Bifold IS200 Instruction Manual

IS200 Intrinsically Safe Actuator Positioner
Operation, Installation and Maintenance Manual
Operation, Installation and Maintenance Manual
ORM0006 –IS200 O&M Rev 0

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 2 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
Manufacturer and Approvals Details
The IS200 is manufactured and maintained solely by:
Orange Instruments Limited Telephone [phone]
Lower Farm Road Fax [phone]
Moulton Park email sales@orangeinstruments,co.uk
Northampton
NN3 6XF
United Kingdom
The IS200 has the following specific approvals
Name and Type ACTUATOR POSITIONER TYPE IS200
Certificate Number Baseefa 03ATEX0686X
Specific Marking of Explosion Protection Ex ia IIC T4 Ga(-40ºC Ta +60ºC)
ATEX Directive Marking II 1 G
Notified body Baseefa 1180
Features
Simple two-step calibration
4-20mA current command signals and current or potentiometer feedback signal.
Actual position calibrated output
MANUAL mode
Stepping mode with adjustable ON and OFF times
Selectable solenoid drive for failsafe operation
Selectable default operation on command signal/feedback signal break
ESD solenoid output / Fault output relaxed by control signal breaks
EC Declaration of Conformity
Manufacturer
Orange Instruments Limited
Lower Farm Road
Moulton Park
Northampton NN3 6XF
United Kingdom
Equipment description
Actuator Positioner Type IS200
II 1 G Ex ia IIC T4 Ga
(-40CTa+60C)
Notified body
Baseefa 1180
Rockhead Business Park
Staden Lane, Buxton
Derbyshire SK17 9RZ
United Kingdom
Harmonised Standards
EN 60079-0:2012
EN 60079-11:2012
Other Standards
Signed
Anthony G. McCormick
ATEX Manager
Orange Instruments

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 3 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
Operation
The IS200 is designed for the closed loop positioning of electro-hydraulic actuators.
The instrument compares two analogue signals, one representing the desired position (command signal) and the other
representing the actual position (feedback signal) of the actuator.
A difference between these two signals will cause one of the IS200 outputs to operate, driving the actuator to the desired
position.
A positional Dead-zone may be adjusted to overcome “hunting” problems associated with mechanical overrun of the
actuator.
The speed of transit of the actuator can be reduced by selecting the stepping mode that provides independently adjustable
on and off times for the open and close solenoid operation.
Physical
The IS200 is housed in a small DIN rail mounted polyester enclosure measuring 85 x 70 x 58h. The circuit boards are
coated with a resist layer that protects the track from moderate condensation and mould growth problems. Connections are
via screw terminals with a capacity of 2.5mm2but the use of ferrules or crimps is recommended. All adjustments are
accessible on the front panel of the enclosure.
Wiring
To comply with the IS Certification the IS200 must be wired as shown in the circuit on Page 7. Wiring should be completed
by suitably trained personnel taking into account the following notes:
To ensure RFI compliance the analogue signals MUST be routed in copper braided screened cables with a fill factor
density of at least 0.7.
The screens should be terminated to the metal of the actuator housing, ideally at a suitable metal cable gland.
Signal cables should be routed separately from power and switching conductors.
Ensure that all supply and signal barriers are present and correctly connected and supplied with power from the safe
area.
Positioner set-up
The solenoid sense and command signal default mode are set up by a sequence of push button operations at power up.
These operations will affect the outputs to the solenoids so it is important that the actuator is isolated hydraulically during
these operations to avoid unwanted movement of the actuator. Note that a low value resistor, 10R, might be required in the
negative lead, Terminal 19, of the retransmitted signal output to reduce instability in the IS200 / barrier loop.
Setting solenoid operating sense
If the actuator has a spring assisted return to a default position it may be necessary to change the sense of the output
solenoid such that at the desired balance point one of the solenoids is energised thus holding the actuator position against
the spring. A one-off operation of the positioner will store the choice in non-volatile EEPROM memory.
1. Hold in the CALIBRATE pushbutton and apply power to the positioner.
2. The CALIBRATE LED will light continuously and pressing the manual DECREASE and INCREASE pushbuttons will
cause the appropriate DECREASE and INCREASE LEDS to “toggle” on and off.
3. Select the pattern of LEDs to reflect what is required at balance e.g. for an actuator that fails downscale the
DECREASE LED should be lit.
4. When satisfied press the CALIBRATE button again.
5. Remove power from the positioner.

