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Operating manual Electro pneumatic positioner ARCAPRO - Version with BUS communication Series 827A.E/X BUS

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Operating manual Electro pneumatic positioner ARCAPRO - Version with BUS communication Series 827A.E/X BUS / 1.0 Original instructions ARCA Regler GmbH. All rights reserved. Cover picture background:
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Operating manual Electro pneumatic positioner ARCAPRO - Version with BUS communication Series 827A.E/X BUS / 1.0 Original instructions ARCA Regler GmbH. All rights reserved. Cover picture background: Freepik.com ARCA Regler GmbH Table of contents Table of contents 1 General data Validity of the manual Contact details Other applicable documents Place of storage of the manual Safety Introduction General safety information Explanation of symbols and notices Warning symbols on the device Intended use Improper modifications to the device Qualified Personnel Liability disclaimer Laws and regulations Conformity to European directives Use in potentially explosive areas Transport, storage and packaging Transport Storage Packaging Type plate Type key Description Function Construction Device Components Motherboard Electrical Connections Pneumatic Connections Purging Air Switch Restrictors Assembly Safety instructions for assembly Mounting a linear actuator Mounting with mounting kit for Integrated Fitting Linear Actuator Mounting with mounting kit Linear actuator IEC 534 Mounting with mounting kit Rotary actuator VDI/VDE 3845 Use of positioners in humid environment Series 827A.E/X BUS / / 80 Table of contents ARCA Regler GmbH 7.5 Positioners that are exposed to high acceleration forces or strong vibrations Slip clutch Transmission ratio selector Electrical connection Electrical connection of basic device Electrical connection options Optional version M12 plug Pneumatic connection Commissioning Preparation for commissioning of linear actuators Automatic initialisation of linear actuators Manual initialisation of linear actuators Preparation for commissioning of rotary actuators Automatic initialisation of rotary actuators Manual initialisation of rotary actuators Copying Initialisation Data (Positioner Exchange) Parameter overview Parameters 1 to Parameters 6 to 54 for Profibus PA Parameters 6 to 47 for foundation fieldbus Parameters A to P Service and maintenance Technical Data Fault removal Disposal and recycling / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 1 General data 1 General data This operating manual contains instructions that enable the product to be safely and properly installed, put into operation and maintained. The target group for this operating manual is exclusively specially trained and authorised technical personnel. Please contact the manufacturer if you encounter problems that cannot be solved with the aid of this operating manual. The product is subject to technical changes at any time. 1.1 Validity of the manual This operating manual applies to the product in the version described in the device pass. 1.2 Contact details Further information about the product can be obtained from: Manufacturer's address ARCA Regler GmbH Kempener Str. 18 D Tönisvorst Tel.: +49 (0) Fax: +49 (0) Other applicable documents The product can be delivered as part of an actuator and equipped with additional components that are described in their own operating manuals. The instructions as well as the warning and safety information contained therein must also be observed. Furthermore, the following documents apply in addition to this operating manual. Device pass Installation drawing 1.4 Place of storage of the manual The operating manual and all other applicable documents are part of the product. They must be kept in the immediate vicinity of the product and must be accessible to the personnel at all times. Series 827A.E/X BUS / / 80 2 Safety ARCA Regler GmbH 2 Safety 2.1 Introduction This manual contains all the information you need for the connection and commissioning of the device. It is addressed to people who mechanically mount, electrically connect, parameterise and commission the device, as well as service and maintenance technicians. This manual applies to devices from firmware version in both non-intrinsically and intrinsically safe versions. We hereby provide notice that the contents of this device manual do not form part of a former or existing agreement, acceptance or of a relationship in law, nor do they modify any such agreement. All obligations arise out of the particular sales contract, and this also contains the whole of any applicable warranty clauses. The terms of this contractual warranty are neither extended nor restricted by any material in this document. The contents reflect the technical level at the time of printing. We reserve the right to make technical changes in the course of further development. WARNING Use of a damaged or incomplete device Risk of explosion! Do not use damaged or incomplete devices. 