VAC D400 Training manual

Neu
Electro-Pneumatic Positioner
D400
Commissioning Instruction - EN
CI/TZIDC/110/120-EN
06.2009
Manufacturer:
ABB Automation Products GmbH
Schillerstraße 72
32425 Minden
Germany
Tel.: [phone]
Fax: [phone]
[email protected]b.com
© Copyright 2009 by ABB Automation Products GmbH
Subject to changes without notice
This document is protected by copyright. It assists the user in safe and efficient operation of the device.
The contents of this document, whether whole or in part, may not be copied or reproduced without prior
approval by the copyright holder.
Content
s

Contents
2 - EN D400 CI/TZIDC/110/120-EN
1Safety....................................................................................................................................................................4
1.1 General information and notes for the reader ................................................................................................4
1.2 Intended use...................................................................................................................................................4
1.3 Target groups and qualifications ....................................................................................................................5
1.4 Warranty provisions........................................................................................................................................5
1.5 Plates and symbols ........................................................................................................................................6
1.5.1 Safety/warning symbols, note symbols...................................................................................................6
1.6 Safety information for electrical installation....................................................................................................7
1.7 Operating safety information ..........................................................................................................................7
2Ex relevant safety instructions ..........................................................................................................................7
3Mounting ..............................................................................................................................................................8
3.1 Operating conditions at installation site..........................................................................................................8
3.2 Mechanical mount ..........................................................................................................................................8
3.2.1 General....................................................................................................................................................8
3.2.2 Mounting on linear actuators.................................................................................................................10
3.2.3 Mounting on rotary actuators ................................................................................................................14
4Electrical connection ........................................................................................................................................17
4.1 Screw terminal assignments ........................................................................................................................18
4.2 Jumper configuration on mainboard (TZIDC-120 only)................................................................................19
4.3 Cable entry ...................................................................................................................................................20
5Pneumatic connection ......................................................................................................................................21
6Commissioning..................................................................................................................................................23
6.1 TZIDC...........................................................................................................................................................23
6.1.1 Operating modes...................................................................................................................................24
6.2 TZIDC-110 / TZIDC-120...............................................................................................................................25
6.2.1 Operating modes...................................................................................................................................26
7Ex relevant specifications ................................................................................................................................27
7.1 TZIDC...........................................................................................................................................................27
7.1.1 ATEX.....................................................................................................................................................27
7.1.2 IECEx Issue No. 3.................................................................................................................................29
7.1.3 CSA International ..................................................................................................................................31
7.1.4 CSA Certification Record ......................................................................................................................33
7.2 TZIDC-110....................................................................................................................................................34
7.2.1 EC-Type-Examination Test Certificate..................................................................................................34
7.2.2 IECEx Issue No. 3.................................................................................................................................35
7.2.3 CSA International ..................................................................................................................................37
7.2.4 CSA Certification Record ......................................................................................................................38
7.2.5 FM Approvals ........................................................................................................................................39
7.3 TZIDC-120....................................................................................................................................................40
7.3.1 EC-Type-Examination Test Certificate..................................................................................................40
7.3.2 IECEx Issue No. 3.................................................................................................................................41
7.3.3 CSA International ..................................................................................................................................43

Contents
CI/TZIDC/110/120-EN D400 EN- 3
7.3.4 CSA Certification Record ......................................................................................................................44
7.3.5 FM Approvals ........................................................................................................................................45

Safety
4 - EN D400 CI/TZIDC/110/120-EN
1 Safety
1.1 General information and notes for the reader
Read these instructions carefully prior to installing and commissioning the device.
These instructions are an important part of the product and must be kept for later use.
These instructions are intended as an overview and do not contain detailed information on all
designs for this product or every possible aspect of installation, operation and maintenance.
For additional information or in case specific problems occur that are not discussed in these
instructions, contact the manufacturer.
The content of these instructions is neither part of any previous or existing agreement, promise
or legal relationship nor is it intended to change the same.
This product is built based on state-of-the-art technology and is operationally safe. It has been
tested and left the factory in a safe, maintenance-free state. The information in the manual must
be observed and followed in order to maintain this state throughout the period of operation.
Modifications and repairs to the product may only be performed if expressly permitted by these
instructions.
Only by observing all of the safety information and all safety/warning symbols in these
instructions can optimum protection of both personnel and the environment, as well as safe and
fault-free operation of the device, be ensured.
Information and symbols directly on the product must be observed. They may not be removed
and must be fully legible at all times.
1.2 Intended use
D400 positioners are electro-pneumatic positioning devices for use
with pneumatically controlled actuators.
The device may only be used for the applications listed in these operating instructions and in
the data sheet.
• The maximum operating temperature must not be exceeded.
• The permissible operating temperature must not be exceeded.
• The housing protection type must be observed during operation.

