EBRO ARMATUREN EP100 User manual

Master Instruction
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D00002-C-04
EP100 Analog Positioner
The analog Positioner EP100 with analog input 4 to
20 mA is designed to operate pneumatic valve
actuators. It offers an easy adjustment by means of
switches and potentiometers. The modular
structure of the EP positioner series enables the
feasibility to re-fitt optional equipment (limit switch).
FEATURES
Configuration by means of switches and
potentiometers
Load 300 
Low air consumption
Angle range up to 95 degree
Supply air pressure up to 6 bar (90 psig)
Single acting or double acting
Mechanical travel indicator
Reverse polarity protection and interlock diode
Attachment to rotary actuators according to
VDI/VDE 3845
Failsafe position in case of failure of
electronics
Protection class IP 65
Additional equipments (compatible to EP200:
Integrated inductive limit switches,
independent of device electronics
Accessories (compatible to EP200:
Gauge attachment for supply air and outputs
Booster relay
Repair and maintenance operations must be carried out by qualified personnel!
avrora-arm.ru
[phone]

2 EP100 Master Instruction
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TABLE OF CONTENTS
CHAP: CONTENT PAGE
1 METHOD OF OPERATION. 3
1.1 General 3
1.2 Block diagram 3
1.3 Operation 3
1.4 Safety Requirements 4
2 LABELS 5
3 DESIGN 6
3.1 Pneumatic accessories 7
4 MOUNTING TO ROTARY
ACTUATORS 8
4.1 Type of mount 8
4.2 Preparation of the positioner 8
4.3 Preparation of the actuator 9
4.4 Mounting of the positioner 9
5 PNEUMATIC CONNECTIONS 10
6 ELECTRICAL CONNECTION 11
7 START-UP 12
7.1 General 12
7.2 Setting of:
- Direction of rotation of
feedback shaft 13
7.3 - Setting of Input Signal Range
- Split Range 14
7.4 - Gain (G) 15
7.5 - Zero (ZERO) and Span (S) 15
7.6 - Damping (D) 15
7.7 - Travel indicator 15
7.8 Air reducing throttles 16
7.9 Basic adjustment of electronics 16
7.10 Pneumatic test 16
CHAP: CONTENT PAGE
8 DECOMMISSIONING 16
9 TROUBLE-SHOOTING GUIDE 17
10 MAINTENANCE 18
10.1 General 18
10.2 Supply filter replacement 18
10.3 Removal of the electronics unit 18
10.3.1 Conversion of positioner 18
10.4 Replacement of mechanical and
neumatic units 19
10.4.1 Amplifier replacement 19
10.4.2 Preamplifier replacement 19
10.4.3 IP-module replacement 19
10.4.4 Feedback unit replacement 19
11 OPTIONS 20
11.1 Limit switch 20
11.1.1 2-wire indicator 21
11.1.2 3-wire indicator 21
11.2 Position feedback 4 –20 mA 21
12 APPENDIX
SYSTEM CONFIGURATION 22
DIMENSIONS 23

EP100 Master Instruction 3
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1 METHOD OF OPERATION
1.1 General
The intelligent positioner EP100 1and the pneumatic
actuator 2form a control loop with the setpoint value w
(from master controller or control system), the output
pressure yand the position x of the actuator on valve 3.
The positioner can be attached to both linear actuators
and rotary actuators.
Actuators with spring force are controlled by a single
acting positioner.
Actuators without spring force are controlled by a
double acting positioner. The positioner can be
operated by means of switches and potentiometers.
For the supply air, we recommend a filter regulator...
1.2 Block diagram
1.3 Operation
The supply of the electronics unit is diverted from
the current signal 4 to 20 mA at the input.
The current value is measured and is suited in
input circuit 9to the desired input range (control
action or split range) via switches S4 - S7. In
circuit 10 the signal is provided with an adjustable
time constant settable via potentiometer
P5.
The resulting internal signal is guided to the analog
control circuit 11 , the gain of which is adjustable
via potentiometer P4. The output of the control
circuit drives the electromechanic converter (IP
module) 12 , which controls the analog single
acting or double acting pneumatic amplifier 14
through the preampifier 13. The output of the
amplifier 14 is the output pressure y (y1,y2) to the
actuator. The pneumatic amplifiers are supplied
with supply air Ps 1.4 to 6 bar (20 to 90 psig).
The position x of the actuator is measured by the position
sensor (conductive plastic potentiometer) 15 . The desired
direction of rotation is set in 17 via switches S1 and S2. The
SPAN is suited to the stroke / rotation angle range via
potentiometer P2, while ZERO is set in 19 via potentiometer
P3. With switch S3 potentiometer P1 provides an internal
zero adjustment in 18 carried out by the manufacturer
(service function). The resulting feedback signal is guided to
control circuit 11.
The IP module receives its maximum drive current via switch
S8 enabling checking of the funktion of the pneumatic unit.
The position x of the actuator is independently displayed at
the mechanical travel indicator 16.
The mechanical limit switch 22 (optional) enables
independent alarm signals.

