ARCAPRO 827A.E/X ∗∗F - ∗∗∗ - Von Rohr ARCA BV ... no.: 827A-FF-BA-09-13_gb ARCA-Regler GmbH D - 47918 Tönisvorst Page 3 von 42 Table of Contents 1 Introduction 4 2 General

Reference no.: 827A-FF-BA-09-13_gb ARCA-Regler GmbH D - 47918 Tönisvorst Page 1 von 42

ARCAPRO 827A.E/X∗ - ∗∗F - ∗∗∗ - ∗

Electropneumatic Positioner for Linear and Quarter-turn Actuators Version with Foundation Fieldbus Operating Instructions


Legal information Warning notice system This documentation notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown be-low are graded according to the degree of danger.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel

The device may only be set up and used in conjunction with this documentation. Commissioning and operation of a device may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards. Prescribed Usage

Note the following:

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software de-scribed. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the in-formation in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

Indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

With a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION

Without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE

Indicates that an unintended result or situation can occur if the corresponding information is not taken into account.

WARNING

ARCA-positioner may only be used for the applications described in the relevant technical documentation. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed.


Table of Contents

1 Introduction 4

2 General safety notes 6

3 Description 8

3.1 Function 8

3.2 Structure 8

3.3 Device Components 9

3.3.1 Motherboard 9

3.3.2 Electric Connections 10

3.3.3 Pneumatic Connections 10

3.3.4 Purging Air Switch 10

3.3.5 Restrictors 12

4 Mounting 12

4.1 Safety notes for mounting 12

4.2 Mounting Linear Actuator 13

4.2.1 Mounting Kit for "Integrated Fitting Linear Actuator" 13

4.2.2 Mounting Kit for "Linear Actuator IEC534" 15

4.3 Mounting Kit for "Quarter-turn Actuator VDI/VDE 3845" 17

4.4 Note on the Use of Positioners in Wet Environments 19

4.5 Positioners exposed to strong acceleration forces or vibrations 20

4.5.1 Slip clutch 21

4.5.2 Leverage ratio switch 21

5 Electrical Connection 22

5.1 Electrical Connection, Basic device 24

5.1.1 Electrical Connection, Basic device not for explosive regions 24

5.1.2 Electrical Connection, Basic device for explosive regions 25

6 Pneumatic Connections 25

7 Commissioning 26

7.1 Preparations for Linear Actuators 28

7.1.1 Automatic Initialization of Linear Actuators 29

7.1.2 Manual Initialization of Linear Actuators 30

7.2 Preparations for Quarter-turn Actuators 31

7.2.1 Automatic Initialization of Quarter-turn Actuators 31

7.2.2 Manual Initialization of Quarter-turn Actuators 32

7.3 Copying Initialization Data (Positioner Exchange) 33

8 Overview of Parameters 34

8.1 Parameters 1 to 5 34

8.2 Parameters 6 to 44 34

8.3 Parameters A to P 36

9 Fault removal 37

10 Service and Maintenance 39

11 Technical Data 40


1 Introduction

This operating instructions contains all information that will be required to connect and to commission the de-vice.

It is aimed at persons who install the device mechanically, connect it electrically and commission it.

Information and tips for projecting, parameterization and service contains the manual that can ordered by us.

This operating instruction is valid for devises from firmware 5.00.00 in not intrinsically safe and intrinsically safe version.

The content reflects the technical status at the time of printing. We reserve the right to make technical changes in the course of further development. Checking the consignment

Design of the nameplate

II 2 G Ex ia IIC T6/T4 Gb Ta = -20 …50/75°C TÜV 12 ATEX 085253 X

1

3 2

9

6 4

11

10

5 8 7

Stellungsregler 827A.X2-00P-M10-G

Mat-Nr. XXXXXXX

F-Nr. X XXXXXX

1 - Manufacturer 2 – Device name 3 - Type 4 - Consult operating instructions 5 - Safety class 6 - Auxiliary power (air supply) 7 - Approval 8 - ATEX marking for hazardous area 9 - Rated signal range 10 - Auxiliary power (voltage) 11 - Manufacturer serial number

WARNING

Using a damaged or incomplete device

Danger of explosion

Do not use any damaged or incomplete devices.


Type key

827A.∗ ∗ – ∗ ∗ F – ∗ ∗ ∗ – ∗

Connection thread G M20x1,5 / G 1/4

electric / N 1/2“ NPT / 1/4“ NPT pneumatic M M20x1,5 / 1/4“ NPT P 1/2“ NPT / G ¼ R PROFIBUS plug M12 / G 1/4 S PROFIBUS plug M12 / 1/4“ NPT

mechanical 0 Standard actuator 2 without (for external potentiometer) pneumatic 1 single-acting

2 double-acting ( only stainless housing )

body M aluminium E stainless housing

communication 0 without communication 1)

H HART 1) P PROFIBUS PA1) F Foundation Fieldbus

binary output 0 without binary outputs 1) B binary module 1) S slot initiator module 1) K contact module 1)

analog - output 0 without analog - output A analog module 1) 2) connection 2 2 - wire

basic device 4 2 / 3 / 4 - wire

Ex - certificate E not explosion protected X II 2 G Ex ia IIC T6/T4 Gb

series Transportation and storage

Environmental protection Devices described in this programming manual can be recycled owing to the low content of noxious sub-stances in their version. Please contact a certified waste disposal company for eco-friendly recycling and to dispose of your old devices. 1) The device type is not described in these operating instructions. Please find the specific device characteristics and technical data in the corresponding

separate documentation. 2) Type 827A.X∗-A∗∗-∗∗∗-∗ only II2G Ex ia IIC T4 Gb

CAUTION

Insufficient protection during storage

The packaging only provides limited protection against moisture and infiltration.

Provide additional packaging as necessary.


2 General safety notes Requirement for safe use

This device left the factory in good working condition. In order to maintain this status and to ensure safe opera-tion of the device, observe these instructions and all the specifications relevant to safety.

Observe the information and symbols on the device. Do not remove any information or symbols from the de-vice. Always keep the information and symbols in a completely legible state. Warning symbols on the device

Symbol Explanation of the warning symbols on the device

Consult operating instructions

Protect the device from shocks (otherwise the degree of protection is not guaranteed)

Laws and directives

Observe the test certification, provisions and laws applicable in your country during connection, assembly and operation: IEC 60079-14 (international) EN 60079-14 (EG) The working reliability regulation (Germany) Conformity with European directives The CE marking on the device shows conformity with the regulations of the following European guidelines: EMC 2004/108/EG Directive of the European Parliament and of the Council on the approximation of the

laws of the Member States relating to electromagnetic compatibility and repealing Direc-tive 89/336/EEC.

ATEX 94/9/EG Directive of the European Parliament and the Council on the approximation of the laws

of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres. .

LVD 2006/95/EC Directive of the European Parliament and the Council on the approximation of the laws

of the Member States relating to electrical equipment designed for use within certain voltage limits.

The applied standards can be found in the EC conformity declaration of the device. Improver device modifications

WARNING

Improver device modifications Danger to personnel, system and environment can result from modifications to the device, particularly in hazardous areas.

Only carry out modifications that are described in the instructions for the device. Failure to observe this requirement cancels the manufacturer's warranty and the product approvals.


Use in areas subject to explosion hazard

WARNING

Unsuitable device for the hazardous area

Danger of explosion

Only use equipment that is approved for use in hazardous area and labelled accordingly.

Make sure that the device is suitable for the area of use.

WARNING

Loss of the safety of the device with type of protection "Intrinsic safety Ex i"

If the device has already been operated in non-intrinsically safe circuits or with a higher voltage, the safety of the device is no longer ensured for use in hazardous areas. There is a danger of explosion.

Connect the device in "intrinsic safety" type of protection solely to an intrinsically safe circuit.

Observe the specifications for the electrical data in the certificate

WARNING

Impermissible accessories and spare parts

Danger of explosion in areas subject to explosion hazard.

Only use original accessories or original spare parts.

Observe all relevant installation and safety instructions described in the instructions for the device or en-closed with the accessory or spare part.

WARNING

Open cable inlet or incorrect cable gland


Close the cable inlets for the electrical connections. Only use cable glands or plugs which are approved for the relevant type of protection.

WARNING

Exceeded maximum ambient or process media temperature


If the maximum permissible ambient and process media temperatures are exceeded, the temperature class of the device is no longer valid.

Make sure that the maximum permissible ambient and process media temperatures of the device are not exceeded.

CAUTION

Electrostatic Sensitive Devices

This device contains electrostatic sensitive devices. Electrostatic sensitive devices may be destroyed by voltages that are undetectable to a human. Voltages of this kind occur as soon as a component or an as-sembly is touched by a person who is not grounded against static electricity. The damage to a module as a result of overvoltage cannot usually be detected immediately. It may only become apparent after a long period of operation.

