SMC Networks IP6000 Series User Manual
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SMC Networks IP6000 Series User Manual

Intelligent valve positioner
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智能阀门定位器
IP6000 系列用户手册
Intelligent Valve Positioner
IP6000 Series User's Manual

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  • Page 1 智能阀门定位器 IP6000 系列用户手册 Intelligent Valve Positioner IP6000 Series User’s Manual...

  • Page 2: Table Of Contents

    Intelligent Valve Positioner IP6000 Series User’s Manual Contents 1. Overview ............................. 60 2. One-key automatic initialization ....................60 3. Technical specifications ......................62 4. Technical data ..........................63 5. Connection description ....................... 64 6. Dimension ........................... 65 6.1. Mechanical dimension ....................65 6.2.
  • Page 3 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.2.15. ACT ......................107 8.3.2.16. REF ......................107 8.3.3. Error message during initialization ..............107 8.3.4. Tips of menu option or function cannot access ............ 108 8.3.5. Menu function options summary description............109 8.4.

  • Page 4: Overview

    Intelligent Valve Positioner IP6000 Series User’s Manual 1. Overview IP6000 series intelligent valve positioner is mounted on pneumatic actuators. It’s used to control air intake and exhaust of the pneumatic actuators to drive the valve position to the set point by calculating both data from 4-20 mA DC signal and feedback position.
  • Page 5 Intelligent Valve Positioner IP6000 Series User’s Manual 4. The actuator type has been set before the positioner leaves the factory. The user only needs one-key operation to execute the automatic initialization (INITA) function to complete the matching of the valve. In the initial interface (NOINI) or manual / automatic mode interface, press and hold button for approx.

  • Page 6: Technical Specifications

    Intelligent Valve Positioner IP6000 Series User’s Manual 3. Technical specifications Remarks: In Install type options, the options marked with * do not support Explosion level option d. The option S(Separate) marked with * does not support Lowest ambient temperature option L(-40℃).

  • Page 7: Technical Data

    Intelligent Valve Positioner IP6000 Series User’s Manual 4. Technical data Shell material Aluminum 4-20mA DC, no-load voltage: 15-24V DC Set-point signal 3.8mA Minimum working current 120Ω Input resistance Normal version:-20°C ~ +70°C Optional version:-40°C ~ +70°C Ambient temperature Highest explosion proof temp for T4 area is +60°C Highest explosion proof temp for T6 area is +40°C...

  • Page 8: Connection Description

    Intelligent Valve Positioner IP6000 Series User’s Manual 5. Connection description OUT2 OUT1 Figure 1. Connection description Electrical Pneumatic Description Description Connection Connection 4-20 mA set-point signal + Air supply enter 4-20 mA set-point signal - OUT1 Pilot air outlet 1...

  • Page 9: Dimension

    Intelligent Valve Positioner IP6000 Series User’s Manual 6. Dimension 6.1. Mechanical dimension Figure 2. Mechanical dimension...

  • Page 10: Mounting Bracket Dimension

    Intelligent Valve Positioner IP6000 Series User’s Manual 6.2. Mounting bracket dimension Figure 3. Normal linear mounting bracket...
  • Page 11 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 4. Remote linear mounting bracket...
  • Page 12 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 5. Rotary mounting bracket (Type A)
  • Page 13 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 6. Rotary mounting bracket (Type B)

  • Page 14: Dimension Of Linear Stroke Feedback Lever

    Intelligent Valve Positioner IP6000 Series User’s Manual 6.3. Dimension of linear stroke feedback lever 6.3.1. Feedback lever A (with driving pin) Short feedback lever Long feedback lever (Suitable stroke: 10 ~ 35mm) (Suitable stroke: 35 ~ 100mm) Figure 7. Dimension of feedback lever A 6.3.2.

  • Page 15: Sensor Dimension For Separate Type

    Intelligent Valve Positioner IP6000 Series User’s Manual 6.4. Sensor dimension for separate type Figure 9. Sensor dimension for separate type...

  • Page 16: Sensor Dimension For Remote Type

    Intelligent Valve Positioner IP6000 Series User’s Manual 6.5. Sensor dimension for remote type Figure 10. Sensor dimension for remote type...

