ABB PositionMaster EDP300 Installation and operation manual

Commissioning Instruction CI/EDP300-EN Rev. C
PositionMaster EDP300
Digital Positioner

2 CI/EDP300-EN Rev. C | PositionMaster EDP300
Short product description
Digital positioner for the positioning of pneumatically controlled
actuators.
Devices firmware version: 01.00.09
Further information
A
dditional documentation on PositionMaster EDP300 is
available to download free of charge at
www.abb.com/positioners.
A
lternatively simply scan this code:
Manufacturer
A
BB Automation Products GmbH
Industrial Automation
Schillerstr. 72
32425 Minden
Germany
Tel: [phone]
Fax: [phone]
Customer service center
Tel: [phone]
Mail: [email protected]
Change from one to two columns

PositionMaster EDP300 | CI/EDP300-EN Rev. C 3
Contents
1Safety............................................................................... 4
1.1General information and instructions .................... 4
1.2Warnings ............................................................. 4
1.3Intended use........................................................ 4
1.4Improper use ....................................................... 4
2Use in potentially explosive atmospheres according to
ATEX and IECEx.............................................................. 5
2.1Product identification ........................................... 5
2.2Ex-marking .......................................................... 5
2.3Installation ........................................................... 5
2.3.1Cable gland ......................................................... 5
2.3.2Operation with flammable gas.............................. 6
2.3.3Operation in temperature class T6 ....................... 6
2.4ATEX and IECEx temperature data....................... 6
2.4.1Type of protection Ex i, intrinsic safety.................. 6
2.4.2Type of protection Ex n - non-sparking ................ 6
2.5ATEX und IECEx electrical data............................ 6
2.5.1Type of protection Ex i, intrinsic safety.................. 6
2.5.2Type of protection Ex n - non-sparking ................ 7
3Use in potentially explosive atmospheres in accordance
with FM and CSA ............................................................ 8
3.1Product identification ........................................... 8
3.2Ex-marking .......................................................... 8
3.3Installation ........................................................... 8
3.3.1Cable gland ......................................................... 8
3.3.2Operation with flammable gas.............................. 8
3.3.3Use in areas with combustible dust...................... 9
3.3.4Operation in temperature class T6 ....................... 9
3.4Temperature data ................................................ 9
3.5Electrical data ...................................................... 9
4Product identification.................................................... 11
4.1Name plate........................................................ 11
5Transport ....................................................................... 11
5.1Inspection.......................................................... 11
5.2Returning devices .............................................. 11
6Installation ..................................................................... 12
6.1Safety instructions ............................................. 12
6.2External position sensors ................................... 12
6.3Mechanical mounting......................................... 13
6.3.1General information............................................ 13
6.3.2Mounting on linear actuators.............................. 13
6.3.3Mounting on control valves ................................ 16
6.3.4Mounting on part-turn actuators ........................ 16
6.4Electrical connections ........................................ 18
6.4.1Electrical connection to positioner / EDP300 Control
Unit.................................................................... 18
6.4.2Electrical connection to the EDP300 remote sensor
.......................................................................... 19
6.4.3Electrical data for inputs and outputs ................. 19
6.4.4Connection on the device .................................. 21
6.4.5Connection to device - EDP300 Control Unit with
EDP300 Remote Sensor .................................... 22
6.4.6Connection to device - EDP300 Control Unit for
remote position sensor ...................................... 23
6.5Installing the option modules.............................. 24
6.5.1Installing the mechanical position indicator ......... 24
6.5.2Installing the mechanical position feedback........ 24
6.5.3Installing the pressure option.............................. 24
6.6Setting the option modules ................................ 25
6.6.1Setting the mechanical position indicator ........... 25
6.6.2Setting the mechanical binary feedback with
proximity switches ............................................. 25
6.6.3Setting the mechanical binary feedback with 24 V
microswitches.................................................... 26
6.7Pneumatic connections...................................... 26
6.7.1Information on double acting actuators with spring-
return mechanism .............................................. 26
6.7.2Connection on the device .................................. 27
6.7.3Air supply........................................................... 27
7Commissioning.............................................................. 28
7.1Safety instructions.............................................. 28
7.2Checks prior to commissioning .......................... 28
7.3Mechanical mounting checks............................. 28
7.3.1Moving to end positions following completion of
Auto Adjust........................................................ 28
7.3.2 Moving to end positions with a new device ........ 28
8Operation....................................................................... 29
8.1Safety instructions.............................................. 29
8.2Parameterization of the device ........................... 29
8.2.1Menu navigation ................................................ 29
8.3Menu levels........................................................ 30
8.3.1Start Auto Adjust function .................................. 31
9Maintenance.................................................................. 31
10Supplemental specifications......................................... 31
10.1Actuator travel ................................................... 31
10.2Housing ............................................................. 32
10.2.1Mounting orientation .......................................... 32
10.3Transmission data and influences....................... 32
10.3.1Seismic vibration................................................ 32
10.3.2Influence of mounting orientation........................ 32
10.3.3Noise emissions................................................. 32
10.4Ambient conditions ............................................ 32
11Additional documents ................................................... 32
12Appendix ....................................................................... 33
12.1Return form ....................................................... 33
12.2Control Drawing 901305.................................... 34