Therefore, avoid electrostatic charge.


Qualified Personnel

Qualified personnel are people who are familiar with the installation, mounting, commissioning, and operation of the product. These people have the following qualifications:

They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety regulations for electrical circuits, high pressures and aggressive as well as hazardous media.

For explosion-proof devices: They are authorized, trained, or instructed in carrying out work on electrical circuits for hazardous systems.

Hey are trained or instructed in maintenance and use of appropriate safety equipment according to the safety regulations.

3 Description 3.1 Function

The electro-pneumatic positioner, in combination with the drive, forms a regulation system. The current position of the drive is detected using a servo potentiometer and is sent back as actual value x. The actual and target values are simultaneously displayed on the digital display.

The reference variable w is provided digitally through the Feldbus..

The positioner works as a predictive five-point positioner, through whose output value ±∆y the integrated valves can be controlled by pulse length modulation.

These positioning signals cause pressure changes in the drive chamber(s) and thus a repositioning of the drive until the regulation deviation returns to zero.

Using three buttons and a digital display with the housing cover removed, operation (manual mode) and configuration (structuring, initialization, and parameterization) can be performed.

Normally the basic device has one binary input (BE1). This can be individually configured, and is particu-larly provided for blocking the operating levels.

To be able to use the positioner in a variety of mechanically different rotational and linear actuators, it has a friction clutch and a switchable gear.

3.2 Structure

The following chapters describe the mechanical and electrical structure, components, and principle functional-ity of the positioner.

The positioner is used to adjust and regulate pneumatic drives. The positioner works electropneumatically, using compressed air as auxiliary power

The positioner can e.g. regulate valves with:

- Linear actuator (Figure 3-1) or - Quarter turn actuator VDI/VDE 3845 (Figure 3-2)

For linear actuators, there are various add-on extensions available

- NAMUR or. IEC 534

- integrated addition (ARCA, SAMSON) - integrated addition according to VDI/VDE 3847

You can mount the positioner on the usual drives and operate it with the usual drives.


The device is available for single-acting and double-acting actuators and for potentially explosive applications and applications that are not potentially explosive.

1 Actuator 2 Positioner, single-acting in metal-housing 3 Lantern 4 Manometer block, single-acting 5 Valve

Figure 3-1 Positioner fitted to a linear actuator Figure 3-2 Positioner fitted to a quarter-turn actuator (single-acting) (double-acting) 3.3 Device Components

Figure 3-3 Structure 3.3.1 Motherboard

The motherboard contains: - CPU - Memory - A/D-converter - Display - Operating buttons - Terminal strips to connect the optional module to the motherboard

1

2

3

4

5

1

2

3

1 Positioner, double-acting in plastic housing 2 Quarter-turn actuator 3 Manometer block, double-acting

1. Bus cable 2. Terminal plate on cover 3. Display 4. Purging air selector 5. Output: Actuating pressure Y1 6. Input: supply air 7. Output: Actuating pressure Y2 1) 8. Control buttons 9. Restrictor Y2 1) 10. Restrictor 11. Restrictor Y1 12. Silencer 13. leverage ratio switch 14. Slip clutch adjusting wheel 15. Connection terminals motherboard 16. Connection terminals for optional module 17. Shield support 2) 1) for double-acting drives 2) only for plastic housing


3.3.2 Electric Connections

The connecting terminals for the base device, the optional analog, binary and slot initiator modules are ar-ranged at the front left-hand edge, and are displaced with respect to one another in a stepped pattern.

An assembly cover secures the components against being pulled out, and prevents incorrect assembly. 3.3.3 Pneumatic Connections

The pneumatic connections (G1/4) are located on the right-hand side of the positioner

Exhaust air outlet E with silencer on the bottom of the device

Actuating pressure Y1 in single-acting and double-act ing actuators

Feedback shaft

Air supply Pz Actuating pressure Y2 on double-acting actuators

Figure 3-4 Pneumatic connections Connection versions

In addition, the rear of the positioner has pneumatic connections for integrated fitting of single-acting linear actuators:

- actuating pressure Y1

- exhaust air outlet E

Except in cases of integrated ARCA fitting, these connections are closed by screws. The exhaust air outlet E can be used to supply the sensing area and the spring chamber with dry, instrumentation-quality air to prevent corrosion.

Figure 3-6 illustrates the versions of the pneumatic connections for the various types of actuator, the position-ing effect and the safety position after failure of the auxiliary power supply.

3.3.4 Purging Air Switch The purging air switch is accessible when the housing is open above the pneumatic connection strip on the valve block. − In the IN position the interior of the housing is flushed by very small quantities of clean, dry instrumentation-

quality air. − In the OUT position, the purging air is fed directly outside.

Figure 3-5 Purging air switch on the valve block

CAUTION

Before working on the control valve

Note that before working on the control valve, you must first move it to the safety position. Make sure that the control valve has reached the safety position. If you only interrupt the pneumatic auxiliary power supply to the positioner, the safety position may in some cases only be attained after a certain delay period.

Purging Air Switch

Pneumatic connection strip


On rotary actuators,it is usual to define theanti-clockwise direction ofrotation – seen looking atthe valve's operatingshaft – as "OPEN".

Open

Closed

up down

OpenClosed

Open

ActuatingpressureConnection

Y1

Y1

Y2

Open

ClosedClosed

Y1

Y1

Y2

Y1

Closed

Y2

Open

Open

Open

Closed

Open

Closed

Closed

Y1

Last position(before failure ofauxiliary power)

Last position(before failure ofauxiliary power)

Y1

Y1

Y2

up

down

down down

down

up

up

upup

down

up

down

up

down

Safety position following failure of the auxiliary power

electrical pneumaticActuator type

Figure 3-6 Pneumatic connection positioning effect


3.3.5 Restrictors Note The exhaust air valve is always open in the de-energized state.

In order to achieve floating times of > 1.5 s on small actuators, it is possible to reduce the air power by means of the restrictors Y1 and Y2.

By turning to the right, the air power is reduced until it is completely blocked

In order to adjust the restrictors, it is recommended that they are closed and then slowly opened (see ini-tialization RUN3).

In case of double-acting valves, ensure that both restrictors have approximately the same setting.

Y 1 Y 2 Figure 3-7 Restrictors

4 Mounting 4.1 Safety notes for mounting

CAUTION

Incorrect mounting

The device can be damaged, destroyed or its functionality impaired through improper mounting. .

Before installing ensure there is no visible damage present on the device.

Make sure that process connectors are clean, and suitable gaskets and glands are used.

Mount the device using suitable tools.

CAUTION

Mechanical impact effect

It is essential that the following sequence is observed during assembly in order to avoid injury or mechanical damage to the positioner/mounting kit:

1. Mechanically mount the positioner

2. Connect the auxiliary electrical power supply

3. Connect the pneumatic auxiliary power

4. Carry out the commissioning procedure

NOTICE

Loss of degree of protection

Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the nameplate is no longer guaranteed.

hexagon socket 2,5 mm


4.2 Mounting Linear Actuator 4.2.1 Mounting Kit for "Integrated Fitting Linear Actuator"

Included with the "integrated fitting linear actuator" are (see Figure 4-1 for identifying numbers):

Serial no.

No. of items

Name Note

1 1 Driver pin cpl. with roller mounted on lever (2)

2 1 Lever

3 2 Washer B6.4 - DIN 125 - A2

4 1 Spring washer A6 – DIN 137A- A2

5 1 Lock washer A6 – DIN 127- A2

6 1 Cylinder head bolt M6 x 25 DIN 7984 - A2

7 1 Hexagonal nut M6 - DIN 934 - A4

8 1 Square nut M6 - DIN 557 - A4

9 2 Cylinder head bolt M8 x 65 - DIN 912 - A2

10 2 Lock washer A8 - DIN 127 - A2

11 2 Screw plug

12 1 O-ring 13 x 2.5

Mounting procedure (see Figure 4-1)

1. Adjust the pin (1) on the previously assembled lever to the value of the stroke range given on the actuator or, if this is not available as a scale value, at the next largest scale value. In case of uncertainty with regard to the real actuator stroke (pneumatic actuators often have a travel resource) you always have to choose the next large scale value. The centre of the pin must be positioned at the scale value. The same value can later be set during the commissioning under the parameter 3.YWAY, in order to display the displacement in mm after the initialization.

2. Push the lever to the stop on the controller axis, and fix it with cylinder head screw (6).

3. Open the rear actuating pressure outlet by removing the screw (13) and the O-ring (14).

4. When fitting with spring chamber exhaust air supply open the exhaust air outlet by removing the screw (15) and the O-ring (16).

5. Seal the actuating pressure outlet with screw plug (11). When fitting with exhaust air supply remove ex-haust air silencer and seal.

