EBRO ARMATUREN EP 501 C User manual

Operating Instructions
Type EP 501
Electropneumatic positioner and process controller

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modification techniques.
Operating Instructions 1710/01_EU-en_00810559 / Original DE

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Table of conTenTs
GENERAL INFORMATION AND SAFETY INSTRUCTIONS ....................................................................................................5
1. Operating instructions .........................................................................................................................................................6
2. Authorized use ........................................................................................................................................................................7
3. Basic safety instructions ....................................................................................................................................................8
4. Use in the Ex area .................................................................................................................................................................9
5. General information ...........................................................................................................................................................10
DESCRIPTION OF SYSTEM ...................................................................................................................................................................11
6. Description and features ................................................................................................................................................13
7. Structure ..................................................................................................................................................................................15
8. Positioner Type EP 501 ....................................................................................................................................................17
9. Process controller Type EP 501 C .............................................................................................................................21
10. Interfaces of the positioner / process controller ..............................................................................................26
11. Technical data .......................................................................................................................................................................27
INSTALLATION ...............................................................................................................................................................................................33
12. Attachment and assembly .............................................................................................................................................34
13. Pneumatic connection ......................................................................................................................................................39
14. Electrical connection - Terminal version for cable gland ..............................................................................41
OPERATION .....................................................................................................................................................................................................45
15. Operating levels ...................................................................................................................................................................46
16. Operating and display elements .................................................................................................................................47
17. Operating states ..................................................................................................................................................................55
18. Activating and deactivating auxiliary functions ...................................................................................................56
19. Manually opening and closing the valve ................................................................................................................58
START-UP ..........................................................................................................................................................................................................59
20. Start-up sequence ..............................................................................................................................................................60
21. Basic setting of the device ............................................................................................................................................61
22. Activation of the process controller ..........................................................................................................................66
23. Basic setting of the process controller ...................................................................................................................67
Type EP 501
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Table of contents

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AUXILIARY FUNCTIONS ..........................................................................................................................................................................85
24. Configuring the auxiliary functions ...........................................................................................................................86
OPERATING STRUCTURE / FACTORY SETTINGS ............................................................................................................... 155
25. Operating structure and factory settings ............................................................................................................ 156
PROFIBUS DP ............................................................................................................................................................................................. 171
26. Description of the PROFIBUS DP ........................................................................................................................... 172
27. Electrical connections ...................................................................................................................................................174
28. Start-up PROFIBUS DP ................................................................................................................................................ 177
MAINTENANCE AND TROUBLESHOOTING .............................................................................................................................. 183
29. Maintenance ....................................................................................................................................................................... 184
30. Error messages and malfunctions ......................................................................................................................... 184
PACKAGING, STORAGE, DISPOSAL ............................................................................................................................................188
31. Packaging and transport .............................................................................................................................................. 189
32. Storage .................................................................................................................................................................................. 189
33. Disposal ................................................................................................................................................................................ 189
ADDITIONAL TECHNICAL INFORMATION ................................................................................................................................. 190
34. Selection criteria for continuous valves ..............................................................................................................191
35. Properties of PID Controllers .................................................................................................................................... 193
36. Adjustment rules for PID Controllers .................................................................................................................... 198
TABLES FOR CUSTOMER-SPECIFIC SETTINGS .................................................................................................................. 202
37. Table for your settings on the positioner ............................................................................................................ 203
38. Table for your settings on the process controller Type EP 501 C ......................................................... 204
Type EP 501
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Table of contents

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Typ EP 501
conTenTs
1. OPERATING INSTRUCTIONS ........................................................................................................................................................6
1.1. Symbols ......................................................................................................................................................................................6
1.2. Definition of the term “device” ........................................................................................................................................6
2. AUTHORIZED USE .............................................................................................................................................................................7
2.1. Restrictions ...............................................................................................................................................................................7
3. BASIC SAFETY INSTRUCTIONS .................................................................................................................................................8
4. USE IN THE EX AREA .......................................................................................................................................................................9
4.1. Basic safety instructions for use in the Ex area ...................................................................................................9
4.2. Safety instructions for the installation and maintenance of Ex devices ...............................................9
5. GENERAL INFORMATION .............................................................................................................................................................10
5.1. Scope of supply ...................................................................................................................................................................10
5.2. Contact address ..................................................................................................................................................................10
5.3. Warranty ...................................................................................................................................................................................10
5.4. Master code ...........................................................................................................................................................................10
General information and safety instructions
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Typ EP 501
General information
Safety instructions
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is
easily accessible to every user and make these instructions available to every new owner of the device.