4 CI/EDP300-EN Rev. C | PositionMaster EDP300
1Safety
Change from one to two columns
1.1 General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who
have been authorized by the plant operator accordingly. The
specialist personnel must have read and understood the
manual and must comply with its instructions.
For additional information or if specific problems occur that are
not discussed in these instructions, contact the manufacturer.
The content of these instructions is neither part of nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be
performed if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed and must be fully legible at all
times.
The operating company must strictly observe the applicable
national regulations relating to the installation, function testing,
repair and maintenance of electrical products.
1.2 Warnings
The warnings in these instructions are structured as follows:
DANGER
The signal word "DANGER" indicates an imminent danger.
Failure to observe this information will result in death or
severe injury.
WARNING
The signal word "WARNING" indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word "CAUTION" indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTICE
The signal word "NOTICE" indicates useful or important
information about the product.
The signal word "NOTICE" is not a signal word indicating a
danger to personnel. The signal word "NOTICE" can also
refer to material damage.
1.3 Intended use
Positioning of pneumatically controlled actuators; designed for
mounting on linear and part-turn actuators.
The device is designed for use exclusively within the stated
values on the name plate and in the data sheet.
— The maximum operating temperature must not be
exceeded.
— The permissible ambient temperature must not be
exceeded.
— The housing protection type must be observed.
1.4 Improper use
The following are considered to be instances of improper use
of the device:
— For use as a climbing aid, e.g. for mounting purposes.
— For use as a support for external loads, e.g. as a support
for piping, etc.
— Material application, e.g. by painting over the name plate
or welding/soldering on parts.
— Material removal, e.g. by spot drilling the housing.

PositionMaster EDP300 | CI/EDP300-EN Rev. C 5
2Use in potentially explosive
atmospheres according to ATEX and
IECEx
NOTICE
Further information on the approval of devices for use in
potentially explosive atmospheres can be found in the type
examination certificates or the relevant certificates at
www.abb.com/positioners.
2.1 Product identification
Depending on the type of explosion protection, an Ex name
plate is attached next to the main name plate on the
positioner.
This indicates the level of explosion protection and the
device's relevant Ex certificate.
2.2 Ex-marking
ATEX
Type Examination Test Certificate ZELM 11 ATEX 0456 X
II 1G Ex ia IIC T6 or T4 Ga
II 1D Ex iaD IIIC T55°C or T100°C Da
Ta = -40°C … 40°C or 85°C
II 3G Ex nA IIC T6 or T4 Gc
II 2D Ex tb IIIC T55°C or T100°C Db
Ta = 40°C … 40°C or 80°C
IECEx
Type Examination Test Certificate IECEx ZLM 11.0001 X
Ex ia IIC T6 or T4 Ga
Ex iaD IIIC T55 °C or T100°C Da
Ta = -40 ° … 40 ° or 85
Ex nA IIC T6 or T4 Gc
Ex tb IIIC T55 °C or T100°C Db
Ta = -40 ° … 40 ° or 80 °C
EAC TR-CU-012
Ex ia IIC T4/T6 Ga X
Ex ia IIIC T100°C/T55°C Da IP65
EX nA IIC T4/T6 Gc X
Ex tb IIIC T100°C/T55°C Db IP65
2.3 Installation
The installation, commissioning, maintenance and repair of
devices in potentially explosive atmospheres must only be
carried out by appropriately trained personnel. Works may be
carried out only by persons, whose training has included
instructions on different types of protection and installation
techniques, concerned rules and regulations as well as general
principles of zoning. The person must possess the appropriate
competences for the type of work to be conducted.
When operating with combustible dusts, comply with
EN 60079-31.
The safety instructions for electrical apparatus in potentially
explosive areas must be in accordance with Directive
2014/34/EC (ATEX) and IEC60079-14 (Installation of electrical
equipment in potentially explosive areas).
Comply with the applicable regulations for the protection of
employees to ensure safe operation.
NOTICE
Observe the device's applicable specifications and special
conditions in accordance with the type examination
certificate or other certificates!
— Any manipulation of the device by users is not permitted.
Only the manufacturer or an explosion protection
specialist may modify the device
— The device may only be operated with instrument air that
is free of oil, water, and dust.
2.3.1 Cable gland
Limited temperature range of the M20 x 1.5 plastic cable
gland for explosion protection variants.
The permissible ambient temperature range of the cable gland
is -20 … 80 °C (-4 ... 176 °F). When using the cable gland,
make sure that the ambient temperature is within this range.
The cable gland must be installed in the housing with a
tightening torque of 3.8 Nm. When installing the connection of
the cable gland and cable, check for tightness to ensure that
the required IP rating is met.

