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Power-Genex SS3L Series Instructions And Operating Manual

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Instruction and Operating
Manual
Smart Valve Positioner
SS3L / SS3R Series
<Software Version 6.06>
Power-Genex Ltd.

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Summary of Contents for Power-Genex SS3L Series

  • Page 1 Instruction and Operating Manual Smart Valve Positioner SS3L / SS3R Series <Software Version 6.06> Power-Genex Ltd.

  • Page 2: Table Of Contents

    SS3L / SS3R Series Contents 2. Overview of Structure ...............................9 3. Specifications ..................................10 3.1. Specifications for Profibus PA Communication ..................11 3.2. Specifications for Fieldbus Communication .................... 12 4. Part Numbering System (order code) ........................13 4.1. Descriptions on Nameplate ..........................14 5.
  • Page 3 SS3L / SS3R Series 11. Description of Parameters Flow ..........................30 11.1. Diagram of Parameters ..........................30 11.2. Main Parameters ............................... 31 11.3. Parameters................................32 11.3.1. Main Parameters ..........................32 11.3.2. CTRL - Parameters (speed control adjustment) ..............32 11.3.3. SUB - Parameter ........................... 32 11.4.
  • Page 4 3. Before machinery/equipment is restarted, take measures to prevent unexpected operation and malfunction. 4. Contact POWER-GENEX beforehand and take special consideration of safety measures if the product is to be used in any of the following conditions. 1. Conditions and environments outside of the given specifications, or use outdoors or in a place exposed to direct sunlight.
  • Page 5 Compliance Requirements 1. The use of POWER-GENEX products with production equipment for the manufacture of weapons of mass destruction (WMD) or any other weapon is strictly prohibited. 2. The exports of POWER-GENEX products or technology from one country to another are governed by the relevant security laws and regulations of the countries involved in the transaction.
  • Page 6 SS3L / SS3R Series 1-3 Precautions Be sure to read before handling. Operation Warning 1. Do not operate the positioner outside the specified range as this may cause problems. (Refer to the specifications.) 2. Design the system to include a safety circuit to avoid the risk of danger should the positioner suffer failure.
  • Page 7 SS3L / SS3R Series 1-4 Precautions Be sure to read before handling. Handling Caution 1. Avoid excessive vibration or impact to the positioner body and any excessive force to the armature, as these actions may cause damage to the product. Handle carefully while transporting and operating.
  • Page 8 SS3L / SS3R Series 1-5 Precautions Be sure to read before handling. Maintenance Warning 1. After installation, repair or disassembly, connect compressed air and conduct tests to confirm appropriate function and leakage. Do not use the positioner when noise from the bleeder sounds louder compared with the initial state, or when it does not operate normally.

  • Page 9: Overview Of Structure

    SS3L / SS3R Series 2. Overview of Structure This product consists of the following parts. • Electronic card comprised of microprocessor, HART modem and LCD • Potentiometer for position feedback • Pilot valve, Torque motor, Pressure gauge and block The followings are descriptions of internal parts without cover. MO, Mode button Positioner body Gauge block...

  • Page 10: Specifications

    SS3L / SS3R Series 3. Specifications Input signal 4 - 20 mA @ 24 VDC Min. / Max. current 3.6 mA / 50mA Communication HART / Profibus PA / Foundation Fieldbus Linear type: 5 - 130mm * Operating angle/ stroke Rotary type: 25 - 120°...

  • Page 11: Specifications For Profibus Pa Communication

    SS3L / SS3R Series With Communication Foundation Communication HART PROFIBUS Fieldbus Input signal / Bus 4 – 20 mA @ 24 VDC 9 – 32 VDC voltage Min. / Max. Current 3.6 mA / 50mA Current Consumption 15 mA 16 mA Voltage drop 8.9 VDC 9.4 VDC...

  • Page 12: Specifications For Fieldbus Communication

    SS3L / SS3R Series 3.2. Specifications for Fieldbus Communication Specification Foundation Fieldbus Version 2.0 Physical layer Model 113,121 (IEC 61158-2) Transmission rate 31.25 kbit/s Supply voltage Bus-powered : 9 ~ 32 VDC 2 AI Function Block 1 AO Function Block Block types 2 DI Function Block 1 Transducer Block...

