ABB TZID User manual

Operating Instructions
42/1854 EN
Electro-Pneumatic Positioner
TZID
Software Revision 5.07

2 Electro-pneumatic positioner TZID 42/18-54 EN
ElectroPneumatic Positioner TZIDC
Operating Instructions
Document No.: 42/18-54 EN
Issued: 03.06
Manufacturer
ABB Automation Products GmbH
Schillerstr. 72
32425 Minden
Germany
Tel: [phone]
Fax: [phone]
[email protected]b.com
© Copyright 2006 by ABB Automation Products GmbH
Modifications reserved
This document is subject to copyright. It is intended to help the user operate the equipment safely
and efficiently. The content may not be copied or reprodcued either in part or in full without the
prior consent of the copyright owner.

42/18-54 EN Electro-pneumatic positioner TZID 3
Table of contents
Important information....................................................................................................... 5
1 Safety summary............................................................................................................ 6
1.1 General safety instructions .....................................................................................6
1.2 Device-specific safety instructions.........................................................................7
1.2.1 General ......................................................................................................... 7
1.2.2 Pneumatic safety .......................................................................................... 7
1.2.3 Electrical safety .............................................................................................. 8
1.3 Explosion protection................................................................................................9
1.4 Correct use................................................................................................................9
1.5 Qualified personnel ................................................................................................10
2 Manufacturer's information.................................................................................... 10
2.1 Delivery....................................................................................................................10
2.2 CE compliance information ...................................................................................10
3 Installing and commissioning............................................................................... 11
3.1 Mechanical mounting.............................................................................................11
3.1.1 General ........................................................................................................ 11
3.1.2 Operating conditions at the installation site .................................................. 12
3.1.3 Mounting to linear actuators ......................................................................... 13
3.1.4 Mounting to rotary actuators......................................................................... 16
3.2 Pneumatic connection ...........................................................................................21
3.2.1 Safety instructions ...................................................................................... 21
3.2.2 Making the pneumatic connection ............................................................... 21
3.3 Electrical connection..............................................................................................23
3.3.1 Safety instructions ........................................................................................ 23
3.3.2 General installation instructions.................................................................... 23
3.3.3 Overview....................................................................................................... 24

4 Electro-pneumatic positioner TZID 42/18-54 EN
3.4 Commissioning ......................................................................................................26
3.4.1 Adapting the positioner to the actuator ........................................................ 26
3.4.2 Adjusting the tolerance band ........................................................................ 27
3.4.3 Adjusting the valve action ............................................................................ 27
3.4.4 Setting parameters for current operation ..................................................... 27
3.4.5 Adjusting low and high alarm limits (supplementary modules for digital
feedback) ..................................................................................................... 28
3.4.6 Adjusting low and high alarm limits (supplementary “mechanical kit for digital
feedback”)..................................................................................................... 28
3.4.7 Restoring the factory setting......................................................................... 29
3.4.8 Performing the Autostroke............................................................................ 29
4 Display and operator panel .................................................................................... 31
4.1 Operating level 1 ....................................................................................................32
4.2 Operating level 2 ....................................................................................................33
5 Maintenance ................................................................................................................ 36
5.1 Functional test/Readjustment ..............................................................................36
5.2 Checking/replacing the filter regulator.................................................................36
5.3 Checking the air filter in the positioner ...............................................................37
5.4 Replacing the pneumatic output unit ................................................................38
6 Technical data ............................................................................................................. 39
6.1 Basic model.............................................................................................................39
6.2 Options ....................................................................................................................43
7 Certificates.................................................................................................................... 45
Appendix A: Error codes............................................................................................... 64

42/18-54 EN Electro-pneumatic positioner TZID 5
Important information
Symbols
In order that you can make the best use of this document and to ensure safety during commis-
sioning, operation and maintenance of the equipment, please note the following explanation of
the symbols used:
As well as the instructions in this document, you must also follow the generally applicable acci-
dent prevention and safety regulations.
If the information in this document is insufficient in any situation, please contact our service de-
partment, who will be happy to help you.
Please read this document carefully before installation and commissioning.
Symbol Signal Word Definitions
DANGER DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
(High level of risk.)
WARNING WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
(Medium level of risk.)
CAUTION CAUTION indicates a potentially hazardous situation
which, if not avoided, could result in minor or moderate
injury.
(Low level of risk.)
NOTICE NOTICE indicates a potentially harmful situation which, if
not avoided, may result in damage of the product itself or
of adjacent objects.
(Damage to property)
IMPORTANT IMPORTANT indicates useful hints or other special
information which, if not observed, could lead to a decline
in operating convenience or affect the functionality.
(Does not indicate a dangerous or harmful situation.)
!
!
!
!