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1.4 Safety requirements
Accident prevention
This device complies with regulations for the prevention
of accidents Power-Driven Work Aids (VGB 5) of 1st
October 1985.
In option “limit switch” do not touch control vane during
operation - danger of injuries!
Electrical safety
This instrument satisfies the conditions for safety class
III, overvoltage category I according to EN 61010-1 or
IEC1010-1.
Any work on electrical parts must be done by qualified
personnel if any supply is connected to the instrument.
The instrument must be used for its designated purpose
and connected in accordance with its connection
diagram (see pages 17 and 27).
Locally applicable installation regulations for electrical
equipment must be observed, e.g. in the Federal
Republic of Germany DIN VDE 0100 resp. DIN VDE
0800. The instrument contains no built-in fuses.
The instrument must be operated with safety extra low
voltage SELV or SELV-E.
Safety precautions taken in the instrument may be
rendered ineffectual if the instrument is not operated in
accordance with the Master Instructions.
Limitation of power supplies for fire protection must be
observed due to EN 61010-1, appendix F
or IEC 1010-1.
Explosion protection
(Only if ordered)
Technical data for explosion protection see Product
Specifications Sheet PSS EVE0107 A-(en).
For installations located in explosive atmospheres, all
relevant national regulations and installation conditions
must be observed, e.g. in the Federal Republic of
Germany ElexV and DIN VDE 0165.
Attention:
When repairing explosion-protected equipment, observe
the national regulations.
Repairs involving parts must be manufacturer’s original
parts.
The following applies to the Federal Republic of
Germany:
Repairs involving parts required for explosion protection
must either be carried out by the manufacturer or by
authorized personnel and confirmed by certificate.
EMC and CE
For notes regarding Electromagnetic compatibility EMC
and CE labels see Product Specifications Sheet PSS
EVE0107 A-(en).
In order to ensure EMC protection, the electronic board
has to be screwed to the housing.

EP100 Master Instruction 5
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2 LABELS
A Nameplate
B Additional label for option “Limit switches”
Nameplate (Example)
EP100 Device specification, Model Code ]
SER.No [ Serial number ]
ECEP [ Number for special engineered version ]

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3 DESIGN
1a Adapter 1/2"-14NPT (see accessories)
1b Cable gland PG 13.5
2Plug, interchangeable by Pos. 1
3Screw terminals 11+ 12- for input (w)
I–to measure input current (see also item 23 )
4Ground connection
5Female thread 1/4-18 NPT for output I (y1)
6Female thread 1/4-18 NPT for air supply (s)
7Female thread 1/4-18 NPT for output II (y2)
8Direct connection hole for output I (y1)
9 Feedback shaft
10 Connection manifold for mounting to linear
actuators
11 Connection base for mounting to rotary actuators
12 Travel indicator
17 Air reducing throttle* for output I
18 Air reducing throttle* for output II
19 Shaft for limit switch connection
20 Cover with window to 12
21 Air vent, dust and water protected
22 Nameplate
23 Connections for current measurement, 2 mm dia.
(integrated in side of terminals)
26 Arrow points to flat of feedback shaft at angle 0°
27 Ball valve for protection class NEMA 4X
* Service only