6. Insert the O-ring (12) in the intermediate bracket recess.

7. Locate the positioner on the actuator in such a way that the roller passes between the pins (17).

8. Align the controller horizontally at the intermediate bracket, and assemble it with the screws (9) and lock washers (10).

CAUTION

Humid environment/dry compressed air

Install the positioner in a humid environment such that the positioner shaft does not freeze at low ambient temperatures.

Ensure that water does not seep through an open enclosure or an open gland. Water may seep through if the positioner is not installed and connected on-site immediately and finally.

As a general rule, the positioner must be operated only with dry compressed air. Therefore, use the custom-ary water separator. An additional dryer is required in extreme cases. The use of dryers is especially impor-tant when you operate the positioner at low ambient temperatures. Set the Purge air switch to the "OUT" position when installing on the pneumatic block, above the pneumatic connections.


1) 2)

3)

14

13

17

12

11

9

10

8

1 1

6

5

3

2

3 4

7

15

16

Figure 4-1 Mounting procedure for integrated fitting


4.2.2 " Mounting Kit for "Linear Actuator IEC534

The "linear actuator IEC 534" mounting kit, stroke 3 … 35 mm, includes (see Figure 4-3 for identifying num-bers): Serial no.

No. of items

Name Note

1 1 NAMUR fitting angle IEC 534 Standardised connecting location for fitting bracket with rib, column or flat surface

2 1 Sensing hoop Guides the roller with the driver pin and turns the lever arm

3 2 Clamping piece Assembly of the sensing hoop to the actuator's spindle

4 1 Driver pin cpl. with roller Mounted on lever (5)

5 1 NAMUR lever For stroke range 3 … 35 mm or (stroke range > 35 … 130 mm, order separately, see figure 4-2)

6 2 U-bolts Only far actuators with columns

7 4 Hexagonal screw M8 x 20 DIN 933–A2

8 2 Hexagonal screw M8 x 16 DIN 933–A2

9 6 Lock washer A8 - DIN 127–A2

10 6 Washer B 8.4 - DIN 125–A2

11 2 Washer B 6.4 - DIN 125–A2

12 1 Spring washer A6 - DIN 137A–A2

13 3 Lock washer A6 - DIN 127–A2

14 3 Cylinder head bolt M6 x 25 DIN 7984–A2

15 1 Hexagonal nut M6 - DIN 934–A4

16 1 Square nut M6 - DIN 557–A4

17 4 Hexagonal nut M8 - DIN 934–A4

Assembly procedure (see Figure 4-3)

1. Assemble the clamping pieces (3) using the hexagonal screws (14) and lock washers (13) to the actuator spindle.

2. Push the sensing hoop (2) into the cut-outs in the clamping piece. Adjust to the required length, and tight-ened the screws so that it is still just possible to push the sensing handle.

3. Adjust the pin (4) on the previously assembled lever to the value of the stroke range given on the actuator or, if this is not available as a scale value, at the next largest scale value. In case of uncertainty with regard to the real actuator stroke (pneumatic actuators often have a travel resource) you always have to choose the next large scale value. The centre of the pin must be positioned at the scale value. The same value can later be set during the commissioning under the parameter 3.YWAY, in order to display the displacement in mm after the initialization.

4. Push the lever to the stop on the controller axis, and fix it with cylinder head screw (14).

5. Assemble the fitting angle (1) with two hexagonal screws (8), lock washer (9) and washers (10) to the rear of the positioner. The choice of the hole row depends on the width of the actuator's intermediate bracket width. The roller should engage in the sensing hoop (2) as close to the spindle as possible, but must not touch the clamping piece.

6. Hold the positioner with the fixing angle to the actuator in such a way that the pin (4) passes inside the sensing hoop (2).

7. Tighten the sensing hoop.

8. Prepare the assembly parts in accordance with the actuator type: - Actuator with a rib: hexagonal bolt (7), washer (10) and lock washer (9). - Actuator with a flat surface: four hexagonal bolts (7) with washer (10) and lock washer (9). - Actuator with columns: two U-bolts (6), four hexagonal nuts (17) with washer (10) and lock washer (9).

9. Attach the positioner with the previously prepared assembly parts to the intermediate bracket. Adjust the height of the positioner so that the horizontal position of the lever is achieved as close as possible to the centre of the stroke. The actuator's lever scale provides orientation here. It is essential that the horizontal lever position is passed through within the range of the stroke.


33°5 10 15 20

25 30 3590°

90° 110 1309070605040

1

2

Figure 4-2 NAMUR lever 3 ... 35 mm (1), NAMUR lever > 35 … 130 mm (2)

2

13

14

3

1 )

3 )

4 )

1

8

9 10

8 9

10

1

7

9

10

7

9

10

17

9

10

6

F itting to lantern w ith colum ns

F itting to lantern w ith fla t surface

16

14

14

13

11

5

11 12

15

2 )

Figure 4-3 Mounting procedure for IEC 534 inear actuator


4.3 Mounting Kit for “Quarter-turn Actuator VDI/VDE 3845"

Included with the "VDI/VDE 3845 quarter-turn actuator" mounting kit are (see Figure 4-4 for identifying num-bers): Serial no. No. of

items Name Note

2 1 Coupling wheel Fitted to the position feedback shaft of the positioner

3 1 Driver pin Fitted to the actuator's shaft stub

4 1 Labels Display of the actuator position, consisting of: 4.1 and 4.2

4.1 8 Scale Various divisions

4.2 1 Pointer Reference point for scale

14 4 Hexagonal screw DIN 933 - M6 x 12

15 4 Retaining washer S6

16 1 Cylinder head bolt DIN 84 - M6 x 12

17 1 Washer DIN 125 – 6.4

18 1 Hexagonal socket bolt Pre-assembled with coupling wheel

19 1 Hexagon key For item 18

Assembly procedure (see Figure 4-4)

1. Attach the VDI/VDE 3845 fitting bracket ((9), actuator-specific, supplied by actuator manufacturer, see Fig-ure 3-8) to the rear of the positioner, and fix it in place with the hexagonal screws (14) and retaining wash-ers (15).

2. Stick the pointer (4.2) on the fitting bracket at the middle of the centring hole.

3. Push the coupling wheel (2) as far as it will go on the positioner axis, pull it back about 1 mm, and tighten the hexagonal socket bolt (18) with the supplied hexagonal key.

4. Place the driver pin (3) on the actuator's shaft stub and tighten it with cylinder head bolt (16) and washer (17).

5. Carefully place the positioner with the fitting bracket on the actuator so that the pin of the coupling wheel engages with the driver pin.

6. Align the positioner / fitting bracket centrally on the actuator, and screw tight (screws are not included with the supply, but are part of the actuator's fitting bracket!).

7. When commissioning according to chapter 7 has been completed, take the actuator to its end position and stick the scale (4.1) on to the coupling wheel (2) according to the direction of rotation and the turning range. The scale is self-adhesive!


3

2

2

9

9

1415

2 )1 )

3 )

4 .2

18

4 )

17

16

4.1

0 % 2 0 4 0 60 8 0 10 0%

5 )

2

3

Figure 4-4 Mounting procedure for VDI/VDE 3845 quarter-turn actuator


18

Positioner

Quarter-turn actuator

Section A - B

Figure 4-5 Mounted positioner for quarter-turn actuator

a = 4 (0,16) b = 12 (0,47) Figure 4-6 Fitting bracket (supplied by actuator manufacturer), dimensions

4.4 Note on the Use of Positioners in Wet Environments

This information provides you with important notes on assembling the positioner in wet environments (frequent heavy rain and/or persistent tropical condensation) in which protection class IP66 is no longer sufficient, in particular when there is a risk that the water might freeze. Avoid the unfavourable mounting positions:

To prevent fluids seeping through during normal operation of the device, e.g. through exhaust air openings.

Otherwise the digital display becomes poorly legible.

CAUTION

Never clean the positioner with a high pressure cleaner. Protection class IP66 is inadequate for this.

Quarter-turn actuator

Positioner fixing plane

2 Coupling wheel 3 Driver pin 4 Labels 4.1 Scale 4.2 Pointer 9 VDI/VDE 3845-fitting bracket 10 Feedback shaft 14 Hexagonal screw M6 x 12 15 Retaining washer S6 16 Cylinder head boltM6 x 12 17 Washer 18 Hexagon key


Figure 4-7 Favourable and unfavourable installation positions

If local conditions force you to operate the positioner in an unfavourable installation position, you can prevent the entry of water through additional measures. Additional measures

The steps necessary to prevent the entry of water depends on the installation position chosen. In certain cases you may need:

- Threaded joint with sealing rings (e. g. FESTO: CK -¼ -PK-6)

- Plastic hose, approx. 20 to 30 cm (e. g. FESTO: PUN- 8x1,25 SW) - Cable ties (number and length depend on the local conditions)

Procedure

1. Arrange the pipes in such a way that rainwater or condensation that runs along the length of the pipes can drop off before reaching the positioner's connection strip.