6 Electro-pneumatic positioner TZID 42/18-54 EN
1 Safety summary
1.1 General safety instructions
This chapter provides important instructions for your safety. Thoroughly read and follow
these instructions.
Proper and safe operation of the TZID positioner requires:
• proper transportation and storage
• mounting, electrical and pneumatic installation and commissioning by qualified per-
sonnel (see chapter 1.5, page 10)
• correct operation according to the instructions in this manual
• correct use (see chapter 1.4, page 9)
• careful maintenance
The regulations, standards and directives referred to in this manual are applicable in Ger-
many. When using the TZID positioner outside the German jurisdiction, the relevant reg-
ulations, standards and directives applicable in the country where the device is used
must be observed.
The TZID positioner has been designed and tested in accordance with
DIN VDE 0411 Part 1 / EN 61 010 Part 1
“Safety Requirements for Electronic Measuring Apparatus”
(based on IEC Publication 348) and has been delivered in a safe condition.
In order to retain the device in a safe condition and ensure safe operation, attentively
read and follow the instructions given in the sections marked with the respective sym-
bols. (See “Important information” on page 5.) Otherwise, persons can be endangered or
the device itself or other devices or equipment may be damaged or fail.
The device must be shut down and secured reliably against unintentional restart if it must
be assumed that safe operation is no longer ensured. Possible reasons for this assump-
tion can be:
• visible damage of the device
• failure of the electrical function
• exposure to a storage temperature of more than 85 °C for a longer time period
• exposure to considerable strain or wear during transport
Only the manufacturer is authorized to repair the device.

42/18-54 EN Electro-pneumatic positioner TZID 7
1.2 Device-specific safety instructions
1.2.1 General
1.2.2 Pneumatic safety
!
WARNING
• Any user-made changes or manipulations of the device are prohibited!
Only the manufacturer or an expert for explosion protection are autho-
rized to modify the device.
!
CAUTION
• The TZID rotating shaft can only be rotated in the direction of the indi-
cating arrow on the shaft. There are no mechanical stops to limit the
actuator movement. Improper mounting can damage the device and
void warranty.
!
WARNING
• Observe the accident prevention rules of the Employers Liability
Insurance Association.
• Observe the safety instructions for the pneumatic actuator used.
The actuator's high actuating power may cause injuries!
!
CAUTION
• Take suitable precautions to ensure that even in case of malfunctions
the positioner’s max. admissible operating pressure of 6 bar (90 psi) is
not exceeded. Otherwise, the positioner and/or the actuator may be
damaged.
• The positioner must be supplied with instrument air exempt from oil,
water and dust according to DIN/ISO 8573-1, Class 3
- Purity: max. particle size 5 µm, max. particle density 5 mg/m3
- Oil content: max. concentration 1 mg/m3
- Pressure dew point: maximum value 10 K below operating temp. 3
Before connecting the air pipes blow them out to remove dust, splinters
and other particles.

8 Electro-pneumatic positioner TZID 42/18-54 EN
1.2.3 Electrical safety
!
WARNING
• Observe the common VDE safety regulations and the accident preven-
tion rules of the Employers Liability Insurance Association.
• Observe the common standards and safety regulations for the installa-
tion and operation of electrical systems.
• When connecting the device, observe all electrical specifications in
these operating instructions or in the data sheet.
• For the electrical installation of explosion-protected devices, observe all
standards, regulations and directives governing explosion protection
and applicable for the construction and use of explosion-protected sys-
tems, especially the DIN/VDE directives, the directives for explosion
protection (VDE 0165 or EN 60079), and the special requirements and
specifications for your devices (see the following chapter "Explosion
protection" and chapter “Certificates”).
• Explosion-proof devices may only be supplied with safe extra-low vol-
tage (SELV) according to EN 60 950.
!
NOTICE
Electromagnetic interference
• Do not lay signal lines close to power lines. Power lines produce inter-
ference in their near vicinity, which may affect measured value trans-
mission on the signal line.