EP100 Master Instruction 7
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3.1 Pneumatic Accessories
When mounting, check the proper seating of the O-rings
and bolt on the accessories with the two M8 bolts. Unused
outputs are closed by means of plastic plugs.
3x
1/4-18 NPT
L x B x H =
101,5 x 60 x 100,5 mm
3x
1/4-18 NPT
Code LEXG -G
Booster for double acting positioner
L x B x H =
121 x 39 x 81 mm
3x
1/4-18 NPT
Code LEXG -M
Connection manifold for double acting
positioner with pressure gauge for supply
air s, outputs y1 and y2
3x G 1/8 für
Manometer*
L x B x H =
100 x 30 x 45 mm
3x
1/4-18 NPT
Code LEXG -N
Connection manifold for single or double
acting positioner with threads G 1/8 for
pressure gauge for supply air s, outputs y(y1)
and (y2) (supplied without pressure gauge)

8 EP100 Master Instruction
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4 MOUNTING TO ROTARY
ACTUATORS
4.1 Type of mount
Applicable to rotary actuators that meet the
VDI/VDE 3845 standard for mounting. Installation
position of positioner:
Mount the positioner so that the pneumatic
connections are in the same direction as the
longitudinal drive axis of the actuator as shown in
the drawing below.
Attention: The feedback shaft 9of the EP100 has
no mechanical stop, therefore may spin round. The
permissible rotation angle range is between +50
and –50 degrees around the arrow at the housing
concerning the flat area of the feedback shaft (also
see detail page 13 bottom). Since a rotary actuator
has a rotary angle of about 90 degrees the
mounting as described in the following must be
carried out very precise.
Attachment of the positioner to the actuator is
made by using the rotary adaptor kit EBZG -R.
Either the side outputs I (or I and II) are used and
the rear output I is closed by means of the lock
screw 522 588 013.
Pneumatic connections: Do not use Teflon tape for
sealant. The fine fibres could disturb the function
of the EP100. Use only Loctite® #243 for
sealant 1).
Screw-type glands for electrical connections are
used as needed. Any unused threaded holes are
closed by plugs.
Caution! Prevent accumulation of water in the
instrument in this mounting position by sealing
cable entry against water. Provide a continuous
supply of dry instrument air.
4.2. Preparation of positioner
Valve must be in failsafe position2) and the direction of
rotation of the actuator drive shaft must be known. These
items are extremely important for proper functioning. These
items can be checked as follows in case they are not clear:
In the single-acting actuator the force of the installed springs
closes. The pressure-less actuator is in failsafe position.
Through manually feeding compressed air it can be seen
whether the actuator drive shaft rotates to the left or to the
right. In the powerless EP100 is y1 pressureless.
In the double-acting actuator without spring reset both air
chambers are basically equal. Failsafe position can be either
“open” or “close”. Therefore, indication of the fail- safe
position has to be determined by engineering. Then the
direction of rotation may be determined by manual feeding of
compressed air. In the powerless EP100 is y1 pressureless
and y2 under pressure.
Bolt 2is screwed into actuator drive shaft 1for subsequent
centering of the rotary adaptor 3. The attachment console is
mounted to the stroke actuator (see photo).
Attachment diagram for bracket
Rotary adaptor
1) Apply only to male thread.
2) Failsafe position: Defined position in case of failure of input signal