6 CI/EDP300-EN Rev. C | PositionMaster EDP300
2.3.2 Operation with flammable gas
Observe the following points when operating a device with
flammable gases:
— The device must be used in accordance with the
specifications in the relevant certificate.
— Only the design with the "Intrinsic Safety" type of
protection has been approved for operation with natural
gas. The pneumatic outputs must be vented in non-Ex
areas.
— The maximum ambient temperature must not exceed
60 °C (140 °F).
— During operation with flammable gases in type of
protection "Ex n", the device may only be operated with
approved cable glands.
— During operation with flammable gases, the cover cap for
the air outlets can be removed, and the air outlets can be
tubed separately. Both pipes may not be joined in one
pipe.
Use in areas with combustible dust
Observe the following points when operating a device with
combustible dust:
— To prevent loss of type of protection, the housing may not
be opened.
— Only use cable glands which are approved for the type of
protection and correspond to IP rating ≥ IP 6X.
— Avoid hazardous propagating brush discharge.
2.3.3 Operation in temperature class T6
During operation in temperature class T6, when the equipment
is partially or fully depressurized, ensure that there is no
possibility of a hazardous atmosphere getting into the
pneumatic system or that any hazardous atmosphere is
removed prior to compression by taking suitable action.
When commissioning in temperature class T6, flush the
pneumatic system with 1.4 (+/- 0.1) bar until all traces of any
explosive mixture have been removed (at least 5 minutes).
Ventilate and evacuate the EDP300 fully several times.
2.4 ATEX and IECEx temperature data
2.4.1 Type of protection Ex i, intrinsic safety
Temperature
class
Ambient temperature Surface temperature
T4 -40 … 85 °C (-40 … 185 °F) 100 °C (212 °F)
T6 -40 … 40 °C (-40 … 104 °F) 55° C (131 °F)
2.4.2 Type of protection Ex n - non-sparking
Temperature
class
Ambient temperature Surface temperature
T4 -40 … 80 °C (-40 … 176 °F) 100 °C (212 °F)
T6 -40 … 40 °C (-40 … 104 °F) 55° C (131 °F)
2.5 ATEX und IECEx electrical data
2.5.1 Type of protection Ex i, intrinsic safety
Basic device
Signal circuit (AI)
Terminals +11 / -12
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Ii= 320 mA Ii= 320 mA
Pi= 1.1 W Pi= 0.8 W
Ci= 6.5 nF without pressure option; 8.8 nF with pressure option
Li= negligibly small
Digital input (DI)
Terminals +81 / -82
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Pi= 500 mW Pi= 400 mW
Ci= 4.2 nF
Li= negligibly small
Digital output (DO)
Terminals +83 / -84
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Pi= 500 mW Pi= 400 mW
Ci= 4.2 nF
Li= negligibly small

PositionMaster EDP300 | CI/EDP300-EN Rev. C 7
Option modules
Module for the emergency shutdown function
Terminals +85 / -86
Temperature class T1 – T6
Ui= 30 V
Pi= 1 W
Ci= 5.3 nF
Li= negligibly small
Module for analog feedback (AO)
Terminals +31 / -32
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Ii= 320 mA Ii= 320 mA
Pi= 1 W Pi= 0.8 W
Ci= 11.3 nF
Li= 150 µH
Module for universal input (UAI)
Terminals +21 / -22
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Ii= 320 mA Ii= 320 mA
Pi= 1 W Pi= 0.8 W
Ci= 11.3 nF
Li= 150 µH
Module for digital feedback (SW1 / SW2)
Terminals SW 1: +41 / -42
SW 2: +51 / -52
Temperature class T1 – T4 Temperature class T6
Per output: Per output:
Ui= 30 V Ui= 28 V
Pi= 0.5 W Pi= 0.4 W
Ii= 250 mA
Ci= 2.2 nF per output
Li= negligibly small
Limit switch (Limit 1 / Limit 2)
Limit monitor with proximity switch1)
Terminals Limit 1: +51 / -52
Limit 2: +41 / -42
Temperature class T1 – T4 Temperature class T6
In accordance with type examination certificate PTB 00 ATEX 2049X
1) No IECEx approval
2.5.2 Type of protection Ex n - non-sparking
Basic device
Signal circuit (AI)
Terminals +11 / -12
Electrical values IN≤ 22 mA; Umax ≤ 30 V
Digital input (DI)
Terminals +81 / -82
Electrical values UN≤ 30 V
Digital output (DO)
Terminals +83 / -84
Electrical values UN≤ 30 V
Option modules
Module for the emergency shutdown function
Terminals +85 / -86
Electrical values UN≤ 30 V
Module for analog feedback (AO)
Terminals +31 / -32
Electrical values IN≤ 22 mA; UN≤ 30 V
Module for universal input (UAI)
Terminals +21 / -22
Electrical values IN≤ 22 mA; Umax ≤ 30 V
Module for digital feedback (SW1 / SW2)
Terminals SW 1: +41 / -42
SW 2: +51 / -52
Electrical values Per output: UN≤ 30 V
Limit switch (Limit 1 / Limit 2)
Limit monitor with proximity switch1)
Terminals Limit 1: +51 / -52
Limit 2: +41 / -42
Electrical values Per output: IN≤ 25 mA; UN≤ 16 V
1) No IECEx approval

