Power-Genex PPR Series User manual

Instruction Manual
PPR Series
Pneumatic-Pneumatic Positioner
1. Read all safety instructions in this manual carefully before using this product. All work
should be done by staff with the necessary training and experience.
2. An air filter regulator should be installed before the positioner.
1. Part Number System
PPR ―Feedback
Shaft
Pressure
Gauge
(SUP.
OUT)
Pilot
Valve
Orifice
Position
Feedback Connectio
n
Threads
Dome
Indicator
High
Temp Mounting Bracket
Description Code Description Code
Feedback Shat:
Pressure
Gauge:
Pilot Valve
Orifice:
Position
Feedback:
N: NAMUR shaft (direct mounting)
A: Fork lever M6x40L
B: Fork lever other size on request
1: 6 bar (90 psi)
2: 10 bar (150 psi)
S: Standard
(actuator volume over 180 ㎤)
M: Small orifice (Φ1.0 or Φ0.7)
(actuator volume 90~180 ㎤)
N: None (standard)
O: Position transmitter
(4~20mA output signal)
L: 2 x SPDT limit switches
M: O+L
Connection
Threads:
(pneumatic)
Dome Indicator:
High
Temperature:
Mounting
Bracket:
3: Rc 1/4
4: NPT 1/4
N: Flat indicator (standard)
D: Dome indicator
T: 70℃(standard)
H: 120℃
(without position feedback option)
85℃
(with position feedback option)
N: None
R: Multi-size NAMUR bracket
for DIN VDI/VDE 3845
F: DHCT bracket 80x30
for fork lever type
E: Multi-size NAMUR bracket
for fork lever type
2. Specifications
PPR
Rotary Type (Cam Feedback)
Single Double
Input Signal 0.2~1.0 kgf/㎠(3 ~ 15psi) (Note 1)
Air Supply Max. 7.0bar (100psi) free of oil, water, and moisture
Standard Stroke 60 ~ 100 ° (Note. 2)
Pneumatic Connections Rc 1/4 or NPT 1/4
Ambient Temperature -20 ~ +70℃
Pressure Gauge Stainless Steel
Output Characteristics Linear
Linearity Within ± 1.0 % F.S Within ± 1.5 % F.S
Sensitivity Within ± 0.2 % F.S Within ± 0.5 % F.S
Hysteresis Within ± 1.0 % F.S
Repeatability Within ± 0.5 % F.S
Air Consumption 5 LPM (Sup. 1.4kgf/㎠)
Flow Capacity 80 LPM (Sup. 1.4kgf/㎠)
Material Aluminum Die-cast Body
Weight 2.5 kg
Note: 1) It is adjustable toset 1/2 spilt range for 3-9psi input signal or 9-15psi input signal.
2) Stroke can be adjusted to 0~60° or 0~100°
3. Mounting and Selecting RA (reverse acting) or DA (direct
acting)
CAUTION: Keep assembly tightly closed during operation.
A. Mounting with NAMUR type
The PPR positioner basically has the NAMUR shaft which can be directly
mounted to the top pinion (VDI/VDE 3845) of the pneumatic rotary
actuator..
①Mount the NAMUR multi-size bracket to the pneumatic rotary actuator
with the enclosed bolts (4 x M5) as shown to the right.
②Mount the positioner to the bracket and insert the positioner feedback
shaft into the actuator top pinion (output shaft) as shown to the right.
③Fix the positioner to the bracket with the enclosed bolts (4 x M6).
A multi-size bracket is assembled for 80x30x20 as a standard
factory setting. But the user can re-assemble it for 80x30x30, 130x30x20, and 130x30x30 according to
requirements as shown below.
B. Mounting with fork lever type
Mount the PPR positioner to the actuator with DHCT
bracket (80x30) as shown to the right. Be sure that the
feedback lever shaft “A” is placed in the orifice for the fork
lever “B” and they are in alignment with a rotary actuator
output shaft.
C. Cam and Indicator Adjustment
WARNING: When adjusting or replacing cams, be sure to shut off air supply to the PPR
positioner. Otherwise, the PPR positioner might react suddenly and cause
damage or injury.
RA (reverse acting) is a standard factory setting.
①Loosen a flange nut on a cam and reverse a cam for DA setting. Match the part of the cam with "0" marked on it with the
center of bearing as shown below. The span adjusting arm unit should now be aligned.
②Tighten the flange nut of the cam after setting the cam.
③After cam installation, proceed to adjust zero and span. Once this is complete, secure the indicator with the bolt (M6) to
the feedback shaft according to the actuator type (RA or DA) as shown below. The position for the indicator should be
arranged in the scale (0-90 degrees) shown on the cover.
