SERVI GROUP OPAT User manual

USER MANUAL
FOR OPAT
ONBOARD PROFIBUS AMPLIFIER TWIN SOLENOID
For Model Type:
BTN, SDE, XS
EX eb ib mb IIC T4 Gb
EU TYPE CERTIFICATE:Presafe 14 ATEX 5271X
IECEx CERTIFICATE:IECEx PRE 14.0036X
Manufacturer:
SERVI AS
RASMUS SOLBERGSVEI 1
1400 SKI
NORGE
Tel [phone]
E-mail: po[email protected]
Distributor:
SERVI AS
RASMUS SOLBERGSVEI 1
1400 SKI
NORGE
Tel [phone]
E-mail: po[email protected]

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Document Details:
Status: Released
Document Number: 1388826
Revision: A2

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TABLE OF CONTENTS
Introduction........................................................................................................................................................................................4
Key data................................................................................................................................................................................................4
ATEX, IECEX – Potentially Explosive Environment............................................................................................. 5
EMC....................................................................................................................................................................................................5
Model Types...................................................................................................................................................................................... 6
BTN – Component overview ........................................................................................................................................6
Exterior Dimensions................................................................................................................................................................. 7
SDE – Component overview ........................................................................................................................................8
Exterior Dimensions.................................................................................................................................................................9
XS – component overview...........................................................................................................................................10
Exterior Dimensions................................................................................................................................................................ 11
Cables, Cable Entries and Earthing .................................................................................................................................12
Marking................................................................................................................................................................................................13
Safe use..............................................................................................................................................................................................14
Installation ..................................................................................................................................................................................15
XS - External solenoid....................................................................................................................................................16
wiring diagram......................................................................................................................................................................17
Opat BTN/SDE - PB................................................................................................................................................................. 17
Opat BTN/SDE - CAN............................................................................................................................................................. 17
Opat XS - PB.................................................................................................................................................................................18
Opat XS - CAN.............................................................................................................................................................................18
Profibus topology.....................................................................................................................................................................19
External sensor .................................................................................................................................................................20
Start-up and Commissioning ........................................................................................................................................ 21
Maintenance Instructions....................................................................................................................................................22
Periodic Maintenance........................................................................................................................................................22
Storage.........................................................................................................................................................................................22
Waste Disposal.......................................................................................................................................................................22
Notes ..................................................................................................................................................................................................23

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INTRODUCTION
OPAT is an electromechanical control unit for proportional directional and pressure relief valves.
It can control two separate solenoids with total power consumption of up to 800 Ma, but not
simultaneously.
OPAT is ATEX and IECEx approved according to NS-EN60079 (IECEx 60079) for use in
potentially explosive atmospheres.
The unit is primarily intended for use with Hawe PM pilot valves. Units with model codes BTN or
SDE feature a built-in solenoid, whereas units with model code XS have a separate connection
housing for an external solenoid. The power consumption of external solenoid must not exceed
800 mA
The control system communicates with Profibus or CANbus, depending on type. All types have a
series of analogue inputs for use when bus communication is not required.
The unit has been manufactured in compliance with applicable regulations and standards, see
Declaration of Conformity for details. As the unit has been type approved according to these
standards, any alteration or modification of the unit which is not specifically described in this
User Manual will void the type approval, and relieve the manufacturer/distributor of any
responsibility.
This User Manual is intended for personnel with relevant training, and it is essential that any
person installing, commissioning or adjusting the unit has in-depth knowledge of the contents
of the User Manual and the following technical data sheets:
Doc. No
Title
Revision
1435693
Technical Manual
A1
1435696
Profibus Manual
A1
KEY DATA
Type Approval:
Presafe 14 ATEX 5271X, 2460
IECEx PRE 14.0036X
Identification:
II 2G Ex eb ib mb IIC T4 Gb
Temperature
Range:
Ambient: -40 to +55°C (-4 to +131°F)
IP Class:
IP67
Max. Current:
1 [A]
External Fuse:
10 [A]
Max. Voltage:
24 VDC SELV DC supply with max.
24VDC +10%
BUS Protocols:
Profibus DP V2
CANbus (proprietary, internal
communication between the units)

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ATEX, IECEX –POTENTIALLY EXPLOSIVE ENVIRONMENT
OPAT has been type approved according to the following EX Standards:
EN 60079-0:2012, EN 60079-7:2015, EN 60079-11:2012, EN 60079-18:2015
IECEx:
IEC 60079-0:2011, IEC 60079-7:2015 IEC 60079-11:2011, IEC 60079-18:2014
EMC
The unit complies with the following standards for EMC compatibility:
DIN EN 61000-4-2
Electrostatic Discharges
DIN EN 61000-4-3
Radiated, Radio-frequency, EM field
DIN EN 61000-4-4
Electrical Fast Transient / Burst Immunity
DIN EN 61000-4-5
Surge Immunity
DIN EN 61000-4-6
Immunity to Conduct Disturbances, Induced by RF
Field
DIN EN 61000-6-3
Radio Disturbances
Germany Lloyd VI – Part 7 2003
Terminal Voltage
Radio Disturbances