42/18-54 EN Electro-pneumatic positioner TZID 9
1.3 Explosion protection
One of the type plates seen below is attached to the positioner to the left of the main type
plate, depending on the positioner’s explosion protection. It indicates the degree of explo-
sion protection and the certificate valid for your positioner. For details please refer to
chapter “Certificates”.
1.4 Correct use
The TZID positioner is an electro-pneumatic positioner for pneumatic final control ele-
ments. It is designed for being attached to linear and rotary actuators following the
instructions in this manual. The positioner may be used only for the applications listed in
these operating instructions or in the data sheet 18-0.20 EN. Any other use is considered
as incorrect.
The signal current circuit and the input and output circuitry must meet the explosion pro-
tection requirements stipulated in the certificates (see the certificates).
The maximum permissible ambient temperature range of -40 °C to +85 °C must not be
exceeded.
!
WARNING
Always observe the specifications and special requirements for your
positioner stipulated in the applicable certificate.
I/P-Umformer / Converter
Doc. 901068 Ri = 1,6 k
TZID
Ω
Schutzart / Protection
II 2 G EEx ia IIC T6
TÜV 99 ATEX 1487
I u. T siehe Zertifikat 0032
KU
ABB Automation
Made in Germany
FM
R
I/P Converter
Type 22/06-65
Made in Germany
Ri = 1600 Ohm
40 VDC max.
Suppply pressure
20-90 psi
APPROVED
CL I
DIV 1, GRP A-D
N.I. CL I
DIV 2, GRP A-D
Exia T3C
CL I
DIV 1, GRP A-D
CL I
DIV 2, GRP A-D
INTRINSICALLY SAFE / SECURITE INTRINSEQUE
PER CONTROL DOCUMENT NO 900844
Fig. 1 Type plates indicating the degree of explosion protection

10 Electro-pneumatic positioner TZID 42/18-54 EN
1.5 Qualified personnel
Only those persons familiar with the installation, commissioning, operation and mainte-
nance of the TZID positioner or similar instruments who have the required qualification
and have read and understood the operating instructions are authorized to work on the
TZID positioner. These persons must be sufficiently trained and experienced and know
the relevant standards and regulations to be able to judge their assigned tasks and rec-
ognize potential hazards. Only persons who are qualified or have been trained ade-
quately and who have the required certificates are authorized to work on explosion-
protected devices.
2 Manufacturer's information
2.1 Delivery
When receiving the delivery please immediately check items and scope for intactness
and completeness. The scope of delivery is stated in the shipping documents. If ordered,
the accessories (e.g. mounting material, pressure gauge block, filter regulator) are added
to the delivery as individual items. Check items and scope of the delivery by means of
the catalog numbers to see if types and quantities are in accordance with your order. If
the positioner is delivered already mounted to the actuator, the positioner, accessories
and actuator or final control element are considered as a common delivery item. A list of
catalog numbers and details of the different versions and accessories can be found in
data sheet 18-0.20 EN.
2.2 CE compliance information
We declare that we are the manufacturer of the TZID positioner and that the product con-
forms with the EMC Directive 89/336/CEE as of May 1989 and meets the requirements
of the following standards:
• EN 55022:1998 “Information technology equipment, Radio disturbance
characteristics, Limits and methods of measurement”
• EN 61000-6-2:8/2002 ”Electromagnetic compatibility (EMC)
Part 6-2: Generic standards - Immunity for industrial environments
• EN 61000-6-3:3/2000 “Electromagnetic compatibility (EMC)
Part 6-3: Generic standards - Emission standard for residential, commercial and
light-industrial environments
The TZID positioner complies with the EC directive for CE conformity certification.

42/18-54 EN Electro-pneumatic positioner TZID 11
3 Installing and commissioning
3.1 Mechanical mounting
3.1.1 General
When mounting the positioner, ensure that the transfer of the stroke or rotation angle for
the position feedback is correct.
The maximum rotation angle is 60° for mounting to linear actuators and 120° for mount-
ing to rotary actuators.
Due to the high-resolution A/D conversion (> 8000 steps) no extra adjustment of the used
angle of rotation is necessary when mounting the positioner. Fine adjustment is done
later in the commissioning phase through electronic configuration (Autostroke).
For safety reasons, the range actually covered by the positioner’s angle of rotation should
not reach the limits of the total range, but should be greater/smaller than these limits by
2 %. While commissioning the positioner, you can determine its angle of rotation by
using an electronic parameter.
The actually used angle of rotation should be at least 20 % of the total range. This value
can also be determined electronically in the commissioning phase.
IMPORTANT
• No further steps are required if the TZID positioner is delivered
mounted to an actuator.
• These operating instructions describe how to mount the positioner to
linear actuators in accordance with DIN/IEC 534 (lateral attachment
to NAMUR) and to rotary actuators in accordance with VDI/VDE
3845. Customized positioners for actuator-specific attachment require
special instructions, which are already delivered with the device or
can be ordered from us.
60°
100%
100%
120°
0%
0%
0°
0°
Lever range (angle of rotation 60° or 120°)
Valve range (determined by Autostroke)
Stroke range (defined manually)
Fig. 2 Range definition for positioner TZID

12 Electro-pneumatic positioner TZID 42/18-54 EN
3.1.2 Operating conditions at the installation site
Ambient temperature: -40 °C ... +85 °C
Relative humidity: 95 % (mean annual value), condensation permissible.
Observe the specifications for protection class IP65 /
NEMA 4X and the technical data in this manual.
Explosion protection: Observe the technical data, and the specifications in the
certificates (see the relevant sections of this manual).
Mounting orientation: any orientation allowed
!
WARNING
Before installing check to ensure that the specifications in terms of safety
and control applicable to the TZID positioner will not be exceeded at the
installation site of the actuator or final control element.