8 CI/EDP300-EN Rev. C | PositionMaster EDP300
3Use in potentially explosive
atmospheres in accordance with FM
and CSA
NOTICE
Further information on the approval of devices for use in
potentially explosive atmospheres can be found in the type
examination certificates or the relevant certificates at
www.abb.com/positioners.
3.1 Product identification
Depending on the type of explosion protection, an Ex name
plate is attached next to the main name plate on the
positioner.
This indicates the level of explosion protection and the
device's relevant Ex certificate.
3.2 Ex-marking
FM
FM Approval 3043773
Control drawing 901305
IS, CL. I, Div. 1, Gr. A, B, C, D, T4 or T6
IS, CL. II, Div. 1, Gr. E, F, G, T4 or T6
IS, CL. III, Div. 1, T4 or T6
Class I Zone 0, AEx ia IIC, T4 or T6
NI, Cl. I, Div. 2, Gr. A, B, C, D, T4 or T6
NI. CI. II, Div. 2, Gr. E, F, G, T4 or T6
NI, Cl. III, Div. 2, T4 or T6
Class I Zone 2, IIC T4 or T6
T4 Ta=(-40 ... +85) °C; (-40 ... +185) °F
T6 Ta=(-40 ... +40) °C; (-40 ... +104) °F
Type 4X
CSA
Certificate 2419437
Control drawing 901305
CL I, Div. 1, Gr. A, B, C, D, T4 or T6
CL II, Div. 1, Gr. E, F, G, T4 or T6
CL III, Div. 1
Class I Zone 0, AEx ia IIC T4 or T6
CL I, Div. 2, Gr. A, B, C, D, T4 or T6
CL II, Div. 2, Gr. E, F, G, T4 or T6
CL III, Div. 2, T4 or T6
Class I Zone 2, AEx nA IIC, T4 or T6
T4 Ta=(-40 ... +85) °C; (-40 ... +185) °F
T6 Ta=(-40 ... +40) °C; (-40 ... +104) °F
IP64
3.3 Installation
The installation, commissioning, maintenance and repair of
devices in areas with explosion hazard must only be carried
out by appropriately trained personnel.
The operator must strictly observe the applicable national
regulations with regard to installation, function tests, repairs,
and maintenance of electrical devices. (e.g. NEC, CEC).
NOTICE
Observe the device's applicable specifications and special
conditions in accordance with the relevant certificate.
— Any manipulation of the device by users is not permitted.
Only the manufacturer or an explosion protection
specialist may modify the device
— The device may only be operated with instrument air that
is free of oil, water, and dust.
3.3.1 Cable gland
Limited temperature range of the M20 x 1.5 plastic cable
gland for explosion protection variants.
The permissible ambient temperature range of the cable gland
is -20 … 80 °C (-4 ... 176 °F). When using the cable gland,
make sure that the ambient temperature is within this range.
The cable gland must be installed in the housing with a
tightening torque of 3.8 Nm. When installing the connection of
the cable gland and cable, check for tightness to ensure that
the required IP rating is met.
3.3.2 Operation with flammable gas
Observe the following points when operating a device with
flammable gases:
— The device must be used in accordance with the
specifications in the relevant certificate.
— Only the design with the IS “Intrinsic Safety ” type of
protection may be operated with natural gas. The
pneumatic outputs must be vented in non-hazardous
areas.
— During operation with flammable gases, the cover cap for
the air outlets must be removed, and the air outlets can be
tubed separately. Both pipes may not be joined in one
pipe.
— The maximum ambient temperature must not exceed
60 °C (140 °F).
See also Control Drawing 901305.

PositionMaster EDP300 | CI/EDP300-EN Rev. C 9
3.3.3 Use in areas with combustible dust
Observe the following points when operating a device with
combustible dust:
— To prevent loss of type of protection, the housing may not
be opened.
— Only use cable glands which are approved for the type of
protection and correspond to IP rating ≥ IP-6X.
— Avoid hazardous propagating brush discharge.
3.3.4 Operation in temperature class T6
During operation in temperature class T6, when the equipment
is partially or fully depressurized, ensure that there is no
possibility of an explosive atmosphere getting into the
pneumatic system or that any explosive atmosphere is
removed prior to compression by taking suitable action.
When commissioning in temperature class T6, flush the
pneumatic system with 1.4 (+/- 0.1) bar until all traces of any
explosive mixture have been removed (at least 5 minutes).
Ventilate and evacuate the EDP300 fully several times.
3.4 Temperature data
NOTICE
Legibility of the display is guaranteed at an ambient
temperature of -20 … 70 °C. At -20°C and lower, legibility
can become limited. Legibility can be compensated by
adjusting contrast. Contrast adjustment can be made
manually directly on the device.
The display can fail at temperatures below -20°C. Moreover,
functioning of the device is guaranteed up to -40°C.
FM
Temperature class Ambient temperature Tamb
T1 ... T4 -40 °C ... 85 °C
T6 -40 °C ... 40 °C
CSA
Temperature class Ambient temperature Tamb
T4 -40 °C ... 85 °C
T6 -40 °C ... 40 °C
3.5 Electrical data
Basic device
Signal circuit (AI)
Terminals +11 / -12
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Ii= 320 mA Ii= 320 mA
Pi= 1.1 W Pi= 0.8 W
Ci= 6.5 nF without pressure option; 8.8 nF with pressure option
Li= negligibly small
Digital input (DI)
Terminals +81 / -82
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Pi= 500 mW Pi= 400 mW
Ci= 4.2 nF
Li= negligibly small
Digital output (DO)
Terminals +83 / -84
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Pi= 500 mW Pi= 400 mW
Ci= 4.2 nF
Li= negligibly small

