005A/ENG
Piping method IP6000 lever type single acting
Installation and Maintenance Manual
Series IP6000/6100-X14 Electro-Pneumatic Positioner
Positive operation (Fig 8)
When the input signal is increased, the stem extends.
IP6100
For future reference, please keep this manual in a safe place
Double acting
OUT1
OUT2
This manual should be read in conjunction with the current product catologue
OUT1
Safety Instructions
These safety instructions are intended to prevent a hazardous situation and/or equipment damage. These instructions indicate the level
of potential hazard by label of “Caution”, “Warning” or “Danger”.
To ensure safety, be sure to observe ISO4414 (Note1), JIS B 8370 (Note2)
and other safety practices.
Note 1: ISO 4414: Pneumatic fluid power – Recommendations for the
application of equipment to transmission and control systems.
Note 2: JIS B 8370: Pneumatic system axiom.
CAUTION :
Operator error could result in injury or
equipment damage.
WARNING : Operator error could result in serious
injury or loss of life.
DANGER : In extreme conditions, there is a
possible result of serious injury or loss of life.
WARNING
1. The compatibility of pneumatic equipment is the responsibility of the person who designs the pneumatic system
or decides its specifications.
Since the products specified here are used in various operating
conditions, their compatibility for the specific pneumatic system
must be based on specifications or after analysis and/or tests to
meet your specific requirements.
2. Only trained personnel should operate pneumatically
operated machinery and equipment.
Compressed air can be dangerous if an operator is unfamiliar
with it. Assembly, handling or repair of pneumatic systems should
be performed by trained and experienced operators.
Span adjusting
lever normal position
IN±
OUT2 is plugged
Fig 12
IP6000
Positive operation (Fig 12)
When the input signal is increased, the cylinder rod extends.
Fig 8
OUT2
Reverse operation (Fig 9)
When the input signal is increased, the stem retracts.
Fig 1
Installation
IP6000 type (Lever type feedback)
1 The unit must be mounted using bolts, firmly fixed through the
mounting holes on the side or rear of the positioner (Fig 3).
No bracket
L-type bracket
External feedback lever
Stroke
Order code Unit number
10~85mm
(Nil)
P368010-20
35~100mm
(E)
P368010-21
50~140mm
(F)
P368010-22
OUT1
Size M
125
110
110
Size N
150
195
275
OUT2
SUP
SUP
Front bracket
Span adjusting
lever reverse position
IN±
Ensure that the air supply system is filtered to 5 micron.
Bracket
Positioner
Bracket
Positioner
Positioner
Span adjusting
lever reverse position
IN±
CAUTION
Explosion protection
Span adjusting
lever normal position
IN±
3. Do not service machinery/equipment or attempt to
remove component until safety is confirmed.
1) Inspection and maintenance of machinery/equipment should
only be performed after confirmation of safe locked-out
control positions.
2) When equipment is to be removed, confirm the safety process
as mentioned above. Switch off air and electrical supplies and
exhaust all residual compressed air in the system.
3) Before machinery/equipment is re-started, ensure all safety
measures to prevent sudden movement of cylinders etc.
(Bleed air into the system gradually to create back-pressure,
i.e. incorporate a soft-start valve).
4. Contact SMC if the product is to be used in any of the
following conditions:
1) Conditions and environments beyond the given specifications, or if product is used outdoors.
2) Installations in conjunction with atomic energy, railway, air
navigation, vehicles, medical equipment, food and beverage,
recreation equipment, emergency stop circuits, press
applications, or safety equipment.
3) An application which has the possibility of having negative
effects on people, property, or animals, requiring special
safety analysis.
OUT2
SUP
Fig 13
OUT1 is plugged
Reverse operation (Fig 13)
When the input signal is increased, the cylinder rod retracts.
This electric-pneumatic positioner is approved as intrinsic safety type of explosion protection (EExibIICT5/T6) by PTB in Germany. When it is used
for explosion application, please take precautions during handlling.
