ABB AV1 Operating Instructions Manual
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ABB AV1 Operating Instructions Manual

ABB AV1 Operating Instructions Manual

Actuators & positioners
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Operating Instructions
Actuators & Positioners
Models AV1/AV2
Characterizable Pneumatic
Positioners
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Summary of Contents for ABB AV1

  • Page 1 Operating Instructions Actuators & Positioners Models AV1/AV2 Characterizable Pneumatic Positioners...
  • Page 2 This document contains proprietary information of ABB Inc., and is issued in strict confidence. Its use, or repro- duction for use, for the reverse engineering, development or manufacture of hardware or software described herein is prohibited.

  • Page 3: Table Of Contents

    TUBING CONNECTIONS .......................3-8 Air Supply Pressure .........................3-8 Air Supply Filtering ........................3-8 Air Supply Quality (Recommended) ..................3-9 Tubing Connections .........................3-9 WIRING TYPE AV2 POSITIONER....................3-10 WIRING TYPE AV1 POSITIONER....................3-13 RADIO FREQUENCY INTERFERENCE..................3-15 WIRING REQUIREMENTS ......................3-15 SECTION 4 - CALIBRATION.......................4-1 INTRODUCTION ..........................4-1 CALIBRATION ..........................4-1 Zero Adjustment ........................4-1...
  • Page 4 Calibrating the 4 to 20-mA Position Transmitter..............A-6 APPENDIX B - QUICK START....................B-1 INTRODUCTION ..........................B-1 PRODUCT IDENTIFICATION (NOMENCLATURE)............... B-1 MOUNTING THE POSITIONER..................... B-2 TUBING CONNECTIONS....................... B-5 TYPE AV2 POSITIONER WIRING ....................B-8 TYPE AV1 POSITIONER WIRING ....................B-10 CALIBRATION..........................B-11...
  • Page 5 APPENDIX C - CAM CHARACTERIZATION ................C-1 INTRODUCTION ..........................C-1 CAM CHARACTERIZATION ......................C-1 CAM SELECTION .......................... C-3 CAM SHAPING ..........................C-5 APPENDIX D - TYPE AV1 PNEUMATIC POSITION TRANSMITTER........D-1 INTRODUCTION ..........................D-1 DESCRIPTION ..........................D-1 INSTALLATION ..........................D-2 CALIBRATION ..........................D-3...
  • Page 6 Stroke Adjustment Screws .......................8-8 9-1. Mounting Kits..........................9-6 9-2. Bypass Valve Assembly ......................9-8 9-3. Type AV1 Positioner ....................... 9-11 9-4. Type AV2 Positioner (Page 1 of 2) ..................9-16 9-4. Type AV2 Positioner (Page 2 of 2) ..................9-17 A-1. Terminal Block Connections ....................A-2 A-2.
  • Page 7 9-27. Cam Selection and Manifold/Gage Block Parts Reference for Type AV1 Positioners .......................9-10 9-28. Shaft Position Transmitter Parts Reference for Type AV1 Positioners ........9-12 9-29. Drive Shaft Parts Reference for Type AV1 Positioners............9-12 9-30. Type AV2 Positioner Parts List .....................9-12 9-31.
  • Page 8 Read these instructions before starting installation; save these instructions for future reference. Contacting the Factory . . . Should assistance be required with any of the company’s products, contact the following: Telephone: 24-Hour Call Center 1-800-HELP-365 E-Mail: [email protected] Read First...

  • Page 9: Section 1 - Introduction

    DESCRIPTION The Type AV1 and Type AV2 positioners are control devices that satisfy a wide range of applications. They provide fast, sensitive and accurate positioning of pneumatic single or double acting actuators.

  • Page 10: Performance Series Option

    INTRODUCTION A mechanical connection from the actuator (i.e., cylinder, valve, etc.) to the position feedback cam in the positioner establishes actual position. Three characterized segments on the cam provide application flexibility by establishing various relationships between the input signal and the actuator position. The characterized curves on the cam provide: Square root relationship.

  • Page 11: Explosionproof I/P Option

    NEMA 4X rat- ing. APPLICATION The Type AV1 and Type AV2 Characterizable Pneumatic Position- ers control the position of a pneumatic actuator. FEATURES Trouble-Free Operation. Proven pilot valve that is quickly •...
  • Page 12 INTRODUCTION valve provide long life and maximum environmental protec- tion. The compact housing increases mounting flexibility. Characterizable Output. Large positioning cam can be • shaped to provide desired relationship between the input sig- nal and the actuator position. Accurate Calibration. Independent zero and span adjust- •...

  • Page 13: Instruction Content

    Introduction Provides a description of this instruction; its sections and uses, along with a brief description of the Type AV1 and Type AV2 posi- tioners. This section also provides reference documents (Table 1-2), product nomenclature (Table 1-2), specifications (Tables 1-3, and 1-5), agency approvals (Table 1-6) and positioner acces- sories (Table 1-7).

  • Page 14: Reference Documents

    Characterizable 4 to 20-mA Input Positioner (actuator moves to 0% or 100% upon loss of signal) Input Signal 20.7 to 103.4 kPa (3.0 to 15.0 psig) (Type AV1) 20.7 to 186.2 kPa (3.0 to 27.0 psig) (Type AV1) 4 to 20 mA (standard intrinsically safe Type AV2) 20.7 to 103.4 kPa (3.0 to 15.0 psig), high temperature applications...