10 CI/EDP300-EN Rev. C | PositionMaster EDP300
Option modules
Module for the emergency shutdown function
Terminals +85 / -86
Temperature class T1 – T6
Ui= 30 V
Pi= 1 W
Ci= 5.3 nF
Li= negligibly small
Module for analog feedback (AO)
Terminals +31 / -32
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Ii= 320 mA Ii= 320 mA
Pi= 1 W Pi= 0.8 W
Ci= 11.3 nF
Li= 150 µH
Module for universal input (UAI)
Terminals +21 / -22
Temperature class T1 – T4 Temperature class T6
Ui= 30 V Ui= 28 V
Ii= 320 mA Ii= 320 mA
Pi= 1 W Pi= 0.8 W
Ci= 11.3 nF
Li= 150 µH
Module for digital feedback (SW1 / SW2)
Terminals SW 1: +41 / -42
SW 2: +51 / -52
Temperature class T1 – T4 Temperature class T6
Per output: Per output:
Ui= 30 V Ui= 28 V
Pi= 0.5 W Pi= 0.4 W
Ii= 250 mA
Ci= 2.2 nF per output
Li= negligibly small
Limit switch (Limit 1 / Limit 2)
Limit monitor with proximity switch1)
Terminals Limit 1: +51 / -52
Limit 2: +41 / -42
Temperature class T1 – T4 Temperature class T6
-25 … 85 °C -25°C … 40°C
1) No IECEx approval
Change from tw o to one column

PositionMaster EDP300 | CI/EDP300-EN Rev. C 11
4Product identification
4.1 Name plate
M10154-01
Supply press: 0,14 ... 1 MP a
Input: analog 4 - 20 mA
Ambient temperature: -40°C ... 85°C
Output: double acting
Loss of electr. Supply: fall safe
IP65 HART
Options:
Analog feedback output
Digital feedback output
Universal analog input
Safety shut down
Pressure sensors
Electr. limit switch
Mech. limit switch, low
Mech. limit switch, high
Contactless pos. Sensor
H
Slot1 Slot2
XX
X
19
j
k
3
4
5
6
7
l
m
n
o
p
8
2
ABB Automation
Schillerstrasse 72
D - 32425 Minden
Made in Germany
Fig. 1: Name plate (example)
1Full type designation 2Order code 3Serial number 4Special version 5Hardware revision / Software revision
6Date of manufacture 7Explosion protection 8Manufacturer 9Supply pressure jInput signal kAmbient temperature range
lOutput mSafety function powered off nCommunications protocol oIP rating pOptions
NOTICE
The name plates displayed are examples. The device identification plates affixed to the device can differ from this
representation.
Change from one to two columns
5Transport
5.1 Inspection
Check the devices immediately after unpacking for possible
damage that may have occurred from improper transport.
Details of any damage that has occurred in transit must be
recorded on the transport documents.
All claims for damages must be submitted to the shipper
without delay and before installation.
5.2 Returning devices
Use the original packaging or a secure transport container of
an appropriate type if you need to return the device for repair
or recalibration purposes.
Include the return form once it has been properly filled out (see
appendix in operating instructions) with the device.
According to the EU Directive governing hazardous materials,
the owner of hazardous waste is responsible for its disposal or
must observe the following regulations for shipping purposes:
All devices delivered to ABB must be free from any hazardous
materials (acids, alkalis, solvents, etc.).
Please contact Customer Center Service acc. to page 2 for
nearest service location.

12 CI/EDP300-EN Rev. C | PositionMaster EDP300
6Installation
6.1 Safety instructions
CAUTION
Risk of injury due to incorrect parameter values!
Incorrect parameter values can cause the valve to move
unexpectedly. This can lead to process failures and result in
injuries.
— Before recommissioning a positioner that was previously
in use at another location, always reset the device to its
factory settings.
— Never start Auto Adjust before restoring the factory
settings.
NOTICE
Before installation, check whether the positioner meets the
control and safety requirements for the installation location
(actuator or valve).
See the "Specifications" section on the data sheet.
Only qualified specialists who have been trained for these
tasks are authorized to mount and adjust the unit, and to
make the electrical connection.
When carrying out any work on the device, always observe the
local accident prevention regulations and the regulations
concerning the construction of technical installations.
6.2 External position sensors
Fig. 2: EDP300 with external position sensors
1EDP300 Control Unit 2Connection cable
3EDP300 Remote Sensor 4Actuator
5Compressed air supply 6Set point signal
7Remote position sensor
NOTICE
If the device is being operated on a cylinder, for reasons
associated with linearity you should run the Auto Adjust
function for rotary actuators (see chapter "Start Auto Adjust
function" on page 31).
AEDP300 control unit with EDP300 remote sensor
In this version, the components are supplied in two housings,
which together form one harmonized unit.
The following points should be observed during installation:
— Housing 1 (EDP300 Control Unit) contains the electronics
and pneumatics and is mounted separately from the
actuator.
— Housing 2 (EDP300 Remote Sensor) contains the position
sensor and is mounted on the linear and rotary actuator.
Mechanical mounting is described in chapter "Mechanical
mounting" on page 13.
— Electrical connections are described in chapter "Electrical
connection to the EDP300 remote sensor" on page 19.
BEDP300 Control Unit for remote position sensor
In this version the positioner is supplied without a position
sensor.
The following points should be observed during installation:
— Housing 1 (EDP300 Control Unit) contains the electronics
and pneumatics and is mounted separately from the
actuator.
— The remote position sensor is mounted on the linear and
rotary actuator. Follow the operating instructions for the
remote position sensor for mechanical mounting!
— Electrical connections are described in chapter
"Connection to device - EDP300 Control Unit for remote
position sensor" on page 23.
M10931
A
B
1 2 3
6 5 4
1 2 7
6 5 4