Bracket
Bracket
Fig 9
IP6100 rotary type single acting (Fig 14)
Specifications
Open circuit voltage
Short circuit current
Effective internal inductivity
Note 1:
Note 2:
Note 3:
1/2 spirit range (Standard).
Stroke adjustment: 0~60°, 0~100°.
Standard air temperature: 20° (298k), absolute pressure: 760mm Hg, Relative humidity: 65%.
Fig 2
OUT1
OUT2
OUT1
OUT2
The positioner must be mounted so that the feedback shaft is aligned
with the shaft of the rotary actuator (Fig 5).
Bracket
(A)
Backlash eliminating spring
Fork lever joints (IP6100 type)
Right angle
(Or 100%)
Input current 0% position
Input current 50% position
Main shaft
Span adjusting
lever normal position
IN±
Fig 6
Single action
actuator
OUT1
OUT1 is plugged
Fork-lever rotary joints are available that tolerate small misalignments
between positioner and actuator shaft.
These are available in two standard sizes.
SUP
The cam
should be
set on the
DA surface
Input current 100% position
(Or 0%)
Feedback lever
Positioner body
Connecting fitting
Valve stem
Fig 4
3 A full scale deflection of 20° is optimum. It should be at least 10°
and at most 30° in order to achieve specified accuracy and
linearity.
Fork lever joint (Fig 7)
Part name
Fork lever assembly MX
Fork lever assembly SX
Side mounting with the fork
lever assembly MX
Pilot valve with output restriction (IP6000, 6100 type)
In general, mounting on a small-size actuator may cause hunting. For
prevention, a pilot valve with a built-in restriction is available. The
restriction is removable.
Orifice size
ø0.7
ø1.0
M6x1
Pilot unit part
Part number
number
P36801080
P368010-28
P36801081
P368010-29
Part number
P368010-36
P368010-37
Fig 10
Rear mounting with the fork
lever assembly SX
IN±
When the input signal is increased, the stem extends. (Positive valve
operation by its reverse operation mode) (Fig 10).
OUT2 is plugged
(B)
OUT2
OUT1
OUT2
SUP
SUP
M6x1
IN±
Actuator main shaft
IN±
Span adjusting
lever reverse position
OUT1 is plugged
OUT2 is plugged
Fig 11
When the input signal is increased, the stem retracts (Fig 11).Double
Fig 7
Single action
actuator
Main shaft
Actuator main shaft
Bracket
External feedback lever (IP6000 type)
The feedback lever is selected according to valve stroke. Consult
factory for strokes less than 10mm.
Fig 5
SUP
Installing feedback lever
Restrictions
Actuator
capacity
90cm3
120cm3
IP6100 type (Rotary cam type feedback)
Reverse operation (B)
When the input signal is increased, the actuator shaft rotates in a
counter-clockwise direction.
OUT2
(MX type: 55)
Input signal
current circuit
2 A connecting fitting, or pin, to transfer the displacement of the
valve stem, must be mounted in a position to ensure that the
feedback lever is at right angles to the valve stem, for an input
current of 50%. Fig 4 below shows the configuration viewed from
the front.
39 (MX type: 63)
Explosion protected
construction
Air port
Electrical connection
Material
Weight
Fig 3
L2=31
Ambient and fluid temperature
Positive operation (A)
When the input signal is increased, the actuator shaft rotates in a
counter-clockwise direction.
63 (SX type: 39)
Item
Input current
Coil resistance
Supply air pressure
Stroke
Sensitivity
Linearity
Hysteresis
Repeatability
Coefficient of temperature
Output flow
Air consumption (Bleed)
IP6000-X14
IP6100-X14
Lever type lever feedback
Rotary type cam feedback
Single action
Double action
Single action
Double action
4~20m ADC (Standard) Note 1
235±15Ω (4~20mADC)
0.14~0.7 MPa (1.4~7.1 kgf/cm2)
10~85mm (Deflection angle 10°~30°)
60°~100° Note 2
Within 0.1% F.S.