WARNING!
The operating instructions contain important safety information.
Failure to observe these instructions may result in hazardous situations.
▶The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger.
▶Failure to observe the warning may result in a fatal or serious injury.
DANGER!
Warns of an immediate danger.
▶Failure to observe the warning may result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation.
▶Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger.
▶Failure to observe this warning may result in a medium or minor injury.
NOTE!
Warns of damage to property.
• Failure to observe the warning may result in damage to the device or the equipment.
indicates important additional information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
→designates a procedure that must be carried out.
1.2. Definition of the term “device”
In these instructions, the term “device” always refers to the Type EP 501, EP 501 C or EP 501 L
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Typ EP 501
General information
Safety instructions
2. AUTHORIZED USE
Incorrect use of the device can be dangerous to people, nearby equipment and the environment.
The device is designed for the open-loop control and closed-loop control of media.
▶If using the device in the potentially explosive area, observe the specifications on the additional plate for Ex
devices.
▶Devices which do not have an additional plate for Ex devices must not be used in the potentially explosive
area.
▶The device must not be exposed to direct sunlight.
▶Pulsating direct voltage (rectified alternating voltage without smoothing) must not be used as operating
voltage.
▶During use observe the permitted data, the operating conditions and conditions of use specified in the con-
tract documents and operating instructions, as described in chapter “Description of System” - “11. Technical
data” in this manual and in the valve manual for the respective pneumatically actuated valve.
▶The device may be used only in conjunction with third-party devices and components recommended and
authorised by EBRO.
▶In view of the wide range of possible application cases, check whether the device is suitable for the specific
application case and check this out if required.
▶Correct transportation, correct storage and installation and careful use and maintenance are essential for reli-
able and faultless operation.
▶Use the Type device only as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
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Typ EP 501
General information
Safety instructions
3. BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the installation, operation and maintenance of the devices.
• local safety regulations – the operator is responsible for observing these regulations, also with reference to the
installation personnel.
Danger – high pressure.
▶Before loosening the pneumatic lines and valves, turn off the pressure and vent the pneumatic lines.
Risk of electric shock.
▶Before reaching into the device or the equipment, switch off the power supply and secure to prevent
reactivation.
▶Observe applicable accident prevention and safety regulations for electrical equipment.
Risk of burns/risk of fire if used continuously through hot device surface.
▶Keep the device away from highly flammable substances and media and do not touch with bare hands.
General hazardous situations.
To prevent injury, ensure that:
▶That the system cannot be activated unintentionally.
▶Installation and repair work may be carried out by authorised technicians only and with the appropriate tools.
▶After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined
or controlled manner.
▶The device may be operated only when in perfect condition and in consideration of the operating instructions.
▶Do not supply the supply pressure connection of the system with aggressive or flammable mediums.
▶Do not supply the supply pressure connection with any liquids.
▶Do not put any loads on the housing (e.g. by placing objects on it or standing on it).
▶Do not make any external modifications to the device housings. Do not paint the housing parts or screws.
▶The general rules of technology apply to application planning and operation of the device.
NOTE!
Electrostatic sensitive components / modules.
The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact
with electrostatically charged persons or objects is hazardous to these components. In the worst case scenario,
they will be destroyed immediately or will fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1 to minimise or avoid the possibility of damage
caused by sudden electrostatic discharge.
• Also ensure that you do not touch electronic components when the operating voltage is present.
The device were developed with due consideration given to the accepted safety rules and are state-of-the-
art. Nevertheless, dangerous situations may occur.
Failure to observe this operating manual and its operating instructions as well as unauthorized tampering with
the device release us from any liability and also invalidate the warranty covering the devices and accessories.
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Typ EP 501
General information
Safety instructions
4. USE IN THE EX AREA
4.1. Basic safety instructions for use in the Ex area
DANGER!
Risk of explosion.
To prevent the risk of explosion, observe not only the basic safety instructions in the respective operating
instructions for operation in the Ex area, but also the following:
▶Installation, operation and maintenance may be performed by qualified technicians only.
▶Observe the applicable safety regulations (also national safety regulations) as well as the general rules of
technology for construction and operation.