EP100 Master Instruction 9
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4.3 Preparation of the actuator
First the rotary adaptor is being prepared:
For attachment to a counter-clockwise or left turning
actuator secure the stud screw 4 on the left side of
the “R” in the threaded hole of the rotary adaptor
(see the big “L” marked drawing below).
For attachment to a clockwise or right turning actuator
secure the stud screw 4 on the right side of the “L” in
the threaded hole of the rotary adaptor (see the big
“R” marked drawing below).
Than the feed back shaft 9should be turned with the
bevelled side (flat part) according to the stud screw 4
(on the 0% position of the rotation indicator). Now screw
and tighten the bolt in the coupling against the flat part
of the feedback shaft (do not screw against the thread!).
Finally turn the feedback shaft in such a way that the
“R” or the “L” of the coupling points to the arrow 10 of
the EP100 housing. Now place the rotary adaptor 3 with
two washers 5 on the feedback shaft 9 of the positioner
against the stop.
Note : When the product temperature rises, than the
drive shaft 1 becomes longer. Therefore, the rotary
adaptor 3 must be mounted so that approx. 1 mm
(0.04 inch) of clearance results between the drive
shaft 1 and the rotary adaptor 3. This is achieved by
placing an appropriate number of washers 5 on the
feedback shaft stub 9 before attaching the rotary
adaptor. Two washers should result in a clearance of 1
mm.
Beginning and end positions of the actuator drive shaft
1 and feedback shaft 9 are marked in the figures below
( the big “L” for the left-rotating actuator and the big
”R” for the right-rotating actuator) by light-grey arrows
for the respective direction of rotation. The feedback
shaft is now in the normal position corresponding to the
failsafe position of the actuator. No shifting of feedback
shaft anymore!
4.4 Mounting of positioner
EP100 positioner and actuator are in failsafe position.
Attach the EP100 on the console in such a way that the
catch of coupling 3 is guided into the groove of shaft 1.
Use bolt 2 to center and align the positioner to the
actuator. Be careful not to shift shafts 1 and 9 and that
both shafts are exactly flush. Fasten the EP100
positioner to the bracket by means of 4 lock washers
and 4 screws M6 x 12.
Direction
of rotation
0 100%
of feedback
shaft 9
10 10
Direction
of rotation
0 100%
of feedback
shaft 9
Counter-clockwise Clockwise or
or left turning actuator right turning actuator

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5 PNEUMATIC CONNECTIONS
Following alignment and mounting of the
positioner to the valve, pneumatic tubing
has to be provided.
The connection illustrations depend on the
respective version.
Explanation of abbreviatons:
s Supply air
y1-d Output 1 for direct mounting,
depressurized at currentless
electronics. When using this
output y1 as to be closed by
means of hex. screw.
y1 Output 1, depressurized at
currentless electronics.
When using this output, y1-d
has to be closed by means
of sealing screw and O-ring.
y2 Output 2 for double-acting actuator.
Full pressure at currentless
electronics. Closed at single-acting
actuator.
n1 Hex. screw with NPT thread
n2 Sealing screw with O-ring

EP100 Master Instruction 11
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6 ELECTRICAL CONNECTION
The safety requirements on page 4 must be
observed!
Unused cable glands should be closed off.
Guide cable through gland 1. The gland is suitable for
cable diameters of 6 to 12 mm (0.24 to 0.47 in).
Observe the tightness of the cable entry.
Provide electrical connection of input line at screw
terminals 3marked 11+ and 12 - . The terminals are
suitable for wire cross-sections of 0.3 to 2.5 mm2 (22
-14 AWG).
Note: When connecting shielded cable connect the
cable shield only to the system! Do not connect the
cable shield to the EP100!
Connection to terminals (pos. 3+, 3–):
11+ Input w+
12–Input w–
The input current can be measured at tip jacks 23+ and 23-
(integrated in terminals, underneath the screws). The tip jacks fit
plugs with a diameter of 2 mm (0.08 in).
In order to improve EMV protection by integration into local
grounding the internal and external grounding conduct
connection 4is available.
Optional equipment ‘limit switch’ (see terminals 40 )
EP100-x-T, U
via inductive sensor
Mark
Signal
41 +
GW1
42 –
GW1
51 +
GW2
52 –
GW2
GW Binary output ext. supplied

