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Power-Genex ASD-5000 Series - User Manual

Power-Genex ASD-5000 Series
71 pages
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Instruction and Operating
Manual
Smart Valve Positioner
ASD-5000 Series
Power-Genex Ltd.
ver 1.0

Table of Contents

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Summary

General Safety Instructions

Hazard Level Indicators

Defines Caution, Warning, and Danger levels for potential hazards.

Product Compatibility & Design Responsibility

User's responsibility for product compatibility and system design.

Trained Personnel Operation

Emphasizes operation by trained personnel only.

Maintenance & Service Safety

Safety measures for inspection and maintenance procedures.

Special Application Conditions

Conditions requiring special consideration before use.

Product Usage and Compliance

Intended Use & Warranty Disclaimer

Product intended for manufacturing industries; warranty terms and disclaimers apply.

Export and WMD Compliance

Prohibits use for WMD manufacturing and outlines export regulations.

Operational Precautions

Operation Warnings

Critical warnings for safe operation of the positioner.

Operation Cautions

Precautions for safe operation and handling.

User Handling Precautions

General precautions for users of the positioner.

Handling and Environment Precautions

Handling & Impact Safety

Precautions regarding vibration, impact, moisture, and magnetic fields.

Air Supply Quality

Requirements for clean, dry, and dust-free compressed air.

Operating Environment Limits

Guidelines for operating temperature, corrosive atmospheres, etc.

Maintenance & Safety Precautions

Maintenance Procedures

Safety steps for maintenance and electrical modifications.

Electrostatic Charging Hazard

Warnings and precautions for electrostatic discharge.

Intrinsic Safety & Earthing

Requirements for intrinsic safety and proper earthing.

Product Overview

ASD-5000 Positioner Components

Lists the main components of the ASD-5000 positioner.

External Parts Identification

Diagram and labels identifying external parts of the positioner.

Technical Specifications

Input & Output Signals

Details on input signal range, HART, and output specifications.

Air Supply & Actuator Compatibility

Instrument air requirements and compatible actuator types.

Environmental & Feedback Options

Environmental influences and feedback options.

Enclosure & Hazardous Area Approvals

Enclosure details, protection class, and hazardous area certifications.

Ordering Information

Model Classification Code Structure

Explanation of the model code for ordering the positioner.

Example Order Code

Illustrates an example of a complete order code.

Nameplate and Operation Principle

Nameplate Information Details

Detailed explanation of information found on the product nameplate.

Principle of Operation Diagram

Block diagram illustrating the device's operating principle.

LCD Display and Buttons

LCD Display Element Labels

Identifies and labels the elements shown on the LCD display.

LCD Display Modes

Display Configurations

Details various display modes for the LCD screen.

Multi-lingual Display Support

Information on supported languages for the display.

Installation Procedures

Mounting on Linear Actuators

General instructions for mounting to linear actuators.

Follower Guide Installation

Steps for installing the follower guide component.

Feedback Lever & Bracket Installation

Procedure for installing the feedback lever and mounting bracket.

Installation Procedures

Mounting on Yoke Types

Instructions for mounting onto cast yoke or pillar yoke.

Mounting on Other Cast Yokes

Guidance for mounting on alternative cast yoke designs.

Installation Procedures

Mounting on Diaphragm Actuators

Instructions for mounting the positioner on diaphragm actuators.

Feedback Pin Follower Guide

Details on installing the feedback pin follower guide.

Installation Procedures

Standard Installation Steps

Step-by-step guide for standard installation.

Installation Procedures

Operating Angle Specifications

Specifies the maximum allowable operating angle for the valve.

Valve Stem Pin Placement

Correct placement of the valve stem pin on the feedback lever.

Installation Direction Guidelines

Visual guidance on proper installation orientation.

Rotary Actuator Mounting

NAMUR Standard Mounting

Confirms support for NAMUR mounting standards.

Assembly and Connection Steps

Steps for assembling and connecting to rotary actuators.

Rotary Actuator Mounting

Fork Lever Type Mounting

Specific instructions for mounting with a fork lever.

Fork Lever Position Adjustment

Guidance on setting the correct position of the fork lever.

Rotary Actuator Mounting

Multi-size Bracket Re-assembly

Instructions for re-assembling the multi-size bracket.

Air Connections

General Air Connection Guidelines

Basic guidelines for air filter, quality, and pressure.

Linear Type Air Connections

Diagrams for direct and reverse acting linear connections.

Rotary Type Air Connections

Rotary Actuator Airflow

Air connection diagrams for rotary actuators.

Orifice Installation for Stability

Guidance on using orifices to prevent hunting.

Auto;Manual Mode Switch

Explanation of the auto/manual mode switch.

Electrical Connections

Terminal Block Overview

Diagram showing the terminal block layout.

Electrical Connections

Input;Output Signal Wiring

Wiring instructions for input and output signals.

Alarm Limit Wiring

Wiring for wet contact alarm limits.

Electrical Connections

Limit Switch Wiring

Wiring for dry contact limit switches (SPDT, P&F).

Earthing Connections

Instructions for internal and external earthing.

Intrinsic Safety Wiring

Intrinsic Safety Guidelines

General rules and precautions for intrinsic safety wiring.

Input Signal Wiring (IS)

Specific wiring for intrinsic safety input signals.

Output Signal Wiring (IS)

Specific wiring for intrinsic safety output signals.

Intrinsic Safety Wiring

Alarm Limit Wiring (IS)

Intrinsic safety wiring for alarm limits.

SPDT Switch Wiring (IS)

Intrinsic safety wiring for SPDT switches.

Intrinsic Safety Wiring

P&F Sensor Wiring (IS)

Intrinsic safety wiring for P&F proximity sensors.