2.2 General safety information Requirement for safe use This equipment has been supplied from the factory in a totally safe condition. To maintain this condition and to ensure safe operation of the device, follow these instructions and observe all safety-relevant information. Pay attention to the notices and symbols on the device. Do not remove any notices or symbols from the device. Keep the notices and symbols in a fully legible condition at all times. 2.3 Explanation of symbols and notices This documentation contains notes that you must observe for your own personal safety and for the avoidance of damage to property. Notes concerning personal safety are highlighted by a warning triangle; notes con- 6 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 2 Safety cerning only damage to property are not marked by a warning triangle. Depending on the danger level, the warning notes are shown in decreasing order of severity as follows: DANGER means that death or serious injuries will occur if the corresponding preventive measures are not taken. WARNING means that death or serious injuries can occur if the corresponding preventive measures are not taken. CAUTION with a warning triangle means that slight injury and/or damage to property can occur if the corresponding preventive measures are not taken. NOTICE indicates an important item of information about the product itself or how the product should be handled, to which special attention should be paid. CAUTION without a warning triangle means that damage to property can occur if the corresponding preventive measures are not taken. ATTENTION indicates that an undesirable event or condition can occur if the corresponding instructions are not observed. If several danger levels occur, the warning note for the respectively highest level will always be used. If a warning note with a warning triangle warns against personal injury, a warning against damage to property may be included in the same warning note. 2.4 Warning symbols on the device Symbol Explanation of the warning symbols on the device Observe the operating manual Protect the device against shocks (otherwise the protection class is not guaranteed) Series 827A.E/X BUS / / 80 2 Safety ARCA Regler GmbH 2.5 Intended use Observe the following: WARNING ARCA positioners may be used only for the applications specified in the associated technical documentation. Proper transport, storage, erection, assembly, installation, commissioning, operation and maintenance are required for trouble-free and safe operation. The permissible environmental conditions must be maintained. Notices in the associated documentation must be observed. 2.6 Improper modifications to the device WARNING Modification to the device Modifications and repairs to the device, in particular in potentially explosive areas, can be dangerous for personnel, the plant and the environment! Modify or repair the device only as described in the instructions for the device. The manufacturer's warranty and the product approvals are rendered null and void if this is ignored. 2.7 Qualified Personnel The device may be set up and operated only in conjunction with this documentation. Startup and operation may be performed only by qualified personnel. Qualified personnel within the meaning of the safety instructions in this documentation are persons who are authorised to commission, earth and mark devices, systems and circuits according to the safety standards. Qualified persons are those who are familiar with the erection, assembly, startup and operation of the product. These persons possess the following qualifications: They are authorised and have been trained or instructed to operate and maintain devices and systems in accordance with the safety standards for electrical circuits, high pressures and aggressive and/ or hazardous media. In the case of devices with explosion protection: they are authorised and have been trained or instructed to carry out work on electrical circuits for plants that are at risk from explosions. They have been trained or instructed in the care and use of appropriate safety equipment in accordance with safety standards. 2.8 Liability disclaimer We have checked the contents of this manual for correspondence to the hardware and software described. Nevertheless, deviations cannot be ruled out; therefore we cannot give any guarantee for full correspondence. The details are checked regularly and any necessary corrections will be included in subsequent editions. 