ABB TZID, Operating Instructions Manual

Page 1: ...Operating Instructions 42 18 54 EN Electro Pneumatic Positioner TZID Software Revision 5 07 ...

Page 2: ...r 72 32425 Minden Germany Tel 49 551 905 534 Fax 49 551 905 555 CCC support deapr de abb com Copyright 2006 by ABB Automation Products GmbH Modifications reserved This document is subject to copyright It is intended to help the user operate the equipment safely and efficiently The content may not be copied or reprodcued either in part or in full without the prior consent of the copyright owner ...

Page 3: ...sonnel 10 2 Manufacturer s information 10 2 1 Delivery 10 2 2 CE compliance information 10 3 Installing and commissioning 11 3 1 Mechanical mounting 11 3 1 1 General 11 3 1 2 Operating conditions at the installation site 12 3 1 3 Mounting to linear actuators 13 3 1 4 Mounting to rotary actuators 16 3 2 Pneumatic connection 21 3 2 1 Safety instructions 21 3 2 2 Making the pneumatic connection 21 3 ...

Page 4: ...6 Adjusting low and high alarm limits supplementary mechanical kit for digital feedback 28 3 4 7 Restoring the factory setting 29 3 4 8 Performing the Autostroke 29 4 Display and operator panel 31 4 1 Operating level 1 32 4 2 Operating level 2 33 5 Maintenance 36 5 1 Functional test Readjustment 36 5 2 Checking replacing the filter regulator 36 5 3 Checking the air filter in the positioner 37 5 4 ...

Page 5: ...bol Signal Word Definitions DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury High level of risk WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury Medium level of risk CAUTION CAUTION indicates a potentially hazardous situation which if not avoided could result...

Page 6: ...ed The TZID positioner has been designed and tested in accordance with DIN VDE 0411 Part 1 EN 61 010 Part 1 Safety Requirements for Electronic Measuring Apparatus based on IEC Publication 348 and has been delivered in a safe condition In order to retain the device in a safe condition and ensure safe operation attentively read and follow the instructions given in the sections marked with the respec...

Page 7: ...n rules of the Employers Liability Insurance Association Observe the safety instructions for the pneumatic actuator used The actuator s high actuating power may cause injuries CAUTION Take suitable precautions to ensure that even in case of malfunctions the positioner s max admissible operating pressure of 6 bar 90 psi is not exceeded Otherwise the positioner and or the actuator may be damaged The...

Page 8: ...es observe all standards regulations and directives governing explosion protection and applicable for the construction and use of explosion protected sys tems especially the DIN VDE directives the directives for explosion protection VDE 0165 or EN 60079 and the special requirements and specifications for your devices see the following chapter Explosion protection and chapter Certificates Explosion...

Page 9: ...er use is considered as incorrect The signal current circuit and the input and output circuitry must meet the explosion pro tection requirements stipulated in the certificates see the certificates The maximum permissible ambient temperature range of 40 C to 85 C must not be exceeded WARNING Always observe the specifications and special requirements for your positioner stipulated in the applicable ...

Page 10: ...or are added to the delivery as individual items Check items and scope of the delivery by means of the catalog numbers to see if types and quantities are in accordance with your order If the positioner is delivered already mounted to the actuator the positioner accessories and actuator or final control element are considered as a common delivery item A list of catalog numbers and details of the di...

Page 11: ...uld be greater smaller than these limits by 2 While commissioning the positioner you can determine its angle of rotation by using an electronic parameter The actually used angle of rotation should be at least 20 of the total range This value can also be determined electronically in the commissioning phase IMPORTANT No further steps are required if the TZID positioner is delivered mounted to an act...

Page 12: ...IP65 NEMA 4X and the technical data in this manual Explosion protection Observe the technical data and the specifications in the certificates see the relevant sections of this manual Mounting orientation any orientation allowed WARNING Before installing check to ensure that the specifications in terms of safety and control applicable to the TZID positioner will not be exceeded at the installation ...

Page 13: ...installed All other items are deliv ered in a separate package The lever is available in two lengths for 10 to 85 mm strokes standard version and for strokes 10 to 150 mm special version to be ordered sepa rately Fasten the angular slide rod 8 to the actuator stem using the screws M6 10 and spring washers 9 1 Angle bracket 2 Spring washer B8 3 Screw M8x20 4 Lever 5 Screw M4x8 6 Spring washer B4 7 ...