  • Page 15: Specifications

    Performance Series — high pneumatic gain for large actuators NOTES: 1. High temperature Type AV1 positioners are only available without manifolds or position transmitters; however, gage blocks are permitted. 2. Explosionproof Type AV2 positioners are not available with position transmitters or manifolds 3.
  • Page 16 INTRODUCTION Table 1-3. Type AV1/2 Positioner Specifications (continued) Property Characteristic/Value 245 Ω at 60°C (140°F) Maximum Standard stroke range (cam selection) AV__1____ 12.7 to 50.8 mm (0.5 to 2.0 in.) linear, rotary input 45° AV__2____ 25.4 to 101.6 mm (1.0 to 4.0 in.) linear, rotary input 90°...

  • Page 17: Capacity (Exhaust To Atmosphere)

    0% to 95% noncondensing NOTES: 1. Performance testing performed on a ABB Type UP10 actuator. 2. Tested according to ISA-S75.13-1989 3. For operation below 4.4°C (40°F), dew point of the supply air must be 10°C (18°F) lower than the lowest expected operating temperature.

  • Page 18: Air Consumption

    INTRODUCTION 0.90 0.80 0.70 0.60 FLOW 0.50 (SCFM) 0.40 0.30 0.20 0.10 0.00 SUPPLY PRESSURE (PSIG) T00800A Figure 1-2. Air Consumption P ERFORMAN CE PERFORMANCE SERIES SERIES STANDARD STANDARD O2 SUPPLYING O1 SUPPLYING OUTPUT AIR FLOW (SCFM) O1 EXHAUSTING O2 EXHAUSTING ERROR (%) T00813A Figure 1-3.

  • Page 19: Expanded First Quadrant View

    INTRODUCTION PERFORMANCE SERIES OUTPUT AIR FLOW (SCFM) STANDARD O1 SUPPLYING POSITION ERROR (%) T00799A Figure 1-4. Expanded First Quadrant View of Figure Table 1-4. Type AV____1__ Potentiometric Position Transmitter Specifications Property Characteristic/Value 2000 Ω, ±20% Total resistance Power rating 1 W up to 70°C (158°F), 0 W at or above 125°C (257°F) 9.9 Ω...
  • Page 20 Appendix D (Type AV1__0___ positioner only). transmitter Air filters ABB recommends installing an air filter in the supply air line to prevent particles from entering the positioner that can lead to malfunctions. Refer to Table 1-12 for filter part numbers.

  • Page 21: Rotary Actuator Retrofit Mounting Kits

    UP3, UP4 258494_1 UP5, UP6 258527_1 AC0404 258528_1 AC0608 258529_1 AC0816 258530_2 AC1016 258527_1 AC0404 ABB part number pilot valve positioner to Type 258528_1 AC0608 AV positioner 258529_1 AC0816 258530_1 AC1016 Table 1-9. Speed Control Orifices Size Part Number 5327327_1 1.02...
  • Page 22 INTRODUCTION Table 1-13. Component Material List Component Material Housing Aluminum Cover Aluminum Inserts Lamond (thermoplastic elstomer) ® Window Lexan (polycarbonate) Screws Stainless steel Range spring 302 stainless steel Pilot valve (stem and body) 303 stainless steel Gain hinge spring 302 stainless steel 302 stainless steel Cam shaft 303 stainless steel...
  • Page 23 INTRODUCTION Table 1-13. Component Material List Component Material ® Gears Delrin (coolymer acetal) Gear hub Brass Additional Type AV2 components Regulator Polysulfone Regulator bracket 304 stainless steel Tubing Nylon I/P converter Copper Copper clad glass laminate ® Monel Nickel-iron ® Noryl (phenylene ether/phenylene) Polyethylene...

  • Page 25: Section 2 - Description And Operation

    SECTION 2 - DESCRIPTION AND OPERATION INTRODUCTION This section describes and explains the functional and physical operation of Type AV1 and AV2 positioners. Figure diagrams the operating principles of the positioners. Figure shows the placement of a positioner in a typical control system.

  • Page 26: Functional Operation

    Downward force from the range spring. The input signal pressure determines the diaphragm force. The Type AV1 positioner uses an external input pressure (either 20.7 to 103.4 kilopascals (3.0 to 15.0 pounds per square inch gage) or 20.7 to 186.2 kilopascals (3.0 to 27.0 pounds per square inch gage)).

  • Page 27: Section 3 - Installation

    • Connect wiring to the positioner. • NOTES: For application in a hazardous location, refer to ABB Prod- uct Application Guide, Installing a Type AV Positioner in a Hazardous Location. Appendix B provides a quick start guide for the Type AV positioner.

  • Page 28: Enclosure Classification

    1-5. ENCLOSURE CLASSIFICATION The standard enclosure for the Type AV1 and Type AV2 position- ers conform to NEMA 3R when a ½-14 NPT street elbow (Fig. 3-1) is installed into the vent hole on the housing. The elbow prevents water or other liquid from entering the enclosure.

  • Page 29: External And Mounting Dimensions

    INSTALLATION 3.00 8.74 2X 0.312-18UNC-2B 76.2 222.1 THRU MOUNTING 6.43 HOLES 163.4 3.66 1.44 93.0 36.5 2.80 0.64 OUTPUT CONN. O1 OUTPUT CONN. O2 71.1 16.2 3.00 1/4-18 NPT. 1/4-18 NPT. 2.50 76.2 NOTE 3 2.11 (SEE NOTE 5) (SEE NOTE 5) 63.5 53.6 AIR FILTER (3)

  • Page 30: Mounting Type Av Positioners

    The Type AV positioner can be used with double acting or single acting actuators. Mounting and external dimensions are shown in Figure 3-1. Figure shows a typical mounting arrangement using a ABB mounting kit. Refer to Figure 9-23 for an exploded view and complete parts list of...