Safety
CI/TZIDC/110/120-EN D400 EN - 5
1.3 Target groups and qualifications
Installation, commissioning, and maintenance of the product may only be performed by trained
specialist personnel who have been authorized by the plant operator to do so. The specialist
personnel must have read and understood the manual and comply with its instructions.
Prior to using corrosive and abrasive materials for measurement purposes, the operator must
check the level of resistance of all parts coming into contact with the materials to be measured.
ABB Automation Products GmbH will gladly support you in selecting the materials, but cannot
accept any liability in doing so.
The operators must strictly observe the applicable national regulations with regards to
installation, function tests, repairs, and maintenance of electrical products.
1.4 Warranty provisions
Using the device in a manner that does not fall within the scope of its intended use, disregarding
this instruction, using underqualified personnel, or making unauthorized alterations releases the
manufacturer from liability for any resulting damage. This renders the manufacturer's warranty
null and void.

Safety
1.5 Plates and symbols
1.5.1 Safety/warning symbols, note symbols
DANGER – <Serious damage to health / risk to life>
This symbol in conjunction with the signal word "Danger" indicates an imminent danger.
Failure to observe this safety information will result in death or severe injury.
DANGER – <Serious damage to health / risk to life>
This symbol in conjunction with the signal word "Danger" indicates an imminent electrical
hazard. Failure to observe this safety information will result in death or severe injury.
WARNING – <Bodily injury>
This symbol in conjunction with the signal word “Warning“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in death or severe injury.
WARNING – <Bodily injury>
This symbol in conjunction with the signal word "Warning" indicates a potential electrical
hazard. Failure to observe this safety information may result in death or severe injury.
CAUTION – <Minor injury>
This symbol in conjunction with the signal word “Caution“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in minor or moderate injury.
This may also be used for property damage warnings.
ATTENTION – <Property damage>!
The symbol indicates a potentially damaging situation.
Failure to observe this safety information may result in damage to or destruction of the product
and/or other system components.
IMPORTANT (NOTICE)
This symbol indicates operator tips, particularly useful information, or important information
about the product or its further uses. It does not indicate a dangerous or damaging situation.
6 - EN D400 CI/TZIDC/110/120-EN

Ex relevant safety instructions
1.6 Safety information for electrical installation
The electrical connections may only be performed by authorized specialist personnel according
to the electrical plans.
Comply with electrical connection information in the instruction. Otherwise, the electrical
protection class can be affected.
The secure separation of contact-dangerous electrical circuits is only ensured when the
connected devices fulfil the requirements of the DIN EN 61140 (VDE 0140 Part 1) (basic
requirements for secure separation).
For secure separation, run the supply lines separated from contact-dangerous electrical circuits
or additionally insulate them.
1.7 Operating safety information
Before switching on the unit make sure that your installation complies with the environmental
conditions listed in the chapter "Technical data" or in the data sheet.
If there is a chance that safe operation is no longer possible, take the unit out of operation and
secure against unintended startup.
When mounting the unit in areas that may be accessed by unauthorized persons, take the
required protective measures.
2 Ex relevant safety instructions
Depending on the type of explosion protection, an Ex label is attached to the left of the
positioner beside the main name plate. It shows the explosion protection and the unit's relevant
Ex certificate.
Requirements / preconditions for safe operation of the positioner:
Important
Observe with the unit’s relevant technical data and the special conditions in accordance with
the relevant certificate.
• Manipulation of the device by users is not permitted. Modifications to the unit may only be
performed by the manufacturer or an explosion protection specialist.
• The splash guard cap must be screwed in place to achieve IP 65 / NEMA 4x protection
class. Operating the unit without splash guard cap is prohibited.
• The unit must be supplied with instrument air that is free of oil, water and dust. Do not use
flammable gas nor oxygen or oxygen-enriched gas.
Important – Use in areas with combustible dust
• To prevent loss of its ignition-proof classification, the housing may not be opened.
• Use only cable glands that conform to protection type ≥IP 65.
• Avoid hazardous sliding brush discharges.
CI/TZIDC/110/120-EN D400 EN - 7

