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AV1
ABB AV1 User Manual
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INTRODUCTION
SPECIFICATIONS
1 - 10
Figure 1-2. Air Consumption
FLO
W
(SCFM)
SU
PPL
Y
PRE
SS
UR
E
(PSIG)
T
00800
A
0.90
0.30
0.10
0.20
0.40
0.80
0.50
0.60
0.70
0.00
20
150
30
40
50
60
70
80
90
100
110
120
130
140
AV2
AV1
Figure 1-3. Output Air Flow vs. Error
Signal — S
tand
ard and Performance Ser
ies
OUTP
UT
AIR
F
LO
W
(SCFM)
ERR
OR
(%)
25
20
-25
15
-15
-20
5
-5
10
-10
-20
-1
0
-15
-5
5
15
20
10
O1
S
UPPL
YING
O2
EXHA
US
TING
O2
S
UPPL
Y
ING
O1
EXHAUS
T
ING
ST
ANDARD
ST
AND
ARD
PER
FOR
MA
NC
E
SERIES
PERFORMANCE
SER
IES
T
00813
A
17
19
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 - Introduction
9
Overview
9
Intended User
9
Description
9
Agency Approvals
9
Performance Series Option
10
Explosionproof I/P Option
11
NEMA 4X Option
11
Application
11
Features
11
Instruction Content
13
Reference Documents
14
Nomenclature
14
Specifications
15
Type AV1/2 Positioner Specifications
15
Nomenclature
15
Capacity (Exhaust to Atmosphere)
17
Air Consumption
18
Output Air Flow Vs. Error Signal - Standard and Performance Series
18
Expanded First Quadrant View
19
Rotary Actuator Retrofit Mounting Kits
21
Speed Control Orifices
21
Pressure Gages
21
Supply Air Regulators with Gages
21
Section 2 - Description and Operation
25
Introduction
25
Operation Diagram
25
Block Diagram
25
Cam
25
Functional Operation
26
Section 3 - Installation
27
Introduction
27
Unpacking and Inspection
27
Enclosure Classification
28
Mounting Considerations
28
External and Mounting Dimensions
29
Mounting Type Av Positioners
30
Electrical Connections
30
Drive Arm Connections
30
Drive Shaft Variations
31
Mounting Using Linkage (Typical)
31
Mounting Using Direct Coupling (Typical)
32
Cam Characteristics
33
Tubing Connections
34
Air Supply Filtering
34
Air Supply Pressure
34
Cam Roller Alignment
34
Cam
34
Air Supply Quality (Recommended)
35
Tubing Connections
35
Port Locations
35
Wiring Type Av2 Positioner
36
Direct Acting, Top Loaded, Single Acting Tubing Example
37
Direct Acting, Bottom Loaded, Single Acting Tubing Example
38
Reverse Acting, Top Loaded, Single Acting Tubing Example
38
Wiring Type Av1 Positioner
39
Reverse Acting, Bottom Loaded, Single Acting Tubing Example
39
Double Acting Tubing Example
40
Wiring Connections
40
Radio Frequency Interference
41
Wiring Requirements
41
Section 4 - Calibration
43
Introduction
43
Calibration
43
Zero Adjustment
43
Calibration Adjustments
44
Span Adjustment
45
Calibration for Particular Application
45
Cam Roller Alignment
45
Zero Adjustment
46
Span Adjustment
46
Zero Adjustment Graph
46
Gain and Speed Adjustments
47
Gain Adjustment
47
Span Adjustment Graph
47
Gain Hinge Springs
47
Orifice
48
Pilot Valve Stroke Adjustment
48
Speed Adjustment
48
Pilot Valve Adjustment
49
Speed Adjustment Screws
49
Troubleshooting Calibration Adjustments
50
Section 5 - Operating Procedures
53
Introduction
53
Equalizing and Air Supply Shutoff Valve
53
Transfer from Automatic to Manual Operation
53
Transfer from Manual to Automatic Operation
53
Section 6 - Troubleshooting
55
Introduction
55
Positioner Errors
55
Section 7 - Maintenance
57
Introduction
57
Preventive Maintenance Schedule
57
Preventive Maintenance Procedures
58
Manifold Filters
58
Positioner with Manifold
59
Manifold with Filter Cover Removed
59
Section 8 - Repair and Replacement
61
Introduction
61
Replacement Procedures
61
Manifold
61
Gain Hinge Spring
62
Positioner with Manifold
62
Pilot Valve Assembly
63
Manifold O-Rings
63
I/P Converter
64
Cam
65
Diaphragm Assembly
65
Diaphragm Assembly Removal
66
Diaphragm Assembly Replacement
66
Pilot Valve Stroke Adjustment
67
Pilot Valve Measurement for Maximum Speed
68
Stroke Adjustment Screws
69
Section 9 - Support Services
71
Introduction
71
Recommended Spare Parts
71
Additional Spare Parts
73
Gain Hinge Springs
73
To 20-Ma Position Transmitter Circuit Board
75
Mounting Kits
77
Rotary Actuator Retrofit Mounting Kits
77
Bypass Valve Assembly
78
Bypass Valve Assembly (Optional)
78
Type AV1 Positioner Parts List
79
Cam Selection and Manifold/Gage Block Parts Reference for Type AV1 Positioners
80
Shaft Position Transmitter Parts Reference for Type AV1 Positioners
82
Type AV2 Positioner Parts List
82
Shaft Position Transmitter Parts Reference for Type AV2 Positioners
85
Appendix A - Position Transmitters
89
Introduction
89
Description and Operation
89
Calibration
90
Calibrating the Potentiometric Position Transmitter
90
Calibrating the Potentiometric Example
92
Potentiometric Application Example
92
Potentiometric Position Transmitter (Exploded View
93
Potentiometer
93
Calibrating the 4 to 20-Ma Position Transmitter
94
To 20-Ma Position Transmitter (Exploded View
95
Appendix B - Quick Start
97
Introduction
97
Product Identification (Nomenclature
97
Mounting the Positioner
98
Mounting Using Linkage (Typical
99
Mounting Using Direct Coupling (Typical
99
Drive Arm Connections
100
Cam Roller Alignment
100
Tubing Connections
101
Port Locations
101
Direct Acting, Top Loaded, Single Acting Tubing Example
102
Reverse Acting, Top Loaded, Single Acting Tubing Example
102
Direct Acting, Bottom Loaded, Single Acting Tubing Example
103
Reverse Acting, Bottom Loaded, Single Acting Tubing Example
103
Type Av2 Positioner Wiring
104
Type AV2 Positioner
104
Double Acting Tubing Example
104
Type AV2 Positioner
105
Wiring Connections
105
Calibration Adjustments
105
Type Av1 Positioner Wiring
106
Type AV1 Positioner
106
Appendix C - Cam Characterization
109
Introduction
109
Cam Characterization
110
Cam Selection
111
Cam Shaping
113
Cam Characteristics
113
Appendix D - Type Av1 Pneumatic Position Transmitter
117
Introduction
117
Description
117
Installation
117
Calibration
117
Pneumatic Position Transmitter Kit
118
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ABB AV1 Specifications
General
Brand
ABB
Model
AV1
Category
Valve Positioners
Language
English
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