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Reference no.: 827A-BA-02-15_gb ARCA-Regler GmbH D - 47918 Tönisvorst Page 1 of 53

ARCAPRO 827A.E/X - - -

Electropneumatic Positioner for

Linear and Quarter-turn ActuatorsVersion without / with HART-Communication

Operating Instructions

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Legal information

Warning notice system

This documentation notices you have to observe in order to ensure your personal safety, as well as to preventdamage to property. The notices referring to your personal safety are highlighted in the manual by a safetyalert 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 willbe used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating toproperty damage.

Qualified Personnel

The device may only be set up and used in conjunction with this documentation. Commissioning and operationof a device may only be performed by qualified personnel. Within the context of the safety notes in this doc-

umentation qualified persons are defined as persons who are authorized to commission, ground and labeldevices, 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 tak-en.

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 intoaccount.

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 toensure that the products operate safely and without any problems. The permissible ambient conditions mustbe adhered to. The information in the relevant documentation must be observed.

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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" 134.2.2 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 Electric Connection 22

5.1 Electric Connection, not intrinsically safe 24

5.1.1 Basic device 24

5.1.2 Options 255.2 Connecting device with type of protection intrinsic safety 28

5.2.1 Basic device 28

5.2.2 Options 30

6 Pneumatic Connections 32

7 Commissioning 33

7.1 Preparations for Linear Actuators 35

7.1.1 Automatic Initialization of Linear Actuators 35

7.1.2 Manual Initialization of Linear Actuators 36

7.2 Preparations for Quarter-turn Actuators 38

7.2.1 Automatic Initialization of Quarter-turn Actuators 38

7.2.2 Manual Initialization of Quarter-turn Actuators 39

7.3 Copying Initialization Data (Positioner Exchange) 39

8 Overview of Parameters 40

8.1 Parameters 1 to 5 40

8.2 Parameters 6 to 52 41

8.3 Parameters A to P 42

9 Fault removal 43

10 Service and Maintenance 46

11 Technical Data 47

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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 changesin the course of further development.

Checking the consignment

Design of the nameplate

II 2 G Ex ia IIC T6/T4 GbTa = -30 …50/80°C

TÜV 12 ATEX 085253 X

1

32

9

64

11

10

5 8 7

Stellungsregler 827A.X4-0BH-M10-G

Mat-Nr. XXXXXXX

F-Nr. X XXXXXX

1 - Manufacturer2 – Device name3 - Type4 - Consult operating instructions5 - Safety class6 - Auxiliary power (air supply)

7 - Approval8 - ATEX marking for hazardous area9 - Rated signal range10 - 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.

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Type key

827A. – – –

Connection thread G M20x1,5 / G 1/4electric / N 1/2“ NPT / 1/4“ NPT pneumatic M M20x1,5 / 1/4“ NPT

P 1/2“ NPT / G 1/4

mechanical 0 Standardactuator 2 without (for external potentiometer)

pneumatic 1 single-acting2 double-acting (only stainless housing)

body M aluminiumE stainless housing

communication 0 without communicationH HART

binary output 0 without binary outputsB binary moduleS slot initiator moduleK contact module

analogue - output 0 without analogue - output A analogue module

connection 2 2 - wirebasic device 4 2 / 3 / 4 - wire

Ex - certificate E not explosion protected

X II 2 G Ex ia IIC T6/T4 Gb(Type 827A.X∗-A∗∗-∗∗∗-∗ only II2G Ex ia IIC T4 Gb)

series

Transportation and storage

Environmental protection

Devices described in this programming manual can be recycled owing to the low content of noxious substanc-es in their version. Please contact a certified waste disposal company for eco-friendly recycling and to disposeof your old devices.

CAUTION

Insufficient protection during storage

The packaging only provides limited protection against moisture and infiltration.

Provide additional packaging as necessary.

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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 directivesObserve the test certification, provisions and laws applicable in your country during connection, assembly andoperation:

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 thelaws of the Member States relating to electromagnetic compatibility and repealing Di-

rective 89/336/EEC.

ATEX 94/9/EG Directive of the European Parliament and the Council on the approximation of the lawsof the Member States concerning equipment and protective systems intended for use inpotentially explosive atmospheres. .