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 4 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
Setting the command signal break default operation
The positioner can be configured to move to a default position or freeze at the current position in the event of the command
or feedback signal faults. These faults are characterised as:
a) the command falling below 1mA - command signal break
b) the potentiometer wiper showing less than 0.25V - potentiometer maximum or wiper break
c) the potentiometer wiper showing more than 4.7V - potentiometer minimum break.
A one-off operation of the positioner will store the choice in non-volatile EEPROM memory.
1. Hold in the MANUAL pushbutton and apply power to the positioner.
2. The MANUAL LED will light continuously and pressing the manual DECREASE and INCREASE pushbuttons will
cause the appropriate DECREASE and INCREASE LEDS to “toggle” on and off.
3. Select the DECREASE LED on for drive downscale on fault,
4. Select the INCREASE LED on for drive upscale on fault.
5. Leave both LEDs off to select freeze at the current position on fault.
6. When satisfied press the MANUAL pushbutton again.
7. Remove power from the positioner.
Setting the stepping option timers
If stepping operation is required, the ON and OFF timers for the open and close solenoids have to be set. This operation is
best performed when the actuator hydraulics are isolated but the settings can be trimmed during normal operation of the
system. Minimum ON / OFF times 20mS. Maximum ON / OFF times 11 seconds.
1. Set DIP switch 3 to ON. This selects timer setting mode. Manual mode is selected automatically.
2. Set DIP switch 1 to ON. Do not select DIP switches 1 and 2 ON together. The DECREASE LED will flash and the
decrease solenoid will operate. Adjust CAL1 potentiometer to vary the ON time and CAL2 potentiometer to vary the
off time. Time the on/off transition over a few cycles to obtain the required result.
3. Press the CALIBRATE button to store the decrease step timer values.
4. Set DIP switch 1 to OFF.
5. Set DIP switch 2 to ON. Do not select DIP switches 1 and 2 ON together. The INCREASE LED will flash and the
increase solenoid will operate. Adjust CAL1 potentiometer to vary the ON time and CAL2 potentiometer to vary the
off time. Time the on/off transition over a few cycles to obtain the required result.
6. Press the CALIBRATE button to store the increase step timer values.
7. Set DIP switch 1 to OFF.
8. Set DIP switch 3 to OFF.
9. The stepping option can be selected by setting DIL switch 4 ON.
10. The above sequence, or part of it, can be selected at any time during normal operation but the actuator will move
during the adjustment so hydraulic isolation is advised.
First time operation
WARNING !!
The actuator and associated mechanical equipment connected to it could possibly move in an unpredictable
manner during initial calibration. Ensure that all personnel take appropriate precautions.
1. Ensure that any end of travel limit switches and mechanical stops are correctly adjusted before operation.
2. Apply power and provide the 4-20mA command signal. Press the Auto/Manual Switch. Check that the Auto/Manual LED
is lit.
3. Operate the Open and Close buttons and confirm that the actuator moves as required.
4. The system must be calibrated before automatic mode is selected.

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 5 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
Calibration
Calibration can only be carried out local to the IS200 unit so it is essential to have either purged the area or to use IS signal
injection and measuring equipment. An alternative is to use the remote DCS to inject and read the actual position signal
and transfer the information by handheld radio. If this approach is used ensure that the radio is operated 2m or more from
the IS200 and associated wiring.
A command signal is required, normally in the range 4-20mA (Terms 20+ and 21-) and a DVM with a 0-10V range to read the
retransmitted position signal (Terms 18+ and 19-).
1. Press the CALIBRATE button, and hold until the CALIBRATE LED goes out. When the button is released, the
CALIBRATE LED will flash briefly once per second and the Manual LED will light.
2. The positioner has been switched automatically into Manual, non-stepping mode so use the INCREASE /
DECREASE buttons to set the actuator to the required position for the minimum, 4mA command signal. This
position can be either fully open or fully close, or indeed anywhere in the mechanical range of the actuator.
3. Set the command signal to 4mA.
4. Adjust the CAL1 potentiometer to give the required output for the chosen position. Note that this not need be 0V to
match the command signal, but can be any value in the range 0-5V.
5. Press and hold the CALIBRATE button until the CALIBRATE LED goes out. Release the button and the
CALIBRATE LED will flash twice briefly every second.
6. Use the INCREASE and DECREASE buttons to set the actuator to the required position for the maximum, 20mA
command signal. As before, this can be any position within the mechanical range of the actuator.
7. Set the command signal to 20mA.
8. Adjust the CAL1 potentiometer to give the required output for the chosen position. Note that this not need be 5V to
match the command signal, but can be any value in the range 0-5V.
9. Press and hold the CALIBRATE button until the CALIBRATE LED goes out. Release the button to complete the
calibration sequence and the Manual LED will extinguish.
General operation
When calibration has been completed the IS200 reverts to automatic mode and to stepping operation if DIL switch 4 is set
ON. The actuator should now follow the command signal input and move to the desired position.
If there is any instability in positioning, particularly if the hydraulic flow rate is high, then the DEADZONE potentiometer can
be set progressively clockwise, half a turn at a time, until stable positioning following a step change can be achieved.
If the command signal or the feedback signal becomes faulty then the selected fail mode will operate. The actuator will
either freeze position, drive down or drive up and the control to the ESD solenoid will be removed. The system will recover
to normal operation when the signals are re-instated. If an ESD solenoid is not required then the ESD output can be used as
a system fault output to the remote DCS if driven through a suitable barrier. If the unit is in "stepping mode" (DIL switch 4 =
ON) then failure mode drive can be either in the selected stepping mode or, if DIL switch 1 is ON, then the unit will fast-fail to
its default position.
All calibration parameters are stored within the processor EEPROM and are restored each time the controller is powered up.
The controller will respond to current command and feedback signal conditions within 100mS of power being applied to the
system
Maintenance
The outside of the enclosure can be cleaned using a damp cloth. Do not use solvents. Do not open the enclosure whilst a
hazard is present.
No internal parts are user serviceable and component level repairs should not be attempted. If a fault occurs then please
return the unit to the Manufacturers describing the nature and circumstances of the problem.