  • Page 13: Part Numbering System (Order Code)

    SS3L / SS3R Series 4. Part Numbering System (order code) Model classification code or ordering information or type designation or model schedule or model numbering system SS3 x — Actuator action Linear type Rotary type Protection class Flameproof ( Ex d IIC T6 ) Feedback lever Linear type 8 ~ 30mm stroke...

  • Page 14: Descriptions On Nameplate

    SS3L / SS3R Series 4.1. Descriptions on Nameplate ᆢ MODEL NUMBER Model number and options are described. ᆢ INPUT SIGNAL Current input signal is described. 4~20mA current is used. Inquire the head office or the agents if other special input signal is required. ᆢ...

  • Page 15: Descriptions Of Lcd Display And Buttons

    SS3L / SS3R Series 6. Descriptions of LCD display and Buttons ① Display of input or output ② Main parameters ③ mA, % display mode ④ Operation of HART ⑤ Up button ⑥ Down button ⑦ Mode button ⑧ Enter button Press "Mode"...

  • Page 16: Installation

    SS3L / SS3R Series 7. Installation Be sure to install the air filter regulator before the positioner and check a supply air pressure required to move the valve. 7.1. Mounting onto Linear Actuator 7.1.1. Installation of Follower Guide ① Follower guide ②...

  • Page 17: Mounting Onto Cast Yoke Or Pillar Yoke

    SS3L / SS3R Series 7.1.3. Mounting onto Cast Yoke or Pillar Yoke < Cast yoke type > < Pillar yoke type > ① Cast yoke ② Mounting bracket ③ Screws(M8) ④ U-bolts ⑤ Pillar yoke 7.1.4. Mounting onto Other Kind of Cast Yoke <...

  • Page 18: Mounting On Diaphragm Actuator

    SS3L / SS3R Series 7.1.5. Mounting on Diaphragm Actuator Feedback Levers "A" type: 8 ~ 30mm stroke "B" type: 8 ~ 70mm stroke "C" type: 8 ~ 130mm stroke "D" type: 80 ~ 200mm stroke 7.1.6. Installation of Feedback Pin Follower Guide www.powergenex.com...

  • Page 19: Standard Installation

    SS3L / SS3R Series 7.1.7. Standard Installation ① Supply air directly to the actuator, adjust the air filter regulator and set air when the valve reaches to 50% stroke. ② Install the feedback pin at around 30% higher point of the stroke indicated on the feedback lever than the required stroke of the control valve and fix with a screw tightly.

  • Page 20: Mounting Onto Rotary Actuator

    SS3L / SS3R Series <Maximum operating ange : 60°> <Indicator position at 50%> <Indicator position at 0% (100%)> <Indicator position at 100% (0%)> 7.2. Mounting onto Rotary Actuator 7.2.1. The SS3R positioner supports NAMUR mounting standard (VDI/VDE 3835, IEC 60534-6-2). ①...
  • Page 21 SS3L / SS3R Series ⓐ Assemble the multi-size bracket to the SS3R positioner with 4 pcs M6 screw. The multi-size bracket is assembled for 80x30x20mm as standard at the factory. If you have other size bracket, see ‘7.2.4 Re-assembling Multi-size Bracket according to Rotary Actuator’. ⓑ...

  • Page 22: Mounting With Fork Lever Type

    SS3L / SS3R Series 7.2.2. Mounting with Fork Lever Type ① SS2R positioner ② Multi-size bracket ③ Rotary pneumatic actuator ④ Fork lever ⑤ Positioner feedback lever 7.2.3. Position of Fork Lever Clockwise movement Counter-clockwise Movement www.powergenex.com...

  • Page 23: Re-Assembling Multi-Size Bracket According To Rotary Actuator

    SS3L / SS3R Series 7.2.4. Re-assembling Multi-size Bracket according to Rotary Actuator (mm) (mm) (mm) (mm) Check L and H on the actuator and re-assemble the multi-size bracket to fit your actuator mounting configuration. www.powergenex.com...