2. Check that the seals for the electrical connections are correctly seated.

3. Check that the seal of the housing cover is not damaged or soiled. Clean or replace it if necessary.

4. If possible, mount the positioner in such a way that the sintered bronze silencer on the underneath of the housing is pointing downwards (vertical installation position). If this is not possible, the silencer should be replaced by a plastic hose using a suitable threaded joint.

Assembling the Threaded Joint with Plastic Hose

1. Unscrew the sintered bronze silencer from the exhaust air opening on the underside of the housing.

2. Screw the threaded joint mentioned above into the outlet opening.

3. Fit the plastic hose mentioned above to the threaded joint and check that it is tightly seated.

4. Use a cable tie to fasten the plastic hose to the fittings in such a way that the opening is pointing down-wards.

5. Check that the hose is not kinked, and that the exhaust air can flow out easily. 4.5 Positioners exposed to strong acceleration forces or vibrations

High acceleration forces occur on fittings that are heavily mechanically stressed, such as breakaway flaps, heavily shaking or vibrating valves or "steam hammer". These forces can be well outside the range specified in the technical data. In extreme cases this can result in displacement of the slip clutch or the leverage ratio switch.

In these cases the positioner is fitted as standard with a locking device for the slip clutch with which displace-ment as a result of the above-mentioned influences is inhibited.

The adjustment function is accessible beneath the black adjusting wheel of the slip clutch and recognisable on the yellow wheel with slots. The null point setting and slip clutch adjustment functions are marked with symbols on an auxiliary plate

The clamping piece for the transmission leverage ratio switch is located under the terminals and is also fitted with a yellow adjusting wheel with slots.


4.5.1 Slip clutch

Procedure

After the positioner has been fitted and fully set into operation, the slip clutch can be locked as follows:

1. Place a commercial screwdriver of about 4 mm wide in a slot in the yellow wheel.

2. Turn the yellow wheel anti-clockwise with the screwdriver until it latches detectably. The slip clutch is thereby locked.

3. A locked slip clutch is to be recognised by an approximately 1 mm wide gap between the yellow and black wheel.

4. If a null point setting is necessary, e.g. after a drive change, the locking is released by a clockwise rotation up to the stop of the yellow wheel. After the null point setting the slip clutch can be fixed again as described above.

4.5.2 Leverage ratio switch

Starting from the neutral position (as-delivered condition) the leverage ratio switch can be adjusted as follows:

1. Plug a conventional 4 mm wide screwdriver into a slot in the yellow wheel.

2. Then turn the adjustment wheel in accordance to the chosen gearing position (33° or 90°) clockwise or anti-clockwise until it snaps in audibly.

3. An adjusted fixed leverage ratio switch is recognizable from the asymmetric position of the adjustment wheel.

4. If you have to switch over the gearing, the adjustment has to be loosen by turning the adjustment wheel into neutral position first.

Figure 4-8 Locking the slip clutch and leverage ratio switch

slip clutch and leverage ratio switch

Figure 4-9 Arrester device

External Travel Acquisition

External travel acquisition is a possibility for those cases in which the measures described above are not suffi-cient, such as when vibration is heavy and persistent, at particularly high or low ambient temperatures, or in the presence of nuclear radiation. In this case the special positioner (see Type Code) is used at a distance from the fitting.

More information contains the appendix to the manual 827.EDP.


5 Electrical connection Basic safety instructions

WARNING

Improper power supply

Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using alternating current instead of direct current.

Connect the device in accordance with the specified power supply and signal circuits. The relevant speci-fications can be found in the certificates or on the nameplate.

WARNING

Unsafe extra-low voltage

Danger of explosion in areas subject to explosion hazard due to voltage flashover

Connect the device to an extra-low voltage with safe isolation

WARNING

Connecting device in energized state


Connect devices in hazardous areas only in a de-energized state.

Exception:

Circuits of limited energy may also be connected in the energized state in hazardous areas.

WARNING

Lack of equipotential bonding

Danger of explosion through compensating currents or ignition currents through lack of equipotential bond-ing.

Ensure that the device is potentially equalized.

Exception:

It may be permissible to omit connection of the equipotential bonding for devices with type of protection "In-trinsic safety Ex i".

WARNING

Unprotected cable ends

Danger of explosion through unprotected cable ends in hazardous areas.

Protect unused cable ends in accordance with IEC/EN 60079-14

WARNING

Improper laying of shielded cables

Danger of explosion through compensating currents between hazardous area and the non-hazardous area.

Only ground shielded cables that run into the hazardous area at one end.

If grounding is required at both ends, use an equipotential bonding conductor.


Owing the reasons pertaining to tightness (IP enclosure rating) and the required tensile strength, only use the cables having a diameter ≥ 8 mm for standard M20x1.5 cable gland, or use a suitable seal insert in case of smaller diameters.

In the NPT version, the positioner is delivered with a coupling. When inserting a counter piece in the coupling, ensure that the maximum permissible torque of 10 Nm is not exceeded.

WARNING

Unsuitable cables and/or cable glands

Danger of explosion in areas subject to explosion hazard if cables and/or cable glands are connected which do not match one another or comply with the technical requirements.

Before taking the device into operation let the device adapt for several hours in the new environment.

Tighten the cable glands in accordance with the torques specified

When replacing cable glands use only cable glands of the same type.

After installations check that the cables are seated firmly.

CAUTION

Condensation in the device

Damage to device through formation of condensation if the temperature difference between transportation or storage and the mounting location exceeds 20 °C

Before taking the device into operation let the device adapt for several hours in the new environment.

CAUTION

Ambient temperature too high

Damage to cable sheath

At an ambient temperature 60 °C, use heat-resistant cables suitable for an ambient temperature at least 20 °C higher.

CAUTION

Connection of voltage source to current input

Device damage if a voltage source is connected to the current input Iw (terminals 6 and 7).

Never connect the current input Iw to a voltage source, otherwise the positioner may be destroyed.

Always use a voltage source with a maximum output current of I = 20 mA.

WARNING

Version „Ex i“

As auxiliary power, control, and signal circuits, only certified intrinsically safe circuits may be connected.

NOTICE

Dissipation of glitch impulses/equipotential bonding

In order to dissipate glitch impulses, the positioner must be connected to a potential equalizing cable (earth potential) using a low resistance.

The positioner have a corresponding terminal on the outer side of the enclosure. This terminal must also be connected to the potential equalizing cable.

For applications in hazardous areas, ensure an adequately suitable equipotential bonding between the haz-ardous and non-hazardous areas.


5.1 Electrical connection, basic device

If the bus shield is fully effective, the interference immunity and the interference emission conform to the speci-fications. The following measures ensure that the bus shield is fully effective:

The shields have been connected to the metallic connections of the positioner. The shields have been laid up to the terminal boxes, the distributor and the transceiver. Safety shutdown

The positioner is equipped with an additional input (terminal 81 and terminal 82) for driving to the safety posi-tion. After activating this function this input must be supplied with uninterrupted, to allow normal positioning operation.

If this power supply is switched off or drops out, the air exhaust valve is automatically opened and the drive will move to the pre-arranged safety position, so that the drive cannot be activated using the keys on the control unit or by means of the master switch.

This function is activated by the coding bridge on the motherboard. This is accessible after removing the mod-ule cover and must be moved from the right position (as delivered) to the left position Installing the bus cable

1. Isolate the buscable as shown in figure 5-2.

2. Open the positioner housing by undoing the four cover screws.

3. Feed the prepared bus cable through the screw-type cable gland.

4. Secure the shield with the cable clip and the two screws to the housing

5. Tighten the screw-type cable gland

6. Connect the red and green wires as shown in figure 5-3 to terminals 6 and 7 of the mother board (the polar-ity is immaterial)

5.1.1 Electrical connection, basic device not for explosive regions

3 2 V

Inpu t: S imu la tion s e nab le

Po si tioner

I nput: Sa fe p osi tio n 81

82

7

6

8

910

3 0 V

Fo unda tio n F ieldbus

Figure 5-1 Electrical connection for basic device, not for explosive regions

Bus cable Cabler shield

Figure 5-2 Preparing the bus cable


Ground potential Terminals Label

Module coverBasic PCBCable clipBus cable

cable glands

Grounding cable

Figure 5-3 Connection the bus cable

5.1.2 Electrical connection, basic device for explosive regions

30 V

24 V

Foundation Fieldbus

Region of no explosive hazard

Intrinsically safe power sources

Region of explosive Zone 1 or Zone 2

Input: Simulations enable

Positioner

Input: Safe position 81

82

7

6

8

910

EEx

EEx

Figure 5-4 Electrical connection of basic device, for explosive regions

6 Pneumatic Connections

WARNING

For reasons of safety, the auxiliary pneumatic energy should only be connected after assembly when, in the presence of an electrical signal, the positioner is switched to the P-manual operating level (delivery status, see leaflet “Concise operating notes”).

