ABB LP10 User manual

—

ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTIONS | OI/LP-EN REV. D

Linear pneumatic piston actuators

Measurement made easy

Overview

LP linear piston actuators are typically used to control

the position of airflow regulating dampers, butterfly

valves, and other similar process regulating devices

on furnaces, boilers and air distribution systems.

They are most often used on windbox dampers in NOx

reduction control systems. When directly connected

to a lever on the damper shaft, these actuators

provide accurate positioning control at minimum.

For more information

Further publications for the LP series of linear

pneumatic piston actuators are available for free

download from:

www.abb.com/actuators

(see links and reference numbers below) or by

scanning this code:

Search for or click on

Data Sheet

Linear pneumatic piston actuators

DS/LP-EN

—

High performance

actuators for

precision damper control

WARNING notices as used in this manual apply to hazards or unsafe practices which could result in

personal injury or death.

CAUTION notices apply to hazards or unsafe practices which could result in property damage.

NOTES highlight procedures and contain information which assist the operator in understanding the

information contained in this manual.

All software, including design, appearance, algorithms and source codes, is owned and copyrighted by

ABB Inc. or its suppliers.

WARNING

INSTRUCTION MANUALS

Do not install, maintain or operate this equipment without reading, understanding and following the proper

ABB Inc. instructions and manuals, otherwise injury or damage may result.

POSSIBLE PROCESS UPSETS

Operation and maintenance must be performed only by qualified personnel and only after securing

equipment controlled by this product. Adjusting or removing this product while it is in the system may

upset the process being controlled. Some process upsets may cause injury or damage.

NOTICE

The information contained in this document is subject to change without notice. ABB Inc. reserves the

right to make minor changes to this publication, such as company name & logos as well as other minor

corrections, without necessarily changing the publication number.

ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this publication

specifically disclaim all liabilities and warranties, express and implied (including warranties of

merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and/or

reliability of the information contained herein and/or for the fitness for any particular use and/or for the

performance of any material and/or equipment selected in whole or part with the user of/or in reliance

upon information contained herein. Selection of materials and/or equipment is at the sole risk of the user

of this publication.

This document contains proprietary information of ABB Inc. and is issued in strict confidence. Its use, or

reproduction for use, for the reverse engineering, development or manufacture of hardware or software

described herein is prohibited. No part of this document may be photocopied or reproduced without the

prior written consent of ABB Inc.

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

TABLE OF CONTENTS

READ FIRST ...................................................................................................................2

1.0 SPECIFICATIONS / FEATURES ...............................................................................3

2.0 THRUST RATINGS ...................................................................................................4

3.0 NOMENCLATURE.....................................................................................................7

4.0 MAINTENANCE.......................................................................................................10

5.0 OUTLINE DIMENSION DRAWINGS .......................................................................12

LP10 .........................................................................................................................12

LP20 .........................................................................................................................16

LP30 .........................................................................................................................20

LP32 .........................................................................................................................22

LP40 .........................................................................................................................24

LP50 .........................................................................................................................26

LP60 .........................................................................................................................28

6.0 PARTS.....................................................................................................................30

7.0 ACCESSORIES: CLEVIS, PINS & MOUNTS ..........................................................36

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

READ FIRST

WARNING

INSTRUCTION MANUALS

Do not install, maintain, or operate this equipment without reading, understanding and following the

proper ABB Inc. instructions and manuals, otherwise injury or damage may result.

RETURN OF EQUIPMENT

All equipment being returned to ABB Inc. for repair must be free of any hazardous materials (acids,

alkalis, solvents, etc). A Material Safety Data Sheet (MSDS) for all process liquids must accompany

returned equipment. Contact ABB Inc. for authorization prior to returning equipment.

Read these instructions before starting installation; save these instructions for future reference.

WARNING

Stay clear of moving components when performing procedures that require the equipment to be

energized. The equipment can operate automatically. There is a risk of entanglement of body parts

if caution is not observed. When possible, remove the supply source or remove the equipment

from the process before servicing.

Contacting ABB Inc.

Should assistance be required with any ABB Instrumentation product, contact the following:

Telephone:

Automation Services Call Center

1-800-HELP-365

Internet: www.abb.com

•Select Instrumentation & Analytical from the Our Offerings section

•Select Contact Directory from the Products & Services tab. Then select your

country location from the Your Country drop-down menu in the center of the page.