Within 0.5% F.S.
Within ±1% F.S.
Within ±2% F.S.
Within 0.75% F.S.
Within 1% F.S.
Within ±0.5% F.S.
Within 0.1% F.S./°C
80l/min (ANR) or more (SUP=0.14 MPa) Note 3
5l/min (ANR) or less (SUP=0.14 MPa) Note 3
-20°C~80°C (Non-explosion proof)
-20°C~80°C (T5)
-20°C~60°C(T6)
Intrinsic safety type of explosion-protection (EExib II CT5/T6)
Approval No. EX-82/2167
NPT 1/4 female
Pg 13.5 (DIN 40430) female
Aluminum diecast body
Approx 2.4 kg
According to EN50014 and EN50020 EEx ib IIC T5/T6 an intrinsically safe explosion-proof
type may only be connected to a certified intrinsically safe electrical circuit with the following
maximum values.
U < 20V
Ik < 100mA
Li < 100mA, effective internal capacity is so slight that it can be neglected.
L=101 (SX type: 67)
Type
Fig 14
The cam
should be
set on the
RA surface
Double acting (Fig 15)
IP6000 type block diagram of operating principle
Positive operation (A)
When the input signal is increased, the actuator shaft rotates in a
clockwise direction.
IP6000 (Lever type feedback)
single action positive operation
Stopper screw
(Do not move)
Reverse operation (B)
When the input signal is increased, the actuator shaft rotates in a
counter-clockwise direction.
Double action
actuator
Main shaft
SUP
Automatic/manual
change-over screw
(Built-in bleed restriction)
Zero
adjusting
spring
O Driven diaphragm
IN current
OUT1
OUT2
SUP
(A)
X
View
Torque
motor
Sensitivity adjusting screw
(Adjusts GAIN)
1 Pilot valve
Restriction
Nozzle
flapper
Diaphragm
Inlet valve B
8 Feedback lever
OUT2
SUP
The cam
should be
set on the
DA surface
IN±
Feedback
spring
9 Span
adjusting lever
4 Counter weight
EXH.
Diaphragm
7 Exhaust
valve
5 Flapper
6 Nozzle
2 Compensation spring
Transmission pin
Lock screw
Zero adjusting screw
N Transmission lever
(B)
Span adjusting screw
J Feedback spring
Double action
actuator
K Plate spring
OUT2
SUP
IN±
Fig 18
IP6000 type (Fig 18)
For reverse position, exchange the shaft of the span adjusting lever to
the opposite side. The span adjusting screw faces upward in this condition. (See 'piping method'.)
Principle of operation
IP6000 type (Fig 16)
When the input current increases, K the plate spring of L the torque motor will work as a pivot, M armature will receive a counter-clockwise torque,
4 the counter weight will be pushed to the left, the clearance between 6 the nozzle and 5 the flapper will increase, and the nozzle back pressure
will decrease. Consequently, 7 the exhaust valve of 1 the pilot valve moves to the right, the output pressure of OUT1 increases and O the diaphragm
moves downwards. The motion of O the diaphragm acts on K the feedback spring through 8 the feedback lever, N the transmission lever and 9
the span adjustment lever to rest at the balance position generated by the input current. 2The compensation spring is for direct feedback of the motion
of 7the exhaust valve to 4 the counter weight to increase the stability of the loop. The zero point should be adjusted by change of 3 the zero adjustment spring tension.