  • Page 31: Drive Shaft Variations

    INSTALLATION the kit. If using the positioner with a rotary actuator, the positioner can be directly connected to the actuator, as shown in Figure 3-6. NOTE: If the actuator is equipped with a Type AV positioner as ordered, verify that all the connections are secure and make any adjustments as required.

  • Page 32: Mounting Using Direct Coupling (Typical)

    INSTALLATION RO TA RY AC TUATO R AC TUATO R SH AF T SE T SC R EW S AV ??? ??1? PO S IT IO N E R C O U PL IN G AV O U T PU T SH AFT T 00 80 3 A Figure 3-6.

  • Page 33: Cam Characteristics

    INSTALLATION square function (Table 3-1). Cam B is in place when the positioner is 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 the application is reverse acting, the reverse acting cam (red radial lines) must be installed and the connections to ports 01 and 02 must be reversed.

  • Page 34: Tubing Connections

    (5 pounds per square inch gage) above the operating pres- sure required by the actuator. Air Supply Filtering An external 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.

  • Page 35: Air Supply Quality (Recommended)

    INSTALLATION Positioners equipped with manifolds have three secondary filters as part of the unit. If the filters become clogged, they can be cleaned (by removing and reverse flushing with air or liquid) or replaced (refer to Table for kit number). Refer to Section 7 manifold filter replacement procedures.

  • Page 36: Wiring Type Av2 Positioner

    INSTALLATION 2. Based on the positioner type, perform one of the following steps (Fig. 3-9): AV11 or AV15: Connect 20.7 to 103.4-kPa (3.0 to 15.0-psig) instrument signal to connection I. AV12 or AV16: Connect 20.7 to 186.2-kPa (3.0 to 27.0-psig) instrument signal to connection I.

  • Page 37: Direct Acting, Top Loaded, Single Acting Tubing Example

    INSTALLATION Refer to Appendix A for detailed information about position trans- mitters. NOTE: Route the wiring inside the positioner so it does not become entangled with moving parts. A cable clamp (Figs. and 4-1) is provided inside the positioner so entanglement can be avoided.

  • Page 38: Reverse Acting, Top Loaded, Single Acting Tubing Example

    INSTALLATION HANDJACK ALTERNATE PIPING FOR DIAPHRAGM ACTUATOR WITH HANDJACK OUTPUT GAGE (O2 PORT) SIGNAL GAGE NOTES: 1. RED CAM ROTATES CLOCKWISE WHEN VIEWED FROM THE FRONT. 2. O2 PORT PLUGGED. 3. STEM MOVES DOWN WITH SIGNAL FAILURE. 4. STEM MOVES UP WITH SUPPLY AIR FAILURE.

  • Page 39: Wiring Type Av1 Positioner

    3. STEM MOVES DOWN WITH SIGNAL OR SUPPLY AIR FAILURE. MOTION WITH INCREASING SIGNAL T00891A Figure 3-13. Reverse Acting, Bottom Loaded, Single Acting Tubing Example WIRING TYPE AV1 POSITIONER This section applies to the following positioners: Type AV1___1__. • Type AV1___2__. • NOTES: If this is a Type AV1___0__ positioner, no electrical wiring is required.

  • Page 40: Double Acting Tubing Example

    N O M EN C LAT U R E – AV 23? ???? – AV 33? ???? – AV 44? ???? AV ??? ?1?? – AV ??? ?2?? T 00 80 7 A Figure 3-15. Wiring Connections WIRING TYPE AV1 POSITIONER 3 - 14...

  • Page 41: Radio Frequency Interference

    (RFI). Caution should be exercised with regard to the use of portable communications equipment in the area. ABB recommends posting appropriate signs in the plant. Refer to the Site Planning and Preparation instruction for additional infor- mation on RFI.

  • Page 43: Section 4 - Calibration

    SECTION 4 - CALIBRATION INTRODUCTION This section contains the following information: Calibration. • Gain adjustment. • Speed control. • Troubleshooting calibration. • NOTES: All procedures in this section assume direct acting opera- tion. The troubleshooting calibration procedure in this section is not required for normal operation.

  • Page 44: Calibration Adjustments

    Use the following steps to adjust the zero: 1. Depending on the nomenclature type, apply one of the follow- ing input signals: Type AV1 20.7 kPa (3.0 psig) input signal pressure. The actuator should move to its fully closed position.

  • Page 45: Span Adjustment

    CALIBRATION CAM ROLLER CAM FOLLOWER ARM T00771A Figure 4-2. Cam Roller Alignment Span Adjustment Setting the span normally requires the alignment of the 100 per- cent radial line of the cam with the center of the cam roller. Use the following steps to adjust the span: 1.

  • Page 46: Zero Adjustment

    CALIBRATION Zero Adjustment The positioner zero adjustment can be used to set initial tension on the range spring so that the actuator will not begin to move from its minimum position until it receives an input signal between zero and 50 percent (Fig. 4-3). This application of suppression is useful when two or more actuators are to be operated in sequence;...

  • Page 47: Gain And Speed Adjustments

    GAIN AND SPEED ADJUSTMENTS Gain and speed adjustment information applies to both the Type AV1 and Type AV2 positioners. This is the gain of the overall posi- tioner. The factory-installed 0.25-millimeter (0.100-inch) gain hinge spring suits most applications. This adjustment is not a mandatory part of calibration.

  • Page 48: Speed Adjustment

    If it is necessary to reduce the speed of operation, 1.02-millimeter (0.04-inch) speed control orifices are available as an option from ABB. These orifices are installed directly into the output ports (01 and 02) of the positioner and have ¼-NPT ports for connecting tubing from the actuator.