8 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 2 Safety 2.9 Laws and regulations The test certificates, regulations and laws applicable to your country must be observed for the connection, assembly and operation. These are, for example: IEC (international) EN (EC) Operational safety ordinance 2.10 Conformity to European directives The CE mark on the device indicates its conformity to the following European directives: 2014/30/EU EMC 2014/34/EU ATEX 2014/35/EU LVD Directive of the European Parliament and of the Council on the harmonisation of the Laws of the Member States relating to electromagnetic compatibility. Directive of the European Parliament and of the Council on the harmonisation of the Laws of the Member States relating to equipment and protection systems intended for use in potentially explosive atmospheres. Directive of the European Parliament and of the Council on the harmonisation of the Laws of the Member States relating to the making available of electrical equipment designed for the use within certain voltage limits. The applied standards can be found in the EC Declaration of Conformity for the device. Series 827A.E/X BUS / / 80 2 Safety ARCA Regler GmbH 2.11 Use in potentially explosive areas WARNING Unsuitable device for potentially explosive areas Risk of explosion! Use only devices that are approved for use in Ex-zones and are marked accordingly. Make sure that the device is suitable for the area of use. WARNING Loss of safety of the device in the ignition protection class Intrinsic Safety Ex i If the device has already been operated on non-intrinsically safe circuits or with a higher operating voltage, the safety of the device for use in potentially explosive areas is no longer guaranteed. There is a danger of explosion! Connect the device in the ignition protection class Intrinsic Safety exclusively to an intrinsically safe electrical circuit. Observe the electrical data in the certificate. WARNING Impermissible accessories and impermissible spare parts Danger of explosion in potentially explosive areas or damage to the device! Use exclusively original accessories and original spare parts. Observe all relevant installation and safety instructions described in the manuals for the device, accessories and spare parts. WARNING Open cable entry or incorrect cable gland Danger of explosion in potentially explosive areas or damage to the device! Seal the cable entries for the electrical connections. Use exclusively cable glands or blanking plugs for this that are approved for the respective ignition protection class. WARNING Exceeding the maximum ambient or media temperature Risk of explosion in potentially explosive areas The temperature class of the device is no longer valid if the maximum permissible ambient or media temperature is exceeded! Make sure that the maximum permissible ambient or media temperature of the device is not exceeded. 10 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 2 Safety CAUTION Electrostatically endangered assemblies The device contains electrostatically endangered assemblies. Electrostatically endangered assemblies can be destroyed by voltages far below the threshold of human perception. These voltages already occur if you touch a component or electrical connection without having electrostatically discharged yourself first. The damage caused to an assembly due to overvoltage is not usually immediately apparent and only becomes noticeable after a lengthy period of operation. Therefore, prevent electrostatic charging. Series 827A.E/X BUS / / 80 3 Transport, storage and packaging ARCA Regler GmbH 3 Transport, storage and packaging 3.1 Transport Transport at a temperature lower than -40 C or higher than +80 C is not permissible. 3.2 Storage NOTICE Improper storage! There is a danger of the product no longer functioning if it is stored improperly. Storage at a temperature lower than -40 C or higher than +80 C is not permissible. It must be stored in roofed-over storage places and that are weatherproof. Openings are sealed with suitable means to prevent the ingress of dirt. These should be removed by technical personnel at the place of installation. CAUTION Inadequate protection during storage The packaging offers only limited protection against moisture and infiltration! Provide additional packaging if necessary. 3.3 Packaging The product is packed in a PE film inside the outer packaging (cardboard box, wooden crate, pallet, lattice box). If the packaging, in particular the PE film, has been opened, the product must be stored immediately in a heated room. The product must be packed in weatherproof or seaworthy packaging for transport by ship, rail or truck. 12 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 4 Type plate 4 Type plate Illustration 1: 827A type plate 1 Manufacturer 2 Device name 3 Type 4 Observe the operating manual 5 Protection class 6 Auxiliary power (air supply) 7 Approval 8 ATEX marking for potentially explosive areas 9 Nominal signal range 10 Auxiliary energy (voltage) 11 Fabrication number Series 827A.E/X BUS / / 80 5 Type key ARCA Regler GmbH 5 Type key 827A. E 2 - A 0 H - M G - LT [1] [2] [3] - [4] [5] [6] - [7] [8] [9] - [10] - [11] 1. Series 827A. 2. Explosion protection 1) E not explosion protected X explosion protected ia 3. Basic device connection 2 2-wire 4 2/3/4-wire 3) 4. Analogue output 0 without analogue output A 5. Binary output analog module 0 without binary output B S K 6. Communication Binary module Slot-type initiator module Contact module 0 without communication H P F HART PROFIBUS PA Foundation Fieldbus 1) 2) 7. Housing material M E Aluminium (single-acting only) Stainless steel 8. Pneumatics 1 single-acting 2 double-acting (except aluminium housing) 9. Mechanical actuator 0 Standard 2 without (for external potentiometer) 