▶Do not repair the device yourself, but replace it with an equivalent device. Repairs may be performed by the
manufacturer only.
▶Do not expose the device to any mechanical and/or thermal loads which will exceed the limits described in the
operating instructions.
4.2. Safety instructions for the installation and
maintenance of Ex devices
DANGER!
Risk of explosion.
To prevent the risk of explosion, observe the following during installation and maintenance in the Ex area:
▶Do not open the device housing.
▶To avoid electrostatic charges, clean the housing surface with a damp cloth only.
▶Secure cable connections, which use circular connectors, with suitable locking clips.
(For example: EXCLIP, FA. Phoenix Contact, Type SAC-M12-EXCLIP-M, Art. no. 1558988 or
Type SAC-M12-EXCLIP-F, Art. no. 1558991.
▶Use only cable and line entry points which have been approved for the respective application area and which
have been screwed into place according to the associated installation instructions.
▶Install pre-assembled cable glands according to the installation instructions supplied by the gland manufacturer.
Before start-up in the Ex area, check whether the cable gland, as described in the associated installation
instructions, has been installed.
▶Close all unnecessary cable glands with lock screws approved for the explosions area.
Maintenance: If installation is performed carefully, maintenance will not be required.
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Typ EP 501
General information
Safety instructions
5. GENERAL INFORMATION
5.1. Scope of supply
In general it consists of the device and the associated operating instructions.
We will provide you with attachment kit for rotary actuators as accessory.
If there are any discrepancies, please contact us immediately.
5.2. Contact address
Germany
EBRO ARMATUREN Gebr. Bröer GmbH
Karlstraße 8
D-58135 Hagen
Tel. + 49 (0) 2331 - 904 0
Fax + 49 (0) 2331 - 904 111
E-mail: [email protected]
International
The international contact addresses can be found on the internet at: www.ebro-armaturen.com
5.3. Warranty
The warranty is only valid if the device is used as intended in accordance with the specified application conditions.
5.4. Master code
Operation of the device can be locked via a freely selectable user code. In addition, there is a non-changeable master
code with which you can perform all operator actions on the device. This 4-digit master code can be found on the
last pages of the printed brief instructions which are enclosed with each device.
If required, cut out the code and keep it separate from these operating instructions.
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Typ EP 501
Description of System
conTenTs
6. DESCRIPTION AND FEATURES................................................................................................................................................13
6.1. General description ...........................................................................................................................................................13
6.1.1. Features .....................................................................................................................................................13
6.1.2. Combination with valve types and mounting versions ....................................................................14
6.2. Designs ....................................................................................................................................................................................14
6.2.1. Type EP 501, positioner ........................................................................................................................14
6.2.2. Type EP 501 C, process controller .....................................................................................................14
7. STRUCTURE ........................................................................................................................................................................................15
7.1. Representation .....................................................................................................................................................................15
7.2. Function diagram ................................................................................................................................................................16
7.2.1. Diagram illustrating single-acting actuator ........................................................................................16
8. POSITIONER TYPE EP 501 .........................................................................................................................................................17
8.1. Schematic representation of the position control ............................................................................................18
8.2. Positioner software ............................................................................................................................................................19
9. PROCESS CONTROLLER TYPE EP 501 C ..........................................................................................................................21
9.1. Schematic representation of process control .....................................................................................................22
9.2. Type EP 501 L with external position sensor .......................................................................................................23
9.3. The process controller software .................................................................................................................................24
10. INTERFACES OF THE POSITIONER / PROCESS CONTROLLER ...........................................................................26
11. TECHNICAL DATA .............................................................................................................................................................................27
11.1. Conformity ..............................................................................................................................................................................27
11.2. Standards ................................................................................................................................................................................27
11.3. Operating conditions ........................................................................................................................................................27
11.4. Rating plate and additional plate for Ex devices ...............................................................................................27
11.5. Mechanical data ...................................................................................................................................................................28
11.6. Electrical data .......................................................................................................................................................................29
11.7. Pneumatic data ....................................................................................................................................................................30
Description of System
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Typ EP 501
Description of System
11.8. Safety end positions after failure of the electrical or pneumatic auxiliary power ...........................31
11.9. Factory settings ...................................................................................................................................................................32
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Typ EP 501
Description of System
6. DESCRIPTION AND FEATURES
6.1. General description
The positioner Type EP 501 / process controller Type EP 501 C is a digital, electro-pneumatic positioner for
pneumatically actuated continuous valves. The device incorporates the main function groups
- Position sensor
- Electro-pneumatic control system
- Microprocessor electronics
The position sensor measures the current positions of the continuous valve.