•Select Service from the Instrumentation & Analytical Product Group listing and

complete the requested information in the pop-up window.

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

1.0 SPECIFICATIONS / FEATURES

Simple Cylinder Actuators From 21/2” dia. x 5” Stroke

to 10”dia. x 16” Stroke

Linear Piston Actuator Assemblies

The LP series of damper drives provide a linear

actuation solution that is ideally suited for

applications to control the position of air

dampers or louvers on furnaces, boilers, and air

distribution systems. They are also used on

Burner Tilts and Overfire air dampers. They are

suitable for Windbox damper control in NOx

reduction control systems.

The conventional assembly, which uses the AV

Positioner series, offers a high-temperature

option up to 250oF. In comparison our digital

TZIDC solution allows for operation up to 185oF.

LP sizes range from a 2.5” diameter cylinder

with a 5” stroke (2.5”x 5”) up to a 10”x 16”

diameter cylinder. The most common sizes,

2.5”x 5” and 4”x 4,” are readily available.

Operation with TZIDC Smart Positioners offers

digital communication, self-calibration,

diagnostics and performance monitoring

functions.

TZIDC Digital Features

•Microprocessor-based

The “AutoStroke” feature calibrates and tunes

the LP assembly automatically. •Local keypad, two line LCD and

position indicator

•Easy local configuration and operation

•Digital communication via HART,

FOUNDATION Fieldbus, and Profibus

FEATURES :

•Remote configuration and monitoring

Configurable operating parameters

High resolution, sensitivity, and fast response

with proven AV and TZIDC Positioners.

•Easy set-up of direct/reverse action, limit

stops, etc.

•Cylinders available with Buna-N or Viton

seals.

•Integrated position feedback

•Temperature range up to 250oF with

AV15, 185oF with TZIDC.

•Analog and/or digital feedback without

additional external devices to calibrate and

maintain

•Easy adaptability to air dampers and

louvers via clevis and pivot pin

mounting.

•Diagnostics and self-monitoring capabilities

•Drop in replacement for many “older”

piston actuators. •Easy trouble-shooting and preventive

maintenance

•Available with built-in 4 to 20ma.

position feedback. •Immunity to shock and vibration allows

installation in high vibration areas

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

2.0 RATINGS

Thrust Ratings

The basic thrust rating of a pneumatic piston is

equal to the area of the piston times the supply

pressure. The minimum supply pressure for both

the TZIDC and the AV1 is 20 psi.

The maximum supply pressure for the

TZIDC is 90 psi and 125 psi for the AV

positioner.

The area of the piston is A = πD2/4. Subtract

approximately 10% for friction losses and

because the rod side of the piston has less area.

An example is shown for an 80 psi air supply:

To find the lever length that would result in 90o

rotation of the damper shaft, multiply the cylinder

stroke length by 0.707.

Please refer to the individual Product

Specifications for details on the AV and TZIDC

Positioner performance.

Operating Torque/Thrust Actuator Type

Characteristic LP10 LP20 LP30 LP32 LP40 LP50 LP60

Area-Retracting (Rod Side) 4.71 in.211.2 in.226.8 in.226.8 in.248.8 in.248.8 in.276.1 in.2

Area-Extending (other side) 4.91 in.211.94 in.228.3 in.228.3 in.250.3 in.250.3 in.278.5 in.2

Force out @ 80 psi1339 lbs. 806 lbs 1930 lbs. 1930 lbs. 3514 lbs. 3514 lbs. 5479 lbs.

Lever Length for 90º Rotation 3.54 in. 2.83 in. 5.66 in. 11.32 in. 5.66 in. 11.32 in. 11.32 in.

Operating Torque @ 80 psi271 ft. lbs. 134 ft. lbs. 643 ft. lbs. 1286 ft.

lbs. 1172 ft. lbs 2341 ft. lbs. 3651 ft. lbs.

Note 1: Use the rod side area x psi to calculate force. Subtract 10% for friction loss.

Note 2: Torque at mid-stroke is 1.4x torque at +/- 45º

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

Suggested Maximum Operating Force vs Pressure

The following tables show the maximum operating force at minimum & maximum supply pressure for the

various LP cylinder sizes.

Note: The Torque calculation values are provided based on the stroke length of the LP and the required

lever arm dimension for 90 deg damper travel.