Page 14: ... a columnar yoke Fasten the angle bracket 1 with the screw 2 and the plain washer 3 to the cast iron yoke 4 Hold the angle bracket 1 in the appropriate position against the columnar yoke 2 Insert the U bolts 5 from the inner side of the columnar yoke through the holes in the angle bracket Slip on the plain washers 3 spring washers 4 and nuts 2 Hand tighten the nuts evenly IMPORTANT Adjust the heig...

Page 15: ...position sensor by shifting the bolt in the lever s oblong hole A scale on the lever helps you to determine the valve stroke range Use the lever scale to set the bolt to the appropriate position A rough adjustment is suffi cient The fine adjustment will be done later in the commissioning phase using the Autostroke function Bolt Lever with scale Increase valve stroke Decrease valve stroke Fig 6 Pos...

Page 16: ...ady fastened to the positioner 1 Hexagon head screw M6x12 2 Plain washer A6 4 3 Spring washer B6 4 Hexagon head screw M5x10 5 Plain washer A5 6 Spring washer B5 7 Mounting bracket 8 Adapter IMPORTANT Pay attention to the following information when mounting the TZID positioner to a rotary actuator Position feedback to the positioner is only possible through counter clockwise rotation seen from the ...

Page 17: ...ty When mounting the positioner make sure that there is a loose fit between the adapter at the positioner and the actuator shaft It must be possible to move the adapter manually within the range of 0 1 0 3 mm If required readjust the mounting bracket The TZID positioner is prepared for this type of mounting when it is delivered No adapter settings are required Couple the positioner s adapter with ...

Page 18: ...Re fasten the setscrews Couple the positioner s adapter with the rotary actu ator s shaft Turn TZID clockwise by approx 15 siehe Fig 11 Fasten TZID with screws Fig 10 Adapter position shifted by 90 Setscrew with flat point Setscrew with cone point Counterclockwise rotation of the actuator Clockwise rotation of the positioner Fig 11 Mounting TZID to an actuator turning counterclockwise shifted by 9...

Page 19: ... 12 Re fasten the setscrews Couple the positioner s adapter with the rotary actu ator s shaft Turn TZID clockwise by approx 105 see Fig 13 Fasten TZID with screws Fig 12 Adapter position shifted by 90 Setscrew with flat point Setscrew with cone point Clockwise rotation of the actuator Clockwise rotation of the positioner Fig 13 Mounting TZID in parallel with an actuator turning clockwise ...

Page 20: ...adapter settings are required Couple the positioner s adapter with the rotary actu ator s shaft Turn TZID clockwise by approx 105 see Fig 15 Fasten TZID with screws Setscrew with flat point Setscrew with cone point Fig 14 Adapter position factory setting Clockwise rotation of the actuator Clockwise rotation of the positioner Fig 15 Mounting TZID to an actuator turning clockwise shifted by 90 ...

Page 21: ...tioner s operating range is between 1 4 and 6 bar WARNING Observe the accident prevention rules of the Employers Liability Insurance Association Observe the safety instructions for the pneumatic actuator used The actuator s high actuating power may cause injuries NOTICE Take suitable precautions to ensure that even in case of malfunctions the positioner s max admissible operating pressure of 6 bar...

Page 22: ... An optional filter regultor can be attached to the pressure gauge block When attaching the filter regulator make sure that the regulator housing is oriented vertically to ensure that condensed water is drained off Set the supply air pressure to a maximum value of 16 bar using the ajdustment spindle Mark Connection piping SUP ZUL IN Air supply pressure 1 4 6 bar 20 90 psi Y1 OUT1 Output pressure t...

Page 23: ...ns for your devices see chapter Certificates Explosion proof devices may only be supplied with safe extra low vol tage SELV according to EN 60 950 When using the positioner intrinsically safe with flammable gas observe the special conditions stipulated in the certificates CAUTION Observe the following instructions They are essential to proper operation and functionality of the positioner General D...

Page 24: ... One is equipped with a cable gland and in the other a pipe plug is mounted In its standard version the TZID positioner is delivered with the cable gland already installed The terminals have the following assignment Cable entries 1 2 14 NPT or M20 x 1 5 Fig 18 Cable entries Connector for LKS adapter Terminal block 8 pole 2 mm jacks for FSK modem Grounding terminal Fig 19 Terminals ...

Page 25: ...d wiring efforts depend on the number of supple mentary modules used Refer to the rating plate or the catalog number for details AI AO SW 1 SW 2 10 V 30 V 4 20 mA 11 12 24 V DC 4 20 mA 31 32 41 42 51 52 41 42 Limit 2 Limit 1 51 52 Digital feedback Analog input Option 1 Base unit Option 2 Analog feedback Option 3 Switches for digital feedback L 1mA H 2mA 5 11V DC L 1mA H 2mA 5 11V DC Fig 20 Termina...