10. Connecting thread electrical/pneumatic G M20x1.5 / G 1/4 N ½ NPT / ¼ NPT M M20x1.5 / ¼ NPT P ½ NPT / G ¼ Q M25x1.5 / ¼ NPT (Ex d only) R M12 plug for input signal / G 1/4 14 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 5 Type key 10. Connecting thread electrical/pneumatic S M12 plug for input signal / 1/4 NPT 11. Options FIP Fail In Place 4 ) LT - 40 C 4 ) SA M12 plug for analogue module SB M12 plug for binary module SS M12 plug for slot-type initiator module SW M12 plug for external displacement sensor 1 ) ATEX approval, other approvals on enquiry 2 ) with HART communication, 2/3/4-wire only 3 ) except PROFIBUS PA and Foundation fieldbus 4 ) on enquiry Example of type designation 827A.E2-A0H-M10-G-LT 827A Positioner - without explosion protection - 2-wire connection - analogue module - without binary output - HART communication, aluminium housing - single-acting - standard mechanical actuator - connecting thread electrical M20x1.5 / pneumatic G 1/4 / - 40 C Series 827A.E/X BUS / / 80 6 Description ARCA Regler GmbH 6 Description 6.1 Function The electro-pneumatic positioner forms, in combination with an actuator, a control system. The present position of the actuator is acquired by means of a servo-potentiometer, and is fed back as the actual value, x. Setpoint and actual value are shown simultaneously on the digital display. A BUS signal supplied to the positioner forms the setpoint w. The positioner operates as a predictive five-point controller, whose output magnitude ±Δy is converted to a pulse length modulated signal to operate the control valves. These control signals cause changes of pressure in the actuating chamber(s), thus adjusting the actuator until the control error becomes zero. After removing the housing cover, the operation (manual mode) and configuration (structuring, initialisation and parameterisation) are done using three buttons and a digital display. Normally the basic device has one binary input (BE1). This binary input can be individually configured and used, for example, to block the operating levels. In order to be able to use the positioner on a large number of mechanically differing rotary and linear actuators, it has a slip clutch and a switchable transmission. 6.2 Construction This section describes the mechanical and electrical construction, the device components and the principles of the positioner's operation. The positioner is used to adjust and regulate pneumatic actuators. The positioner operates electro-pneumatically. Compressed air provides its auxiliary energy. The positioner can be used, for instance, to regulate valves with: a linear actuator (Fig. 2) or a VDI/VDE 3845 rotary actuator (Fig. 3) Linear actuators may be mounted in a number of ways. NAMUR or IEC 534 integrated mounting (ARCA, SAMSON) integrated mounting according to VDI/VDE 3847 The positioner can be mounted and operated on all normal actuators. 16 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 6 Description The device is available for single-acting and double-acting actuators as well as for potentially explosive and non-potentially explosive applications Actuator 2 Positioner, single-acting in metal housing 3 Yoke 4 Manometer block, single-acting 5 Valve Illustration 2: Positioner mounted on a linear actuator (single-acting) Positioner, double-acting, in stainless steel housing 2 Rotary actuator 3 Manometer block, double-acting Illustration 3: Positioner mounted on a rotary actuator (double-acting) Series 827A.E/X BUS / / 80 6 Description ARCA Regler GmbH 6.3 Device Components Supply air input 2 Output: actuating pressure Y1 3 Display 4 Output: actuating pressure Y2 * ) 5 Operating Buttons 6 Restrictor Y1 6.1 Restrictor Y1 *) 6.2 Restrictor Y2 * ) 7 Transmission ratio selector 8 Silencer 9 Slip clutch adjusting wheel 10 Basic device connecting terminals 11 Connecting terminals Option modules 12 Blinding plug 13 Cable gland 14 Clamping plate for cover 15 Purging air switch * with double/acting devices Illustration 4: Construction Motherboard Located on the motherboard are: CPU Memory A/D converter Display Operating Buttons Connecting strips for the connection of the option modules to the motherboard Electrical Connections The connecting terminals of the basic device as well as the analogue, binary and slot-type initiator module are located at the front left-hand edge and offset to each other in a staircase form. An assembly cover secures the components against being pulled out, and prevents incorrect assembly. 18 / / 1.0 Series 827A.E/X BUS ARCA Regler GmbH 6 Description Pneumatic Connections The pneumatic connections are located on the right-hand side of the positioner Actuating pressure Y1 in singleacting and double-acting actuators 2 Feedback shaft 3 Air supply P Z 4 Actuating pressure Y2 on double-acting actuators 5 Exhaust air outlet E with silencer on the underside of the device Illustration 5: Pneumatic connections Connection variants The following pneumatic connections are located at the rear of the positioner for the integrated fitting of single-acting linear
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