Contents

2 What is TZIDC Positioner?................................................................................................................... 2

2.1 Working Principle ......................................................................................................................... 2
2.2 Technical Specifications .............................................................................................................. 3
2.3 Components .................................................................................................................................. 4
2.4 Number Plate ...................................................................................................................................... 5
2.5 Schematic Diagram ............................................................................................................................. 5
2.6 Connection Diagram ........................................................................................................................... 6
2.7 Instrument air filtration system of the TZIDC .................................................................................... 6
2.7.1 Supply Air Quality ........................................................................................................................... 6
2.7.2 Overview of air filter system ........................................................................................................... 6
2.7.3 Supply air filter ............................................................................................................................ 7
2.7.4 Internal pneumatic module Filter ................................................................................................. 7
2.7.5 Pneumatic output Filter ................................................................................................................ 8
2.8 Mechanical Mounting ......................................................................................................................... 8
2.8.1 Mounting on Linear Actuator ...................................................................................................... 9
2.8.2 Procedure for attaching follower guide to actuator ...................................................................... 9
2.8.3 Procedure for mounting lever and bracket on positioner ........................................................... 10
2.8.4 Position of Actuator Bolt ........................................................................................................... 10
2.8.5 Mechanical Mounting on Part Turn Actuator ............................................................................ 11
2.8.6 Mounting the Adaptor on Positioner .......................................................................................... 11
2.8.7 Screwing the mounting bracket onto the positioner ............................................................ 12
............................................................................................................................................................ 12
2.8.8 Screwing the Positioner on the Actuator .................................................................................... 12
2.9 Operating the TZIDC Positioner ....................................................................................................... 13
2.9.1 Parameterization of the device ................................................................................................... 13
2.10 Configuring the TZIDC .................................................................................................................. 14
2.10.1 Commissioning ........................................................................................................................ 14
2.10.2 Manually Setting the End Positions ......................................................................................... 15
2.10.3 Changing the Zero Position of TZIDC Positioner ................................................................... 15
2.11 ABB Positioner TZIDC installed at our Power Plant ..................................................................... 16

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 ABB TZIDC POSITIONER
2 What is TZIDC Positioner?

A positioner is the device which ensures that the position of pneumatic valve or actuator matches
the command signal at all times. Electronic positioners, such as the TZIDC , use an electronic sensor
to detect valve stem position, a microprocessor to compare that sensed stem position against the
control signal by mathematical subtraction (error = position − signal), then a pneumatic signal
converter and relay(s) to send air pressure to the valve actuator.
The TZIDC is an electronically configurable positioner designed for mounting to pneumatic linear or
rotary actuators. An I/P module (Current to pressure converter) is used to control the pneumatic
actuator.
The well-proven I/P module proportionally converts the permanent electrical set point signal from the
CPU into a pneumatic signal used to adjust a 3/3-way valve.
The positioner has a built-in operating panel providing a 2-line LCD and 4 pushbuttons for optimal
local configuration, commissioning and operational monitoring. The standard TZIDC model has a
local communication interface (LKS connector).

2.1 Working Principle

The command signal (sent from the process loop controller, PLC, or other control system) tells the
positioner where the valve stem should be positioned. The first controller inside the positioner (PI)
calculates how much air pressure at the actuator should be needed to achieve the requested stem
position. The next controller (PID) drives the I/P (current-to-pressure) converter as much as necessary
to achieve that pressure.

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2.2 Technical Specifications
 Input
 4-20 mA current (two wired loop)
 Load voltage at 20mA should be at least 9.7 Volts
 Air Supply at inlet
 Supply Pressure should be 1.4 to 6 bar
 Air should be free of oil, water and dust
 Max particle size allowed is 5 Um
 Max Particle density allowed is 5mg/m^3
 Compressed Air Output
 Range is from 0 to 6 bar
 Air capacity is 5 kg/h when input supply pressure is 1.4 bar

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  Air capacity is 13kg/h when input supply pressure is 6 bar
 Communication
 Via HART Protocol 5.9
 Local communication connector LKS is present
 HART communication via 20mA signal line is also available
 Ambient Temperature Range
 -40 to 80 Degree Celsius
 Housing
 Aluminum

2.3 Components

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2.4 Number Plate

2.5 Schematic Diagram

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2.6 Connection Diagram

2.7 Instrument air filtration system of the TZIDC

2.7.1 Supply Air Quality
The TZIDC digital positioner requires compressed air as the energy source; the compressed air must meet
the requirements of instrument air quality according to the following table.