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MODEL TYPES
BTN – COMPONENT OVERVIEW
Figure 1
Pos
Component
Torque
1
Threaded cable entry M20x1.5
See Nipple Manual
2
Fastening screws for top cover
6 Nm
3
Top cover
4
Earthing connection M5, 10 mm depth
6 Nm
5
Name plate
6
Fastening screws for OPAT
5.5 Nm
7
LED status lamps
8
Attachment surface, OPAT to valve
9
Solenoid
10
Emergency controls
6 Nm
5
7
10
6
4
3
1
2
9
8

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Exterior Dimensions
Figure 2

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SDE – COMPONENT OVERVIEW
Figure 3
Pos
Component
Torque
1
Threaded cable entry M20x1.5
See Nipple Manual
2
Fastening screws for top cover
6 Nm
3
Top cover
4
Earthing connection M5, 10 mm depth
6 Nm
5
Name plate
6
Fastening screws for OPAT
5,5 Nm
7
LED status lamps
8
Attachment surface, OPAT to valve
9
Solenoid
10
Emergency controls
6 Nm
1
2
3
6
4
7
9
10
8
5

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Exterior Dimensions
Figure 4

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XS – COMPONENT OVERVIEW
Figure 5
Pos
Component
Torque
1
Threaded cable entry M20x1.5
2
Fastening screws for top cover
6 Nm
3
Top cover
4
Earthing connection M5, 10 mm depth
6 Nm
5
Name plate
6
Fastening holes OPAT
See Installation
7
LED status lamps
5
7
2
4
6
1
3

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Exterior Dimensions
Figure 6

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CABLES,CABLE ENTRIES AND EARTHING
All cables used with the unit must as a minimum withstand a temperature of 90°C (194°F).
Always adhere to the cable manufacturer’s instructions regarding bending radius etc. When
using Profibus, a Profibus approved cable is recommended.
The required cable cross-section depends on the load on the cable, the number of units etc., and
must be considered carefully. The largest permissible cross-section in the connection clamps is
2.5 mm2.
Electric cables must meet all applicable regulatory requirements of the countries in which the
unit is used.
The threads in the cable entries are M20X1.5, with a total of 5 entries on BTN and SDE, and 7
entries on XS. The thread depth is 15 mm.
Any cable bushings or connection blocks used with the unit must be approved for the EX zone in
which the unit is installed. The cable entries must withstand a temperature of 90°C (194°F).
If any of the threaded cable entries are not used, they must be sealed off with an EX approved
plug.
The unit is fitted with earthing connections on the inside of the top cover (Pos 3, Figure 1 and 3).
These must be used for earthing shielded cables, unless special cable entries for shielded
cables are used. Use only screws and spring washers in AISI 316 stainless steel.
Internal earthing:
Figure 7
The unit may be connected to an exterior earthing system using the unit’s external earthing
connection (Pos 4 in Figure 1 and 3). If the screw in the external earthing connection is
replaced, a M5 x 10 screw and spring washer in min. A4-70 (AISI 316) quality must be used.
The spring washer is required to maintain the ATEX certification. The unit must be earthed using
minimum 4 mm2cable and suitable cable terminals.
M5x0.8 – 10 mm depth

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MARKING
The name plate must not be removed or painted over.
Figure 8
Model and specifications are indicated by ticking the boxes under TYPE ID on the name plate:
ID
Modelltype
PB
Profibus DP V1
SLA (CAN)
Slave (CANbus -proprietary)
BTN
Bottom-mounted solenoid, see Figure 1
PN
Profinet (future version)
ETH
Ethernet (future version)
SDE
Side-mounted solenoid, see Figure 3
XS
OPAT for external solenoid, see Figure 5
C
Terminal for cable connection has spring clamps.
S
Terminal for cable connection has screw clamps.