  • Page 17: Installation

    Intelligent Valve Positioner IP6000 Series User’s Manual 7. Installation 7.1. Linear stroke (normal type or remote type) Linear actuator mounting components Name Amount Note ① U-shaped rod Rotate the feedback lever in the working process ② Clamping assembly Mount U-shaped rod to actuator M6 hexagon socket ③...
  • Page 18 Intelligent Valve Positioner IP6000 Series User’s Manual confirmation, power off the positioner. 2. Install the U-shaped rod that matches the feedback lever A or the driving pin that matches the feedback lever B to the actuator. Figure 12. U-shaped rod installation...
  • Page 19 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 14. Driving pin installation ⑪ Install the driving pin on the main stem of the valve. The slot height of the feedback lever B is 6.2 mm. Therefore, if the user does not use the provided driving pin, it should be noted that the diameter of the driving pin used is 6 mm, and the thread size of the driving pin and the main stem of the valve must be the same.
  • Page 20 Intelligent Valve Positioner IP6000 Series User’s Manual the manufacturer. 4. Mount feedback lever and linear mounting bracket to the positioner or the remote sensor. Figure 16. Feedback lever A and mounting bracket installation (normal type) Figure 17. Feedback lever A and mounting bracket installation (remote type)
  • Page 21 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 18. Feedback lever B and mounting bracket installation (normal type) Figure 19. Feedback lever B and mounting bracket installation (remote type)  Mount the feedback lever A or B ⑤ to the feedback axis on the rear of the positioner or the remote sensor.
  • Page 22 Intelligent Valve Positioner IP6000 Series User’s Manual 5. Fix linear mounting bracket to the actuator. Figure 20. Valve mid-stroke point Figure 21. Feedback lever B and driving pin connection Figure 22. Installation with actuator (Feedback lever A)
  • Page 23 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 23. Installation with actuator (Feedback lever B)  Input air to the valve cylinder, adjust the valve position to the mid-stroke point according to the stroke ruler on the valve, as shown in Figure 20.
  • Page 24 Intelligent Valve Positioner IP6000 Series User’s Manual 6. Overall schematic diagram. Figure 24. Linear stroke for normal type (Feedback lever A)
  • Page 25 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 25. Linear stroke for remote type (Feedback lever A)
  • Page 26 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 26. Linear stroke for normal type (Feedback lever B)
  • Page 27 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 27. Linear stroke for remote type (Feedback lever B)

  • Page 28: Rotary Stroke (Normal Type Or Remote Type)

    Intelligent Valve Positioner IP6000 Series User’s Manual 7.2. Rotary stroke (normal type or remote type) Rotary actuator mounting components Name Amount Note ① Adapter Mounted on the positioner main stem. Hexagon socket ② 8，fix adapter to the positioner main stem.
  • Page 29 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 28. Four cases of installation matching...
  • Page 30 Intelligent Valve Positioner IP6000 Series User’s Manual  Pay attention to the difference between the remote type and the normal type. For the installation of the remote type, please refer to the installation of the normal type. Figure 29. Comparison of the feedback axis pointers (remote type and normal type) 1.
  • Page 31 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 31. Rotary stroke mounting bracket installation 4. Mount the rotary stroke mounting bracket to the actuator. Figure 32. Installation with actuator...
  • Page 32 Intelligent Valve Positioner IP6000 Series User’s Manual 5. Overall schematic diagram. Figure 33. Rotary stroke for normal type...
  • Page 33 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 34. Rotary stroke for remote type...

  • Page 34: Separate Type

    Intelligent Valve Positioner IP6000 Series User’s Manual 7.3. Separate type Separate type mounting components Name Amount Note ① Sensor Feedback the valve opening position ② Mounting plate Connect the positioner and the actuator ③ Ф20 O-ring × ④ Fastener Fix the mounting plate, G1/4 Thread ⑤...
  • Page 35 Intelligent Valve Positioner IP6000 Series User’s Manual value of the displacement sensor. Otherwise, the positioner cannot match the actuator. Maximum valve stroke D range L1, L2 reference range 46~54 mm 25 mm 4~29 mm Lock nut Adjusting nut Figure 36. D value adjustment ...
  • Page 36 Intelligent Valve Positioner IP6000 Series User’s Manual Fix the mounting plate. Figure 38. Fix the mounting plate ③ ② Put the O-ring into the corresponding sealing groove of the mounting plate , fix the ② ④ mounting plate to the corresponding position of the actuator with the fastener , and tighten it with an Allen wrench.
  • Page 37 Intelligent Valve Positioner IP6000 Series User’s Manual ⑤ Fix the positioner on the mounting plate with hexagon head bolts and tighten with a wrench. 4. Connect the sensor. Figure 40. Connect the sensor ⑥ Insert the sensor connector into the corresponding position of the sensor and tighten. (Note:...