Cable Entry Management

Cable Gland Installation

Instructions for installing cable glands.

Blind Plug Installation

Instructions for installing blind plugs.

Auto-Calibration Procedure

Initiating Auto-Calibration

Steps to start the auto-calibration process.

Changing Display Modes

How to switch between different display configurations.

Parameter Flow Diagrams

Overall Parameter Structure

Diagram showing the hierarchical structure of parameters.

Main Parameter Overview

Display Variable Settings

Parameters for controlling display variables.

Manual & Monitoring Parameters

Parameters for manual operation and monitoring.

Auto Tune & General Parameters

Parameters for auto-tuning and general settings.

Test & Lock Parameters

Parameters for testing and locking functions.

Detailed Parameter Settings

Core Parameters (Input to Dead Band)

Detailed settings for input, PID, and dead band.

Control & Speed Adjustment Parameters

Parameters for speed, damping, sensitivity, and linearization.

Sub-Menu Parameters

Parameters accessible via the sub-menu.

Parameter Setting Functions

Lock Functionality

How to enable or disable parameter locking.

Display Mode Settings

Options for changing the display mode and values.

Parameter Setting Functions

Manual Mode Operation

Procedure for operating the valve manually.

Monitoring Mode Functions

How to check status, errors, and mileage.

Parameter Setting Functions

Auto-Calibration Mode

Details on performing auto-calibration.

Parameter Setting Functions

Initializing Settings (Reset)

Resets all settings to factory defaults.

Start;End Calibration Re-adjustment

Recalibrates the start and end points of the valve.

Cold Start (Re-booting)

Restarts the positioner program.

Test Modes

Performing Valve Test

Steps to execute a valve test.

Test Modes

Installation Check Procedure

Procedure to verify correct installation status.

Parameter Flow Diagrams

Main Menu Flow

Diagram illustrating the main menu structure.

Detailed Parameter Categories Flow

Flow diagram showing parameter categories.

Input Signal Configuration

Setting Input Signal Type

Configures the input signal type (4-20mA or 20-4mA).

Input Signal Response Behavior

Describes how the positioner responds to input signals.

Valve Characteristic Selection

Linear Characteristic Setting

Sets the valve control to a linear characteristic.

Shape Mode Configuration

Allows selection and adjustment of shape modes for valve curves.

Valve Characteristic Selection

User Defined Characteristic Setup

Enables user to create custom valve characteristic curves.

Span Adjustment

Adjusting Valve Opening Range

Sets the maximum range of valve opening.

Dead Band Setting

Adjusting Dead Band Value

Sets the dead band to account for SV/PV differences.

PID Gain Tuning

PID Gain Adjustment Overview

Introduction to adjusting PID gain parameters.

Proportional Gain (P-Gain) Tuning

Adjusting the proportional gain for control.

Integral Gain (I-Gain) Tuning

Adjusting the integral gain for control.

PID Gain Tuning

Differential Gain (D-Gain) Tuning

Adjusting the differential gain for control.

Control Speed Adjustment

Actuator Response Speed Setting

Adjusts the response speed of the actuator.

Control Speed Adjustment

1 st Damping Limit Adjustment

Sets the first damping limit for control range.

2 nd Damping Limit Adjustment

Sets the second damping limit for control.

Control Speed Adjustment

Sensitivity Setting

Adjusts the sensitivity based on actuator size.

Lever Compensation for Linear Type

Auto-compensation for feedback lever pin position.

Control Speed Adjustment

Linearization Adjustment

Fine-tunes position control for improved accuracy.

Sub-Menu Parameters

Sub-Menu Parameter List

Lists parameters available within the sub-menu.

Valve Shut-off Control (Full Close)

Ensuring Complete Valve Closure

Safety function to ensure the valve closes completely.

Output Signal Configuration

Position Transmitter Output Signal Setup

Configures the output signal for position transmitter function.

LCD Display Rotation

Rotating LCD Display Orientation

Allows changing the orientation of the LCD display.

Software Limit Switches (Alarm)

Configuring 24 VDC Alarm Limits

Sets software-based alarm limits for 24VDC outputs.

Input Signal Calibration

Calibrating Input Signal Values

Matches calibrator signals to positioner settings.

HART Communication Address

Setting HART Communication Address

Selects the HART communication polling address.

Partial Stroke Testing (PST)

Configuring PST Parameters

Sets parameters for Partial Stroke Testing.

Partial Stroke Testing (PST)

Setting Response Time for PST

Adjusts the valve response time during PST.

Pressure Sensor Monitoring

Monitoring Internal Pressure Readings

Displays readings from internal pressure sensors.

Maintenance and Service

Preliminary Check Points

Checks for voltage, connections, and air quality before maintenance.

Spare Parts Identification

Identifies key spare parts with part numbers.

Spare Parts Replacement

Pilot Valve Replacement Procedure

Step-by-step guide for replacing the pilot valve.

Torque Motor Replacement Procedure

Step-by-step guide for replacing the torque motor.

Parts List

List of Spare Parts

Comprehensive list of available spare parts.

Product Dimensions

ASD-5000 Linear Type Dimensions

Technical drawings and measurements for the linear type.

Product Dimensions

ASD-5000 Rotary Type Dimensions

Technical drawings and measurements for the rotary type.

Warranty Information

Warranty Period and Terms

Details on the product's warranty period and conditions.

Contacting Power-Genex Support

Information on how to contact support for service.

Power-Genex ASD-5000 Series Specifications

General IconGeneral
Input Signal4-20 mA
Supply Pressure1.4 - 7 bar (20 - 100 psi)
ProtectionIP66
Enclosure RatingNEMA 4X, IP66
Housing MaterialAluminum

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