SUP
Input
current terminal
The cam
should be
set on the
RA surface
Feedback
lever
Stem stroke
OUT
IP6100 type block diagram of operating principle
L Torque motor
OUT1
Span
adjusting
lever
Driven
diaphragm
Span adjusting lever shaft
3 Zero adjusting spring
Main shaft
Inlet valve
Compensatory
spring
Inlet valve A
OUT1
Exhaust
valve
M Armature
Zero
adjusting
spring
IN current
Restriction
Nozzle
flapper
Torque
motor
Diaphragm
Exhaust
valve
Inlet valve
Cam
Feedback
shaft
Oscillating
actuator
Angle of rotation
OUT
Compensatory
spring
Fig 15
Fig 16
Feedback
spring
IP6100 (Rotary type cam feedback)
double action positive operation
View X
Automatic/manual change-over screw
(Built-in bleed restriction)
Stopper screw
(Do not move)
SUP
OUT2
Sensitivity adjusting screw
(Adjusts GAIN)
OUT1
1 Pilot valve
Inlet valve A
For reverse position, set by turning over the
cam and reversing connections of outlets
OUT1 and OUT2.
Inlet valve B
4 Counter weight
2 Compensation spring
Span
adjusting
lever
Diaphragm
5 Flapper
6 Nozzle
IP6100 type (Fig 17)
When the input current increases, L the plate spring of M the torque motor will work as a pivot, N armature will receive a counter-clockwise torque,
4 the counter weight will be pushed to the left and the clearance between 6 the nozzle and 5 the flapper will increase, and the nozzle back pressure will decrease. Consequently, 7 the exhaust valve of 1 the pilot valve moves to the right, the output pressure of OUT1 increases, that of OUT2
decreases and P the rotary actuator moves. The motion of P the actuator acts on J the feedback spring through K the feedback shaft, 8 the cam,
9 the span adjustment lever and O transmission lever to rest at the balance position generated by the input current. 2 The compensation spring is
for direct feedback of the motion of 7 the exhaust valve to 4 the counter weight to increase the stability of the loop. The zero point should be adjusted by change of 3 the zero adjustment spring tension.
Span adjusting unit
7 Exhaust
valve
8 Cam
9 Span
adjusting lever
Pilot valve unit 1
O Transmission lever
Pairing
3 Zero adjusting spring
Mini-terminal unit
Torque
(No terminal box)
motor unit
Feedback shaft
assembly
Zero adjusting screw
J Feedback spring
K Feedback shaft
L Plate spring
M Torque motor
Input
current terminal
Feedback lever unit
P
Oscillating
actuator
Terminal joint unit
(No terminal box)
N Armature
Fork joint
Terminal box unit
Fig 17
Fig 19
Maintenance and parts replacement simplified due to
modular construction (Fig 19)
Maintenance
1. Periodically examine the compressed air cleaning system, and
ensure clean air is supplied. Dirty air will cause positioner malfunction.
2. When removing/dismantling the pilot valve 1 apply grease to the
O-ring of the sliding section (Toray silicone SH45 grease).
3. If the fixed orifice becomes clogged, remove the pilot valve
auto/manual change over screw and clean it by inserting a
ø0.2mm wire into the aperture. If a new orifice is required, isolate
the air supply and remove the stopper screw of the pilot valve.
4. Inspect the positioner annually and replace any worn/damaged
parts. If the environment is severe inspect at more frequent
intervals.
When you enquire about the product, please contact the following
SMC Corporation:
ENGLAND
Phone 01908-563888
TURKEY
Phone 212-2211512
ITALY
Phone 02-92711
GERMANY Phone 6103-402-0
HOLLAND
Phone 020-5318888
FRANCE
Phone 01-64-76-10-00
SWITZERLAND Phone 052-396 31 31
SWEDEN
Phone 08-603 07 00
SPAIN
Phone 945-184100
AUSTRIA
Phone 02262-62-280
Phone 902-255255
IRELAND
Phone 01-4501822
GREECE
Phone 01-3426076
DENMARK Phone 70 25 29 00
FINLAND
Phone 09-68 10 21
NORWAY
Phone 67-12 90 20
BELGIUM
Phone 03-3551464
POLAND
Phone 48-22-6131847
PORTUGAL Phone 02-610 8922