42/18-54 EN Electro-pneumatic positioner TZID 13
3.1.3 Mounting to linear actuators
A mounting kit is available for mounting the positioner to a linear actuator in accordance
with DIN/IEC 534. Fig. 3 gives you an overview.
The lever (4, standard version), the screw (5), the spring washer (6) and the spring (14)
are included in the positioner’s delivery. All other items are part of the mounting kit which
has to be ordered separately.
The TZID positioner comes with the lever (4) already installed. All other items are deliv-
ered in a separate package. The lever is available in two lengths: for 10 to 85 mm strokes
(standard version) and for strokes 10 to 150 mm (special version, to be ordered sepa-
rately).
Fasten the angular slide rod (8) to the actuator stem using the screws M6 (10) and spring
washers (9).
1 Angle bracket
2 Spring washer B8
3ScrewM8x20
4Lever
5ScrewM4x8
6 Spring washer B4
7PlainwasherA8,4
8 Angular slide rod
9 Spring washer B6
10 Screw M6x10
11 Bolt
13 Nut M6
14 Spring
15 Spring washer B6
16 Plain washer A6, 4
17 U-bolt
18 Nut M8
18
2
3
32
1
17
8
9
10
20 30 40 50 60 70 80
6
5
7
7
11 14
13
15
16
14
4
4
Fig. 3 Mounting kit for linear actuators

14 Electro-pneumatic positioner TZID 42/18-54 EN
Actuators ready for attachment in accordance with DIN/IEC 534 have two vertically
arranged threaded holes M6 in the stem.
Fasten the angle bracket to the positioner and to the actuator’s cast iron yoke or colum-
nar yoke using the screws and spring washers (2, 3). Proceed as shown in Fig. 4 and
Fig. 5.
Mounting the positioner to a cast iron yoke
Mounting the positioner to a columnar yoke
• Fasten the angle bracket (1)
with the screw (2) and the plain
washer (3) to the cast iron yoke
(4).
• Hold the angle bracket (1) in the
appropriate position against the
columnar yoke (2).
• Insert the U-bolts (5) from the
inner side of the columnar yoke
through the holes in the angle
bracket.
• Slip on the plain washers (3),
spring washers (4) and nuts (2).
Hand-tighten the nuts evenly.
IMPORTANT
Adjust the height of the positioner at the cast iron yoke or the columnar
yoke until the lever is horizontal (at visual check) at half valve stroke.
1
2
34
Fig. 4 Mounting to cast iron yoke
1
2
3
4
5
6
Fig. 5 Mounting to columnar yoke

42/18-54 EN Electro-pneumatic positioner TZID 15
Adjusting the stroke
The positioning travel (stroke) is transmitted to the positioner via the bolt. You can adapt
the valve stroke range to the operating range of the position sensor by shifting the bolt in
the lever’s oblong hole. A scale on the lever helps you to determine the valve stroke
range.
Use the lever scale to set the bolt to the appropriate position. A rough adjustment is suffi-
cient. The fine adjustment will be done later in the commissioning phase using the
Autostroke function.
Bolt Lever with scale
Increase valve stroke
Decrease valve stroke
Fig. 6 Positioner linkage