  • Page 24: Air Connections

    SS3L / SS3R Series 8. Air Connections ① Be sure to install the air filter regulator before the positioner. ② Supply air should not contain water, oil or moisture. ③ It is recommended to set a supply air pressure 10% higher than the actual operating pressure of the actuator.

  • Page 25: Electrical Connections

    SS3L / SS3R Series 9. Electrical Connections ① Be sure to supply the rated voltage and current stated on this manual. Otherwise, it may cause a serious damage or malfunctions. ② Check polarity of + and – exactly and connect wires. ③...

  • Page 26: Measuring Output Signal

    SS3L / SS3R Series 9.2. Measuring Output Signal 9.2.1. With mA loop calibrator Position Transmitter Specifications Output signal 4 – 20mA, 2-wire Power supply 12 – 30 VDC Output current limit 30mA DC 9.2.2. With multi-meter Linearity ±0.75% F.S Operating temperature -20 ~ +80℃...

  • Page 27: Wiring Alarm Limits

    SS3L / SS3R Series 9.4. Wiring Alarm Limits 24VDC should be supplied for alarm limits. 9.5. HART Connection Note that wires for HART communication should be connected to terminals No. 1 and No. 2 together with wires for input signals. For reference, there is no distinction in + and –...

  • Page 28: Wiring Spdt Micro Switches

    SS3L / SS3R Series 9.7. Wiring SPDT Micro Switches Micro Switch Specifications Type SPDT 10.1A @ 250 Rating code Operating -25 ~ +85℃ temperature 9.8. Setting Micro Switches a) Push the red cam down and move. b) Turn the red cam until it touches the limit switch. And push up. c) Do the same procedure with the blue cam.

  • Page 29: Quick Auto-Calibration

    SS3L / SS3R Series 10. Quick Auto-Calibration 10.1. Quick Auto-Calibration Supply 4-20mA input signal and push the MODE button for 5 seconds, the auto-calibration process will start. In case of a reverse acting actuator, RA is displayed and a countdown begins. 5→4→3→2→1→END→RUN (auto-calibration is completed) In case of a direct acting actuator, DA is displayed and a countdown begins.

  • Page 30: Description Of Parameters Flow

    SS3L / SS3R Series 11. Description of Parameters Flow 11.1. Diagram of Parameters Note that the PST function (Partial Stroke Testing) is loaded at the factory on demand only when requested. www.powergenex.com...

  • Page 31: Main Parameters

    SS3L / SS3R Series 11.2. Main Parameters Ref. Parameter Description Function DISP DISPLAY changes the LCD display mode PVPR PV % value shows the current position by % 11.4.2 SVMA Input signal mA value shows the input signal by mA PV % value shows the current position by % in a reverse way PV-R...

  • Page 32: Parameters

    SS3L / SS3R Series 11.3. Parameters 11.3.1. Main Parameters Ref. Parameter Description Function Default 11.5.1 INPU Input signal 4…20mA or 20…4mA 4…20mA 11.5.2 R / DA RA / DA Reverse acting or direct acting Linear, E.Q. % (1:25 or 1:50), 11.5.3 L / E.Q Characteristic...

  • Page 33: Setting Of Main Parameters

    SS3L / SS3R Series 11.4. Setting of Main Parameters The following abbreviations will be used hereafter. MODE ENTER DOWN 11.4.1. LOCK ON / OFF LOCK ① LOCK ON : Saves all setting values. ② LOCK OFF : Be sure to LOCK OFF when it is necessary to read or change the selected parameters and the saved setting values.

  • Page 34: Manual Mode (Default: 0)

    SS3L / SS3R Series 11.4.3. Manual Mode (default: 0) The valve can be moved to 0 – 100% manually. MSET 11.4.4. Monitor Mode CHEK OK 0 ㆍㆍㆍOK 12 MILE You can check the error codes and a total valve runtime. 11.4.1 MON blinks Select CHEK...