  • Page 49: Pilot Valve Adjustment

    CALIBRATION 0.030 STEM IS FLUSH WITH BODY 0.030 STEM POSITION AT STEM POSITION TOP STEM POSITION LOWER BALANCE CONDITION ADJUSTMENT SCREW ADJUSTMENT SCREW T00777A Figure 4-5. Pilot Valve Adjustment ⁄ 2. Use a -inch Allen wrench (the wrench must be at least 5-inches long) to turn the lower adjustment screw clockwise the same amount as the top adjustment screw to insure speed of operation is the same in both directions (if desired).

  • Page 50: Troubleshooting Calibration Adjustments

    CALIBRATION TROUBLESHOOTING CALIBRATION ADJUSTMENTS The I/P converter of the Type AV2 positioner comes from the fac- tory completely calibrated. Use the following procedures only when operating difficulties occur. The corrective action column of Table indicates when to use the troubleshooting calibration. The purpose of this procedure is to adjust the I/P converter so that a four to 20-milliamp input signal will produce a 20.7 to 103.4-kilo- pascal (3.0 to 15.0-pounds per square inch gage) signal.
  • Page 51 CALIBRATION T00779A Figure 4-7. I/P Adjustment TROUBLESHOOTING CALIBRATION ADJUSTMENTS 4 - 9...

  • Page 53: Section 5 - Operating Procedures

    SECTION 5 - OPERATING PROCEDURES INTRODUCTION This section details the equalizing valve of the optional manifold (Type AV___1___ positioner). NOTE: This section only applies when the positioner is equipped with a manifold assembly. EQUALIZING AND AIR SUPPLY SHUTOFF VALVE The equalizing valve, supplied with the manifold assembly, allows the actuator to be manually or automatically operated.
  • Page 54 OPERATING PROCEDURES 2. If the manual operator does not lock the actuator in position: a. The piston must be positioned from prior knowledge of the actuator position versus signal or the actuator may jump when transferred to automatic. b. Push the valve handle in and turn it to the AUTO position. 3.

  • Page 55: Section 6 - Troubleshooting

    3-13 and 3-14). tion. Pneumatic signal AV1: Check input signal connection for leaks at I port. leak. AV2: Check signal at I port. If pressure is between 20.7 and 103.4 kPa (3.0 and 15.0 psig) and responds to input signal change then problem exists elsewhere.
  • Page 56 TROUBLESHOOTING Table 6-1. Positioner Errors Error Probably Cause Corrective Action Excessive air con- Leakage at the joint Remove manifold and check O-rings. Refer to Manifold sumption (exhaust of the manifold Section loud) assembly (if equipped). Pilot valve body seal Remove pilot valve body and check O-rings. Refer to Pilot is leaking.

  • Page 57: Section 7 - Maintenance

    INTRODUCTION The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB recommends that all equipment users practice a preventive maintenance pro- gram that will keep the equipment operating at an optimum level.

  • Page 58: Preventive Maintenance Procedures

    MAINTENANCE Table 7-1. Preventive Maintenance Schedule (continued) Interval Preventive Maintenance Tasks (months) Check all air connections for leakage while positioner is under pressure. Use a soapsuds solution. Check the signal diaphragm for leaks. use a soapsuds solution. Clean pilot valve and stem with low residue solvent. Refer to REPAIR AND REPLACEMENT Section...

  • Page 59: Positioner With Manifold

    MAINTENANCE 6. Transfer positioner back automatic operation (Section FILTER COVER COVER SCREW VALVE HANDLE ALLEN SCREWS AUTO T00738A Figure 7-1. Positioner with Manifold O-RINGS AUTO TP00780A Figure 7-2. Manifold with Filter Cover Removed MANIFOLD FILTERS 7 - 3...

  • Page 61: Section 8 - Repair And Replacement

    SECTION 8 - REPAIR AND REPLACEMENT INTRODUCTION This section provides procedures that detail removal and replace- ment of positioner components. Disconnect the supply signal source or remove the equip- ment from the process before servicing. Failure to do so WARNING can cause unexpected movement posing a risk of bodily injury.

  • Page 62: Gain Hinge Spring

    REPAIR AND REPLACEMENT 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). Not all of the Allen screws are the same length. Be sure each screw mates correctly.

  • Page 63: Pilot Valve Assembly

    REPAIR AND REPLACEMENT O-RINGS T00781A Figure 8-2. Manifold O-Rings 4. Remove the four hinge screws (Item 42) while holding the beam assembly steady (Item 6). Remove the two screws that connect the beam to the hinge first. 5. Remove the gain hinge spring. 6.

  • Page 64: I/P Converter

    REPAIR AND REPLACEMENT Tools Required: Flat-tip screwdriver. 1. Transfer the positioner from automatic to manual operation (Section 2. Remove the positioner cover by removing the two cover screws. 3. Carefully unhook the ends of the valve clip (Item 5). Remove the valve clip from the valve body.

  • Page 65: Cam

    REPAIR AND REPLACEMENT 5. Slide the I/P converter out from under the screws and remove it from the housing. 6. Disconnect the two air lines from the I/P converter. When replac- ing the I/P converter, remove the portion of the air line tubing that was connected to the I/P converter or replace the tubing.

  • Page 66: Diaphragm Assembly Removal

    REPAIR AND REPLACEMENT DIAPHRAGM ASSEMBLY REMOVAL Tools Required: Allen wrench. • Adjustable wrench. • 1. Transfer the positioner from automatic to manual operation (Section 2. Using an Allen wrench, remove the four diaphragm cover screws (Item 45) and remove the diaphragm cover. 3.