The microprocessor electronics continuously compare the current position (actual value) with a set-point position
value specified via the standard signal input and supplies the result to the positioner/process controller.
If there is a control difference, the electro-pneumatic control system corrects the actual position accordingly.
6.1.1. Features
• Models
- Positioner (positioner) Type EP 501
- Process controller with integrated positioner, Type EP 501 C.
• Position sensors
- Intern high resolution conductive plastic potentiometer or
- Extern non-contact, non-wearing position sensor (remote).
• Microprocessor-controlled electronics
for signal processing, control and valve control.
• Operating module
Operation of the device is controlled by four keys. The 128 x 64 dot matrix graphics display enables you to
display the set-point or actual value and to configure and parameterize via menu functions.
• Control system
The control system consists of 2 solenoid valves and 4 diaphragm reinforcers. In single-acting actuators the
working connection 2 must be sealed with a threaded plug.
• Feedback (optional)
The feedback is implemented either via 2 proximity switches (initiators), via binary outputs or via an output
(4 – 20 mA / 0 – 10 V).
When the valve reaches an upper or lower position, this position can be relayed e.g. to a PLC via binary outputs.
The operator can change the initiators or limit positions via control lugs.
• Pneumatic interfaces
Internal thread G1/4“
• Electrical interfaces
Circular plug-in connector or cable gland
• Housing
Plastic-coated aluminium housing with hinged cover and captive screws.
• Mounting
On rotary actuator according to VDI/VDE 3845.
• Optional
Remote version for DIN rail mounting or for mounting bracket
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Typ EP 501
Description of System
6.1.2. Combination with valve types and mounting versions
The positioner Type EP 501 / process controller Type EP 501 C can be mounted on different continuous
valves. For example on valves with piston, membrane or rotary actuator. The actuators can be single-acting or
double-acting.
• For single-acting actuators, only one chamber is aerated and deaerated during actuation. The generated
pressure works against a spring. The piston moves until there is an equilibrium of forces between compressive
force and spring force. To do this, one of the two air connections must be sealed with a threaded plug.
• For double-acting actuators the chambers on both sides of the piston are pressurised. In this case, one
chamber is aerated when the other one is deaerated and vice versa. In this design, no spring is installed in the
actuator.
Two basic device versions are offered for the positioner Type EP 501 / process controller Type EP 501 C; they
differ in the attachment option and in the position sensor.
Device version NAMUR:
An internal position sensor is used which is designed as a rotary potentiometer.
The device is mounted directly on the actuator or attached to the side.
Device version Remote:
An extern position sensor (linear or rotative) via a digital interface.
The device is attached to a wall either with a DIN rail or with a mounting bracket (remote design).
6.2. Designs
6.2.1. Type EP 501, positioner
The position of the actuator is regulated according to the position set-point value. The position set-point value is
specified by an external standard signal (or via field bus).
6.2.2. Type EP 501 C, process controller
Type EP 501 C also features a PID controller which, apart from actual position control, can also be used to
implement process control (e.g. level, pressure, flow rate, temperature) in the sense of a cascade control.
The process controller is linked to a control circuit. The position set-point value of the valve is calculated from the
process set-point value and the actual process value via the control parameters (PID controller). The process set-
point value can be set by an external signal.
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Typ EP 501
Description of System
7. STRUCTURE
The positioner Type EP 501 and process controller Type EP 501 C consist of the micro-processor controlled elec-
tronics, the position sensor and the control system.
The device is designed using three-wire technology. Operation is controlled by four keys and a 128x64 dot matrix
graphics display.
The pneumatic control system for single-acting and double-acting actuators consists of 2 solenoid valves.
7.1. Representation
Pressure-relief valve
Mechanical position indicator
Operating module with display and keys
Working connection 2
(connection: A2)
Supply pressure connection 1.4 – 7 bar
(connection: P)
Working connection 1
(connection: A1)
Air exhaust connection/air exhaust filter
Internal position sensor
Shaft for position sensor
Cable gland
Electronic module
Control system
Figure 1: Structure, Type EP 501
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Typ EP 501
Description of System
7.2. Function diagram
7.2.1. Diagram illustrating single-acting actuator
The black lines in “Figure 2” specify the function of the positioner circuit in Type EP 501.