Instrumentation Air Requirement

Purity Maximum Particle Size: 5 µm
Maximum Particle Density:5mg/m^3
Oil Content Maximum Concentration: 1 mg/m^3
Pressure Dew Point 10 K Below Operating Temperature

2.7.2 Overview of air filter system

A unique feature of the TZIDC is the integrated and serviceable air filter system to protect the positioner
from dust and contamination to help protect the internal parts of the positioner. These internal filters
cover the following 3 areas:
A) Supply air
B) Internal pneumatic module
C) Pneumatic Output 1 and 2

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2.7.3 Supply air filter
The instrument air supply is filtered with this first stage filter to protect the TZIDC against dust and other
contaminants from entering the positioner via the air supply.

2.7.4 Internal pneumatic module Filter

The internal pneumatic module is additionally protected against dust and other elements through a high
quality sintered filter (Fig. item 1) located inside the module. The following 3D-CAD picture shows the
pneumatic module with the sintered air filter partly removed for better visibility.

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2.7.5 Pneumatic output Filter
The Out 1 & Out 2 air filter elements (Fig item 1) protect the TZIDC from any debris and other particles
that may be inside the actuator from entering the positioner during the decompressing sequence of the
actuator when the air passes through the TZIDC.

2.8 Mechanical Mounting

TZIC can be used for linear as well as part turn rotary actuators. While mounting on actuator, it
should be mounted in such a way that arrow 1 on the mounting feedback shaft must move between
the arrow mark 2.

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2.8.1 Mounting on Linear Actuator
For Mounting on linear actuator, following mounting kit is used.

2.8.2 Procedure for attaching follower guide to actuator

1. Tighten the screws so that they are hand-tight.
2. Attach the follower guide 1 and clamp plates 2 with screws 4 and spring washers 3 to
the actuator stem.

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2.8.3 Procedure for mounting lever and bracket on positioner
Attach the lever 6 to the feedback shaft 5 of the positioner (can only be mounted in one position due to
the cut shape of the feedback shaft). Using the arrow marks 4, check whether the lever moves within the
operating range (between the arrows). Hand-tighten the screw 7on the lever. Hold the prepared positioner
(with the mount bracket 1 still loose) on the actuator so that the follower pin for the lever enters the
follower guide to determine which tap holes on the positioner must be used for the mount bracket. Secure
the mount bracket 1 with screws 2 and washers 3 using the relevant tap holes on the positioner housing.
Tighten the screws as evenly as possible to ensure subsequent linearity. Align the mount bracket in the
oblong hole to ensure that the operating range is symmetrical (lever moves between the arrow marks 4).

2.8.4 Position of Actuator Bolt

The actuator bolt for moving the potentiometer lever can be mounted permanently on the lever itself or on
the valve stem. Depending on the mounting method, when the valve moves the actuator bolt performs
either a circular or a linear movement with reference to the center of rotation of the potentiometer lever.
Select the chosen bolt position in the HMI menu in order to ensure optimum linearization. The default
setting is actuator bolt on lever.

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2.8.5 Mechanical Mounting on Part Turn Actuator
For mounting on part turn actuator, following mounting kit is used

2.8.6 Mounting the Adaptor on Positioner

Determine the mounting position (parallel to actuator or at 90° angle). Calculate the rotational direction of
the actuator (right or left). Move the rotary actuator into the home position. Pre-adjust feedback shaft. To
ensure the positioner will operate within the operating range, the mounting position as well as the home
position and direction of rotation of the actuator must be taken into account when determining the adapter
position on the feedback shaft 1. For this purpose, the feedback shaft can be adjusted manually so that the
adapter 3 can be attached in the correct position. Place the adapter in the proper position on the feedback
shaft and fasten with threaded pins 2. One of the threaded pins must be locked in place on the flat side of
the feedback shaft.