PositionMaster EDP300 | CI/EDP300-EN Rev. C 13
6.3 Mechanical mounting
6.3.1 General information
Fig. 3: Operating range
Arrow 1on the device feedback shaft (position feedback
point) must move between the arrow marks 2.
Fig. 4: Measuring and operating ranges of the positioner
1Measuring range 2Operating range
Operating range for linear actuators:
The operating range for linear actuators is ±45° symmetrically
to the longitudinal axis. The usable span within the operating
range is at least 25° (recommended figure 40°). The usable
span does not necessarily need to run symmetrically to the
longitudinal axis.
Operating range of rotary actuators:
The usable span is 90°, which must be entirely within the
measuring range, but does not necessarily need to run
symmetrically to the longitudinal axis.
NOTICE
During installation make sure that the actuator travel or
rotation angle for position feedback is implemented correctly.
6.3.2 Mounting on linear actuators
For mounting on a linear actuator in accordance with DIN /
IEC 534 (lateral mounting as per NAMUR), the following
attachment kit is available:
Fig. 5: Components of attachment kit
1Screw 2Washer 3Attachment bracket 4Level with
follower pin (for travel 10 … 35 mm (0.39 … 1.8 inch) or 20 … 100 mm
(0.79 … 3.94 inch) 5Washers 6Screws 7U-Bolts
8Washers 9Nuts jScrews kSpring washers lClamp
plates mFollower guide
M10408-01
12
M11103
+45°
-45°
-135°
+135°
1
2
M10413-01
1
2
3
4
5
6
7
8
9
j
k
l
m

14 CI/EDP300-EN Rev. C | PositionMaster EDP300
Fig. 6: Attaching a follower guide to the multi-turn actuator
1. Tighten the screws so that they are hand-tight.
2. Attach the follower guide 1and clamp plates2with
screws 4and spring washers 3to the actuator stem.
Fig. 7: Mount lever and bracket to positioner
1. Attach the lever 6to the feedback shaft 5of the
positioner (can only be mounted in one position due to the
cut shape of the feedback shaft).
2. Using the arrow marks 4, check whether the lever
moves within the operating range (between the arrows).
3. Hand-tighten the screw 7on the lever.
4. Hold the prepared positioner (with the mount bracket 1
still loose) on the actuator so that the follower pin for the
lever enters the follower guide to determine which tap
holes on the positioner must be used for the mount
bracket.
5. Secure the mount bracket 1with screws 2and
washers 3using the relevant tap holes on the positioner
housing.
Tighten the screws as evenly as possible to ensure
subsequent linearity. Align the mount bracket in the
oblong hole to ensure that the operating range is
symmetrical (lever moves between the arrow marks 4).
Fig. 8: Mounting on a cast iron yoke
1. Attach the mount bracket 2with screw 4and washer
3to the cast iron yoke 1.
or
Fig. 9: Mounting on a columnar yoke
1. Hold the mount bracket 3in the proper position on the
columnar yoke 2.
2. Insert the U-bolts 1from the inside of the columnar
yoke 2through the holes of the mount bracket.
3. Add the washers 4and nuts 5.
 Tighten the nuts so that they are hand-tight.
NOTICE
Adjust the height of the positioner on the cast iron yoke or
columnar yoke until the lever is horizontal (based on a visual
check) at half stroke of the valve.
M10411-01
1
2
3
4
M10409-01
4
5
6
7
123
M10418-01
1234
M10419-01
1
2
3
45

PositionMaster EDP300 | CI/EDP300-EN Rev. C 15
M10420-02
2
1
Fig. 10: Positioner linkage
1Increasing linkage 2Reducing linkage
The scale on the lever indicates the link points for the various
stroke ranges of the valve.
Move the bolt with the follower pin in the oblong hole of the
lever to adjust the stroke range of the valve to the working
range for the position sensor.
Moving the link point inwards increases the rotation angle of
the position sensor. Moving the link point outwards reduces
the rotation angle of the position sensor.
Adjust the actuator stroke to make use of as large an angle of
rotation as possible (symmetrical around the center position)
on the position sensor.
Recommended range for linear actuators:
-30° … 30°; minimum range: 25°
NOTICE
After mounting, check whether the positioner is operating
within the sensor range.
Position of actuator bolt
The actuator bolt for moving the potentiometer lever can be
mounted permanently on the lever itself or on the valve stem.
Depending on the mounting method, when the valve moves
the actuator bolt performs either a circular or a linear
movement with reference to the center of rotation of the
potentiometer lever. Select the chosen bolt position in the HMI
menu in order to ensure optimum linearization. The default
setting is as follows:
Fig. 11: Actuator bolt on lever (rear view)
1Potentiometer lever 2Actuator bolts cValve spindle
dValve lamp ePositioner
Fig. 12: Actuator bolt on valve (rear view)
1Potentiometer lever 2Actuator bolts cValve spindle
dVent lamp ePositioner
M11031
1 2 3
5 4
M11032
1 2 3
5 4