  • Page 67: Pilot Valve Stroke Adjustment

    REPAIR AND REPLACEMENT 6. Replace the washer (Item 54) and screw (Item 53). Torque the screw to 0.35 Nm (50 in.-oz.) while securing the diaphragm support (Item 23) so it does not rotate. NOTE: Item 53 is replaced by SEM screw NBMHA13006A as of November 23, 2009/Serial Number 3K620000029936 &...

  • Page 68: Pilot Valve Measurement For Maximum Speed

    REPAIR AND REPLACEMENT b. If manual override is not available, disconnect (and secure) the linkage. Plug ports 01 and 02 if necessary. 2. Apply the supply pressure. 3. Apply the maximum input signal to the positioner: AV11: 103.4 kPa (15.0 psig). •...

  • Page 69: Stroke Adjustment Screws

    REPAIR AND REPLACEMENT TOP ADJUSTMENT SCREW SIGNAL DIAPHRAGM HINGE SPRING LOWER ADJUSTMENT SCREW RANGE SPRING ALLEN WRENCH ACCESS T00778A Figure 8-4. Stroke Adjustment Screws PILOT VALVE STROKE ADJUSTMENT 8 - 9...
  • Page 70 REPAIR AND REPLACEMENT PILOT VALVE STROKE ADJUSTMENT 8 - 10...

  • Page 71: Section 9 - Support Services

    A list of parts that can be ordered for replacement. Additional spare parts Positioner illustrations Illustrations that point out all major components of the Type AV1 and AV2 positioners. A parts list is included along with part num- bers. RECOMMENDED SPARE PARTS ABB suggests that the following items be kept on hand in case replacement is necessary.
  • Page 72 SUPPORT SERVICES Table 9-3. AV Diaphragm Assembly Kit No. 258486_2 (for Types AV15 and AV16) Item Part No. Description Item Part No. Description 5400288_5 Small diaphragm 5400294_1 Diaphragm ring 5400292_1 Diaphragm 5400288_4 Large diaphragm spacer (AV15) 5400293_1 Diaphragm 5400283_6 Large diaphragm support (AV15) (AV16) 5400293_2...

  • Page 73: Additional Spare Parts

    SUPPORT SERVICES Table 9-7. Pilot Valve Assembly Kit No. 258488_3 (for Types AV11___P, AV12 ___P and AV2___P) Item Part No. Description 5400259_1 Valve stem 5400260_2 Valve body 5400261_1 Valve clip 1951398_12 O-rings — 19984_1 O-ring lubricant Table 9-8. Pilot Valve Assembly Kit No. 258488_4 (for Types AV15_0/3__P and AV16_0/3__P) Item Part No.
  • Page 74 SUPPORT SERVICES Table 9-12. Manifold Assembly Kit No. 258491 _ 1 (replaces 5400282_1 or 5400282 _2 (for replacement or field addition, Type AV___1/2___)) Item Part No. Description Item Part No. Description 5400282 Manifold assembly NBAHA16024 Manifold screws 5311428_207 Manifold O-rings —...

  • Page 75: To 20-Ma Position Transmitter Circuit Board

    SUPPORT SERVICES Table 9-17. Gage Block Assembly Kit No. 258569_3 (for replacement or field addition, Types AV15_3 and AV16)_3) Item Part No. Description Item Part No. Description 5400318 Manifold, gage 1951779_207 O-rings NKJHA16004 Set screw, socket NBAHA16020 Screw, hex socket hex hdlss cup pnt head cap 1951041...
  • Page 76 SUPPORT SERVICES Table 9-21. Positioner Mounting Kit Number 5327321_13 Valve Stem Diameter 0.750 to 1.000 in. (Fig. 9-1) Item Part Number Description Item Part Number Description 5400266_1 Positioner mounting bracket 0.190-32 x 0.875 Screw, pan head machine (2 req) 0.250-20 x 0.750 Screw, socket head (3 req) 197120_5 Nut, elastic stop (2 req) 0.250...

  • Page 77: Mounting Kits

    Type AV positioner 258493 UP3, UP4 258494 UP5, UP6 258527 AC0404 258528 AC0608 258529 AC0816 258530 AC1016 258527 AC0404 ABB part number pilot valve positioner to Type 258528 AC0608 AV positioner 258529 AC0816 258530 AC1016 ADDITIONAL SPARE PARTS 9 - 7...

  • Page 78: Bypass Valve Assembly

    SUPPORT SERVICES Table 9-24. Bypass Valve Assembly (Optional) Parts List (Part No. 5326945 1 — Fig. 9-2) Item Part Number Description 5327226 3-way valve 5326946 Air line connection assy 195159 Elbow connector 195727 Brass nipple 195171 Wheatherhead tee 1962833 Designation plate NBZAC16006 Screw, pan head NTJAC09030...

  • Page 79: Type Av1 Positioner Parts List

    SUPPORT SERVICES Table 9-25. Type AV1 Positioner Parts List for Figure Item Part No. Description Item Part No. Description 5400253_3 Housing 197865_2 Stroke adjustment screw Refer to Table 9-26 Cover assembly 197865_1 Stroke adjustment screw 5400259_1 Valve stem NKJHA16004 Zero adjustment set screw...

  • Page 80: Cam Selection And Manifold/Gage Block Parts Reference For Type Av1 Positioners

    2 5400295 2 1945803 1 1951779 10 5400288 6 1951755 Omit 1951799 206 Omit Omit Table 9-27. Cam Selection and Manifold/Gage Block Parts Reference for Type AV1 Positioners (Fig. 9-3) Item (Part Number) Item (Quantity) Type 5400289 — — — —...
  • Page 81 SUPPORT SERVICES 82 94 15 44 1 2 3 4 5 56 49 VIEW WITH COVER REMOVED INSIDE OF COVER FRONT VIEW 33 71 SIDE VIEW T00783A Figure 9-3. Type AV1 Positioner ADDITIONAL SPARE PARTS 9 - 11...