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 6 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
IS200 dimensions and front panel
Enclosure can be fitted on Standard Symmetric EN50054 component mounting rail –35 x 7.5. Use purpose-designed tool
for adjusting small potentiometers.
12345678910 11 12
FLT
1DZ
DEC INC
MAN
IS200
ORANGE INSTRUMENTS LTD
Lower Farm Road, Moulton Park
Northampton NN3 6XF
United Kingdom
ACTUATOR POSITIONER TYPE
IS200
Cert No. Baseefa 03ATEX0686X
II 1 G EEx ia IIC T4
(-20°CTa+60°C)

ELECTROSTATIC CHARGE RISK
CLEAN WITH A DAMP CLOTH ONLY
123456711
8910 12
13 14 15 16 17 18 19 23
20 21 22 24
3
DIP
12
ON
4
2
CALIBRATE
Ga

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 7 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
Zone of Operation
The IS200 is an intrinsically safe device approved for operation in the following environment according to Specific Marking of
explosion protection:
Ex ia IIC T4 Ga (-40ºC Ta +60ºC) Ta = ambient temperature
IEC CENELEC North America
Zone 0 –continuous hazard present. Division 1
Gas Group –IIC (hydrogen, acetylene, carbon disulphide) Class 1A (Hydrogen)
Class 1B (acetylene)
Surface temperature –T4 135ºC –Ambient temperature -40ºC to +60ºC
Physical Description
Size –70mm wide, 58mm high, 85mm deep
Weight –0.25kg
Enclosure –Lexan (Top cover), Noryl (Base section)
Equipment rating –IP40
Specification
Note that all supplies and signals to and from safe areas MUST pass through appropriate Instrinsically Safe barriers before
connection to the IS200. See circuits on Page 7.
COMMAND SIGNAL INPUT
4-20mA nominal 240R input impedance
ANALOGUE POSITION OUTPUT SIGNAL
0-4.9V can be calibrated anywhere in this range –10R resistor required in loop
FEEDBACK SIGNAL INPUT
Potentiometer 3-wire, any value greater than 200R
4-20mA nominal 240R input impedance
SWITCHED OUTPUTS x 3
PhotoMOS relays. Maximum load 130mA each.
INSTRUMENT SUPPLY
24V dc nominal safe area supply via an IS power supply
SOLENOID SUPPLY
24V dc nominal safe area supply via an IS power supply
USER ADJUSTMENTS
DEC Button to close actuator in Manual
INC Button to open actuator in Manual
MAN Button to toggle auto/manual mode
CAL Button to selects Calibrate mode and store calibration data
DIP Switch 1 - Set stepping timers –DECREASE ON and OFF (Select fast-fail during normal operation)
DIP Switch 2 - Set stepping timers –INCREASE ON and OFF
DIP Switch 3 - Stepping timers setting mode select
DIP Switch 4 - Select stepping mode
Minimum ON time 5mS.
Minimum OFF time 500mS
Maximum ON time 300mS
Maximum OFF time 150 Seconds
DZ Potentiometer to set positioning dead zone - clockwise to increase
CAL1 Calibration adjustment and ON time for stepping mode
CAL2 Adjustment for OFF time for stepping mode
PERFORMANCE - the following applies to the IS200 only, characteristics of the feedback element, actuator system and
isolating barriers response will have additional effects.
Conversion 10 bit max normal conversion range (4-20mA) = 1 in 800.
O/P switch res. +/-1 bit theoretically, modified to up to +/-5% of span by dead band .
Accuracy (Theo.) 0.125% span based on conversion resolution of 1 in 800.