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7 START-UP
7.1 General
First of all, the nameplate should be checked,
especially with respect to references to Ex / non- Ex,
input signal, single / double acting.
Before starting the positioner the EP100 has to be
mounted to the actuator; an input signal 4 to 20 mA or
split range have to be available. The supply air
connection must have sufficient capacity and
pressure of 1.4 to 6 bar (20 to 90 psig) and should not
exceed the maximum operating pressure of the
actuator.
The EP100 can be adjusted by means of switches
and potentiometers when the housing cover is
opened.
Attention: Configuration using switches and
potentiometers may interfere with operation of the
actual process! During configuration it is
recommended that there is no flow through the
valve.
At initial start-up various adjustments have to be set.
The following procedure is recommended:
Setting of direction of rotation of feedback lever
(chapter 7.2)
Setting of input signal range e.g. 4 to 20 mA or
split range (chapter 7.3)
Setting of gain (chapter 7.4)
Setting of zero and span (chapter 7.5)
Setting of damping (time constant, chapter 7.6)
The position indicator 12 is attached to the
desired position after selection of the
transmission at indicator shaft (chapter 7.7)
The air capacity throttles at the pneumatic
output (screws 17 and 18 underneath of the
SERVICE openings) are factory-set to the
operating value and are normally not reset
(exception see chapter 7.8).
When attaching the housing cover make sure
that the venting opening points to the bottom
Settings via switches and potentiometers
For the setting of the EP100 and the adjustment of
various parameters 8 dip switches and 5
potentiometers are available.
See electronics imprint as follows:
1) Adjustment of electronic board (in workshop, see page 17)
The potentiometers are for the setting of:
Zero point (ZERO): P3
Span (S): P2
Gain (G): P4
Damping (D): P5
Electronics alignment: P1 1)
Single-threaded potentiometers with limited rotation angle to
set gain (G) and damping (D) are available, where the actual
position is indicated by an arrow. To set zero point (ZERO),
span (S) and the electronics alignment1) multiplethreaded
potentiometers (approx. 30 rotations) without rotation
limitation are used.
The switches are for the setting of:
Direction of rotation of feedback lever (switches 1, 2)
Electronics adjustment (switch 3) 1)
Signal range (switches 4, 5, 6 and 7)
Pneumatic test (switch 8)
The switch numbers (1 through 8) are imprinted on the
electronics. The possible switch position (“I” and “II”) are
imprinted below switch 8. The switch positions are defined as
follows:
Switch Position “I”: Switch Position II:
Caution!
Switches 3 and 8 must be during operation in position “I”.
Prior to resetting switches 1 to 8 it is recommended to shut-
off the respective part of the installation since processes are
activated influencing and disturbing the current process.
Therefore, it is recommended that no medium flows through
the valve during configuration..

EP100 Master Instruction 13
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7.2 Setting of direction of rotation
of feedback shaft
If the actuator moves from starting to end position,
the direction of rotation of the feedback shaft is to
the right or left hand, depending on the mounting
method of the positioner selected and on the
configuration of the actuator (spring closes/ opens/
double-acting).
For proper functioning this direction of rotation
must be set at positioner (via switches 1+2).
The direction of rotation is defined as direction of
rotation of the feedback shaft from the starting to
the end position looking at the positioner from the
front. See following illustration (shown is: left hand
mounting, spring closes, direction of rotation L).
Direction of rotation of feedback shaft for a rotary
actuator:
Actuator opens
rotating to the left
Actuator opens
rotating to the right
L
R
Direction of rotation of feedback shaft of the double-acting
actuator is a. o. determined by the mounting side and the
tubing of the pneumatic outputs to the actuator. It has to be
considered that in a powerless EP100 the output y1 will
become pressureless and y2 contains air supply pressure.
The direction of rotation of the feedback shaft is set via
switches 1+2; see the following illustration.
L: left-hand rotating feedback shaft switch 1+2 on “I”
R: right-hand rotating feedback shaftt: switch 1+2 on “II”
Remarks:
If the direction of rotation is not in the right manner, the
actuator moves to the end position with full force, and the
positioner cannot be controlled.
Definitions
Stroke stroke range of the membrane actuator is
defined for rotary actuator as angle, angle
range.
0 % position is the mechanical impact at actually closed
valve (caution if using handwheel and
mechanically adjustable stroke limitation!)
100 % position is the mechanical impact at actually open
valve.