NOTICE

Ensure correct air-quality! Oil-free, instrument quality air with no water or dust, solid material content max. 1 mg/m3 (standard atmospheric conditions), max. particle size 1 m, oil content max. 0.1 mg/m3 (standard atmospheric conditions), pressurised dew point 20 K below the lowest ambient temperature.

When working on the compressed air system ensure that any contamination present such as water, oil, swarf, soldering material residues etc. are expelled by blowing out


Procedure

- If appropriate, connect manometer block for air supply and actuating pressure.

- Connection via internal thread G 1/4 DIN 45141

PZ Air supply 1,4 to 7 bar Y1 Actuating pressure 1 for single-acting and double-acting actuators Y2 Actuating pressure 2 for double-acting actuators E Exhaust air output (remove silencer if necessary)

- Safety position at failure of auxiliary electrical power:

Single-acting: Y1 vented Double-acting: Y1 max. actuating pressure (supply pressure) Y2 vented

- Connect actuating pressure Y1 or Y2 (only on double-acting actuators) according to the desired safety posi-tion.

- Connect air supply to PZ.

Note

So that spring-loaded pneumatic actuators can reliably exploit the maximum possible travel, it is necessary that the supply pressure exceeds the maximum required final pressure of the actuator by a sufficient margin.

After installing the pneumatic connections, check the tightness of the entire control valve. Besides continuous air consumption, the positioner may try to compensate the position deviation due to leakage. This will lead to premature wear in the entire control unit. 7 Commissioning

(see leaflet "Concise operating notes") Basic safety instructions

WARNING

Improper commissioning in hazardous areas

Device failure or danger of explosion in hazardous areas

Do not commission the device until it has been mounted completely and connected.

Before commissioning take the effect on other devices in the system into account.

WARNING

Loss of explosion protection

Danger of explosion in hazardous areas if the device is open or not properly closed. .

WARNING

Opening device in energized state


Only open the device in a de-energized state.

Check prior to commissioning that the cover, cover locks, and cable inlets are assembled in accordance with the directives.

Exception: Devices having the type of protection "Intrinsic safety Ex i" may also be opened in energized state in hazardous areas.


Safety notes for operation with natural gas

For operation with natural gases actuator medium an electric connection acc to explosion protection „ia“ cate-gory 2G is needed. More information and safety notes see for manual 827A-GHB-natural gas General Information

After installing the positioner on a pneumatic actuator, you must supply electric and pneumatic auxiliary power to it.

The positioner is in the "P manual mode" before initialization. At the same time, "NOINI" blinks in the lower line of the digital display.

Adjust the positioner as per the respective actuator with the help of the initialization process and by setting the parameters. If required, use the "PRST" parameter to cancel the adjustment of the positioner on the actuator. The positioner is again in the "P manual mode" after this process.

WARNING

Water in compressed air line

Device damage and possibly loss of type of protection. The factory setting for the purging air selector is "IN". In the "IN" position, water from the compressed air line may enter the device from the pneumatics during initial commissioning.

Before commissioning, make sure that no water is present in the compressed air line. If you cannot be sure that there is no water in the compressed air line:

Set the purging air selector to "OUT". In this way, you prevent water from the compressed air line from penetrating the device.

Only set the purging air selector to "IN" again when all water has been discharged from the compressed air line.

NOTICE

Loss of degree of protection

Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the nameplate is no longer guaranteed.

Make sure that the device is securely closed.

WARNING

Commissioning and operation with pending error

If an error message appears, correct operation in the process is no longer guaranteed.

Check the gravity of the error

Correct the error

If the device is faulty: - Take the device out of operation. - Prevent renewed commissioning.

NOTICE

During the initialization process, the operating pressure must be at least one bar more than that required to close or open the valve. However, the operating pressure should not be greater than the maximum permissible operating pressure for the actuator.

The leverage ratio switch can be set only when the positioner is open. Therefore, check this setting before closing the enclosure.


Types of initialization

- Automatic initialization

The initialization takes place automatically. In this case, the positioner determines, one after another, the effective working direction, the travel distance or rotation angle and the actuator's adjustment times and adjusts the control parameters to match the dynamic behaviour of the actuator.

- Manual initialization

The travel distance or rotation angle of the actuator can be set manually. The other parameters are automatically determined, just as in the case of automatic initialization. This function is useful on actua-tors with soft end stops

- Copying Initialization Data (Positioner Exchange)

In devices with HART functionality, the initialization data of one positioner can be read and copied into another positioner. This allows a faulty device to be exchanged, without having to interrupt a running process in order to carry out initialization.

You have to define a few parameters for the positioner before initialization. Owing to the preset values, you cannot adjust further parameters for initialization.

You can use a suitably configured and activated binary input to protect the configured settings against acciden-tal adjustment. 7.1 Preparations for Linear Actuators

1. Assemble the positioner with the appropriate mounting kit

The position of the leverage ratio switch in the positioner is particularly important here.

Stroke lever Position leverage ratio switch 5 to 20 mm short 33° (i.e. down) 25 to 35 mm short 90° (i.e. up) 40 to 130 mm long 90° (i.e. up n)

2. Connect a suitable source of current or voltage

3. Connect the actuator and the positioner to the pneumatic lines, and activate the positioner's auxiliary pneumatic power.

4. The positioner is now in the “P–manual" operating mode. The top line of the display now shows the current potentiometer voltage (P) in percent, e.g.: “P37.5“, while "NOINI" flashes on the bottom line:

5. Check that the mechanics can move freely over the entire active range by moving the actuator with the

and buttons as far as the end positions. The value P5.0 may not be fallen below and P95.0 may not be exceeded. The difference of the two values must be greater than 25.0

You can move the actuator rapidly by pressing the button for the opposite direction as well while continuing to hold down the first direction button.

6. Now move the actuator so that the lever is horizontal. The display should show a value between P48.0 and P52.0. If this is not the case, make appropriate adjustments to the slip clutch. The closer you can get to the "P50.0" value, the more accurately the positioner can determine the travel.


7.1.1 Automatic Initialization of Linear Actuators When you can move the actuator correctly, leave it in a central position and start the automatic initialization:

1. Hold the button pressed for longer than 5 s. This will bring you to the configuration mode Display:

2. Switch to the second parameter by pressing the button briefly. Display: or

It is essential that this value matches the setting of the leverage ratio switch (33° or 90°))

3. Use the button to move on to the following display:

You only have to set this parameter if you want to have the total stroke determined displayed in mm at the end of the initialization phase. To do this, you select the value in the display at which you have set the driver pin on the scale at the lever.


5. Start the initialization by pressing the button for longer than 5 s.

Display:

"RUN1" to "RUN5" appear in sequence in the lower display during the initialization process.

Depending on the actuator, the initialization process can take up to 15 min and it is completed when the fol-lowing display appears:

The first line also contains the stroke that has been determined, in mm, if the lever length has been given with the 3.YWAY parameter.

The following display appears after briefly pressing the button:

To leave the Configuration mode, press the button for longer than 5 s. The software status will be dis-played after about 5 s. When the button is released, the device will be in manual operation mode.

You can interrupt an initialization that is in progress at any time by pressing the button. Your previous set-tings will be retained. The parameters will only be returned to the factory settings if you have carried out a "Preset".

After successful initialization slipping clutch and leverage ratio switch can be adjusted if necessary


7.1.2 Manual Initialization of Linear Actuators With this function the positioner can be initialized without having to move the actuator hard against the end stops. The start and end positions of the travel are set manually.

When you can move the actuator correctly, leave it in a central position and start the manual initialization. The other initialization steps (optimisation and control parameters) are carried out in the same way as under auto-matic initialization.

1. Hold the button pressed for longer than 5 s. This will bring you to the configuration mode Display:

2. Switch to the second parameter by pressing the button briefly.

Display: or

It is essential that this value matches the setting of the leverage ratio switch (33° or 90°)) 3. Use the button to move on to the following display:

You only have to set this parameter if you want to have the total stroke determined displayed in mm at the end of the initialization phase. To do this, you select the value in the display at which you have set the driver pin on the scale at the lever.

4. Press the button twice to move on to the following display:


Display:

6. After 5 s the display changes to:

(The potentiometer settings shown here and below are only illustrative examples.)

Now use the and buttons to move the actuator to the position that you wish to define as the first of the two end positions. Then press the button. This will register the current position as end position 1, and will move on to the next step.

If the message "RANGE" appears on the lower line, the selected end position is outside the permitted measurement range. There are a number of ways to correct this error:

- adjust the slip clutch until "OK" appears, then press the button again, or

- use the and buttons to move to a different end position, or

- interrupt the initialization by pressing the button. You must then change to P-manual operation and correct the travel and the displacement accession in accordance with chapter 7.1

7. When Step 6 has been successfully completed, the following display appears:

Now use the and buttons to move the actuator to the position that you wish to define as the second

end position. Then press the button. This will cause the current position to be registered as end position 2.