LVD 2006/95/EC Directive of the European Parliament and the Council on the approximation of the lawsof the Member States relating to electrical equipment designed for use within certainvoltage limits.

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

Improver device modifications

WARNING

Improver device modificationsDanger to personnel, system and environment can result from modifications to the device, particularly inhazardous areas.

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

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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 ofthe 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

Danger of explosion in areas subject to explosion hazard. 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 classof the device is no longer valid.

Make sure that the maximum permissible ambient and process media temperatures of the device are notexceeded.

CAUTION

Electrostatic Sensitive Devices

This device contains electrostatic sensitive devices. Electrostatic sensitive devices may be destroyed byvoltages 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 aresult of overvoltage cannot usually be detected immediately. It may only become apparent after a longperiod of operation.

Therefore, avoid electrostatic charge.

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Qualified Personnel

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

They are authorized, trained or instructed in operating and maintaining devices and systems according tothe 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 currentposition of the drive is detected using a servo potentiometer and is sent back as actual value x. The actualand target values are simultaneously displayed on the digital display.

The set point w forms a current applied to the positioner, which in two-wire mode is also used to power the

positioner. In 3- and 4-wire mode, power is supplied through a 24-V power input. The positioner works as a predictive five-point positioner, through whose output value ±Δy 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 thedrive until the regulation deviation returns to zero.

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

Normally the basic device has one binary input (BE1). This can be individually configured, and is particular-ly 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 afriction clutch and a switchable gear.

3.2 Structure

The following chapters describe the mechanical and electrical structure, components, and principle functionali-ty 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.

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The device is available for single-acting and double-acting actuators and for potentially explosive applications

and applications that are not potentially explosive.

1 Actuator2 Positioner, single-acting in metal-housing3 Lantern4 Manometer block, single-acting5 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. Input: supply air2. Output: Actuating pressure Y13. Display

4. Output: Actuating pressure Y2 *) 5. Control buttons6. Restrictor Y16.1 Restrictor Y1 *) 6.2 Restrictor Y2 *) 7. Leverage ratio switch8. Silencer 9. Slip clutch adjusting wheel 10. Connection terminals motherboard11. Connection terminals for optional module12. Blinding plug13. Cable gland14. Terminal plate on cover15. Purging air selector

*) for double-acting drives

1

2

3

4

5

1

2

3

1 Positioner, double-acting in plastic housing2 Quarter-turn actuator3 Manometer block, double-acting

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3.3.2 Electric Connections

The connecting terminals for the base device, the optional analogue, 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 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-acting 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 linearactuators:

- actuating pressure Y1

- exhaust air outlet E

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

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 thevalve 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 thatthe control valve has reached the safety position. If you only interrupt the pneumatic auxiliary power supplyto the positioner, the safety position may in some cases only be attained after a certain delay period.

Purging air switch

Pneum. connection strip

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On rotary actuators,it is usual to define theanti-clockwise direction of rotation – seen looking athe valve's operating

shaft – as "OPEN".

Open

Closed

up down

OpenClosed

Open

ActuatingpressureConnection

Y1

Y1

Y2

Open

losedClosed

Y1

Y1

Y2

Y1

Closed

Y2

Open

Open

Open

Closed

Open

Closed

Closed

Y1

Last position(before failure of auxiliary power)

Last position(before failure of auxiliary power)

Y1

Y1

Y2

up

down

down down

down

up

up

upup

down

up

down

updown

Safety position following failure of the auxiliary power

electrical pneumatic Actuator type

Figure 3-6 Pneumatic connection positioning effect

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3.3.5 Restrictors

NoteThe 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 initial-ization RUN3).

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

Y1 Y2

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 mechanicaldamage 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 thenameplate is no longer guaranteed.

Hexagon socket 2,5 mm

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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):

Serialno.

No. ofitems

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 actuatoror, if this is not available as a scale value, at the next largest scale value. In case of uncertainty with regardto the real actuator stroke (pneumatic actuators often have a travel resource) you always have to choosethe 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 inmm 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 ambienttemperatures.

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 im-portant 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.

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1) 2)

3)

14

13

17

12

11

9

10

8

11

6

5

3

2

3

4

7

15

16

Figure 4-1 Mounting procedure for integrated fitting

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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):

Serialno.