Page 26: ...tuator The positioner can be adapted to the operational data of the actuator in the Autostroke mode In this operating mode a program is started which determines all relevant data and transmits them to the positioner No manual adjustment is required Refer to the sec tion about operating level 2 Display 2 0 Autostroke for details about the Autostroke Successful self adaptation using the Autostroke f...

Page 27: ... action Changing over from direct to reverse action Call up operating level 2 display 2 0 Autostroke Press and hold the Down push button Wait until the displayed countdown from 3 to 0 is finished then release the Down button Press and hold the Down button again Wait until the displayed countdown from 3 to 0 is finished then release the Down button The display shows the code P31 which is flashing i...

Page 28: ...tioner has been mounted to the actuator and after an Autostroke has been performed Observe the direction of action of the NC and NO switches Direction of action NC Control lug out of proximity switch state 1 control current 3 mA Control lug within proximity switch state 0 control current 1 mA Direction of action NO Control lug out of proximity switch state 0 control current 1 mA Control lug within...

Page 29: ... button 3 4 8 Performing the Autostroke The Autostroke function is started via the operator panel see section Display and opera tor panel The individual steps and thus the progress is indicated on the display The following is a reference list Display Autostroking function 10 Fully depressurize the actuator 11 Save position of fully depressurized actuator 12 Determine and save resolution A D conver...

Page 30: ...eps 10 to 32 200 Parameters only steps 40 to 120 200 Zero only refer to the list below for the steps and their meaning1 Display Autostroking function 10 Move actuator to closed position 11 Save closed position 12 Determine and save resolution A D conversion 13 Zero adjustment 200 Autostroke completed 1 A Zero Autostroke requires that the range has been determined before using the TZID software ...

Page 31: ...ror code appears on the dis play Refer to the Appendix for a reference list of the error codes with their reasons and suggestions for help When the positioner is started the software revision level 5 0 at the time when this document is prepared is shown on the display for a short time Reset Mode Operating mode 1 0 1 1 1 2 1 3 2 0 2 1 2 2 2 3 Controlling adaptive Controlling fixed Manual control up...

Page 32: ...ntil reaching the set point Controlling fixed means that the values determined by Autostroke are no longer read justed automatically The display of the position as a percentage between 0 and 100 is the same as for adaptive control Display 2 Manual control In this mode the valve can be adjusted manually by pressing the Up towards 100 and Down towards 0 buttons Pressing both buttons simultaneously w...

Page 33: ... the high alarm limit is shown by the display for a short time Then the alarm limit in referred to the stroke of 0 100 is shown 4 2 Operating level 2 You can only access and exit operating level 2 for configuration through special manual entries Calling up operating level 2 1 Press and hold Up and Down buttons simultaneously 2 Press Reset briefly and release 3 Wait until displayed countdown from 3...

Page 34: ...ling up operating level 2 you can also select four operating modes 0 1 2 3 Display 2 0 Autostroke In Autostroke mode the positioner adapts itself automatically to the following operating parameters Actuator action direction of action with compressed air Travel of the actuator valve from stop 0 to stop 100 Positioning time for both directions pressurizing and depressurizing the actuator Control par...

Page 35: ...2 2 and then the deter mined value Normally the default angle of rotation 0 100 is indicated Do not confound this read ing with the 0 100 display of the stroke The angle of rotation in for a stroke of 0 and of 100 can be seen by pressing the Up and Down buttons Press both buttons together for a quick run Note that the order in which the buttons are pressed determines the direction The scanned valu...

Page 36: ...l check can be performed Due to the electronic function no mechanical adjustment is possible During operation the positioner s zero can be checked and readjusted if required When the system is switched off an Autostroke can be performed to re adapt the positioner to the operating conditions 5 2 Checking replacing the filter regulator If the optional filter regulator is installed it collects conden...

Page 37: ...hort time If polluted air is supplied for a longer time the filter is clogged with dirt Proceed as follows 1 Switch off compressed air supply 2 Remove the screw plug retaining the air filter 3 Remove the filter element using tweezers and check the degree of pollution Replace the filter element if required Spare filter elements can be ordered from ABB under catalog number 7942511 4 Insert the filte...