  • Page 38: Position Feedback Module

    Intelligent Valve Positioner IP6000 Series User’s Manual Figure 41. Sensor connector 7.4. Position feedback module If it is required，feedback module is available when user selects. Feedback module is shown in Figure 42. Figure 42. Feedback module Installation of feedback module：...
  • Page 39 Intelligent Valve Positioner IP6000 Series User’s Manual Figure 43. Remove the circuit board protective cover  Install the feedback module according to the position as shown below, and connect electrical connectors of the module with the connectors on the circuit board according to the corresponding colors, fix the feedback module with M3 spring washer and M3 pan head screw, and finally install the circuit board protective cover.

  • Page 40: Operation

    Intelligent Valve Positioner IP6000 Series User’s Manual off. 8. Operation 8.1. Interface description User’s operating interface includes one LCD screen and 4 buttons. LCD display description Position Description  Display the percentage value of angle sensor in the initial interface (NOINI) or when running the initialization function.

  • Page 41: Display And Operation Of Main Interface

    Intelligent Valve Positioner IP6000 Series User’s Manual  Enter submenu, enable or confirm parameter modification in menu mode.  Run initialization or reset to factory settings.  Run initialization in initial interface (NOINI) or in operating mode. 8.2. Display and operation of main interface Positioner is in the uninitialized state before initialization.

  • Page 42: Menu And Functions

    Intelligent Valve Positioner IP6000 Series User’s Manual in Figure 46. Automatic mode Manual mode Figure 46. Operating mode interface 8.3. Menu and functions 8.3.1. Display and operation of menu Press and hold button for approx. 3s to enter the menu. The menu interface will display as Figure 47.

  • Page 43: Inita

    Intelligent Valve Positioner IP6000 Series User’s Manual parameter will flash. Press buttons to set parameter and press button to confirm. 8.3.2.2. INITA The function is auto initialization. It will automatically detect action direction, actual physical stroke of valve and control parameters.