Mounting
3 Mounting
Caution - Risk of injury!
Incorrect parameter values can cause the valve to move unexpectedly. This can lead to
process failures and result in injuries.
Before recommissioning a D400 positioner that was used at another
location, the device must always be reset to factory settings. Never start Autoadjust before
restoring factory settings.
3.1 Operating conditions at installation site
Important
Before installation, check whether the D400 positioner meets the
control and safety requirements for the installation location (actuator or valve).
See the „Specifications“ chapter in the operating instructions or on the data sheet.
3.2 Mechanical mount
3.2.1 General
Fig. 1: Operating range
The arrow (1) on the positioner feedback shaft (and the lever) must move through the area
marked by the arrows (2).
8 - EN D400 CI/TZIDC/110/120-EN

Mounting
M00410
12
3
4
+30° +60°
-60°
-30°
+100°
+100°
0°
0°
VOITH
Fig. 2: Positioner range
1 Sensor range for linear actuators
2 Sensor range for rotary actuators
3 Operating range for linear actuators
4 Operating range for rotary actuators
Important
During installation make sure that the actuator travel or rotation angle for position feedback is
implemented correctly.
The maximum rotation angle for position feedback is 60° when installed on linear actuators and
120° on rotary actuators. The minimum angle is always 25°.
CI/TZIDC/110/120-EN D400 EN - 9

Mounting
3.2.2 Mounting on linear actuators
For mounting on a linear actuator in accordance with DIN / IEC 534 (lateral mount per NAMUR)
a complete mounting kit is available, and consists of the items in the following table:
Fig. 3: Mounting kit for linear actuators
• Lever (4) with follower pin, for stroke adjustment 10 ... 35 mm (0.39 ... 1.38 inch) or
20 ... 100 mm (0.79 ... 3.94 inch)
• Follower guide (13) with two screws (10), spring washers (11) and clamp plates (12)
• Mount bracket (3) with two screws (6) and two shims (5)
• Screw (1) and shim (2) for mounting to cast iron yoke
• Two U-bolts (7) with two shims (8) and two nuts (9) for mounting to columnar yoke
Required tools:
- Wrench, size 10 / 13
- Allen key, size 4
10 - EN D400 CI/TZIDC/110/120-EN

Mounting
Procedure:
1. Attach follower guide to actuator
Fig. 4
Important
Hand tighten the screws.
• Attach the follower guide (1) and clamp plates (2) with screws (4) and spring washers (3) to
the actuator stem
2. Mount the lever and bracket on the positioner
Fig. 5
• Attach the lever (6) to the feedback shaft (5) of the positioner (can only be mounted in one
position due to the flat on the side of the shaft)
• Using the arrow marks (4) check whether the lever moves within the operating range
(between the arrows)
• Hand-tighten the screw (7) on the lever
• Hold the prepared positioner with loose mount bracket (1) to the actuator so that the follower
pin for the lever enters the follower guide to determine which holes on the positioner must be
used for the mount bracket
• Attach the mount bracket (1) with screws (2) and shims (3) to the proper holes on the
positioner housing. Tighten the screws as evenly as possible to ensure subsequent linearity.
Align the mount bracket in the oblong hole to ensure that the operating range is symmetrical
(lever moves between the arrows (4))
CI/TZIDC/110/120-EN D400 EN - 11

Mounting
3.a Mounting on cast iron yoke
Fig. 6
• Attach the mount bracket (2) with screw (4) and shim (3) to the cast iron yoke (1)
or
3.b Mounting on columnar yoke
Fig. 7
• Hold the mount bracket (3) in the proper position on the columnar yoke (2)
• Insert the U-bolts (1) from the inside of the columnar yoke (2) through the holes for the
mount bracket
• Add the washers (4) and nuts (5). Hand tighten the nuts
Important
Adjust the height of the positioner on the cast iron yoke or columnar yoke until the lever is
horizontal (based on visual check) at half stroke of the valve.
12 - EN D400 CI/TZIDC/110/120-EN

