in the Fig B 9 appropriate direc tion toward cam to increase in order to align the 100 radial line with the center of the cam roller 3 Slide the span adjustment assem bly in the Fig B 9 appropriate direc tion toward cam to i...

Page 93: ...B 4 Servo Motor Speed Adjustment Coarse and Fine Coarse Adjustment Switch Position Factory Set Speed seconds Fine Adjustment Speed Range seconds 4 26 0 21 0 to 42 0 3 13 5 12 0 to 22 0 2 8 0 7 0 to 13 0 1 5 0 4 5 to 8 0 SERVO MOTOR WIRE CONNECTION EM I ELECTRONICS HOUSING T00317A COARSE FINE ...

Page 94: ... control signal pressure applied to the positioner The control characteristics for which the cams are shaped are listed in Table 3 1 and are shown in Figures C 1 C 2 and C 3 The figures show a family of curves for each cam whose boundaries are estab lished by a span adjustment Table C 1 lists control signal pressures of specific Type AV3 positioners which corresponds to the signal span percent val...

Page 95: ...50 10 90 60 40 70 30 80 20 90 10 100 0 SOLID LINE INDICATES FO RWARD TRAVEL DIRECT ACTING DASHED LINE INDICATES REVERSE TRAVEL REVER SE ACTING LIM ITED SIGNAL LIM ITED TRAVEL 100 40 10 20 30 90 50 60 70 80 0 SC ALE OF SIGNAL RANGE SC ALE TRAVEL T00793A 0 100 20 80 30 70 40 60 50 50 10 90 60 40 70 30 80 20 90 10 100 0 S OLID LINE INDICATES FO RWARD TRAV EL DASHED LINE INDICATES REVERSE TRAVEL LIMIT...

Page 96: ... required for your system Steps in selecting a standard cam for a particular application are 1 With the B linear cam in place determine and plot the actual controlled medium versus piston or valve position characteristic by manually adjusting valve position and measuring the controlled medium Fig C 4 Table C 1 Relationship of Input to Output for I P Converter AV3 of Control Signal I P Converter of...

Page 97: ...alve characteristic that will produce the results of Figure C 7 from a cylinder or actuator which performs as in Figure C 4 In the examples shown the required curve is a mirror image of the Step 1 curve taken about the Step 2 curve Fig C 7 4 Compare the curve plotted in Step 3 with the cam curves shown in Figures C 1 C 2 and C 3 Select a standard cam shape in this case a C cam whose characteristic...

Page 98: ...alues shown in Table C 1 for the particular positioner being used Together the radial lines and concentric arcs form a polar dia gram on which a new cam shape and characteristic can be plotted NOTE Before cutting any cam make sure that shaping will involve removal of cam material and not build up of cam material For exam ple if the characteristic plotted lies between the A and B cams Figs C 1 and ...

Page 99: ... 60 percent travel radial line of the cam a mark is placed at concentric line 4 rep resenting that pressure 3 Draw a line through the points located in Step 2 This will be the desired cam shape NOTE If a cam shape has too steep a rise the cam follower may become locked A cam with too steep a rise may be replaced with a cam with a gentler rise if sufficient angularity is introduced into the drive l...

Page 100: ... Shaping C 5 Square 1 2 Square root 1 2 Capacity 1 7 Capacity graph 1 8 Connecting tubing 3 7 Consumption air 1 7 Consumption graph 1 8 D Deadband 1 7 Description and operation 2 1 Drive arm stroke dimensions 3 5 E Enclosure classification 1 7 3 2 Errors 6 1 Exploded view Type AV3 9 6 Type AV4 9 11 External dimensions 3 3 F Fail in place 1 1 Features positioner 1 2 Filtering supply air 3 8 Functio...

Page 101: ...1 5 Removing and replacing cam 8 7 Repeatability 1 6 Replacement of positioner components 8 1 Replacement procedures Servo assembly and electronics circuit board 8 5 Replacing Diaphragm assembly 8 8 Gain hinge spring 8 3 Motor control circuit board 8 5 Pilot valve body 8 4 Servo assembly 8 5 Resolution 1 6 Retro fit mounting kits 1 10 Reverse acting operation 3 5 Routine service items 7 1 S Servo ...

Page 102: ... 4 14 Tubing connections 3 8 Tubing example Double acting 3 11 Single acting 3 10 U Unpacking and inspection 3 1 V Vibration effect 1 7 Voltage supply 1 6 W Weight 1 7 Wiring Connections 3 9 Diagram 3 11 Z Zero adjustment Type AV3 4 2 Type AV4 4 4 ...

Page 103: ...ione 243 20016 Pero Milano Italy Tel 39 02 33928 1 Fax 39 02 33928 240 ABB Instrumentation Ltd Howard Road St Neots Cambs England PE19 3EU Tel 44 0 1480 475 321 FAX 44 0 1480 217 948 ABB Inc Instrumentation Division 125 East County Line Road Warminster PA 18974 USA Tel 215 674 6000 FAX 215 674 7183 ABB Automation Products GmbH Industriestr 28 D 65760 Eschborn Germany Tel 49 0 6196 800 0 Fax 49 0 6...

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