  • Page 82: Shaft Position Transmitter Parts Reference For Type Av1 Positioners

    SUPPORT SERVICES Table 9-28. Shaft Position Transmitter Parts Reference for Type AV1 Positioners (Fig. 9-3) Item (Part Number) Item (Quantity) Type 27, 50, 59, 61, 75, 77, 78 83, 84, 86, 87, 89 Omit Omit — Omit Omit Omit 6639542...
  • Page 83 SUPPORT SERVICES Table 9-30. Type AV2 Positioner Parts List for Figure (continued) Item Part No. Description Item Part No. Description 5400295 Diaphragm cover 07958063 I/P converter 5400296 Exhaust mesh 1943187 Cable clip (2 req) 193243 Large position transmitter gear NDPAC15004 Pan head screw 1951652 Barb fitting (2 req)
  • Page 84 SUPPORT SERVICES Table 9-31. Cam and Drive Shaft Parts Reference for Type AV2 Positioners (Fig. 9-4) (continued) Item (Part Number) Item (Quantity) Type AV231 5400260 5400289 5400287 114B095U01 Omit Omit Omit Omit AV231 5400260 5400289 5400287 1943573 Omit Omit AV231 5400260 5400289 5400287...

  • Page 85: Shaft Position Transmitter Parts Reference For Type Av2 Positioners

    SUPPORT SERVICES Table 9-31. Cam and Drive Shaft Parts Reference for Type AV2 Positioners (Fig. 9-4) (continued) Item (Part Number) Item (Quantity) Type AV271 5400260 5400289 5400287 114B095U01 Omit Omit Omit Omit AV271 5400260 5400289 5400287 1943573 Omit Omit AV271 5400260 5400289 5400287...
  • Page 86 SUPPORT SERVICES FRONT VIEW INSIDE OF COVER 93 94 SIDE VIEW T00784A Figure 9-4. Type AV2 Positioner (Page 1 of 2) ADDITIONAL SPARE PARTS 9 - 16...
  • Page 87 SUPPORT SERVICES Figure 9-5. Type AV2 Positioner (Page 2 of 2) Table 9-34. Conversion Kits Part No. Application Description 258651_1 AV23 I/P Conversion Kit NOTE: 1. Replaces older I/Ps that required an internal 22 psi pressure pre-regulator. ADDITIONAL SPARE PARTS 9 - 17...

  • Page 89: Appendix A - Position Transmitters

    APPENDIX A - POSITION TRANSMITTERS INTRODUCTION This appendix provides operation and calibration information for ABB position transmitter options. Refer to Table (potentiomet- ric position transmitter) or Table (four to 20-milliamp position transmitter) for position transmitter performance specifications. A position transmitter provides additional control features to Type AV positioners and can be ordered through nomenclature.

  • Page 90: Calibration

    POSITION TRANSMITTERS CALIBRATION There are two procedures for calibration; one for the potentiomet- ric option (Type AV ) and another for the four to 20-milli- ____ amp option (Type AV ____ Calibrating the Potentiometric Position Transmitter This calibration example using the potentiometric position trans- mitter can be used as a guide for other applications.
  • Page 91 POSITION TRANSMITTERS The resistive change of the potentiometer is approximately 9.9 ohms (nominal) per degree of cam rotation, with a total resistance of 2000 ohms (nominal). Application of the potentiometric option must consider the possibil- ity of end resistance wrap-around. POTENTIOMETRIC APPLICATION EXAMPLE A customer has a Type AV positioner with a 90-degree, direct act- ing cam, potentiometric position transmitter, along with a 24-VDC...

  • Page 92: Potentiometric Application Example

    POSITION TRANSMITTERS tolerance of the potentiometer. Figure is a schematic diagram of this application example. Ω 2000 ±20% 200-912.8Ω Ω 2380 NOMINAL OUTPUT ADJUSTMENT – – 24 VDC T00787A Figure A-2. Schematic Diagram CALIBRATING THE POTENTIOMETRIC EXAMPLE The calibration information is based on the application put forth in POTENTIOMETRIC APPLICATION EXAMPLE.

  • Page 93: Potentiometric Position Transmitter (Exploded View

    POSITION TRANSMITTERS FLAG LARGE GEAR SMALL GEAR SET SCREW MOUNTING BRACKET POTENTIOMETER Ω (2000 NOTES: 1. SOME HARDWARE ITEMS HAVE BEEN OMITTED FOR CLARITY. 2. IDENTIFIED ITEMS PERTAIN TO THE POSITION TRANSMITTER OPTION ONLY. TERMINAL BLOCK TB1 T00788A Figure A-3. Potentiometric Position Transmitter (Exploded View) Table A-1.

  • Page 94: Calibrating The 4 To 20-Ma Position Transmitter

    POSITION TRANSMITTERS 3. Connect the field wiring to the terminal block. Connect a DC voltmeter between TB1-1 (-) and TB1-2 (+). 4. Move the actuator to the 80% position. Adjust the resistor in series with the 24-VDC supply until the voltmeter reads five VDC. 5.