16 CI/EDP300-EN Rev. C | PositionMaster EDP300
6.3.3 Mounting on control valves
Fig. 13: Integral mounting to control valves
1Washers 2Screws 3O-ring 4Lever
Fig. 14: Integral mounting on control valves using adapter plate
1O-Ring 2Adapter plate 3Adapter
6.3.4 Mounting on part-turn actuators
For mounting on part-turn actuators in accordance with
VDI / VDE 3845, the following attachment kit is available:
Fig. 15: Components of attachment kit
— Adapter 1with spring 5
— Four screws M6 4, four spring washers 3, and four
washers 2for attaching the mounting bracket 6to the
positioner
— Four screws M5 7, four spring washers 8, and four
washers 9for attaching the mounting bracket to the
actuator
Required tools:
— Wrench, size 8 / 10
— Allen key, size 3
M10130-01
1
2
3
4
5
6
7
8
9

PositionMaster EDP300 | CI/EDP300-EN Rev. C 17
Fig. 16: Mounting the adapter on the positioner
1. Determine the mounting position (parallel to actuator or at
90° angle)
2. Calculate the rotational direction of the actuator (right or
left).
3. Move the rotary actuator into the home position.
4. Pre-adjust feedback shaft.
To ensure the positioner will operate within the operating
range (see chapter "General information" on page 13), the
mounting position as well as the home position and
direction of rotation of the actuator must be taken into
account when determining the adapter position on the
feedback shaft 1. For this purpose, the feedback shaft
can be adjusted manually so that the adapter 3can be
attached in the correct position.
5. Place the adapter in the proper position on the feedback
shaft and fasten with threaded pins 2. One of the
threaded pins must be locked in place on the flat side of
the feedback shaft.
Fig. 17: Screwing the mounting bracket onto the positioner
1Mounting bracket
Fig. 18: Screwing the positioner onto the actuator
NOTICE
After mounting, check whether the operating range for the
actuator matches the measuring range for the positioner, see
chapter "General information" on page 13.
M10424-01
12
3
M10421-01
1

18 CI/EDP300-EN Rev. C | PositionMaster EDP300
6.4 Electrical connections
DANGER
Risk of explosion for devices with local communication
interface (LCI)
A local communication interface (LCI) may not be operated in
hazardous areas.
Never use the local communication interface (LCI) on the
main board in a hazardous area.
WARNING
Risk of injury due to live parts!
When the housing is open, contact protection is not provided
and EMC protection is limited.
Before opening the housing, switch off the power supply.
The electrical connection may only be established by
authorized specialist personnel.
The electrical connection information in this manual must be
observed; otherwise, the IP rating may be adversely affected.
Safe isolation of electrical circuits which are dangerous if
touched is only ensured if the connected devices satisfy the
requirements of DIN EN 61140 (VDE 0140 Part 1) (basic
requirements for safe isolation).
To ensure safe isolation, install supply lines so that they are
separate from electrical circuits which are dangerous if
touched, or implement additional isolation measures for them.
Change from tw o to one column
6.4.1 Electrical connection to positioner / EDP300 Control Unit
Fig. 19: Electrical connection EDP300
ABasic device BOptions CEDP Remote Sensor Connection / remote position sensor (only with EDP Control Unit version) DOptions,
limit monitor with proximity switch or microswitches (not in EDP300 Control Unit version)
Change from one to two columns
Connections for inputs and outputs
Terminal Function / comments
+11 / -12 Analog input AI or field bus connection
+81 / -82 Digital input DI
+83 / -84 Digital output DO2
+51 / -52 Limit alarm SW1
(Option module)
+41 / -42 Limit alarm SW2
(Option module)
+31 / -32 Analog feedback AO
(Option module)
+85 / -86 Emergency shutdown module
(Option module)
+21 / -22 Universal input UAI
1 / 2 / 3 EDP300 remote sensor
(Only for options EDP300 Remote Sensor or EDP300 for
remote position sensor)
Terminal Function / comments
+51 / -52 Limit switch Limit 1 with proximity switch
(optional)
+41 / -42 Limit switch Limit 2 with proximity switch
(optional)
51 / 52 / 53 Limit switch Limit 1 with microswitch
(optional)
41 / 42 / 43 Limit switch Limit 2 with microswitch
(optional)
Change from tw o to one column
M10239-03
+11 -12 +81
-82 +83-84
DI DOAI
+51 -52
SW2
+41 -42
SW1
+31 -32
AO
+85-86123
A
D
AB
UAI
-22+21
+51 -52 +41 -42
41 42 43 51 52 53
DLimit 1 Limit 2
Limit 1 Limit 2
C