Mounting
Fig. 8: Linkage for positioner
1 larger
2 smaller
The scale on the lever indicates the link point for the various stroke ranges of the valve.
Move the bolt with the follower guide into the oblong hole of the lever to adjust the stroke range
of the valve to the operating range for the position sensor.
Moving the link point inward increases the rotation angle of the sensor. Moving the link point
outward reduces the sensor's rotation angle.
Adjust the actuator stroke to make use of as large an angle of rotation as possible (symmetrical
around the center position).
Recommended range for linear actuators: between -28 ... 28°
Minimum angle: 25°
Important
After mounting the unit check whether the positioner is operating within the sensor range.
CI/TZIDC/110/120-EN D400 EN - 13

Mounting
3.2.3 Mounting on rotary actuators
For mounting on rotary actuators in accordance with VDI / VDE 3845, the following mounting kit
is available:
Fig. 9
• Adapter (1) with spring (5)
• each four screws M6 (4), spring washers (3) and shim (2) to attach the mounting bracket (6)
on the positioner
• each four screws M5 (7), spring washers (8) and shim (9) to attach the mounting bracket on
the actuator
Required tools:
- Wrench, size 10 / 13
- Allen key, size 3
14 - EN D400 CI/TZIDC/110/120-EN

Mounting
Procedure:
1. Mounting the adapter on the positioner
Fig. 10
• Determine the mounting position (parallel to actuator or at 90° angle)
• Calculate the rotational direction of the actuator (right or left)
• Move the rotary actuator into home position
• Based on the mounting position as well as the home position and rotational direction of the
actuator, determine in which position the feedback shaft (1) for the positioner must be pre-
adjusted and in which position the adapter (2) must be placed to enable the positioner to
travel within the proper range (the arrow on the rear of the device must travel within the
admissible range, see Fig. 1)
• Pre-adjust feedback shaft
• Place the adapter in the proper position on the feedback shaft and fasten with set screws (3).
One of the set screws must be locked in place on the flat side of the feedback shaft
CI/TZIDC/110/120-EN D400 EN - 15

Mounting
2. Attach mounting bracket on the positioner
Fig. 11
1 Mounting bracket
3. Attach positioner to the actuator
Fig. 12
Important
After mounting the unit check whether the operating range for the actuator matches the sensor
range on the positioner.
16 - EN D400 CI/TZIDC/110/120-EN

4 Electrical connection
Warning! Risk of explosion! (TZIDC only)
It is prohibited to use the integrated communication interface (LKS) in an Ex area.
Never use the integrated communication interface (LKS) on the mainboard with a positioner
that is being used in an explosion risk area.
1. Strip the wire by approx. 6 mm (0.24 inch).
2. To connect the signal lines, the emergency shutdown module and the proximity switches or
micro switches, insert the wire ends from the left into the respective screw terminals and
hand-tighten the screws (access from above). To connect a plug-in module, insert the wire
ends from above in the appropriate screw terminals and hand-tighten the screws (access
from the side).
Fig. 13: Terminal connection diagram
A Basic model
B Options
1 Analog input / Bus connector
2 Digital input 1)
3 Digital output 1)
4 Digital feedback 1)
5 Analog feedback 1)
6 Proximity switches
7 Microswitches
8 Emergency shutdown module
1) TZIDC only
Important
Keep cable shields as short as possible and connect on both sides.
CI/TZIDC/110/120-EN D400 EN - 17

Electrical connection
4.1 Screw terminal assignments
Fig. 14
1 Module for analog position feedback 1)
2 Module for digital feedback 1) or service switch of
emergency shutdown module
3 Module for digital position feedback 1) or terminals of
the shutdown module
4 Installation kit for digital position feedback, either
proximity switches or 24 V microswitches
5 Same as 4
6 Digital output DO 1)
7 Digital input DI 1)
8 Signal 4 ... 20 mA / Bus connector
9 Grounding screw
1) TZIDC only
18 - EN D400 CI/TZIDC/110/120-EN

4.2 Jumper configuration on mainboard (TZIDC-120 only)
M00494
1
2
Fig. 15
1 Simulation
2 Write access
There are two jumpers on the mainboard that can be used to activate or block simulation mode
and write access. Set the jumpers as shown below:
M00495
1
2
Fig. 16
1 Block (Simulation blocked 1))
2 Activate (Write access enabled 1))
1) Default setting (complies with Fieldbus Foundation standard)
CI/TZIDC/110/120-EN D400 EN - 19