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SAFE USE
If an error occurs that is not described in this manual or the Technical Manual, immediately take
the unit out of operation, and contact the manufacturer/distributor.
Do not open /dismount the cover in a potentially explosive atmosphere. The unit is
constructed in compliance with Protection Class IP67, but this only applies if the lid is
correctly installed.
All work performed on the unit, such as installation, maintenance, replacements or similar, shall
be performed by personnel with the required training and qualifications according to applicable
regulations in the country of use. The personnel must also have sufficient knowledge of the unit,
to ensure that no errors occur due to faulty mounting, connection, adjustment, or similar.
Changing the parameters of the unit during operation shall only occur if the operator carrying
out the modification has the necessary training, to ensure correct functioning of the unit. The
operator shall also ensure that the change in parameters does not cause unwanted movement
of the machine on which the unit is installed, resulting in personal injuries or damage to
property. See separate manual for bus communication and parameter adjustment. Note
especially that all changes in parameters will have immediate effect, also during operation.
The unit must under no circumstance be opened or dismounted in a potentially explosive
atmosphere. A so-called «hot permit» or similar must be issued at the operator’s own risk and
responsibility.
The safety instructions given in the Technical Manual (adjustment manual) for the control board
must be followed at all times.
Do not try to remove or puncture the moulding inside the unit with a sharp object. The moulding
is soft, and this may damage the electronics on the control board.
Protect the LED lamps from sharp objects, and do not try to insert anything into the openings.
The unit has the following surface treatment:
Solenoid: DIN 50979 Fe//ZnNi8//Cn//T0
Other: Anodising
According to IEC 60079-0 2011, Chap. 7.4, it is not permitted to paint the unit with a paint layer
thicker than 0.2 mm.

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1
3
2
Figure 10 – Example of installation on Hawe SLF 5
Figure 9
INSTALLATION
In order to avoid personal injury or damage to equipment and property, the installation must
comply with NS-EN 60079-0 (ISO 60079-0) in addition to the requirements set out in this
manual.
The unit must be mounted in such a way that it is protected against external heat sources which
can make the surrounding temperature exceed the permissible temperature. In particular, heat
sources emitting radial heat (e.g. direct sunlight) must be taken into consideration.
Do not install the unit so that it carries more weight than its own. Cables must be fastened using
suitable equipment (cable ducts etc.).
The supply voltage must be SELV DC with a maximum outlet voltage of 24 VDC +10%.
Install a 10 Amp fuse in the safe zone on the power supply of the first unit (Master) in the
assembly.
Attach the unit to the valve with the screws in
Pos. 10 (Figure 7). Use only the original screws
included in the delivery of the unit.
Make sure the O-rings around the pilot valves are
in place – follow the instructions from the valve
manufacturer.
Connect the unit according to the wiring diagram
on the next page. See the Technical Manual for
details.
Install the cover when the unit is connected.
Make sure that no cables are trapped during the
installation.
Po
s
Componen
t
Torqu
e
1
OPAT
2
Fastening
screws
5.5 Nm
3
Hawe SLF 5

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XS - EXTERNAL SOLENOID
Type XS has a connection housing for an external solenoid. A Hawe Twin Solenoid or other
solenoid with a max. current of 800 mA may be used.
Ensure that the external valve’s EX approval meets the requirements of the zone in which you
are installing the valve.
The external solenoids are to be connected in the additional module for OPAT XS. Dismount
Position 4 in Figure 11 to access the connection clamps.
The unit is not a barrier. Solenoids requiring such equipment cannot be used without
making further adjustments.
The total power consumption of the solenoid must not exceed 800 mA. It is possible to use two
solenoids with a current of 800 mA each, but they cannot be activated simultaneously. This
limitation is also applied in the control board.
Figure 11
Pos
Component
1
OPAT
2
Fastening holes, throughgoing Ø5,5
3
Fastening holes, threaded M5x0.8 –
6mm depth
3
2
1
4

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WIRING DIAGRAM
Connecting cables:
For type S: Strip the cable 9 mm from the end, torque 0.4 – 0.5 Nm.
For type C: Strip the cable 10 mm from the end.
The wiring diagram can also be found in the Technical Manual.
Opat BTN/SDE - PB
Figure 12
Opat BTN/SDE - CAN
Figure 13

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Opat XS - PB
Figure 14
Opat XS - CAN
Figure 15

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Profibus topology
Figure 16
The CANbus protocol that is used in the CAN edition of the unit is a proprietary protocol and
cannot be used with CANopen or similar. A PB version is functioning as master on the CANbus
network. Commands to the CAN units are sent to the CAN master via Profibus.
If you are using the unit in a Profibus network, or other bus network, see the separate manual for
bus communication, addressing and related information.
GSD files for communication with Profibus can be obtained by request from the distributor.

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EXTERNAL SENSOR
When OPAT is used with an external sensor, it is important to ensure that the sensor meets the
EX requirements for the zone in which it is installed. Also pay close attention to the ambient
temperature. Always follow the manufacturer’s instructions for the sensor.
The unit is not a barrier. Solenoids requiring such equipment cannot be used without
making further adjustments.
The sensor’s maximum power consumption must not exceed 100 mA.
Compatible signal types are 0-20mA, 4-20mA, ±10VDC.