  • Page 95: To 20-Ma Position Transmitter (Exploded View

    POSITION TRANSMITTERS a. Remove the cam, by removing the screw, flag, nut and washer (Fig. and Table A-2). FLAG LARGE GEAR SMALL GEAR SET SCREW MOUNTING BRACKET POTENTIOMETER Ω (2000 NOTES: 1. SOME HARDWARE ITEMS HAVE BEEN OMITTED FOR CLARITY. 2.
  • Page 96 POSITION TRANSMITTERS b. Loosen the set screw on the hub of the small gear using a ⁄ -in. Allen wrench (Fig. and Table A-2). c. Use a screwdriver to adjust the shaft on the potentiometer until the ohmmeter reads 1000, ±10 Ω. While adjusting the resistance, hold the gears and cam shaft stationary so rotation does not occur.

  • Page 97: Appendix B - Quick Start

    Characterizable 4 to 20-mA Input Positioner (actuator moves to 0% or 100% upon loss of signal) Input Signal 20.7 to 103.4 kPa (3.0 to 15.0 psig) (Type AV1) 20.7 to 186.2 kPa (3.0 to 27.0 psig) (Type AV1) 4 to 20 mA (standard intrinsically safe Type AV2) 20.7 to 103.4 kPa (3.0 to 15.0 psig), high temperature applications...

  • Page 98: Mounting The Positioner

    Performance Series — high pneumatic gain for large actuators NOTES: 1. High temperature Type AV1 positioners are only available without manifolds or position transmitters; however, gage blocks are permitted. 2. Explosionproof Type AV2 positioners are not available with position transmitters or manifolds.

  • Page 99: Mounting Using Linkage (Typical

    QUICK START MOUNTING BRACKET TYPE AV POSITIONER PAN HEAD MACHINE SCREW ADJUSTABLE ELASTIC CONNECTING LINK STOP NUT STEM CLAMP, NOTE: DRIVE ARM SHOULD BE CLAMP PLATE PERPENDICULAR WITH THE ACTUATOR AT MIDSTROKE. ADJUSTABLE STUD FRONT VIEW SIDE VIEW T00802A Figure B-1. Mounting Using Linkage (Typical) RO TA RY AC TUATO R AC TUATO R SH AF T...

  • Page 100: Drive Arm Connections

    QUICK START 0.193-200 4.9-5.1 STROKE STROKE (45° OR HALF CAM) (90° OR FULL CAM) 2.00 4.00 50.8 101.6 1.75 3.50 44.5 88.9 1.50 3.00 38.1 76.2 1.25 2.50 31.8 63.5 1.00 2.00 0.33 0.35 25.4 50.8 0.75 1.50 19.1 38.1 0.50 1.00 12.7...

  • Page 101: Tubing Connections

    QUICK START TUBING CONNECTIONS 1. Connect the required supply air to connection S (Fig. B-5). NOTE: Maximum torque for ¼-NPT fittings is 13.6 Nm (10.0 ft-lbs). G AG E G AG E PO RT S PO RT S C O N D U IT C O N N EC T IO N V IE W W ITH G AG E V IE W W ITH M A N IFO L D...

  • Page 102: Direct Acting, Top Loaded, Single Acting Tubing Example

    QUICK START HANDJACK ALTERNATE PIPING FOR DIAPHRAGM ACTUATOR WITH HANDJACK OUTPUT GAGE (O1 PORT) SIGNAL GAGE NOTES: 1. BLACK CAM ROTATES COUNTERCLOCKWISE WHEN VIEWED FROM THE FRONT. 2. O2 PORT PLUGGED. 3. STEM MOVES UP WITH SIGNAL OR SUPPLY AIR FAILURE. MOTION WITH INCREASING SIGNAL T00890A...

  • Page 103: Direct Acting, Bottom Loaded, Single Acting Tubing Example

    QUICK START HANDJACK OUTPUT GAGE (O2 PORT) SIGNAL GAGE NOTES: 1. BLACK CAM ROTATES COUNTERCLOCKWISE WHEN VIEWED FROM THE FRONT. 2. O2 PORT PLUGGED. 3. STEM MOVES UP WITH SIGNAL FAILURE. 4. STEM MOVES DOWN WITH SUPPLY AIR MOTION WITH FAILURE.

  • Page 104: Type Av2 Positioner Wiring

    QUICK START DIRECT ACTING REVERSE ACTING (BLACK) CAM (RED) CAM MOTION WITH MOTION WITH INCREASING SIGNAL INCREASING SIGNAL NOTE: IN ANY INSTALLATION, DIRECTION OF PISTON TRAVEL CAN BE REVERSED BY USING THE REVERSE ACTING CAM (LOCATED IN POSITIONER COVER) AND REVERSING THE O1 AND O2 CONNECTIONS.

  • Page 105: Type Av2 Positioner

    QUICK START T B1 C O N N E C T IO N S N O M EN C LAT U R E – AV 23? ???? – AV 33? ???? – AV 44? ???? AV ??? ?1?? – AV ??? ?2?? T 00 80 7 A Figure B-11.

  • Page 106: Type Av1 Positioner Wiring

    The grounding screw located inside the AV enclosure is a safety ground and should not be used to ground the shielded pair. The positioner must be grounded to avoid ground loop conditions. TYPE AV1 POSITIONER WIRING This section applies to the following positioners: Type AV1___1__. •...
  • Page 107 QUICK START CALIBRATION Table presents calibration procedures for Type AV1 and Type AV2 positioners in table format. Table B-2. Calibration Procedures Procedure Procedure Zero 1. Apply 20.7 kPa (3.0 psig) input signal pres- Zero 1. Turn on supply air. Apply a 4-mA input sig- sure to the positioner.