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 8 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
7 8 1
2
-+
+
-
+
-
11
12
MK72-S13-Ex0
16V
24V dc
16V
1
-
2
24V dc
7
+ -
8 + 16
-15
+
16V
1
-
2
24V dc
7
+ -
8 + 3
-4
+
16V
1
-
2
24V dc
7
+ -
8 + 8
-9
+
4-20mA
15
6
4-20mA Command
-MK35-Li-Ex0 -
2
24V dc
+ 7
+ -
8 + 20
-21
+
0-4.9V
19
8
-KFD0-CC-Ex1 -
2
+ + 18
-19
+
+
-
6
7
2-
1+
13 -
14 +
or Fault O/P
ESD Soln.
Instument Supply
ESD/Fault
22
23
24
+5V max
Wiper
0V min
Supply ESD/Fault Output
Increase Soln.
Supply Increase Solenoid
Decrease Soln.
Supply Decrease Solenoid
Command
Signal
Retransmitted
Position Signal
Feedback
Potentiometer
Increase
Solenoid
Decrease
Solenoid
One solenoid supply
required if INC and DEC
solenoids are not
energised simultaneously
ESD/Fault supply is only
required if option is used
1000R or greater
Feedback Pot.
+
-
Alt. F/B
Device
Must be IS
4-20mA
24V dc SAFE HAZARDOUS
IS200 POSITIONER
0-20mA Actual Position
5
6
5
6
MK72-S13-Ex0
5
6
MK72-S13-Ex0
5
6
MK72-S13-Ex0
(2-wire device
24Vdc excitation required from DCS)
Accuracy (actual) 0.5% span based on 25% turn down of feedback range.
Typical system wiring diagram for an Intrinsically Safe installation
10R Resistor

IS200 Electro-Hydraulic Actuator Positioner
Orange Instruments Limited.
Drwg. No.: 1357-007 Issue : K Date : 07/10/2013 Page : 9 of 9
Iss c - Certificate number added. Iss D - Ta changed to -20 to +60
Iss E - Details of fail modes, timers and retrans. O/P added. Retrans. Signal barrier changed to KFD0-CC-Ex1
Iss F –Details of change in Max/min on & off times + addition of 10R in line with pos o/p –ve
Iss G –Stepping times range change to allow finer adjustment 15/11/2007
Iss H –CE Cert. of Conformity details added, Ta to –40degC, 60079:0,26 mods 25/06/2008
Iss J –Harmonised standards in C of C modified to meet current status 04/08/2008
Iss K - Markings changed to meet EN 60079-0:2012 02/10/2103
ATEX Certified Equipment - Change Authority ATEX Manager ONLY
IS200 Terminal Descriptions
All wiring should be in suitable braided or armoured cable with blue outer casing or sleeving. Terminate braids at one end
only to local metal enclosures.
Terminal Description Voltage Comment
1 Increase Solenoid +ve output <16V Always at supply potential
2 Increase Solenoid –ve output <16V Set to 0V to energise solenoid
3 Increase Solenoid Supply +ve <16V Must be an isolated, IS supply
4 Increase Solenoid Supply 0V 0V
5 No connection
6 Decrease Solenoid +ve output <16V Always at supply potential
7 Decrease Solenoid –ve output <16V Set to 0V to energise solenoid
8 Decrease Solenoid Supply +ve <16V Not required if only one solenoid
9 Decrease Solenoid Supply 0V 0V is ever energised at one time
10 No connection
11 Instrument Supply +ve <16V Must be an isolated, IS supply
12 Instrument Supply 0V 0V
13 ESD Solenoid/Fault -ve output <16V Set to 0V to energise solenoid
14 Increase Solenoid +ve output <16V Always at supply potential
15 Increase Solenoid Supply 0V
16 Increase Solenoid Supply+ve <16V Must be an isolated, IS supply
17 No connection
18 Actual position signal +ve <5V Scaled to actuator movement
19 Actual position signal -ve <5V Fit 10R resistor in loop
20 Command signal +ve (4-20mA) <5V 240R shunt
21 Command signal -ve (4-20mA) <5V
22 Feedback potentiometer maximum 5V Potentiometer >1000R
23 F/B potentiometer wiper / 4-20mA +ve <5V Current signal optional - IS source
24 F/B potentiometer minimum / 4-20mA -ve <5V