Motorized Butterfly Valve Control

(Old-fashion)
 Your mission (should you choose to
accept it)
Create a control strategy for the butterfly valve
w/ motorized damper actuator.
 Damper w/ Motorized Actuator

Actuator

Mechanical linkage
Butterfly valve
Motorized Actuator
 Components inside the motorized
actuator.

This is not of the same type as shown in the previous slide, but it shows similar components
Anyway.
 Motorized Actuator
Input/Outputs
Actuator
PLC
DO – Command Open
DO – Command Close
AI – Position feedback 0-100%
DI – Valve Fully Closed Limit Switch
DI – Valve Fully Open Limit Switch
 Command Open
Input/Outputs
Actuator
PLC
DO – Command Open

When the PLC turns this Digital Output

signal ON, power is applied to the forward command
of the motor inside the actuator. The forward rotation
of the motor then turns the butterfly valve open.
 Command Close
Input/Outputs
Actuator
PLC
DO – Command Close

When the PLC turns this Digital Output

signal ON, power is applied to the reverse command
of the motor inside the actuator. The reverse rotation
of the motor then turns the butterfly valve close.
 Actual Position feedback
Input/Outputs
Actuator
PLC

AI – Position feedback 0-100%

The PLC receives 4-20mA as the valve position feedback. This signal is required so that
the PLC can monitor the actual position of the valve and compare it with the setpoint position.
For example, if the setpoint is 50% and the actual position is only at 25%, then the PLC should
give an open command (forward motor) until the actual position equals the setpoint. If the setpoi
is lower than the actual position, then the PLC should command a close command (reverse motor
until the actual position equals the setpoint.
 Limit switches
Input/Outputs
Actuator
PLC

DI – Valve Fully Closed Limit Switch

DI – Valve Fully Open Limit Switch

If the mechanical limit of the actuator is reached, the any command to the actuator must be
OFF. This functions as safety switches so that the motor inside the actuator prevents any further
rotation once the fully open/closed limits were reached.
 Modes of Control
Manual When operator presses the “Command Open” button from the HMI, the PLC
activates the “Command Open” DO, making the motor actuator rotate forward.
When the operator presses the “Command Close” button from the HMI, the PLC
activates the “Command Close” DO, making the motor actuator rotate in reverse.
These buttons are momentary. As the buttons are pressed, the command to the
actuator activates. As the buttons are released, the command to the actuator de-
activates.

Auto The operator only enters a setpoint, then the program automatically
opens/closes the valve until the setpoint equals the actual position.
 Input/Output List
Hardware Outputs
• YS1 – Command Open. When this is active, actuator moves forward, opening the
valve.
• YS2 – Command Close. When this is active, actuator moves in reverse, closing the
valve.

Hardware inputs
• ZSO – Fully Open Limit Switch. When this is active, then the mechanical limit of the
actuator rotation is reached and any command open to the actuator must be
deactivated.
• ZSC – Fully Closed Limit Switch. When this is active, then the mechanical limit of
the actuator rotation is reached and any command close to the actuator must be
deactivated.
• PV – Actual Position of the Valve in %.
 Input/Output List
Software Outputs
• YSA – Open Fault Timeout. Command Open has been active for 30 seconds and SP
is still greater than PV. Latches on fault, reset required. Disables any valve
command open.
• YSB – Close Fault Timeout. Command Close has been active for 30 seconds and SP
is still less than PV. Latches on fault, reset required. Disables any valve command
close.
• YSC – Position fault. Both ZSO and ZSC are active. No latching logic and therefore
no reset required.

Software inputs
• HSA – Auto/Man Selection
• HSB – Manual Command Open
• HSC – Manual Command Close
• HSD – Manual Command reset
Logic Diagram
When in Manual, the Operator presses
The HSB button to open the valve.

When in Manual, the Operator presses

The HSC button to close the valve.
 Manual comman open/close
Note that the YS1 and YS2 are non-latching. Which means, when the
operator releases the HSB and HSC buttons, the valve remains at its last
position. This is a safer control rather than latching YS1 or YS2 where in
once the HSB or HSC button is pressed, then the valve will continuously
open/close. If that happens and the operator forgets to cancel the
command, then the valve will go fully open/close.

In this logic, we prefer that the valve stays at last position if there are no
command open/close from the operator is active.
 Logic Diagram
When in Auto, the PLC compares the actual (PV)
from the setpoint (SP) position.

This is your Auto Open Command

This is your Auto Close Command

 Auto open/close
SP is an analog value where the PV is compared to. If the SP is greater than PV, then
the SP>PV is True. If the SP is less than the PV, the SP<PV is True.
If the setpoint position is greater than the actual position, the open the valve more. If
the setpoint is less than the actual position, then close the valve more.
Function of limit switches
When the open limit switch is active, stop activati
Open command.

When the closed limit switch is active, stop activati

close command.
 Open fault timeout

If command open is active and the actual valve position is still less than the setpoint for
30 seconds, then the valve might have a problem because it is taking to long to open.
 Close fault timeout

If command close is active and the actual valve position is still greater than the setpoint
for 30 seconds, then the valve might have a problem because it is taking to long to
close.
Fault timeout deactivates command open.

Fault timeout deactivates command close.