LP10

LP20

Cylinder diameter 2.5"x5"

Cylinder diameter 4"x4"

Lever for 90 deg 3.53" Lever for 90 deg 2.83"

Supply

psi Force

lbf Torque

ft-lb

Supply

psi Force

lbf Torque

ft-lb

40 170 35 40 403 67

45 191 40 45 454 76

50 212 44 50 504 84

55 233 48 55 554 92

60 254 53 60 605 101

65 276 57 65 655 109

70 297 62 70 706 118

75 318 66 75 756 126

80 339 71 80 806 134

85 360 75 85 857 143

90 382 79 90 907 151

Table 1 Table 2

LP30

LP32

Cylinder diameter 6"x8" Cylinder diameter 6"x16"

Lever for 90 deg 5.66" Lever for 90 deg 11.31"

Supply

psi Force

lbf Torque

ft-lb Supply

psi Force

lbf Torque

ft-lb

40 965 322 40 965 643

45 1,085 362 45 1,085 723

50 1,206 402 50 1,206 804

55 1,327 442 55 1,327 884

60 1,447 483 60 1,447 964

65 1,568 523 65 1,568 1,045

70 1,688 563 70 1,688 1,125

75 1,809 603 75 1,809 1,205

80 1,930 643 80 1,930 1,286

85 2,050 684 85 2,050 1,366

90 2,171 724 90 2,171 1,447

Table 3 Table 4

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

LP40

LP50

Cylinder diameter 8"x8" Cylinder diameter 8"x16"

Lever for 90deg 5.66" Lever for 90deg 11.31"

Supply

psi Force lbf Torque

ft-lb Supply psi Force

lbf Torque

ft-lb

40 1,757 586 40 1,757 1,171

45 1,976 659 45 1,976 1,317

50 2,196 732 50 2,196 1,463

55 2,416 806 55 2,416 1,610

60 2,635 879 60 2,635 1,756

65 2,855 952 65 2,855 1,902

70 3,074 1,025 70 3,074 2,049

75 3,294 1,098

75 3,294 2,195

80 3,514 1,172 80 3,514 2,341

85 3,733 1,245 85 3,733 2,488

90 3,953 1,318 90 3,953 2,634

Table 5 Table 6

LP60

Cylinder diameter 10"x16"

Lever for 90deg 11.31"

Supply

psi Force lbf Torque ft-

40 2,740 1,826

45 3,082 2,054

50 3,425 2,282

55 3,767 2,510

60 4,109 2,738

65 4,452 2,966

70 4,794 3,195

75 5,137 3,423

80 5,479 3,651

85 5,822 3,879

90 6,164 4,107

Table 7

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

3.0 NOMENCLATURE

“Simple Cylinder” type Linear pneumatic piston actuators are supplied with either type AV conventional

or type TZID intelligent positioners mounted on the cylinder. Cylinders are supplied with a threaded clevis

on the rod end and a standard MP pivot on the base. Base mounting pivots may be ordered as an

accessory.

The cylinders can be supplied with either Buna-N nitrile rubber seals suitable for 200oF (93oC) operation

or Viton seals suitable for 300oF (148oC) operation. The Buna-N seals have a lower breakaway pressure,

offering smoother modulating control. High temperature Viton seals are inherently higher friction and tend

to stick and breakaway, causing somewhat jerky motion. The operating temperature for the AV15 & AV16

is 250oF (121oC). All other positioners have a 185oF (85oC) maximum ambient. Buna-N seals are

recommended unless temperatures > 200oF (93oC) dictate Viton.

The TZIDC-200 is for Explosion Proof application Class I Div 1 Gr. C-G. Refer to the AV or TZIDC

positioner specifications for positioner details and specifications.

The maximum supply pressure with type TZIDC positioners is 90 psi. The maximum supply pressure with

type AV positioners is 125 psi.

Please refer to the individual Instruction Books for the AV and the TZIDC

positioners for details on the two types of positioners (Refer to table of Reference

Documentation shown below).

Document Description

D-APE-AV1234_ Characterizable Positioner Type AV1, AV2, AV3, AV4 specification

10/18-0.22 EN Electro-Pneumatic Positioner TZIDC specification

10/18-0.32 EN Electro-Pneumatic Positioner TZIDC-200 specification

PN25039 Characterizable Positioner Type AV1 and AV2 instruction

PN25058 Characterizable Positioner Type AV3 and AV4 instruction

P-E88-25-001 Closed Loop Control Using Type AV Positioner

P-P88-001 Installing a Type AV Positioner in a Hazardous Location

42/18-84 EN TZIDC Positioner Operating Instructions

42/18-73 EN TZIDC-200 Positioner Operating Instructions

45/18-79 EN TZIDC/TZIDC-200 Configuration Instructions

Refer to table on next page for LP Nomenclature details.