PositionMaster EDP300 | CI/EDP300-EN Rev. C 19
6.4.2 Electrical connection to the EDP300 remote sensor
Fig. 20: Electrical connection to the EDP300 remote sensor
ABasic device BOptions
1Position sensor 2 Limit monitor with proximity switches (option) 3Limit monitor with microswitches (option)
Change from one to two columns
Connections for inputs and outputs
Terminal Function / comments
1 / 2 / 3 EDP300 Control Unit
+51 / -52 Limit switch Limit 1 with proximity switch
(optional)
+41 / -42 Limit switch Limit 2 with proximity switch
(optional)
51 / 52 / 53 Limit switch Limit 1 with microswitch
(optional)
41 / 42 / 43 Limit switch Limit 2 with microswitch
(optional)
6.4.3 Electrical data for inputs and outputs
NOTICE
When using the device in potentially explosive atmospheres,
note the additional data in chapter "Use in potentially
explosive atmospheres according to ATEX and IECEx" on
page 5 and in chapter "Use in potentially explosive
atmospheres in accordance with FM and CSA" on page 8 !
Set point signal analog (two-wire technology)
Terminals +11 / -12
Nominal operating range 4 ... 20 mA
Limit values Maximum: 50 mA (overload)
Minimum: 3.6 mA
Starting at 3.8 mA
Load voltage 9.7 V at 20 mA
Impedance 485  at 20 mA
Digital input DI
Terminals +81 / -82
Supply voltage 24 V DC (12 ... 30 V DC)
Input "logical 0" 0 ... 5 V DC
Input "logical 1" 11 ... 30 V DC
Input Current Maximum 4 mA
Digital output DO
Terminals +83 / -84
Supply voltage 5 ... 30 V DC
(Control circuit in accordance with DIN
19234/NAMUR)
Switching state logical “0”: Current > 0,35 mA … < 1,2 mA
“1”: Current > 2,1 mA
Direction of action standard logical "0" or logical "1"
(configurable)
M10949
AB
123
123
+51 -52 [phone]
51 52 53
Limit 1 Limit 2
Limit 1 Limit 2

20 CI/EDP300-EN Rev. C | PositionMaster EDP300
Option modules
Module for analog feedback AO1)
Without signal from the positioner (e. g. “no power” or
“initializing”) the module sets the output to > 20 mA (alarm
level).
Terminals +31 / -32
Signal range 4 ... 20 mA (configurable split ranges)
Supply voltage, two-wire
technology
24 V DC (10 ... 30 V DC)
Characteristic curve rising or falling (configurable)
Characteristic curve
deviation
< 1 %
Module for digital feedback SW1, SW2 1)
Two switches for digital position feedback (position adjustable
within the range of 0 ... 100 %, ranges cannot overlap)
Terminals +41 / -42, +51 / -52
Supply voltage 5 ... 11 V DC
(Control circuit to DIN 19234/NAMUR)
Signal current < 1,2 mA: Switching state logical "0“
> 2,1 mA: Switching state logical "1“
Direction of action standard logical "0" or logical "1"
(configurable)
Module for universal input UAI1)
Module for a 4 … 20 mA input for universal use.
The range can be scaled. It is used for advanced valve
diagnostics. For example, an ultrasonic sensor can be
connected to detect a faulty valve seat or a phonometer can
be connected to detect cavitation.
The limit values for detecting up-scaling can be freely
selected.
Terminals +21 / -22
Nominal operating range 4 ... 20 mA
Load voltage 8 V at 20 mA
Impedance 400  at 20 mA
Module for the emergency shutdown function1)
When the 24 V DC signal is interrupted, the I/P module
executes the respective safety function, depending on the
mechanical construction.
The positioner output 1 is depressurized, and the valve is
moved to the safe position. In case of a double-acting
actuator, output 2 is additionally pressurized.
The emergency shutdown module works independently of the
mother board, i.e., all information from the final control
element is available in the control system at any time.
Terminals +85 / -86
Supply voltage 24 V DC (20 ... 30 V DC)
(electrically isolated from the input signal)
Safe position Active at < 5 V DC
1) There are two slots for the option modules. Any combination of different option
modules is possible. However, identical option modules cannot be combined.
Limit switch
The limit switch can either be equipped with proximity
switches or with potential-free microswitches.
Limit switch Limit 1 / Limit 2 with proximity switches
Two proximity switches for independent position signaling.
Terminals +41 / -42, +51 / -52
Supply voltage 5 ... 11 V DC
(Control circuit in accordance with DIN
19234/NAMUR)
Output "logical 0" < 1.2 mA
Output "logical 1" > 2.1 mA
Switching point Adjustable between 0 … 100 %
Direction of action Metal tag in proximity
switch
Metal tag outside
proximity switch
Type SJ2-SN (NC; log.
1)
< 1.2 mA > 2.1 mA
Limit switch Limit 1 / Limit 2 with 24 V - microswitches
Terminals 41 / 42 / 43, 51 / 52 / 53
Supply voltage maximum 24 V AC/DC
Load rating Maximum 2 A
Change from tw o to one column