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7.3 Setting of Input Signal Range
The following input signal ranges can be set for the
EP100 via switches 4 to 7:
0%
100%
item
S4
S5
S6
S7
4mA
20mA
A
I
I
I
I
4mA
12mA
B
I
I
II
I
12mA
20mA
C
I
I
II
II
20mA
4mA
D
II
II
I
I
20mA
12mA
E
II
II
II
I
12mA
4mA
F
II
II
II
II
The switch positions for the setting of various
signal ranges are imprinted on the electronics. See
illustration.
For 4 to 20mA the switches 4 to 7 are set to
position “I” (as shown).
This concludes the setting of the input signal
range!
Split Range
If several positioners are operated at one current
loop in sequence with the standard signal 4 to 20
mA, individual valve positions may be allocated to
each device, which also may overlap if necessary.
This function is useful if an additional control range
is demanded which cannot be covered by one
valve only. A valve of smaller nominal size can be
applied overtaking the smallest quantities; a
parallel mounted valve of bigger nominal size
takes on the larger quantities.
Example: Setting the signal range to 12 to 20 mA
It is recommended to shut off current of the
positioner prior to resetting of the input signal
range (turn-off input signal).The switches 4 and 5
are set to position “I” and switches 6 and 7 to
position “II”.
The individual switch positions are shown in the
following illustration.
Split range, subdivision of input signal range Example: At low
current, only the smaller valve positions; from approx. 50 %
the large valve is added

EP100 Master Instruction 15
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7.4 Setting of gain (G)
The loop amplification of the positioner is set via
potentiometer P4 for gain (G). The maximum
possible gain is thereby determined by the stability
behavior of the control loop. It is selected in such a
way that the actuator no longer oscillates at
constant given input value.
Rotation to the right P4: amplification is increased
Rotation to the left P4: amplification is reduced
If the positioner control loop oscillates, gain (G)
must be reduced. It has to be considered that a
change of gain changes the control deviation,
therefore, requiring setting of the potentiometer for
the position range (zero and span).
7.5 Setting of zero (ZERO) and
span (S)
Following settings in chapters 7.2 through 7.4 at
initial startup setting of zero point (ZERO) and
span (S) are performed as follows:
a)Enter starting value of command variable
(beginning of stroke).
b) Turn potentiometer P3 for zero point (ZERO)
until actuator just begins to move from its end
position.
Rotation to the right P3: zero point is increased
Rotation to the left P3: zero point is reduced
c) Enter final value of variable (end of stroke)
d) Turn potentiometer P2 for span (S) until
actuator exactly reaches its end position.
Rotation to the right P2: span is increased
Rotation to the left P2: span is reduced
These settings influence amplification, therefore
adjusting in chapter 7.4 may become necessary!
7.6 Setting of damping (D)
Potentiometer P5 for damping (D) influences the
dynamic behavior of the actuator at a
discontinuous change of the input signal. The input
signal is provided with an additional time constant
for this purpose. The time constant is only
noticeable in the position control loop if the time
constant set via potentiometer is larger than the
position time of the actuator.
Rotation to the right P5: damping is increased
Rotation to the left P5: damping is reduced
The effect of the positioning time may be checked
by entering input signal jumps. The range limits
and the gain are not influenced by a change.
7.7 Setting of the travel indicator
The mechanical travel indicator is coupled to the feedback
shaft of the positioner by a gear. The gear has two selectable
ratios 1 : 2 and 1 : 6. 1).
Selection of gear ratio:
For rotation angles of the feedback shaft less than 30° select
a ratio 1 : 6. This gear selection amplifies the feedback shaft
rotation angle six times and for example, a 20° angle is
shown as 120°.
For rotation angles greater than 30 ° select a ratio of 1 : 2.
This gear selection amplifies the shaft rotation angle by a
factor of two and for example, a 45° angle is shown as 90°.
For rotary actuators the rotation angle is equal to the rotation
angle of the actuator. Consequently, a 90° rotation angle will
result in a 180° display angle for the 1 : 2 gear ratio.
Setting gear ratio:
Remove travel indicator 12. Pull out pin 12b for a ratio 1 : 2 or
push in the pin for a ratio 1 : 6. Use a smooth turning
operation to free the gears and to set pin 12b against the
stop. See illustration.
Turn the travel indicator 12 to the desired position, put it on
the gear shaft against the stop and pinch the wire ring for
secure coupling.
1) The values are rounded for making easier calculations. The exact ratios
are 1 : 1.83 and 1 : 6.28:

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7.8 Air reducing throttles
Attention: Service only
Air flow to the actuator may be reduced via air
reducing throttles 17 and 18 .
Ex-factory the air capacity is non-throttled;
generally, this is the most favorable setting. In the
non-throttled condition the screw head is even with
the amplifier surface. Since the flatness of the
screw heads is not visible in the installed
electronics, the basic setting can be restored as
follows:
turn off air supply
carefully turn air reducing throttle screw
clockwise until impact, thereafter 5 complete
return rotations (counterclockwise)
restart air supply
Reducing of output air capacity
Attention: Service only
Output air capacity may be reduced in exceptional
cases only in small volume actuators with a small
spring range if after optimization of the control still
oscillating tendency exists (amplification of control
loop is too high). For this purpose turn air reducing
throttle screws 17 and 18 to a maximum of 5
rotations clockwise.
Caution: Amplifier may be damaged if a loud
noise can be heard from amplifier resulting from
too strong reducing. Immediately turn back
throttles significantly!
7.9 Basic adjustment of electronics
Attention: Service only
The electronics unit has been sufficiently factory-
adjusted; an adjustment at delivery is not required.
The potentiometer is secured by means of lacquer
against unintentional operating.
In the event an adjustment of the electronics
becomes necessary (e.g. following exchange of
electronics) the procedure is as follows:
a)Enter input current 4 mA.
b) Switch S3 to “II”: positioner control loop is
opened.
c) Turn potentiometer P1 until actuator just begins
to move from its end position.
d) Return S3 to “I”.
7.10 Pneumatic test
Attention: Service only
To check the pneumatic parts of the positioner by directly
applying current to the IP module (no control).
Procedure: Put switch 8 in position ”II” (see illustration).
Attention!
Resetting of switch 8 initiates actions influencing and possibly
disturbing the current process! Therefore, no medium should
flow through the valve during these settings.
Setting switch 8 to position “II” actuates a pneumatic test
checking the function of the positioners pneumatic system
including its control. If switch 8 is set from position “I”
(condition of operation) to position “II”, the pressure in the
actuator goes to nearly air supply pressure. The actuator
moves to the direction associated with maximum pressure.
If no reaction is shown, check:
- does air supply exist?
- is plug connected to IP module?
If these items are okay, possibly the electronics or a
pneumatic part are defect. Exchange see page 18.
During operation switch 8 must be in position “I” at all times!
8 DECOMMISSIONING
Before decommissioning the unit, disconnect supply air and
the electrical input signal.

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9 DIAGNOSIS
Fault
Possible cause
Beseitigung
Actuator does not react
to existing input signal or
to changes of input signal
Pneum. connections were interchanged
Check pneum. connections,
see page 10
Electric connections were interchanged
Check electric connections,
see page 11
Wrong setting of zero and span
Check, see page 15
IP module or pneumatic part defective
Carry out Pneumatic Test,
possibly change part, see page 19
Direction of rotation interchanged
Change direction of rotation
Output pressure does not reach
full capacity
Supply air capacity insufficient
Check air supply
IP module defect
Carry out Pneumatic Test, possibly
change module, see page 19
Filter in air supply connection plugged
Exchange filter, see page 18
Actuator moves to end position
Positioner mounted on wrong side or
switch1+2 set faulty (R/L)
Check mounting side as per table
page 13
Pneumatik test still active (switch 8 = “II”)
Return switch 8 to “I”, see page 16
Pneumatic connections were
interchanged (double-acting version)
Check connections, see page 10
Unstable behaviour,
position control circuit oscillates
Gain too high
Reduce gain, see page 15
Friction on valve packing too great
Loosen packing gland slightly or
replace
Piston actuator:
Friction at cylinder too great
Reduce gain, see page 15
Stroke range cannot be set
Positioner does not fully decompose
pressure
Check air supply (max. 6 bar)
Check gain, see page 15
Carry out pneumatic test
(switch 8 = “II”), see page 16
Pneumatic test is without effect
No air supply
Connect air supply
No input signal
Connect input signal
IP module is not connected, or
IP module or a pneumatic part defective
Connect IP module, or
exchange part (workshop)