  • Page 35: Auto-Calibration Mode

    SS3L / SS3R Series 11.4.5. Auto-Calibration Mode AUTO TUNE RSET STEN COLD If necessary, initialize all setting values to the original values set after auto-calibration or return them to the factory setting values. 11.4.5.A Performing Auto-Calibration ① Reverse acting (RA) is a standard factory setting. Even if air lines are connected wrongly by mistake, the SS2 positioner detects automatically and performs auto- calibration for direct acting (DA).

  • Page 36: Self-Test Mode

    SS3L / SS3R Series 11.4.6. Self-Test Mode TEST MONT • The current valve mounting situation is shown. If the value is far away from 0, the valve will suffer from a poor linearity and hysteresis. Move the positioner and try to reach closer to 0 for the best linearity and hysteresis.

  • Page 37: Parameters Flow Diagram

    SS3L / SS3R Series 11.5. Parameters Flow Diagram The colored cells stand for the standard factory settings. All setting values return to the standard factory settings if RESET begins. www.powergenex.com...

  • Page 38: Inpu] Change Of Input Signal (Default: 4-20Ma)

    SS3L / SS3R Series 11.5.1. [INPU] Change of Input signal (default: 4-20mA) INPU 4-20 20-4 It is possible to make the positioner respond to 20-4mA input signals optionally even though 4- 20mA input signals are supplied. 11.5.2. [R/DA] Selection of Direct Acting (DA) or Reverse Acting (RA) (default: RA) R/DA 11.5.3.
  • Page 39 SS3L / SS3R Series Linear EQ% ( 1 / 25 ) EQ% ( 1 / 50 ) Quick Open User set(17point) - For the user setting, Example 1) User Set Value Ex-1 Ex-2 Valve Point Parameter Input Signal (mA) Opening% (set value) Example 2) 10MA...

  • Page 40: Span] Span Adjustment (Default: 100)

    SS3L / SS3R Series NOTES 1. This user setting has a linear characteristic as standard. 2. 5MA means % corresponding to 5mA. 3. Input all 4MA to 20MA for a required user set characteristic curve. ※ If Shut Off option is set, the set value at 4mA is maintained during interval of the Shut Off setting value as shown in Example 2). The curve goes according the user set value after interval of the Shut Off setting value.

  • Page 41: Pid-Gain

    SS3L / SS3R Series 11.5.6. PID-Gain P-GN I-GN D-GN 11.5.6.A P-Gain (Proportional Gain) P-GN Auto Set The micro-processor calculates P-Gain value during auto-calibration process in consideration of sizes of the valve and the actuator. If a hunting problem happens, decrease P-Gain value. If an oscillation problem happens, increase P-Gain value.

  • Page 42: Ctrl] - Control Speed Adjustment

    SS3L / SS3R Series 11.5.7. [CTRL] – Control Speed Adjustment CTRL ⇒ SPED KISP GNLT CNLT HDGP 11.5.7.A [SPED] – Response Speed Adjustment (default: 1000) SPED 1…1000 This is to adjust the response speed of the actuator. (Min: 1, Max: 1000) 11.5.7.B [GAP] –...

  • Page 43: Dead] Setting Of Dead Band (Default: 0.5)

    SS3L / SS3R Series 11.5.7.E [CNLT] – Control Limit (default: automatically-set) CNLT AUTO 50-1250 CNLT is to limit a control range and set automatically during an auto-calibration process. When 0% - 100% input signal is supplied, a recognition range of the positioner is settled according to CNLT.