[RA] [DA]
4. Air Connections
5. Internal View
Never move the seat adjuster. It was already set at the factory precisely.

6. Span and Zero Adjustment
①Check the proper installation of the PPR positioner and the feedback shaft.
②Check the proper position of a cam according to the actuator type (direct acting or reverse acting).
③Connect all air connections.
④Supply air and set the input signal to 3psi. Turn the zero adjusting screw clockwise or counter clockwise to set the zero
position.
⑤Check the stroke of the control valve by setting the input signal to 15psi. If the stroke does not meet 100%, turn the span
adjusting screw clockwise or counter clockwise until 100% is reached.
⑥Set the input signal back to 3psi and adjust the zero adjusting screw until the zero point is reached.
⑦Repeat the process of ④to ⑥until the desired set points are reached.
⑧If the strokes of the control valve perfectly meet 0% and 100%, each setting point of 6, 9, and 12psi is
automatically reached.
7. Wire Diagrams for Position Transmitter and Limit Switches
CAUTION: Always check that the electrical load is within the range stated on the nameplate.
Failure to remain within electrical ratings may result in damage to or premature
failure of the electrical switches, sensors or transmitter electronics.
8. Position Transmitter (4…20mA output signal)
A. Board View
B. Specifications
Power Supply Rating 5.5 ~ 30V DC loop-powered
Recommended Power Supply 24V DC
Output Signal 4~20mA
Operating Temperature -20º to 70℃
Load Impedance 0~600 ohms
Max. Output 30mA DC
Linearity ± 1.0 %
Hysteresis 1.0 % of full scale
Repeatability ± 0.5 % of full scale
Adjustment Zero and Span in terminal box
C. With mA Loop calibrator D. With multimeter tester
E. Span and Zero Adjustment
①Select RA or DA on a board in the terminal box. For reference, RA (reverse acting) is a standard factory setting.
②Supply 4mA input signal and turn the zero adjusting screw on a board clockwise or counter clockwise until output signal
becomes 4mA.
③Supply 20mA input signal and turn the span adjusting screw on a board clockwise or counter clockwise until output
signal becomes 20mA.
④Repeat the process of ②to ③until output signal approaches input signal.
1. Be sure that Span and Zero of the EPR positioner should be exactly set before
setting Span and Zero of the position transmitter.
2. Be sure that 5.5 - 30V DC should be supplied in case of using the mA tester
(multimeter tester).
3. Check a loop power if the output power indicating lamp ⑥is not on.
9. Limit Switches (open and close)
Contacts SPDT Form C
AC Rating 16A 1/2HP 125/250VAC
DC Rating 0.6A 125VDC / 0.3A 250VDC
Adjustment Cams with set screws (L-wrench included for setting)
10. Optional Restricted Pilot Valve Orifice
WARNING: Before removing the pilot valve, be sure to disconnect the positioner from the
signal and compressed air source
For improved control using smaller actuators, a restricted pilot valve orifice kit is
included with the positioner. To install, the pilot valve must be removed from the
positioner. Remove four screws holding the pilot valve to the positioner body. As
you remove the pilot valve, be sure to hold the compensation spring in place.
Flip the valve so the bottom faces you. Remove the o-rings from the out 1 and
out 2 ports (as shown in the diagram at right). Place the orifice plates in their
place with new o-rings above them, and re-install the pilot valve, making sure
the compensation spring is back in place. The positioner is now set up for
smaller actuators.
11. Troubleshooting Tips
Troubles Solutions
There happens a hunting with a
small pneumatic actuator
The actuator is very small. Install two orifices at the bottom of the pilot
valve as instructed in 10. Optional Restricted Pilot Valve Orifice.
If the actuator is not small, check if a position shaft is inserted into the
output shaft of the actuator exactly. If there is a gap between these shafts,
make it tight.
The valve always opens
regardless of input signal.
The orifice of the Auto/Manual screw on the pilot valve is clogged.
Disconnect supply air and clean the orifice with a wire attached inside of
the EPR positioner cover as shown below.
Never move the seat adjuster. It was already set at the factory
precisely.
The valve always opens or
closes with input signal
The air connections are not made properly. Check again if the pneumatic
actuator type is RA (reverse acting) or DA (direct acting) and make the
proper air connections. See 7. Air Connections.
Linearity is very poor Re-set Zero and Span.
Hysteresis is very poor Tighten a mounting bracket.
12. Dimensions
Power-Genex Ltd.
44B9L, 434-9, Nonhyun-dong,
Namdong-gu, Incheon 405-848 Korea
Tel: [phone] Fax: [phone]
www.powergenex.com [e-mail]