18 EP100 Master Instruction
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10 MAINTENANCE
10.1 General
The positioner EP100 requires little maintenance.
When replacing components during repair work, the
safety requirements on page 4 must be observed!
10.2 Supply filter replacement
An obstructed supply filter can be replaced. Unscrew
the air supply fitting, remove the filter and exchange
the filter with a new one.
10.3 Removal of electronics unit
Pull off travel indicator 12 . To remove the electronics
unit 40, loosen the 7 screws at front, see illustration
below.
Lift off electronics unit vertically to top. Disconnect
plugs 41 and 42 (see page 25) from the board. Do not
use tools to remove plugs because components could
be damaged.
Tight-fitting plugs can be easily removed by tilting
them diagonally inward before pulling them off.
Connect plugs 41 and 42 to the new electronics unit
40 and attach the new unit by using the 7 screws at
front (attention with the cables).
10.3.1 Conversion of positioner
Positioner of the EP series consist of identical
mechanical and pneumatic components and
accessories.
A conversion to either a “digital” or “intelligent”
positioner is possible by simply exchanging the
electronics unit.
Procedure:
a) exchange electronics unit, see chapter 10.3
b) mark change on nameplate
c) start-up - see associated master instructions:
Reference to explosion-proof devices:
Conversion of the electronics unit has to be
considered as change to explosion-proof device, and
therefore, only permitted in accordance with country
specific regulations.
Valid in the Federal Republic of Germany: Conversion
to be certified as change according to § 9 ElexV by an
authorized expert.

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10.4 Replacement of mechanical
and pneumatic units
First remove the electronics unit 40 (see preceding
page).
10.4.1 Amplifier replacement
Release the pneumatic amplifier 43 from the base
plate and replace O-rings between the amplifier and
base plate1).
Use 3 O-rings for a single-acting amplifier and 5 O-
rings for a double-acting amplifier. If replacing a
single-acting amplifier with a double acting, remove
sealing screw 44 before installation.
The air capacity throttle screws have to be released
until the screw head is even with the amplifier surface
( = no throttling).
10.4.2 Preamplifier replacement
Unscrew the preamplifier 45 from the base plate by
removing screws 46 and 47 .
Replace 4 O-rings between preamplifier 45 and base
plate1) and install new preamplifier.
10.4.3 Replacement of IP module
Remove the IP module 48 from base plate and
replace with new IP module. Replace the O-ring
between IP module and base plate and install new IP
module.
10.4.4 Replacement of Feedback unit
First remove feedback lever or rotary adapter from
feedback shaft. Now remove retaining ring from
feedback shaft 9 (see page 6). Remove screws and
pull out complete unit 49 consisting of feedback shaft,
gears and position sensor.
Insert new feedback unit 49 and secure with screws.
Remember to replace the retaining ring at feedback
shaft.
1) The base plate consists of a manifold and air ducts. O-rings are
required to guarantee sealing of the mounted elements.

20 EP100 Master Instruction
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11 OPTION
11.1 Limit switch
Rebuild to this option resp. exchange
Remove three screws 1 including tooth lock washer
from plastic cover.
Attach limit indicator 2 so that the flattened shaft end
19 contacts the groove of the limit indicator shaft in
the positioner.
Attach limit indicator by means of three screws 3 and
washers. The feedback shaft at back of positioner
should easily be turnable, thereby also moving the
vanes of the limit indicator. If this is not the case,
loosen screws 3 and flush- align the shafts of
positioner and limit switch (turn coupling shaft several
times).
Replace short travel indicator 12 by long travel
indicator.
Screw high cover 20 (or standard cover with insert
frame) on housing.
Switch functions
Feedback lever, feedback shaft and the control vanes
are all connected to each other, without an
intermediate transmission. The control vanes are
therefore moving simultaneously with the same angle
rate as the feedback lever. The length of the control
vane corresponds with the swing angle of 120°.
Both control vanes are located on different planes.
Each control vane can be seen independently from
the other, because each has its own sensor.
By adjusting the screws (after loosening the center
screw 10 ), the control vanes can be adjusted
relatively to the angle rate, so that e.g. one vane dives
into and another dives out of the sensor (see
illustration).
Setting limit switch trigger points
Loosen center screw 10 (1-2 turns; do not remove!),
otherwise the control vanes will be damaged during
the following steps.
Set trigger point switch GW1:
Turn screw at number 1 until desired switch behavior
is reached.
Set trigger point switch GW2:
Turn screw at number 2 until desired switch behavior
is reached.
To fix switch points retighten center screw 10.
Do not touch control vanes during operation, danger
of injuries!
Levels of control vanes (illustration without cover)