If the message "RANGE" appears on the lower line, the selected end position is outside the permitted measurement range. There are a number of ways to correct this error:

- adjust the slip clutch until "OK" appears, then press the operating mode switch again, or

- use the and buttons to move to a different end position, or


- interrupt the initialization by pressing the button. You must then change to P-manual operation and correct the travel and the displacement accession in accordance with chapter 7.1

If the message "Set Middl" appears, the lever arm must be moved to a horizontal position with the aid of the and buttons, and the button then pressed. This will set the reference point for the sine correction

on linear actuators.

8. The rest of the initialization will now proceed automatically. "RUN1" to "RUN5" will appear in sequence on the lower line of the display. The following display appears when the initialization has been completed suc-cessfully:

The first line also contains the stroke that has been determined, in mm, if the lever length has been given with the 3.YWAY parameter.

After briefly pressing the button the lower line will again show 5.INITM. You are then once more in the Configuration operating mode


After successful initialization slipping clutch and leverage ratio switch can be adjusted if necessary. 7.2 Preparations for Quarter-turn Actuators In the positioner, place the leverage ratio switch in the 90° position (the usual adjustment angle for quarter-turn actuators).

1. Assemble the positioner with the appropriate mounting kit.

2. Connect a suitable source of current or voltage.

3. Connect the actuator and the positioner to the pneumatic lines, and activate the positioner's auxiliary pneumatic power

4. The positioner is now in the “P-manual“ .The top line of the display now shows the current potentiometer voltage (P) in percent, e. g.: “P37.5 “while “NOINI“ flashes on the bottom line

5. Check that the mechanics can move freely over the entire active range by moving the actuator with the

and buttons as far as the end positions. The value P5.0 may not be fallen below and P95.0 may not be exceeded. The difference of the two values must be greater than 25.0.

You can move the actuator rapidly by pressing the button for the opposite direction as well while continuing to hold down the first direction button. 7.2.1 Automatic Initialization of Quarter-turn Actuators When you can move the actuator correctly through its range, leave it in a central position and start the auto-matic initialization:

1. Hold the button pressed for longer than 5 s. This will bring you to the configuration mode. Display:

2. Hold the button pressed for longer than 5 s. This will bring you to the configuration mode.

Display:

3. Switch to the second parameter by pressing the button briefly. This has automatically been set to 90°.

Display:

It is essential that this value matches the setting of the leverage ratio switch (33° or 90°)




Display:

"RUN1" to "RUN5" appear in sequence in the lower display during the initialization process.

Depending on the actuator, the initialization process can take up to 15 min and it is completed when the fol-lowing display appears:

The upper value gives the actuator's full turning angle (e.g. 93.5°). The following display appears after briefly pressing the button:


You can interrupt an initialization that is in progress at any time by pressing the button. Your previous set-tings will be retained. The parameters will only be returned to the factory settings if you have carried out a "Preset".

After successful initialization slipping clutch and leverage ratio switch can be adjusted if necessary. 7.2.2 Manual Initialization of Quarter-turn Actuators With this function the positioner can be initialized without having to move the actuator hard against the end stops. The start and end positions of the travel are set manually

When you can move the actuator correctly, leave it in a central position and start the manual initialization. The other initialization steps (optimisation and control parameters) are carried out in the same way as under auto-matic initialization.

1. Hold the button pressed for longer than 5 s. This will bring you to the configuration mode. Display:

2. Use the button to set the YFCT parameter to "turn"

Display:

3. Switch to the second parameter by pressing the button briefly.

Display:

Ensure that the leverage ratio switch is in the 90° position.

4. Press the button twice to move on to the following display:

The following steps are identical to steps 5) to 8) in the initialization of linear actuators.

Following successful initialization, the pivoting range that has been determined is shown on the upper display in degrees

After briefly pressing the button the lower line will again show 5.INITM. You are then once more in the Con-figuration operating mode.


To leave the Configuration mode, press the button for longer than 5 s. The software status will be displayed after about 5 s. When the button is released, the device will be in manual operation mode.

After successful initialization slipping clutch and leverage ratio switch can be adjusted if necessary. 7.3 Copying Initialization Data (Positioner Exchange) Electropneumatic positioners can be replaced in a running system without interrupting the process. By copying and transferring the device and initialization data, it is possible to commission a replacement

positioner without needing to initialize it. An electropneumatic positioner uses the communication interface to transfer data. The following steps are required to exchange a positioner:

1. Prerequisite is that the positioner to be replaced and all ist parameters is in the project database. The replacement instrument should be online on the bus.

2. Fix the actuator in its current position (mechanically or pneumatically).

3. Read and note the current position value from the display of the positioner that is being replaced. If the electronics are faulty, find the current position by measurement at the actuator or valve

4. Dismount the positioner. Fit the lever arm of the positioner to the replacement device. Mount the replace-ment device to the fittings. Put the leverage ratio switch in the same position as on the faulty device. Download the device data and initialization dat.

5. Now transfer all parameters from the projected positioner to the new positioner. With the NI Configurator this can be done by right clicking the appropriate blocks in the function block application window, chosing ”Replace With ...” and selecting the new blocks. Do this also with the Transducer Block. In order to transfer the parameter INIT_VALUES (Initialization parameters), you have to set SERVICE_UPDATE (Save/Reset) to 9 (Enable Write INIT--Values), then click ”Write changes” and set SERVICE_UPDATE to 3 (Set device to state INIT). Now the positioner is initilisid with the same parameters as the old one

6. If the actual value displayed does not accord with the value noted from the faulty positioner, set the correct value with the slip clutch.

7. The positioner is now ready for operation.

The accuracy and the dynamic behaviour may not be as good as they would be following a proper initialization. In particular the position of the hard end stops and the associated servicing data may be inaccurate. An initiali-zation must therefore be carried out at the next opportunity.

NOTICE

Deferred initialization

Initialize the replacement positioner as soon as possible. The following properties can be ensured only after initializing: Optimum adjustment of the positioner as per the mechanical and dynamic properties of the actuator. Unrestricted accuracy and dynamic behaviour of the positioner Deviation-free position of the hard end stops Correctness of the maintenance data


8 Overview of Parameters 8.1 Parameters 1 to 5 Parameters 1 to 5 are the same for all versions of positioner. These parameters are used to adjust the posi-tioner to the actuator. Normally the parameter setup is sufficient to be able to operate the positioner on an ac-tuator.

If you want to get to know the positioner in detail, gradually try out the effects of the remaining parameters by systematic testing. Parameter Function Parameter values

(bold = factory setting) Unit

Type of position actuator turn (quarter-turn actuator)

WAY (linear actuator) LWAY (linear actuator without sine correction)

ncSt (quarter-turn actuator with NCS) -ncSt (quarter-turn actuator with NCS, inverse direction

of action ncSL (linear actuator with NCS)

1.YFCT

ncSLL (linear actuator with NCS and lever)

Nominal angle of rotation of the feedback message ( - Parameter does not appear if 1.YFCT = “turn”, “LWAY” or “ncS_” has been selected. - Set the leverage ratio switch accordingly)

33°

2.YAGL

90°

°

Range of stroke (optional setting) - The parameter only appears for "WAY" and for "ncSLL". - When used the value must correspond with the set range of stroke on the actuator. Carriers must be scaled to the

actuator's stroke value, or if this is not scaled they then must be set to the next largest scaled value.