No. ofitems

Name Note

1 1 NAMUR fitting angle IEC 534 Standardised connecting location for fitting bracket with rib, columnor 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 – A211 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 actuatoror, if this is not available as a scale value, at the next largest scale value. In case of uncertainty with regardto the real actuator stroke (pneumatic actuators often have a travel resource) you always have to choosethe next large scale value. The centre of the pin must be positioned at the scale value. The same value canlater be set during the commissioning under the parameter 3.YWAY, in order to display the displacement inmm 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 rearof 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 nottouch the clamping piece.

6. Hold the positioner with the fixing angle to the actuator in such a way that the pin (4) passes inside thesensing 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 theheight of the positioner so that the horizontal position of the lever is achieved as close as possible to thecentre of the stroke. The actuator's lever scale provides orientation here. It is essential that the horizontallever position is passed through within the range of the stroke.

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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

910

8

9

10

1

7

9

10

7

9

10

17

9

10

6

Fitting to lanternwith columns

Fitting to lanternwith flat surface

16

14

14

13

11

5

11

1215

2)

Figure 4-3 Mounting procedure for IEC 534 inear actuator

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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. ofitems

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 tightenthe 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 andstick 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!

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3

2

2

9

9

14

15

2)1)

3)

4.2

18

4)

17

16

4.1

0% 20 40 60 80 100%

5)

2

3

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

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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 (frequentheavy rain and/or persistent tropical condensation) in which protection class IP66 is no longer sufficient, inparticular when there is a risk that the water might freeze.

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 wheel3 Driver pin4 Labels4.1 Scale4.2 Pointer9 VDI/VDE 3845-fitting bracket10 Feedback shaft14 Hexagonal screw M6 x 1215 Retaining washer S616 Cylinder head boltM6 x 1217 Washer18 Hexagon key

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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.

Figure 4-7 Favourable and unfavourable installation positions

If local conditions force you to operate the positioner in an unfavourable installation position, you can preventthe 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 cas-es 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 candrop 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 bereplaced 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 inthe technical data. In extreme cases this can result in displacement of the slip clutch or the leverage ratioswitch.

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 onthe yellow wheel with slots. The null point setting and slip clutch adjustment functions are marked with symbolson an auxiliary plate

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

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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 there-by locked.

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

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

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 adjustmentwheel.

4. If you have to switch over the gearing, the adjustment has to be loosen by turning the adjustment wheel intoneutral 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 inthe presence of nuclear radiation. In this case the special positioner (see Type Code) is used at a distancefrom the fitting.

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

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5 Electric connection

Basic safety instructions

WARNING

Improper power supply

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

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

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Two-wire mode

Note

To maintain the auxiliary power, the current iy must be 3.6 mA

5.1 Electric connection, not intrinsically safe

5.1.1 Basic device

+

J

4 … 20 mA Positioner

Binary input 1

6 7 8 9

10 +3 V

HART-Communicator

A E

Figure 5-1 2- wire connection, not for explosive regions Type 827A.E2

+ 4 … 20 mA

Binary input 1

HART-Communicator

5

4

3

+3 V

6

7

8

9

10

A

2

E

Positioner

J

Figure 5-2 2-wire connection, not for explosive regions Type 827A.E4

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+

4 … 20 mA

2

3

Binaryinput 1

J

*) only for 3-wire connection

+

18 … 30 V

HART-Communicator

6

10

9

8

7

E

A

U4

5

*)

*)

Positioner

Figure 5-3 3/4-wire connection not for explosive regions Type 827A.E4

5.1.2 Options

Analogue module

UH 61

62 J

E

Analog module

+

+

35 V

Figure 5-4 Analogue module not for explosive regions

Binary module

BE2

Fault signal

Limit value A1

Limit value A2

Binary module

+

12

+13 V

+4,5 V

21

22

+

+ 3 V

31

32

41

42

51

52

+

+

1K

1K

1K

11 30 V

35 V

35 V

35 V

Figure 5-5 Binary module not for explosive regions

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Slot initiator module

Fault signal

Limit value A1

Limit value A2


3132

41

42

51

52

+

+

+

2K1

10K

8,2 V

8,2 V

8,2 V

Figure 5-6 Slot initiator module not for explosive regions

Contact module

DANGER

Low-voltage supply -Version not intrinsically safe

When you supply the module in the non-intrinsically safe version with low voltage, you must be sure to ob-serve the following safety rules before starting work on the device:

1. Isolate the device from power. Use a circuit breaker positioned near the device to do this.

2. Make sure that the device cannot be switched back on inadvertently.

3. Make sure the device is truly isolated from power.

WARNING

Protection against mechanical influences

In order to guarantee the degree of protection IP66, you must protect the module against mechanical influ-ences. This is achieved by selecting a suitable installation location or by installing a suitable protection de-vice. This required protection applies to the operation of the module with the following voltages:- > AC 16 V

- > DC 35 V, low voltage

NOTICE

Maximal values for terminals 41/42 und 51/52

The following maximum values concern only terminals 41, 42, 51, and 52:

- Maximum voltage: AC 250 V or DC 24 V

- Maximum current: AC/DC 4 A

No safe separation between the terminals can be guaranteed.

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fault signal

Contact module

llimit value A1

limit value A2

31

32

41

51

52

+

+

+ 1K21

10K

DC 24V

35 V

41

42 AC/DC 4A

DC 24V

AC/DC 4A

max. AC 250V

max. AC 250V

Figure 5-7 Contact module not for explosive

Connecting the contact module (Figure 5-8)

1. Loosen the screw (18) on the transparent cover (19).

2. Pull the transparent cover (19) up to the front end stop.

3. Tighten every cable in the corresponding terminal.

4. Slide the transparent cover (19) up to the end stop of the motherboard.

5. Tighten the screw (18) on the transparent cover (19).

6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the provided cable tie(20) for this purpose.

Figure 5-8 Connection the cables

NOTICE

To observe before connecting

Only qualified personnel is permitted to install and connect the contact module.

Isolate all wires from power and make sure the device is truly isolated from power.

Construct the cross-sectional area of the connection cables in such a way that it is appropriate for the

permitted current load.

Selected the wires on the basis of the following rule: The temperature at which the wires are permitted tobe used must be 25°C above the maximum ambient temperature.

18 Screw19 Cover20 Cable tie

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5.2 Connecting device with type of protection intrinsic safety

5.2.1 Basic device

+

J

4… 20 mA

Positioner

Binary input 1

6

7

8

9

10

+3 V

A

E

Region of noexplosive hazard

Intrinsically safepower source

EEx

Region of explosive hazard, Zone 1 or Zone 2

Figure 5-9 2- wire connection, for explosive regions, Type 827A.X2

+ 4 … 20 mA

Region of explosive hazard, Zone 1 or Zone

2

Intrinsically safepower source

J

Binary input 1

HART-Communicator

EEx

5

4

3

+3 V

67

8

9

10

A

2

E Positioner


Figure 5-10 2- wire connection, for explosive regions Ex Type 827A.X4

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+

4 … 20 mA


2

3

Binary input 1

J

*) only for 3-wire connection

+

18 … 30 V

HART-Communicator

Intrinsically safe powersources

6

10

9

8

7

E

AEEx

+3 V

U4

5


*) *)

EEx

Positioner

Figure 5-11 3/4- wire connection, for explosive regions Ex Type 827A.X4

Split-Range

Figure 5-12 Series connection of two positioners, e.g. split range (auxiliary power supplied separately

Intrinsically

safe

feed

sources

L+

Iy

M

M

Positioning range 2

Positioning range 1

+3V

+3V

BE 1

BE 1

8

10

9

5

7

6

8

4

10

9

3

2

7

6

5

4

3

2

I

EEx

U

EEx

Region of nohazard


#

#

+ 0/4 … 20 mA

+ 18 … 30 V Device 1

Device 2

E A

E A

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5.2.2 Options

Analogue module

UH 62

61

J

E

Analog module

+

+


Intrinsically safe power sources

J

EEx

U

+

30 V

Region of no explosive hazard

Figure 5-13 Analogue module for explosive regions

Binary module

BE2

Fault signal

Limit value A1

Limit value A2

Binary module

ntrinsically safe

switching amplifiermeeting

DIN EN 60947-5-6

(old DIN 19234)