  • Page 109: Appendix C - Cam Characterization

    APPENDIX C - CAM CHARACTERIZATION INTRODUCTION This section provides cam shaping information. Cam shaping is the process of changing the shape of the cam by cutting or form- ing so the control signal produces the desired control characteris- tic. The standard cam normally does not require shaping. CAM CHARACTERIZATION Selecting or shaping these cams allows you to obtain a piston (or valve) position versus control signal characteristic that will pro-...

  • Page 110: Cam Characterization

    CAM CHARACTERIZATION LIMITED TRAVEL SCALE = % OF SIGNAL RANGE LIMITED SIGNAL SOLID LINE INDICATES FORWARD TRAVEL (DIRECT ACTING) DASHED LINE INDICATES REVERSE TRAVEL (REVERSE ACTING) SCALE = % TRAVEL T00792A Figure C-2. Cam B, Linear Relationship SCALE = % OF SIGNAL RANGE LIMITED TRAVEL...

  • Page 111: Cam Selection

    Table relates the percentage of control signal to input (current) and output (pounds per square inch gage) values of the I/P converter. Table C-1. Control Signal Pressure Conversions (AV1) Control System Spans Control System Spans % of % of 20.7 to 103.4 kPa...
  • Page 112 CAM CHARACTERIZATION % OF PISTON OR VALVE TRAVEL % OF CONTROLLED MEDIUM T00795A Figure C-4. Regulated Device Characteristics 2. Plot the exact control medium versus control signal character- istic given or desired for the application. This is usually a linear function (Fig.

  • Page 113: Cam Shaping

    CAM CHARACTERIZATION 3. Using values determined in Steps 1 and 2, plot a curve for the exact control signal versus piston (or valve) characteristic that will produce the results of Figure from a cylinder or actuator that performs as shown 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.
  • Page 114 CAM CHARACTERIZATION lines in between are equal intervals of rotation. These lines are indexes of percentage of piston (or valve) travel. The concentric arcs on the cam correspond to actual control sig- nal pressure values shown in Table for the particular posi- tioner being used.
  • Page 115 CAM CHARACTERIZATION CAM RADIAL LINES 20.0 18.4 16.8 15.2 13.6 SIGNAL RANGE EXAMPLE: CONTROLLED MEDIUM (4-20 mA) CONCENTRIC 12.0 REQUIRED AT 7.8 PSIG TO BE AT LINES 60% OF PISTON TRAVEL. 10.4 % OF PISTON OR VALVE TRAVEL T00797A Figure C-7. Graph to Cam Data Transfer CAM SHAPING C - 7...

  • Page 117: Appendix D - Type Av1 Pneumatic Position Transmitter

    APPENDIX D - TYPE AV1 PNEUMATIC POSITION TRANSMITTER INTRODUCTION This appendix covers the optional pneumatic position transmitter kit that is available for Type AV1 positioners. This option is only available for Type AV1__0___ positioners. The topics covered are: Description. •...

  • Page 118: Pneumatic Position Transmitter Kit

    TYPE AV1 PNEUMATIC POSITION TRANSMITTER SUPPLY OUTPUT SIGNAL T00798A Figure D-1. Pneumatic Position Transmitter Kit Table D-1. Pneumatic Position Transmitter Kit (258492_1) Item Number Part Number Quantity Description 5400307_2 Air line ¼ MRO-B Street tee 195727_2 Brass nipple ¼-18 NPT Brass pipe plug —...
  • Page 119 TYPE AV1 PNEUMATIC POSITION TRANSMITTER CALIBRATION Make sure the position transmitter is at maximum gain (Table 4-1) prior to making any adjustments. The positioner comes with the maximum gain hinge spring installed from the factory. The following description is based on a 20.7 to 103.4-kilopascal (3.0 to 15.0-pound per square inch gage) output for zero to...
  • Page 120 TYPE AV1 PNEUMATIC POSITION TRANSMITTER 15. Repeat Steps 8 through 14 until the positioner is calibrated. NOTE: Moving the span adjustment assembly toward the valve body provides a longer actuator stroke for a given signal change (i.e., increases the range of travel for the cam follower arm).
  • Page 121 Index Numerics 4 to 20 mA position transmitter........A-1 Deadband ..............1-8 Calibration............. A-6 Description ..............1-1 Diaphragm assembly replacement ......8-5 Direct acting ..............3-6 Direct coupling mounting ........3-6, B-3 Accessories .............. 1-12 Double acting actuator tubing connections ..3-14, B-8 Accuracy..............1-8 Drive arm connections ........
  • Page 122 Index (continued) Mounting..............3-4 Direct coupling......... 3-6, B-3 Orifice ................. 4-6 Drive arm connections......3-4, B-4 Drive shaft variations ........3-5 Linkage ............ 3-5, B-3 Mounting considerations ........3-2 Performance series ............ 1-2 Mounting dimensions, explosionproof ....3-3 Pilot valve Mounting dimensions, standard ......3-3 High gain...............
  • Page 123 Vibration effect ............1-8 Air consumption ..........1-8 Capacity ............1-8 Deadband ............1-8 Weight.................1-9 Enclosure classification........1-8 Wiring Gain ..............1-8 AV1 ..............3-13 Humidity limits..........1-9 AV2 ..............3-10 Hysteresis ............1-8 Grounding ............3-11 Input impedance ..........1-7 Wiring requirements..........3-15 Input range............1-7 Linearity ............
  • Page 124 Index (continued) Zero suppression...........4-4 Zero suppression ............4-4 Graph ..............4-4 Index - 4...
  • Page 126 We reserve all rights in this document and in the subject matter and illustrations Fax: +44 (0)1453 829 671 contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts - is forbidden without prior written consent of ABB. Copyright © 2011 ABB ABB Inc.

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