OFF 5 | 10 | 15 | 20 (short lever 33°) 25 | 30 | 35 (short lever 90°)

3.YWAY

40 | 50 | 60 | 70 | 90 | 110 | 130 (long lever 90°)

mm

4.INITA Initialization (automatic) NOINI | no / ###.# | Strt 5.INITM Initialization (manual) NOINI | no / ###.# | Strt

8.2 Parameters 6 to 44 These parameters are used to configure the following additional functions of the positioner: Target value preparation Actual value preparation Binary signal processing Tight closing function Boundary value detection Parameter Function Parameter values


6.TSUP Setpoint ramp OPEN Auto / 0 ... 400 % 7.TSDO Setpoint ramp CLOSED 0 ... 400 % 8.SFCT Setpoint function

Linear Lin 1 : 25 1 - 25 1 : 33 1 - 33

Equal percentage

1 : 50 1 - 50 25 : 1 n1 - 25 33 : 1 n1 - 33

Inverse equal percentage

50 : 1 n1 - 50 Freely adjustable FrEE 9.SL0 ... 29.SL20 Setpoint turning point (Interpolation points appear only upon selection of 12.SFCT = "FrEE") 9SL0 at 0 % 10SL1 .... 5 % ... 0.0 ... 100.0 % 28.SL19 95 % 29.SL20 100 % 30.DEBA Dead zone of closed-loop controller Auto / 0.1 ... 10.0 % 31.YA Start of the manipulated variable limit 0.0 ... 100.0 %


Parameter Function Parameter values


32.YE End of the manipulated variable limit 0.0 ... 100.0 % Manipulated variable scaling

Mechanical MPOS 33.YNRM

On flow FLOW

34.YCDO Lower value for tight closing 0.0 ... 100 % 35.YCUP Upper value for tight closing 0.0 ... 100 %

Function of BE1 Normally open (Action on switch closed or

High-Level)

Normally closed (Action on switch open or Low-

Level)

None OFF Message only on -on Block configuration bloc1 Block configuration and manual bloc2 Move valve to position YE uP -uP Move valve to position YA doWn -doWn Block movement StoP -StoP

36.BIN1

Partial-Stroke-Test PST -PST Alarm function Normal

(High level without fault) Inverted

(Low level without fault)

without OFF A1 = Min, A2 = Max

A1 = Min, A2 = Min

37.AFCT

A1 = Max, A2 = Max 38.A1 Trigger threshold, alarm 1 0.0 ... 10.0 ... 100 % 39.A2 Trigger threshold, alarm 2 0.0 ... 90.0 ... 100 %

40. FCT Function for fault message output („+“ means: Logical OR combination)

Normal (High level without fault)

Inverted (Low level without fault)

Fault Fault + not automatic Fault + not automatic + BE

41. TIM Monitoring time for setting of fault message "regulation deviation"

Auto / 0 ... 100 s

42. LIM Response threshold for fault message "regula-tion deviation"

Auto / 0 ... 100 %

Preset (factory setting) results in "NOINI"! no Nothing activated no Strt Start of factory setting Strt

43.PRST

oCAY Display after pushing button for 5 s oCAY Activation of extended diagnostics

Off OFF Single-level message On1 Two-level message On2

44.XDIAG

Three-level message On3


8.3 Parameters A to P These parameters are used to set the extended diagnostic functions of the positioner. Note Parameters A to P and their sub-parameters are only displayed when the extended diagnostics has been acti-vated using parameter "XDIAG" with parameter value "On1", "On2" or "On3". Parameter Function Parameter values


A. PST Partial-Stroke-Test with the following parameters:

A1.STPOS Starting position 0.0 ... 100.0 % A2.STTOL Starting tolerance 0.1 ... 2.0 ... 10.0 % A3.STEP Step height 0.1 ... 10.0 ... 100.0 % A4.STEPD Step direction uP / do / uP do A5.INTRV Test interval OFF / 1 ... 365 d A6.PSTIN Partial-Stroke-Test reference step time NOINI / (C)##.# / Fdini / rEAL s A7.FACT1 Factor 1 0.1 ... 1.5 ... 100.0 A8.FACT2 Factor 2 0.1 ... 3.0 ... 100.0 A9.FACT3 Factor 3 0.1 ... 5.0 ... 100.0

b. DEVI General control valve fault with the following parameters: b1.TIM Time constant Auto / 1 ... 400 s b2.LIMIT Limit 0.1 ... 1.0 ... 100.0 % b3.FACT1 Factor 1 0.1 ... 5.0 ... 100.0 b4.FACT2 Factor 2 0.1 ... 10.0 ... 100.0 b5.FACT3 Factor 3 0.1 ... 15.0 ... 100.0

C. LEAK Pneumatic leakage with the following parameters: C1.LIMIT Limit 0.1 ... 30.0 ... 100.0 % C2.FACT1 Factor 1 0.1 ... 1.0 ... 100.0 C3.FACT2 Factor 2 0.1 ... 1.5 ... 100.0 C4.FACT3 Factor 3 0.1 ... 2.0 ... 100.0

d. STIC Friction (slip-stick effect) with the following parameters: d1.LIMIT Limit 0.1 ... 1.0 ... 100.0 % d2.FACT1 Factor 1 0.1 ... 2.0 ... 100.0 d3.FACT2 Factor 2 0.1 ... 5.0 ... 100.0 d4.FACT3 Factor 3 0.1 ... 10.0 ... 100.0

E. DEBA Dead zone monitoring with the following parameters:

E1.LEVEL3 Threshold 0.1 ... 2.0 ... 10.0 %

F. ZERO Zero point monitoring with the following parameters:

F1.LEVEL1 Threshold 1 0.1 ... 1.0 ... 10.0 % F2.LEVEL2 Threshold 2 0.1 ... 2.0 ... 10.0 % F3.LEVEL3 Threshold 3 0.1 ... 4.0 ... 10.0 %

G. OPEN Displacement of the upper stop with the following parameters:

G1.LEVEL1 Threshold 1 0.1 ... 1.0 ... 10.0 % G2.LEVEL2 Threshold 2 0.1 ... 2.0 ... 10.0 % G3.LEVEL3 Threshold 3 0.1 ... 4.0 ... 10.0 %

H. TMIN Monitoring of the lower limit temperature with the following parameters:

H1.TUNIT Temperature unit °C °F °C/°F H2.LEVEL1 Threshold 1 -40 ... -25 ... 90 -40 ... 194 H3.LEVEL2 Threshold 2 -40 ... -30 ... 90 -40 ... 194

H4.LEVEL3 Threshold 3 -40 ... 90 -40 ... 194

J. TMAX Monitoring of the upper limit temperature with the following parameters:

J1.TUNIT Temperature unit °C °F J2.LEVEL1 Threshold 1 -40 ... 75 ... 90 -40 ... 194

°C/°F

J3.LEVEL2 Threshold 2 -40 ... 80 ... 90 -40 ... 194 J4.LEVEL3 Threshold 3 -40 ... 90 -40 ... 194

L. STRK Monitoring the path integral with the following parameters:

L1. LIMIT Limit for the number of changes of direction 1 ... 1E6 ... 1E8 L2.FACT1 Factor 1 0.1 ... 1.0 ... 40.0 L3.FACT2 Factor 2 0.1 ... 2.0 ... 40.0 L4.FACT3 Factor 3 0.1 ... 5.0... 40.0

O. DCHG Monitoring the changes in direction with the following parameters::

O1.LIMIT Limit for the number of changes of direction 1 ... 1E6 ... 1E8 O2.FACT1 Factor 1 0.1 ... 1.0 ... 40.0 O3.FACT2 Factor 2 0.1 ... 2.0 ... 40.0 O4.FACT3 Factor 3 0.1 ... 5.0... 40.0

P. PAVG Position mean value calculation with the following parameters:

P1.TBASE Time base of the mean value generation 0.5h / 8h / 5d / 60d / 2.5y P2.STATE State of the position mean value calculation IdLE / rEF / ###.# / Strt P3.LEVEL1 Threshold 1 0.1 ... 2.0 ... 100.0 % P4.LEVEL2 Threshold 2 0.1 ... 5.0 ... 100.0 % P5.LEVEL3 Threshold 3 0.1 ... 10.0 ... 100.0 %


9 Fault removal Diagnostic guide

See Table

In which operating mode does the fault appear?

- Initialization 1

- Manual operation and automatic operation 2 3 4 5

In what environment and under what boundary conditions does the fault appear?

- Wet environment (e.g. severe rain or constant condensation) 2

- Vibrating (oscillating) fittings 2 5

- Impact or shock loading (e.g. “steam hammer” or breakaway flaps) 5

- Damp (wet) compressed air 2

- Dirty compressed air (contaminated with solid particles) 2 3

When does the fault appear?

- Regularly (reproducible) 1 2 3 4

- Sporadically (not reproducible) 5

- Mostly after a certain length of time of operation 2 3 5

Table 1 Fault symptoms Possible cause(s) Remedial measures

Positioner remains in “RUN 1“ mode.

- Initialization from end position started and

- Failure to wait for reaction time of max. 1 min.

- Mains pressure not connected or too low.

- Up to 1 min waiting time is required

- Do not start initialization from end position

- Check mains pressure


- Leverage ratio switch and Parame-ter 2 (YAGL) and also actual stroke are not in agreement.

- Stroke on lever incorrectly adjusted.

- Piezo valve(s) are not switching (see Table 2)

- Check settings: Leverage ratio switch (10 in fig.1) and parameter 2

- Check stroke on lever

- see Table 2


- Actuator travel time too long - Open restrictor completely and/or set PZ pressure to highest permis-sible value.

- If necessary use booster

Positioner remains in “RUN 5“ mode, does not get to “FINISH“ (waiting time > 5 min)

- “Slack” (play) in the positioner – actuator – fitting

- Quarter-turn actuator: Check that grub screw on the coupling wheel is tight

- Linear actuator: Check that lever on the positioner shaft is tight

- Remove any other play between actuator and fitting.



- “CPU test“ flashes in the display (approx. every 2 s)

- Piezo valve(s) are not switching.