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 2.8.7 Screwing the mounting bracket onto the positioner

2.8.8 Screwing the Positioner on the Actuator

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2.9 Operating the TZIDC Positioner
The positioner has two modes 1) Operation Mode 2) Configuration Mode
Operating Level
On the operating level the positioner operates in one of four possible operating modes (two for automatic
control and two for manual mode). Parameters cannot be changed or saved on this level.
Configuration Level
On this level most of the parameters of the positioner can be changed locally. On the configuration level
the active operating mode is deactivated. The I/P module is in neutral position. The control operation is
inactive.

2.9.1 Parameterization of the device

There are four following buttons on the TZIDC positioner.

 In order to change the parameters, we need to move from operating level to configuration level
 For that you need to press and hold up button, down button and enter button. After sometime
countdown will start. At this point release enter button. After countdown release hold button as
well, and configuration level is on.
 There are 11 parameter groups in configuration level
 In order to move from one parameter to another, you need to press and hold enter and mode
button and press up or down button.
 In order to move within one parameter group, you need to press and hold the mode button and
press up or down button
 After changing the parameter, press and hold enter for 3 seconds. Parameters would be changed
and positioner would be back to Operating level.

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2.10 Configuring the TZIDC

2.10.1 Commissioning
In order to commission the TZIDC you need to perform the following actions
 Open the pneumatic air supply.
 Switch on the electrical power supply and feed in the set point signal 4 ... 20 mA.
 Press and hold the Mode Button, then press up button and select the 1.3 ( Manual Adjustment
within the sensor range)
 Check the mechanical end positions by pressing up and down buttons. These should be
between -58 to +58 for rotary actuators and -28 to 28 for linear actuator.
 For rotary actuator, press enter and hold. Keep Pressing the “enter button until Adj-Rot is
appeared.
 For linear actuator, press mode and hold. Keep pressing the “mode” button until Adj-lin is
appeared.
 Release the Enter or mode Button. (according to actuator type, enter for rotary, mode for
linear)
 Press and hold it again.
 Countdown will start; release the Enter/mode button.

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  Run Window will appear and auto calibration starts
 If Auto adjust is successful, the parameters will be stored automatically and the positioner
will revert to operating mode 1.1.
 Commissioning of the positioner is now complete, and the device is ready for operation

2.10.2 Manually Setting the End Positions

 Enter TZIDC configuration level by pressing and holding the Up button, Down button and Enter
button at same time.
 After sometime countdown will start. At this point release the enter button. At end of countdown,
release up and down buttons as well.
 Go to Parameter 6 (Manual Adjust) by pressing and holding the Enter and Mode button at same
time and pressing up button.
 Min-VR will be displayed. Use the Up and Down Buttons to set desired position as 0 % or 4mA
signal. Press and hold enter to save the new zero position.
 Now go to parameter 6.1 by pressing and holding the mode button and pressing the up button.
 Max-VR will be shown.
 Use the arrow button to drive the actuator to the position which is desired 100% or 20mA
position. Press and hold the enter button to save the new 100% or 20mA position.
 Now go to Parameter group 3 by pressing and holding the Mode and enter button and pressing the
down button.
 Set Parameter 3.0 (Min_ RGE) to 0.1%
 Go t parameter 3.1 (Max_Rge) by pressing and holding Mode button and pressing up button. Set
it to 99.9%
 Go to parameter group ‘2’ by pressing and holding the “enter” and mode button and pressing the
down button.
 Further go to parameter 2.4 ( Shut-Cls) and set it to off
 Go to parameter 2.5 (Shut_Opn) and ensure that it is off.
 Go to parameter 2.8 to exit and save. Press and hold the enter button. New end positions will be
saved.

2.10.3 Changing the Zero Position of TZIDC Positioner

 Enter the configuration level by pressing and holding the Up, down and Enter button at same
time. Countdown will start. At this point release the enter button. After Countdown release the Up
and Down Button as well
 Now go to parameter group ‘3’ by pressing and holding the mode button and pressing the up
button.
 Further go to parameter 3.2(Zero Position) by pressing and holding the mode button and pressing
the up button. Use the Up button to change the zero position from clockwise to counter clockwise
or vice versa.
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  Press enter and hold to save and exit.

2.11 ABB Positioner TZIDC installed at our Power Plant

 At Secondary air duct entering the furnace at burner location. There are total 10 positioners at
each corner for secondary air duct to control the damper via linear actuators.

 At primary air ducts before entering the mills, the damper is controlled via linear actuator and
positioner

 At auxiliary steam header to control the pneumatic control valve.

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