Page 38: ... and remove the old output unit 4 Insert the new output unit Make sure that the gasket with its cutting is posi tioned correctly 5 Re insert the Torx head screws and torque them to 350 Ncm 31 in lbs 6 Connect the plug Make sure that the plug snaps in properly The connector is protected against polarity reversal 7 Switch on compressed air supply CAUTION Prior to starting any work on the pneumatic o...

Page 39: ...n request Function for single or double acting actuators air is vented from actuator or actuator is blocked if input signal 3 9 mA Shut off point Setable to 0 20 of signal when the value falls below the set value the positioner immediately sets the valve to the closed position Travel Angle of rotation 60 nominal range for attachment to linear actuators in acc with DIN IEC 534 120 nominal range for...

Page 40: ...00 Characteristic curve travel f signal linear equal percentage 1 25 or 1 50 or 25 1 or 50 1 and freely configurable with 20 reference points Characteristic deviation 0 5 Tolerance band sensitivity 0 3 10 adjustable Resolution A D conversion 8 000 steps Sample rate 20 milliseconds Influence of ambient temperature 0 5 for every 10 C change in temperature Influence of vibration 1 up to 10 g and 80 H...

Page 41: ... 1867 X Type Explosion proof Zone 2 Device class II 3G EEx n A II Temperature class T4 T5 T6 Permissible ambient temp T4 40 C Tamb 85 C T5 40 C Tamb 65 C T6 40 C Tamb 50 C FM Intrinsically safe CL I II III Div 1 Grp A B C D E F G Non incendive CL I II III Div 2 Grp A B C D E F G Explosion proof CL I II III Div 1 Grp B C D E F G CSA Intrinsically safe Enclosure 4X T4 max 85 C CL I Div 1 Grp A B C D...

Page 42: ...ctions Screw terminals internal for 2 5 mm2 NOTICE Do not expose the terminals to strain Cable entry Threades holes depending on model and order 1 2 14 NPT or M20 x 1 5 TZID is delivered with the cable gland already installed Pneumatic connections Threaded holes G 1 4 or 1 4 18 NPT Weight 2 9 kg TZID with aluminum case 5 6 kg TZID with stainless steel case Mounting orientation as required but no o...

Page 43: ...rection of action Normally logical 0 or logical 1 configurable Model standard or intrinsically safe Switch assignment 1 switch for alarms 2 switches for min or max position adjustable between 0 and 100 Mechanical kit for digital position feedback 2 proximity switches for current circuits acc to DIN 19234 Control voltage 5 25 V DC Signal current 1 mA switching state logical 0 Signal current 3 mA sw...

Page 44: ... for supply pressure and output pressure Plastic or stainless steel case Ø 40 mm Supply pressure range 0 10 bar 0 140 psi Output pressure range 0 10 bar 0 140 psi or 0 4 bar 0 60 psi With connection block and attachment material for TZID Connection block made of aluminum varnished black or of stainless steel Filter regulator with attachment material All metal version brass varnished black Bronze f...

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Page 64: ...eedback is out of range None Correct the alarm limit setting E18 Stop of angle of rotation reached Control stopped current position blocked Check the mechanical linkage for position sensing If required reset it to the adjusted range E19 Positioning time out None Check the actuator valve Check the air tubing E20 Autostroke disabled None Enable Autostroke only possible via a PC with the appropriate ...

Page 65: ...ustment in operating mode 2 3 out of range None Set the zero adjustment to the permissible range E34 Automatic control not active operating mode 1 2 1 3 2 1 2 2 2 3 or 2 0 during Autostroke None Activate automatic control in operating mode 1 0 or 1 1 if you want to terminate the inactive state E37 Signal out of range 4 20 mA None Set the signal to the range 4 20 mA E40 Setting of parameters disabl...

Page 66: ...ad Saving data in the non volatile memory is no longer possible Replace the device E79 EEPROM defective Output depressurized or blocked depending on setting for the model Replace the device E92 Short time interruption of input signal 20 ms Output depressurized or blocked depending on setting for the model Check the input signal E93 Watchdog internal self monitoring Output depressurized or blocked ...

Page 67: ...fy the information contained herein without notice Printed in the Fed Rep of Germany 03 06 ABB 2005 42 18 54 EN Rev B ABB Ltd Salterbeck Trading Estate Workington Cumbria CA14 5DS UK Tel 44 0 1946 830 611 Fax 44 0 1946 832 661 ABB Inc 125 E County Line Road Warminster PA 18974 USA Tel 1 215 674 6000 Fax 1 215 674 7183 ABB Automation Products GmbH Schillerstr 72 32425 Minden Germany Tel 49 551 905 ...