- Water in the valve block (caused by wet compressed air)

- Actuator will not move at all or only in one direction in both manual and automatic operating modes.

- Dampness in the valve block

- In its early stages the fault can be removed by subsequent operation with dry air (if necessary in the dryer at 50 to 70°C).

- Otherwise repair

- Screw between cover and valve block not screwed tight or cover jammed.

- Tighten screw, if necessary remove cause of jam.

- Dirt (chips, particles) in valve block - Repair or new unit

- Piezo valve(s) are not switching (also no soft “clicking” audible if

or - button depressed in manual operating mode).

- Deposits on contacts between elec-tronics board and valve block; these can occur as a result of abrasion from long-term loading caused by severe vibration..

- Clean all contact surfaces with spirit, if necessary bend valve block contact springs a little.


- Actuator does not move - Compressed air < 1.4 bar - Set incoming air pressure to > 1.4 bar.

- Restrictor valve(s) closed (screw(s) at the right-hand stop)

- Open restrictor screw(s) by turning to the left

- Piezo valve(s) are not switching (however soft “clicking” audible if or button depressed in manual operating mode).

- Dirt in the valve block - Repair or new unit

- Pneumatic leakage in the posi-tioner – actuator system. Begin leakage test in “RUN 3“ (initiali-zation)

- Remove source of leakage in actua-tor and/or feed

- In the case where actuator is intact and feed is fully sealed: Repair or new unit

- In steady-state automatic oper-ating mode (constant setpoint) and in manual operating mode one Piezo valve is constantly switching.

- Dirt in the valve block (see above) - Repair or new unit


- Static friction in the stuffing box of fitting or actuator too large.

- Reduce static friction or increase dead zone (parameter DEBA) until the oscillating movement stops

- Slack (play) in the positioner - actua-tor - fitting system

- Quarter-turn actuator: Check that grub screw on the coupling wheel is tight

- Linear actuator: Check that lever on the positioner shaft is tight

- Remove any other play between actuator and fitting.

- In steady-state automatic oper-ating mode (constant setpoint) and in manual operating mode both Piezo valves are constantly switching alternately; actuator oscillates about a mean value.

- Actuator too fast - Increase travel times by means of restrictor screws.

- If fast travel time is necessary, in-crease dead zone (parameter DEBA) until the oscillating movement stops.

- Positioner does not drive fitting up to the stop (with a 100% in-put signal)

- Supply pressure too low - Increase supply pressure



- Null point moves about sporadi-cally (> 3 %)

- As a result of impact or shock loading accelerations occur that are so high that the slip clutch is displaced (e.g. by “steam hammer” in steam pipe-work)

- Remove causes of shock loading.

- Re-initialise positioner, lock slip clutch (see chapter 4.1.2)

- Electrical auxiliary power source inadequate ( 3,6 mA)

- Control electrical auxiliary power source

- With very high long-term loading caused by vibration (oscillations)::

- Equipment functionality com-pletely fails: also no indication in the display

- Screws on the electrical con-necting terminals can work loose.

- Electrical connecting terminals and/or electronic components can be shaken loose

- Tighten screws and secure with sealant

- Repair

- As a preventative measure mount positioner on rubber-metal mounts

10 Service and maintenance Basic safety instructions

WARNING

Impermissible repair of the device

Repair must be carried out by authorized personnel only.

WARNING

Impermissible accessories and spare parts


Only use original accessories or original spare parts. Observe all relevant installation and safety instructions described in the instructions for the device or en-

closed with the accessory or spare part.

WARNING

Improper connection after maintenance


Connect the device correctly after maintenance. Close the device after maintenance work.

CAUTION

Penetration of moisture into the device

Device damage

Make sure when carrying out cleaning and maintenance work that no moisture penetrates the inside of the device.


The positioner requires almost no maintenance. Filters are fitted to the pneumatic connections to protect the positioner against large particles of dirt. Dirt present in the input air can collect on the filter and then adversely affect the operation of the positioner (increased travel time). In such a case, the filters can be cleaned as fol-lows:

1. Switch off the auxiliary pneumatic energy and disconnect the hose lines.

2. Carefully remove the metal filters from the holes and clean them (e.g. with compressed air).

3. Insert the filters

4. Connect the hose lines again and turn on the auxiliary pneumatic power. 11 Technical Data General data for the base device Degree of protection IP66 to EN60529

Climatic class in accordance with IEC 721

Storage 1K5 but -40 C … + 80 C 1)

Transport 2K4 but -40 C … + 80 C 1)

Operation without purging air 3K3 but -30 C 3) … + 80 C 2)

with purging air 4K3 but -30 C 3) … + 80 C 2)

Shock resistance 10 g to 100 Hz

recommended continuous operating range of the entire fitting 30 m/s2

CAUTION

Releasing key lock

Improper modification of parameters could influence process safety.

Make sure that only authorized personnel may cancel the key locking of devices for safety-related appli-cations.

WARNING

Electrostatic charge

Danger of explosion in hazardous areas if electrostatic charges develop e.g. when cleaning plastic enclo-sures with a drycloth.

Prevent electrostatic charging in hazardous areas.

WARNING

Enclosure open

Danger of explosion in hazardous areas as a result of hot components and/or charged capacitors inside the device. Isolate the device from power, before open the device in a hazardous area.

Exception Devices having the type of protection "Intrinsic safety Ex i" may also be opened in an energized state in hazardous areas.

WARNING

Dust layers above 5 mm

Danger of explosion in hazardous areas. Device may overheat due to dust build up. Remove any dust layers in excess of 5 mm.


CE marking Applicable directives and standards see declaration of con-

formity Fitting orientation Any, although in wet environments the pneumatic connections

and exhaust opening must not face upwards

Connections

electrical Screw terminals 2,5 AWG28-12

Cable feed through M 20x1.5 or (cable feed through ½ –14 NPT on request)

pneumatic Internal thread G 1/4 DIN 45141 (Internal thread 1/4 –18 NPT on request)

1) If commissioning at 0 C it is important that the valves are flushed for long enough with a dry medium. 2 See the electrical data for devices protected against explosion hazard. 3) Reduced refresh rate in on the LCD display below -10 C.

Pneumatic data for the base device

Auxiliary power (air supply)

Medium Instrument quality air meeting DIN ISO 8573-1, class 2

Pressure 1,4 … 7 bar

Electrical data for the base device

Type 827A.E Type 827A.X

Ignition protection type accord-ing to EN 50014 and EN 50020

- II2G Ex ia IIC T4/T6 Gb

Ambient temperature - 30 … + 80 C T4 - 20 … + 75 C

T6 - 20 … + 50 C

Electrical connection See Figure 5-1 See Figure 5-4

Communication

H1 communication to specification of the Fieldbus Foundation, group 3, class 31 PS (Publisher/Subscriber) 1 resource block (RB2), 1 analog output function block (AO), 1 PID function block (PID), 1 transducer block (standard advanced positioner valve)

Physical layer profile 123, 511

Block execution times Analog output function block 60 ms; PID function block 80 ms

Power supply Bus-powered Bus-powered

Bus voltage DC 9 ... 32 V DC 9 ... 24 V

Current consumption 10.5 mA ± 10 % 10.5 mA ± 10 %

Fault current 0 0

For connection to -

circuits with certified FISCO power supply with max. Ui = 17,5 V Ii = 380 mA Pi = 5,32 W

-

circuits with certified barrier with max. Ui = 17,5 V Ii = 380 mA Pi = 5,32 W

Internal capacitance - Negligible small

Internal inductance - 8 μH


Type 827A.E Type 827A.X

Safety shutdown

Input resistance > 20 kΏ > 20 kΏ

Signal status 0: active DC 0 ... 4.5 V DC 0 ... 4.5 V

Signal status 1: inactive DC 13 ... 30 V DC 13 ... 30 V

For connection to -

certified intrinsically safe circuits with max. Ui = 30 V Ii = 100 mA Pi = 1 W

Internal capacitance - Negligible small

Internal inductance - Negligible small

Binary input BE1 Suitable for dry contact, max. contact load ≤ 5 μA at 3 V

Electrical isolation Bus connection and safety shutdown electrically isolated, Bus connection and BE1 electrically connected

Bus connection and safety shutdown electrically isolated, Bus connection and BE1 electrically connected

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights created by the granting of patents or registration of a design are reserved. Technical data subject to change without notice.

ARCA-REGLER GmbH D-47913 Tönisvorst Phone: +49-(0)2156/7709-0 Fax: +49-(0)2156/7709-50...55 E-Mail [email protected]

Documents

ARCAPRO 827A.E/X ∗∗F - ∗∗∗ - Von Rohr ARCA BV ... no.: 827A-FF-BA-09-13_gb ARCA-Regler GmbH D - 47918 Tönisvorst Page 3 von 42 Table of Contents 1 Introduction 4 2 General