  • Page 44: Sub Parameter

    SS3L / SS3R Series 11.5.9. SUB Parameter Ref. Parameter Description Function Default 11.5.9.A Shut-off 0…9.9% 0.3% 11.5.9.B Full-open 0…9.9% 0.3% 11.5.9.C Output signal 4…20mA or 20…4mA 4…20mA 11.5.9.D Split range 4…12mA or 12…20mA 4…20mA Change of display 11.5.9.E Forward or reverse direction position on LCD Alarm limit low, 0…10%,...
  • Page 45 SS3L / SS3R Series 11.5.9.B [FOPN] Valve Full Open Control (default: 0.3) FOPN 0-9.9 The valve can be fully open manually. And it is possible to change 0% to 9.9%. For reference, 0.1% means that the positioner responds to 0.016mA. Therefore, the standard value of 0.3% means that a valve is fully open at 19.952mA.
  • Page 46 SS3L / SS3R Series 11.5.9.F [ALRM] Setting of Alarm Limits (default: 0 – 10%, 90 – 105%) ALRM AL1L AL1H AL2L AL2H ⇕ ⇕ ⇕ ⇕ 0000 0010 0090 0105 You can set an opening point or a closing point of a control valve. AL1 (L, H) is set to 0 – 10% and AL2 (L, H) is set to 90 –...
  • Page 47 SS3L / SS3R Series For example, see the below in order to re-set AL2 to 80 – 100%(AL2L = 80, AL2H = 100). ① AL2L Setting ② AL2H Setting How to wire the Alarm Limits 24VDC should be supplied for alarm limits. www.powergenex.com...
  • Page 48 SS3L / SS3R Series 11.5.9.G [ICAL] – Setting of Input Signal (default: factory setting) ICAL IN4M IN20 This is to match 4mA and 20mA input signals from a signal calibrator with the internal setting 0% and 100% of the positioner and save onto memory. If 4mA output signal is measured as 4.2mA and 20mA output signal as 19.8mA with a signal calibrator on site, 4.2mA can be recognized as 0% and 19.8mA as 100% by re-setting with ICAL.
  • Page 49 SS3L / SS3R Series 11.5.9.I [POLL] – HART Communication Polling Address (default: 0) POLL 0 ~ 15 This is to select one of HART communication polling address (0 ~ 15) on site. The default address is “0”. As an unexpected problem can happens during communication, try to select after disconnecting HART communication.
  • Page 50 SS3L / SS3R Series 11.5.9.K [ADDR] - PROFIBUS Communication Address (default: 126) ADDR 0 ~ 126 This is to select one of PROFIBUS communication address (0 ~ 125) on site. The default address is “126”. www.powergenex.com...

  • Page 51: Maintenance / Service

    SS3L / SS3R Series 12. Maintenance / Service 12.1. Preliminary Check Points 12.1.1. Voltage - The positioner commonly requires 4-20mA @ 24VDC for operation. - Voltage drop (impedance): Without HART – 8.7VDC (435Ω @ 20mA) With HART – 9.4VDC (470Ω @ 20mA) 12.1.2.
  • Page 52 SS3L / SS3R Series 12.4 Exchanging the Positioner Spare Parts ① Begin procedure after complete removal of supply air. ② Re-start auto-calibration procedure after exchanging spare parts 12.4.1 How to Exchange SS3L / SS3R Pilot Valve ① Disassemble the Pilot valve cover. ②...

  • Page 53: Troubleshooting

    SS3L / SS3R Series 13. Troubleshooting 13.1. Error Codes and Recommended Actions If the positioner doesn’t work properly and on LCD blinks, try to take action as below. DATA DATA blinks Error Cause Symton Action Code Low input current CMLO (3.7mA) Data on LCD are shown too dim Re-check 4 –...

  • Page 54: Spare Parts

    SS3L / SS3R Series 14. Spare Parts 14.1. SS3 Parts www.powergenex.com...

  • Page 55: List Of Spare Parts

    SS3L / SS3R Series 14.2. List of Spare Parts Part No. Description PG-SS3-01 Air line body ass’y PG-SS3-02 SS3 pilot valve ass’y PG-SS3-03 Coil ass’y PG-SS3-04 Airline plate PG-SS3-05 Gauge PG-SS3-06 PV cover 6.10 PG-SS3-07 Flame arrest 4.14 PG-SS3-08 Airline body 4.16 PG-SS3-09 Vent Unit...

  • Page 56: Dimensions

    SS3L / SS3R Series 15. Dimensions 15.1. SS3L (linear type) www.powergenex.com...

  • Page 57: Ss3R (Rotary Type)

    SS3L / SS3R Series 15.2. SS3R (rotary type) www.powergenex.com...
  • Page 58 - In case that the products are damaged by fire, earthquake, storm, flood, thunder, lighting, other natural disasters, riot, war, exposure to radioactivity 4. If maintenance is required, please contact distributors or Power-Genex directly. A proper and satisfactory customer service will be provided.

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