LP LINEAR PISTON ACTUATORS INSTRUCTION MANUAL

Code

Linear Pneumatic Piston Actuator

For quantity greater than 3 call

1 : Cylinder Size

2-1/2 in. Diameter, 5 in. Stroke (63.5 mm x 127 mm)

4 in. Diameter, 4 in. Stroke (101.6 mm x 101.6 mm)

6 in. Diameter, 8 in. Stroke (152.4 mm x 203.2 mm) 30

6 in. Diameter, 16 in. Stroke (152.4 mm x 406.4 mm)

8 in. Diameter, 8 in. Stroke (203.2 mm x 203.2 mm)

8 in. Diameter, 16 in. Stroke (203.2 mm x 406.4 mm)

10 in. Diameter, 16 in. Stroke (254 mm x 406.4 mm)

Non Standard Option

2 : Cylinder Seals

Buna-N Cylinder Seals -40 … 185 °F (-40 °C … 85 °C) B

Viton Cylinder Seals 30 ... 250 °F (-1°C ... 121 °C) V

Non Standard Option X

3 : Positioner Type (See Note A)

AV15, Input 3 … 15 psi (0.2 ... 1 bar) 250 °F (121 °C) 1

AV16, Input 3 ... 27psi (0.2 ... 1.86 bar), 250 °F (121 °C) 2

AV232_ _00, 4 ... 20 mA, 185 °F (85 °C) 3

AV11, 3 ... 15 psi (0.2 ... 1 bar), 185 °F (85 °C) 4

AV12, 3 ... 27 psi (0.2...1.9 bar), 185 °F (85 °C ) 5

TZIDC, HART 4 ... 20 mA, 185 °F (85 °C), Fail Safe A

TZIDC, HART 4 ... 20 mA, 185 °F (85 °C), Fail in Place B

TZIDC-200 (Explosion proof), HART, 4 ... 20 mA, 85 °C (185 °F), Fail Safe C

TZIDC-200 (Explosion proof), HART, 4 ... 20 mA, 185 °F (85 °C), Fail in Place D

TZIDC-110, Profibus PA, 185°F (85 °C), Fail Safe K

TZIDC-110, Profibus PA, 185°F (85 °C), Fail in Place L

TZIDC-210 (Explosion proof), Profibus PA, 185°F (85 °C), Fail Safe M

TZIDC-210 (Explosion proof), Profibus PA, 185°F (85 °C), Fail in Place N

TZIDC-120, Foundation Fieldbus, 185°F (85 °C), Fail Safe P

TZIDC-120, Foundation Fieldbus, 185°F (85 °C), Fail in Place R

TZIDC-220 (Explosion proof), F. Fieldbus, 185°F (85 °C), Fail Safe S

TZIDC-220 (Explosion proof), F. Fieldbus, 185°F (85 °C), Fail in Place T

Non Standard Option X

4 : Position Feedback and Direction Control (See Note B)

No Position Feedback, Piston Retracted at 4 mA/min Input signal 0

With 4 ... 20 mA Position Feedback, Piston Retracted at 4 mA/min Input signal (Note:

1) 1

No Position Feedback, Piston Extended at 4 mA/min Input signal 2

With 4-20 mA Position Feedback, Piston Extended at 4 mA/min Input signal (Note:

1) 3

Non Standard Option X

5 : Travel Switches

No Travel Switches 0

With 2 Digital Switches in TZIDC Only (with FM / CSA Approval) (Note:

2) 1

With 2 Micro Switches in TZIDC (no FM/CSA Approval) (See Note C) (Note:

3) 2

Non Standard Option X

6 : Equalizing Manifold/Gage Block

No Equalizing Manifold or Gage Block 0

Equalizing Manifold with Gage Ports only (See Note D) (Note:

4) 1

Gage Block including Gages (for TZIDC only) No Equalizing Manifold (Note:

3) 2

Gage Block with Gage ports only (for AV only) No Equalizing Manifold (See Note D) (Note:

5) 3

Non Standard Option X

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