16 Electro-pneumatic positioner TZID 42/18-54 EN
3.1.4 Mounting to rotary actuators
A mounting kit is available for mounting the positioner to a rotary actuator in accordance
with VDI/VDE 3845. Fig. 7 gives you an overview:
The TZID positioner is mounted to the rotary actuator using a mounting bracket (7),
which has to be ordered separately. At the positioner’s back you can find four threaded
holes M6 arranged on a 50 mm circle diameter, into which the mounting bracket’s fasten-
ing screws (1) are screwed. The screws, plain washers (2) and spring washers (3) are
included in the positioner’s scope of delivery, just as the screws, plain washers and
spring washers (4, 5, 6) for attaching the mounting bracket to the actuator.
The adapter (8) is used to couple the accordingly dimensioned positioner shaft with the
actuator shaft. Positioners ready for attachment to a rotary actuator are delivered with
the adapter already fastened to the positioner.
1 Hexagon head screw
M6x12
2 Plain washer A6, 4
3 Spring washer B6
4 Hexagon head screw
M5x10
5 Plain washer A5,
6 Spring washer B5
7 Mounting bracket
8 Adapter
IMPORTANT
Pay attention to the following information when mounting the TZID
positioner to a rotary actuator:
- Position feedback to the positioner is only possible through counter-
clockwise rotation (seen from the device’s front). A built-in return
springs turns the shaft until reaching the stop on the right-hand side in
the unloaded state.
- The air signal output via OUT1 determines the direction of rotation
(counterclockwise or clockwise).
- You can attach the positioner to the actuator either in parallel or shifted
by 90°.
- Prior to mounting the positioner to a double acting rotary actuator, set
the shaft to the end position, i.e. to the same position which single act-
ing actuators reach through the spring load or which the air signal
OUT2 of the positioner causes.
- Position the actuator shaft in such a way that the groove is at right
angles to the longitudinal axis.
1, 2, 3
4, 5, 6 7
8
Fig. 7 Mounting to rotary actuators

42/18-54 EN Electro-pneumatic positioner TZID 17
Before mounting the positioner:
• Determine the actuator’s direction of rotation (counterclockwise or clockwise).
• Determine the mounting position (in parallel with the actuator or shifted by 90°).
Mounting TZID in parallel with an actuator turning counterclockwise
!
NOTICE
- The TZID rotating shaft can only be rotated in the direction of the indicat-
ing arrow on the shaft. There are no mechanical stops to limit the actua-
tor movement. Improper mounting can damage the device and void
warranty.
- When mounting the positioner, make sure that there is a loose fit
between the adapter at the positioner and the actuator shaft. It must be
possible to move the adapter manually within the range of 0.1...0.3 mm.
If required, readjust the mounting bracket.
The TZID positioner is prepared
for this type of mounting when it
is delivered. No adapter settings
are required.
• Couple the positioner’s
adapter with the rotary actu-
ator’s shaft.
• Turn TZID clockwise by
approx. 15° (see Fig. 9).
• Fasten TZID with screws.
Setscrew
with flat point
Setscrew
with cone point
Fig. 8 Adapter position (factory setting)
Counterclockwise
rotation of actuator
Clockwise rotation
of positioner
Fig. 9 Mounting TZID in parallel with an
actuator turning counterclockwise

18 Electro-pneumatic positioner TZID 42/18-54 EN
Mounting TZID shifted by 90° to an actuator turning counterclockwise
• Undo the setscrews on the
shaft adapter.
• Shift the adapter by 90°, as
shown in Fig. 10.
• Re-fasten the setscrews.
• Couple the positioner’s
adapter with the rotary actu-
ator’s shaft.
• Turn TZID clockwise by
approx. 15° (siehe Fig. 11).
• Fasten TZID with screws.
Fig. 10 Adapter position (shifted by 90°)
Setscrew with
flat point
Setscrew with
cone point
Counterclockwise
rotation of the
actuator
Clockwise rotation of
the positioner
Fig. 11 Mounting TZID to an actuator turning
counterclockwise, shifted by 90°

42/18-54 EN Electro-pneumatic positioner TZID 19
Mounting TZID in parallel with an actuator turning clockwise
• Undo the setscrews on the
shaft adapter.
• Shift the adapter by 90°, as
shown in Fig. 12.
• Re-fasten the setscrews.
• Couple the positioner’s
adapter with the rotary actu-
ator’s shaft.
• Turn TZID clockwise by
approx. 105° (see Fig. 13).
• Fasten TZID with screws.
Fig. 12 Adapter position (shifted by 90°)
Setscrew with
flat point
Setscrew with
cone point
Clockwise
rotation of
the actuator
Clockwise rotation
of the positioner
Fig. 13 Mounting TZID in parallel with an
actuator turning clockwise

20 Electro-pneumatic positioner TZID 42/18-54 EN
Mounting TZID shifted by 90° to an actuator turning clockwise
The TZID positioner is prepared
for this type of mounting when it
is delivered. No adapter settings
are required.
• Couple the positioner’s
adapter with the rotary actu-
ator’s shaft.
• Turn TZID clockwise by
approx. 105° (see Fig. 15).
• Fasten TZID with screws.
Setscrew
with flat point
Setscrew
with cone point
Fig. 14 Adapter position (factory setting)
Clockwise
rotation
of the
actuator
Clockwise rotation
of the positioner
Fig. 15 Mounting TZID to an actuator turning
clockwise, shifted by 90°