Region of explosive hazard, Zone 1 or Zone 2Region of no explosive hazard

+

11

121

21

22

+31

32

41

42

51

52

EEx

EEx

EEx

EEx

+

+

+ 3 V

2K1

2K1

2K1

10K

10K

10K

25,2 V

8,2 V

8,2 V

8,2 V

Figure 5-14 Binary module for explosive regions

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Intrinsically safe

switching amplifier meetingDIN EN 60947-5-6(old DIN 19234)


Fault signal


Limit value A1

Limit value A2

EEx

EEx

EEx

31

32

41

42

51

52

+

+

+2K1

10K

2K1

10K

2K1

10K

8,2 V

8,2 V

8,2 V

Figure 5-15 Slot initiator module for explosive regions

Contact module

Contact module connecting see Figure 5-8

NOTICE

Maximal values for terminals 41/42 und 51/52

The following maximum values concern only terminals 41, 42, 51, and 52:- Maximum voltage: DC 30 V

- Maximum current: DC 100 mA

- Maximum performance:750 mW

No safe separation between the terminals can be guaranteed.

NOTICE

To observe before connecting

Only qualified personnel is permitted to install and connect the contact module.

Isolate all wires from power and make sure the device is truly isolated from power.

Construct the cross-sectional area of the connection cables in such a way that it is appropriate for thepermitted current load.

Selected the wires on the basis of the following rule: The temperature at which the wires are permitted tobe used must be 25°C above the maximum ambient temperature.

Operate the Ex-version only in intrinsically safe circuits with approved switching amplifiers.

NOTICE

Preparing the cables or stranded wires - Version intrinsically safe

1. Insulate the cables in such a way that the insulation is flush with the terminal when plugging in the wires.

2. Fit ferrules to the ends of stranded wires.

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Intrinsically safeswitchingamplifier meeting

DIN EN 60947-5-6(old DIN 19234)


Fault signal

Contact-module

limit value A1

limit value A2

EEx

3132

41

51

52

+

+

+ 1K21

10K

Umax DC 30V

DC 8,2V

41

42Imax 100 mA

Umax DC 30V

Imax 100 mA

Figure 5-16 Contact module for explosive regions

6 Pneumatic Connections

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 barY1 Actuating pressure 1 for single-acting and double-acting actuatorsY2 Actuating pressure 2 for double-acting actuatorsE Exhaust air output (remove silencer if necessary)

- Safety position at failure of auxiliary electrical power:

Single-acting: Y1 ventedDouble-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.

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

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Note

So that spring-loaded pneumatic actuators can reliably exploit the maximum possible travel, it is necessarythat 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 continuousair consumption, the positioner may try to compensate the position deviation due to leakage. This will lead topremature 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 accordancewith the directives.

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

state in hazardous areas.

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 duringinitial 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 frompenetrating the device.

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

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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 powerto it.

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

Adjust the positioner as per the respective actuator with the help of the initialization process and by setting theparameters. 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.

Types of initialization

- Automatic initialization

The initialization takes place automatically. In this case, the positioner determines, one after another, theeffective working direction, the travel distance or rotation angle and the actuator's adjustment times andadjusts 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 au-

tomatically determined, just as in the case of automatic initialization. This function is useful on actuatorswith soft end stops

- Copying Initialization Data (Positioner Exchange)

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

You have to define a few parameters for the positioner before initialization. Owing to the preset values, youcannot adjust further parameters for initialization.

You can use a suitably configured and activated binary input to protect the configured settings against acci-dental adjustment.

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 requiredto close or open the valve. However, the operating pressure should not be greater than the maximumpermissible operating pressure for the actuator.

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

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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 auxiliarypneumatic power.

4. The positioner is now in the “P –manual" operating mode. The top line of the display now shows the currentpotentiometer 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 theand buttons as far as the end positions. The value P5.0 may not be fallen below and P95.0 may not beexceeded. 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 continuingto 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 andP52.0. 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 modeDisplay:

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 theend of the initialization phase. To do this, you select the value in the display at which you have set the driv-er pin on the scale at the lever.


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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 givenwith 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 (see chap-ter 4.1.2).