  • Page 44: Sdir

    Intelligent Valve Positioner IP6000 Series User’s Manual 4095). For option 4mA, set the front-end input signal to 4mA signal; for option 20mA, set the front-end input signal to 20mA signal. For example, when the front-end input signal is 4mA, value 650 will flash on LCD.
  • Page 45 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.2.6. CHAR The characteristic curve is the relationship between set-point value and valve stroke. In the actual control system, it is usually required to make the controlled variable have specific control characteristics (such as linearity). The user can choose and set the corresponding characteristic curve to achieve the control requirements.
  • Page 46 Intelligent Valve Positioner IP6000 Series User’s Manual Valve stroke ( % ) Set-point value ( % ) Figure 49. CHAR 8.3.2.7. FREE Set value of FrEE characteristic curve in CHAR function option. Sub-function options of FREE are FR 0, FR 5, …，FR 100, 21 set points in total.
  • Page 47 Intelligent Valve Positioner IP6000 Series User’s Manual Valve stroke ( % ) Set-point value ( % ) Figure 50. FREE 8.3.2.8. DB Set Dead band zone of positioner. The system does not adjust the valve stroke when the gap between the stroke value and the position set-point value is not bigger than the dead band value.
  • Page 48 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.2.9. LIM This function limits the automatic adjustment range in the whole valve physical stroke. The LIM sub-function options L MIN and L MAX of set the minimum and maximum limits of the stroke respectively.
  • Page 49 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.2.11. CUT This function is used for the positioner to fully close or open the valve in automatic mode. When the function is enabled, sign CU displays in the left bottom in main interface.
  • Page 50 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.2.12. POS This function is used to set the standard of position display and feedback signal output. Select this function in the menu interface, press button to start setting, and the parameter will flash.
  • Page 51 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.2.13. FACT All setting parameters in the menu reset to factory default values. Select this function in the menu interface, press and hold button for approx. 3s to reset to factory setting. Then the system is in an uninitialized state and the LCD displays FINSH.
  • Page 52 Intelligent Valve Positioner IP6000 Series User’s Manual requirements. requirements.  If it’s in the manual initialization  When running the manual initialization, operation process, press the difference from buttons to re-calibrate END 1 and END 1 to END 2 END 2, make sure that difference doesn’t meet the...
  • Page 53 Intelligent Valve Positioner IP6000 Series User’s Manual 8.3.5. Menu function options summary description Options Functions Parameter value Factory settings 1 TYPE Actuator type setting Lin Turn FLin ELin 2 INITA Auto initialization 3 INITM Manual initialization Calibrate 4mA set point 4 CAL→4 mA...
  • Page 54 Intelligent Valve Positioner IP6000 Series User’s Manual point of the linear feedback lever 8.4. HART DD file description 8.4.1. Device dynamic variable description Dynamic variable Description Position setpoint percentage value Position percentage value 8.4.2. Device custom function description The device custom function is in the Detailed setup directory of the DD file. The function options...
  • Page 55 Intelligent Valve Positioner IP6000 Series User’s Manual STEP1, STEP2, STEP3 Initialization steps. ERR 1, ERR 2, ERR 3, ERR 4 Initialization error message. The options and descriptions in the Setpoint directory are shown in the following table: Options Description Device dynamic variable.
  • Page 56 Intelligent Valve Positioner IP6000 Series User’s Manual 8.6. Adjust air flow 1. Remove the circuit board protective cover. Figure 55. Remove the circuit board protective cover NOTE：Must install or remove the circuit board protective cover when the device is powered off.
  • Page 57 Intelligent Valve Positioner IP6000 Series User’s Manual ① ② Figure 56. Air flow adjustment ① Restrictors Y1 ② Restrictors Y2，only for double-acting actuator. 9. Trouble shooting Contents Possible reasons Solutions Error electrical connections. Check the electrical connections No current output from current...
  • Page 58 Intelligent Valve Positioner IP6000 Series User’s Manual Others Consult with manufacturer. 10. Warranty terms If the product is found to have quality problems which are confirmed by our company staff, customers have after-sale services for product maintenance or free replacement in the warranty period.
  • Page 59 V230227 本说明书内容变更，恕不另行通知。 相关技术更新本公司保留最终解释权。 The changed contents of this manual are not noticed. The Company reserves the final interpretation for related technical updating...
  • Page 60 附件 智能阀门定位器气源要求 全系列产品（包含 1500、1600、1880、IP5500、IP6000 系列） 按照技术要求，全系列的智能阀门定位器气源要求为 3 级，提供符合气源要求的压缩空 气，可以确保定位器的正常使用。 露点 3 级：露点为-20°C。 （若定位器实际工作环境温度低于-20°C，则使用的压缩空气露点需 相应低于定位器实际工作环境温度-10°C） 固体颗粒大小和密度 3 级：5.0mg/m3（对应粒径为 5.0um） ，不允许有粒径大于 5.0um 的颗粒 进入。 含油量 3 级：1.0mg/m3，每单位立方米的空气累积油含量不超过 1.0mg。 流程示例 ○ ○ 图1. 流程图 ○ 在主管路中配备压缩空气干燥机，过滤掉压缩空气中产生的大部分水分，过滤后的压力露 点可达到-20°C； ○ 选择任意与图 2 一致的调压过滤器组合安装在定位器管路的前端， 安装时需过滤减压阀 （空 气过滤器）在前，油雾分离器在后，要求过滤器过滤粒径在...
  • Page 61 AC20D-A~AC40D-A 系列 AC20C-A~AC40C-A 系列 图2. 调压过滤器组合 过滤器选型推荐 选型组合 SMC AC20C-02G-A AC20D-02G-A AC30D-02G-A 选型编号 入口侧压缩空气质量略低于定位器使 入口侧压缩空气质量符合定位器使 用要求时 用要求时 基础参数 流体：空气...
  • Page 62 环境温度及使用温度：-5~60°C（未冻结） 耐压：1.5MPa 使用压力范围：0.05~1.0MPa 设定压力范围：0.05~0.7MPa 过滤精度：AW:5um、AFM：0.3um（捕集效率 99.9%） 杯体材质：聚碳酸酯 结构：溢流型 主体尺寸：20 主体尺寸：30 ○ ○ 额定流量： 额定流量： 主体尺寸：20 ○ 150L/min 330L/min 额定流量：200L/min 杯体保护罩：标准 杯体保护罩： 标准 杯体保护罩：标准（钢带） （钢带） 装备（聚碳酸酯） 质量：0.39kg 质量：0.33kg 质量：0.66kg 螺纹种类（无记号） ：Rc ○ 螺纹种类（无记号） ：Rc 选型参数 ○ 接口管径 02：1/4 ○ 接口管径 02：1/4 ○...
  • Page 63 注意事项 1. 应视工况要求选择不同性能的调压过滤器，避免因工作环境的高温、低温、高压、腐蚀 等原因导致调压过滤器失效,详见末尾附录选型表。 2. 定期巡查过滤器的使用情况，若使用频繁的工况应提高巡查次数，避免因过滤器滤芯堵 塞导致的故障问题（故障举例：○ 过滤失效，导致定位器进入异物，致使定位器故障；○ 滤芯堵塞，导致气源供应异常，定位器无法正常工作等） 。 3. 采用自动排水功能的调压过滤器需要避免排水孔的堵塞，定期巡查可避免过滤器故障导 致滤杯内大量积水。手动排水的应视工况下过滤器的积水速率，定时人工排水。 4. 按照调压过滤器的使用说明， 定期维护或更换不合格的产品， 可避免不必要的故障出现。...

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