The grey part of the diagram indicates the additional function of the superimposed process control circuit in Type
EP 501 C.
* Control system
1: Aeration valve
2: Bleed valve
Compressed-
air supply
Position
sensor
Process
controller
Positioner
Control
system*
1
2
Process
set-point
value
Process
actual
value
Position set-
point value
Exhaust air
Type EP 501 / EP 501 C Continuous valve with
single-acting actuator
Sensor
Actual position
Nominal position
Figure 2: Structure, positioner Type EP 501 / process controller EP 501 C
The remote design has the position sensor situated outside the device directly on the continuous valve
and is connected to the latter by a cable.
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Typ EP 501
Description of System
8. POSITIONER TYPE EP 501
The position sensor records the current position (POS) of the pneumatic actuator. The positioner compares this
actual position value with the set-point value (CMD) which is specified as a standard signal. If there is a control dif-
ference (Xd1), the actuator is aerated and deaerated via the control system. In this way the position of the actuator
is changed until control difference is 0. Z1 represents a disturbance variable.
Valve opening
Continuous
valve
Control system
Solenoid valves
Position sensor
PositionerPosition set-
point value
CMD Xd1 B1
E1
PK
Z1
POS
Position control circuit
+-
Figure 3: Position control circuit in Type EP 501
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Typ EP 501
Description of System
8.1. Schematic representation of the position control
4 – 20 mA 0 – 20 mA 0 – 10 V 0 – 5 V
DIR.CMD SPLTRNG CHARACT CUTOFF X.TIME
DIR.ACT X.LIMIT
X.CONTROL DBND
POS
CMD
INP
POS CMD TEMP INPUT
Figure 4: Schematic representation of position control
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Typ EP 501
Description of System
8.2. Positioner software
Configurable auxiliary functions Effect
Correction line to adjust the operating characteristic
CHARACT
Selection of the transfer characteristic between
input signal and stroke (correction characteristic)
Sealing function
CUTOFF
Valve closes tight outside the control range. Specification
of the value (in %), from which the actuator is completely
deaerated (when 0%) or aerated (when 100%).
Sense of effective direction of the controller set-
point value
DIR.CMD
Reversal of the sense of effective direction of the set-
point value
Sense of effective direction of the actuator
DIR.ACT
Adjustment of the sense of effective direction between
aeration state of the actuator and the actual position
Signal range splitting
SPLTRNG
Splitting of the standard signal range to two or more
positioners
Stroke limit
X.LIMIT
Mechanical valve piston movement only within a defined
stroke range
Limiting the control speed
X.TIME
Input of the opening and closing time for the entire stroke
Insensitivity range
X.CONTROL
The positioner is initially actuated from a control dif-
ference to be defined
Code protection
SECURITY
Code protection for settings
Safety position
SAFEPOS
Definition of the safety position
Signal level error detection
SIG.ERROR
Check the input signals for sensor break.
Warning output on the display and start up of the safety
position (if selected)
Binary input
BINARY. IN
Switch over AUTOMATIC / MANUAL or
Start up of the safety position
Analogue feedback (option)
OUTPUT
Status signal set-point value or actual value
2 binary outputs (option)
OUTPUT
Output of two selectable binary values
User calibration
CAL.USER
Change to the factory calibration of the signal input
Factory settings
SET.FACTORY
Reset to factory settings
Serial interface
SER.I/O
Configuration of serial interface
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Typ EP 501
Description of System
Configurable auxiliary functions Effect
Setting display
EXTRAS
Adjustment of the display of the process level
SERVICE For internal use only
POS.SENSOR Setting interface remote path sensor (available for Type
EP 501 L only. See chapter “24.2.19. POS.SENSOR –
Setting interface remote path sensor”.
Simulation software
SIMULATION
For simulation of the device functions
DIAGNOSE (Option) Monitoring of processes
Table 1: Positioner software. Configurable auxiliary functions
Hierarchical operating concept for easy operation on the following operating levels
Process level On the process level switch between AUTOMATIC mode
and MANUAL mode.
Setting level On the setting level specify certain basic functions during
start-up and, if required, configure additional functions
Table 2: The positioner software. Hierarchical operating concept.
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