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 endstops. 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. Theother 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 modeDisplay:

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 theend of the initialization phase. To do this, you select the value in the display at which you have set the driv-er pin on the scale at the lever.

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

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5. Start the initialization by pressing the button for longer than 5 s.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 willmove on to the next step.

If the message "RANGE" appears on the lower line, the selected end position is outside the permittedmeasurement 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 andcorrect 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 position2.

If the message "RANGE" appears on the lower line, the selected end position is outside the permittedmeasurement 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 andcorrect 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 correctionon 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 givenwith the 3.YWAY parameter.

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


played 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 (seechapter 4.1.2).

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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-turnactuators).

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 auxiliarypneumatic power

4. The positioner is now in the “P-manual“ .The top line of the display now shows the current potentiometervoltage (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 theand buttons as far as the end positions. The value P5.0 may not be fallen below and P95.0 may not beexceeded. 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 tohold 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:


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°)


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 upper value gives the actuator's full turning angle (e.g. 93.5°). The following display appears after brief-

ly pressing the button:

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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 (see chap-

ter 4.1.2).

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 endstops. 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. Theother initialization steps (optimisation and control parameters) are carried out in the same way as under auto-matic initialization.


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 displayin 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 (see chap-ter 4.1.2).

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 replacementpositioner 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. The device parameters and initialization data (determined at initialization time) of the device needing re-placement are read in and saved using SIMATIC PDM or HART Communicator. This step is not required ifthe device has been parameterised with SIMATIC PDM and the data already stored.

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

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3. Read and note the current position value from the display of the positioner that is being replaced. If theelectronics 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. Down-load the device data and initialization data from the SIMATIC PDM or the handheld device

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

6. 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.

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 bysystematic testing.

Parameter Function Parameter values(bold = factory setting)

Unit

1.YFCT Type of position actuator normal reversed

quarter-turn actuator turn -turn

linear actuator turnWAY

-turnWAY

linear actuator without sine correction LWAY -LWAY

quarter-turn actuator with NCS ncSt -ncSt

quarter-turn actuator with NCS ncSL -ncSL

linear actuator with NCS and lever ncSLL -ncSLL

2.YAGL 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° °

90°

3.YWAY 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 mm

5 | 10 | 15 | 20 (short lever 33°)

25 | 30 | 35 (short lever 90°)

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

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

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

NOTICE

Deferred initialization

Initialize the replacement positioner as soon as possible. The following properties can be ensured only afterinitializing:

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

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8.2 Parameters 6 to 52

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

6.SCUR Current range of set point

0 ... 20 mA 0 MA4 ... 20 mA 4 MA

7.SDIR Setpoint setup

Rising riSE

Falling FALL

8.SPRA Setpoint split range start 0.0 ... 100.0 %

9.SPRE Setpoint split range end 0.0 ... 100.0 %

10.TSUP Setpoint ramp OPEN Auto / 0 ... 400 s

11.TSDO Setpoint ramp CLOSED 0 ... 400 s

12.SFCT Setpoint function

Linear Lin

Equal percentage 1 : 25 1 - 25

1 : 33 1 - 331 : 50 1 - 50

Inverse equal percentage 25 : 1 n1 - 25

33 : 1 n1 - 33

50 : 1 n1 - 50Freely adjustable FrEE

13.SL0 ... 33.SL20 Setpoint turning point (Interpolation points appear only upon selection of 12.SFCT = "FrEE")

13.SL0 at 0 %14.SL1 .... 5 % ... 0.0 ... 100.0 %32.SL19 95 %33.SL20 100 %

34.DEBA Dead zone of closed-loop controller Auto / 0.1 ... 10.0 %

35.YA Start of the manipulated variable limit 0.0 ... 100.0 %

36.YE End of the manipulated variable limit 0.0 ... 100.0 %

37.YNRM Manipulated variable scaling

MechanicalMPOS

On flow FLOW38.YDIR Manipulated variable direction of action for display and position feedback

Rising riSE

Falling FALL

39.YCLS Manipulated variable tight closing

None no

Top only uP

Bottom only do

Top and bottom uP do

40.YCDO Lower value for tight closing 0.0 ... 0.5 ... 100 %41.YCUP Upper value for tight closing 0.0 ... 99.5 ... 100 %

42.BIN1 Function of BE1 Normally open

(Action on switch closed orHigh-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

Partial-Stroke-Test PST -PST

43.BIN2 Function of BE2 Normally open

(Action on switch closed orHigh-Level)

Normally closed

(Action on switch open or Low-Level)

None OFF

Message only on -on

Move valve to position YE uP -uP

Move valve to position YA doWn -doWn

Block movement StoP -StoP

Partial-Stroke-Test PST -PST

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Unit

44.AFCT Alarm function Normal(High level without fault)

Inverted(Low level without fault)

without OFF

A1 = Min, A2 = Max

A1 = Min, A2 = Min

A1 = Max, A2 = Max45.A1 Trigger threshold, alarm 1 0.0 ... 10.0 ... 100 %

46.A2 Trigger threshold, alarm 2 0.0 ... 90.0 ... 100 %

47. 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

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

Auto / 0 ... 100 s

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

Auto / 0 ... 100 %

50.PRST Preset

Reset of all parameters, that are resettablewith "Init", "PArA" and "diAg"

ALL

Reset of initialization parameters1.YFCT up to 5.INITM. Init

Reset of parameters6.SCUR up to 49.LIM.

PArA

Reset of parameters A up to P of extendeddiagnostics function as well as parameter52.XDIAG

diAg

51.PNEUM Fail in place

Standard valve block Std

Fail in place valve block FIP

52.XDIAG Activation of extended diagnosticsParameters A up to P appears only if parameter 51.XDIAG is activated with On1, On2 or On3. The contents of the parameters A upto P appears also only if the selected parameter is activated with On.

Off OFF

Single-level message On1

Two-level message On2

Three-level message On3

8.3 Parameters A to P

These parameters are used to set the extended diagnostic functions of the positioner.

NoteParameters 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".

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.STRKH Stroke height 0.1 ... 10.0 ... 100.0 % A4.STRKD Stroke direction uP / do / uP do A5.RPMD Ramp mode OFF / On A6.RPRT Ramp rate 0.1 ... 1.0 ... 100.0 %/s A7.FLBH Behaviour after fail of PST Auto / Hold / AirIn / AirOu A8.INTRV Test interval OFF / 1 ... 365 d A9.PSTIN Partial-Stroke-Test reference step time NOINI / (C)##.# / Fdini / rEAL s AA.FACT1 Factor 1 0.1 ... 1.5 ... 100.0 Ab.FACT2 Factor 2 0.1 ... 3.0 ... 100.0 AC.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 sb2.LIMIT Limit 0.1 ... 1.0 ... 100.0 %b3.FACT1 Factor 1 0.1 ... 5.0 ... 100.0b4.FACT2 Factor 2 0.1 ... 10.0 ... 100.0b5.FACT3 Factor 3 0.1 ... 15.0 ... 100.0

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Unit

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 ... 100.0C3.FACT2 Factor 2 0.1 ... 1.5 ... 100.0C4.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 ... 100.0d3.FACT2 Factor 2 0.1 ... 5.0 ... 100.0d4.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. TMINMonitoring of the lower limit temperature with the following parameters:

H1.TUNIT Temperature unit °C °F °C/°FH2.LEVEL1 Threshold 1 -40 ... -25 ... 90 -40 ... 194

H3.LEVEL2 Threshold 2 -40 ... -30 ... 90 -40 ... 194H4.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 °C/°FJ2.LEVEL1 Threshold 1 -40 ... 75 ... 90 -40 ... 194J3.LEVEL2 Threshold 2 -40 ... 80 ... 90 -40 ... 194J4.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 ... 1E8L2.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 ... 1E8O2.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 / 2.5yP2.STATE State of the position mean value calculation IdLE / rEF / ###.# / StrtP3.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 %

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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 faultappear?

- 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 start-ed and

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

- Mains pressure not connected or toolow.

- Up to 1 min waiting time is required

- Do not start initialization from endposition

- Check mains pressure


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

- Stroke on lever incorrectly adjusted.

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

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

- Check stroke on lever

- see Table 2


- Actuator travel time too long - Open restrictor completely and/orset PZ pressure t

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