ABB VAC D500, Commissioning Instructions

Page 1: ...Commissioning Instruction CI EDP300 EN Rev A D500 Electro Pneumatic Positioner ...

Page 2: ...2 32425 Minden Germany Tel 49 551 905 534 Fax 49 551 905 555 Contact us Valve Accessories Controls 205 678 0507 Office 205 678 0510 Fax www vacaccessories com Copyright 2012 by ABB 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 rep...

Page 3: ... option 16 4 4 Setting the option modules 16 4 4 1 Setting the mechanical position indicator 16 4 4 2 Setting the mechanical binary feedback with proximity switches 17 4 4 3 Setting the mechanical binary feedback with 24 V microswitches 17 5 Pneumatic connection 18 6 Commissioning 19 6 1 Checks prior to commissioning 19 6 2 Mechanical mounting checks 19 6 2 1 Moving to end positions following comp...

Page 4: ... be performed if expressly permitted by these instructions Only by observing all of the safety instructions 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 legib...

Page 5: ...r 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 injuries This symbol in conjunction with the signal word CAUTION indicates a potentially dangerous situation Failure to observe this safety information may result in minor ...

Page 6: ...t e g by using air cushioned packaging 1 6 Storage conditions The device must be stored in dry and dust free conditions The device is also protected by a desiccant in the packaging The desiccant guarantees sufficient protection for approximately 150 days It can be regenerated at a temperature of 90 C 114 F within 4 h Remove the desiccant prior to commissioning the actuator or the electronics If yo...

Page 7: ...l Data or on the data sheet If there is a chance that safe operation is no longer possible take the device out of operation and secure it against unintended startup Prior to installation check the devices for possible damage that may have occurred as a result of improper transport Details of any damage that has occurred in transit must be recorded on the transport documents All claims for damages ...

Page 8: ...or a fee 1 12 2 RoHS Directive 2002 95 EC With the Electrical and Electronic Equipment Act ElektroG in Germany the European Directives 2002 96 EC WEEE and 2002 95 EC RoHS are translated into national law ElektroG defines the products that are subject to regulated collection and disposal or reuse in the event of disposal or at the end of their service life ElektroG also prohibits the marketing of e...

Page 9: ...insic Safety type of protection has been approved for operation with natural gas The pneumatic outputs must be vented in non Ex areas The maximum ambient temperature must not exceed 60 C 140 F During operation with flammable gases in type of protection Ex n the device may only be operated with approved cable glands IMPORTANT NOTE Use in areas with combustible dust To prevent loss of its type of pr...

Page 10: ...the installation location actuator or valve See the Specifications section on the data sheet 3 2 Mechanical mounting 3 2 1 General information Fig 2 Working range The arrow 1 on the positioner feedback shaft position feedback point must move between the arrow marks 2 Fig 3 Sensor and operating ranges of the positioner 1 Sensor range for linear actuators 2 Sensor range for part turn actuators 3 Wor...

Page 11: ...t on positioner Fig 6 1 Attach the lever 6 to the feedback shaft 5 of the positioner can only be mounted in one position due to the cut shape of the feedback shaft 2 Using the arrow marks 4 check whether the lever moves within the operating range between the arrows 3 Tighten the screw 7 on the lever so that it is hand tight 4 Hold the prepared positioner with the mount bracket 1 still loose on the...

Page 12: ...alf stroke of the valve Positioner linkage Fig 9 1 Increasing linkage 2 Reducing linkage The scale on the lever indicates the link points for the various stroke ranges of the valve Move the bolt with the follower pin in the oblong hole of the lever to adjust the stroke range of the valve to the working range for the position sensor Moving the link point inwards increases the rotation angle of the ...

Page 13: ...rt turn actuators For mounting on part turn actuators in accordance with VDI VDE 3845 the following mounting kit is available Fig 12 Adapter 1 with spring 5 Four screws M6 4 four spring washers 3 and four shims 2 for attaching the mounting bracket 6 to the positioner Four screws M5 7 four spring washers 8 and four shims 9 for attaching the mounting bracket to the actuator Required tools Wrench siz...

Page 14: ...on of the actuator must be taken into account when determining the adapter position on the feedback shaft 1 For this purpose the feedback shaft can be adjusted manually so that the adapter 3 can be attached in the correct position 5 Attach the adapter to the feedback shaft in the correct position and fasten with threaded pins 2 One of the threaded pins must be locked in place on the flat side of t...

Page 15: ...to the respective screw terminals and tighten the screws so that they are hand tight access from above To connect a plug in module insert the wire ends from above into the appropriate screw terminals and tighten the screws so that they are hand tight access from the side 4 1 Connection diagram Fig 16 A Basic device B Options 1 Analog input 2 Digital input 3 Digital output 4 Binary feedback 5 Analo...

Page 16: ...shutdown module option must be performed at least every 2 years For this purpose the positioner must move the valve into the safety position with the 24 V DC signal terminals 85 86 interrupted 4 3 1 Installing the pressure option M10144 1 2 3 Fig 18 Printed circuit board 1 I P converter pneumatics 2 Position sensor 3 Pressure option 4 4 Setting the option modules 4 4 1 Setting the mechanical posit...

Page 17: ...dback shaft until it closes the contact i e until shortly before entering the proximity switch The slot sensor enters proximity switch 2 when the feedback shaft is rotated counter clockwise as viewed from the front 3 Attach the housing cover and screw it onto the housing 4 Tighten the screws so that they are hand tight 4 4 3 Setting the mechanical binary feedback with 24 V microswitches 1 Loosen t...

Page 18: ...s labeled according to the tap holes available We recommend that you use a line with dimensions of 12 x 1 75 mm The level of supply air pressure required to apply the actuating force must be adjusted in line with the output pressure in the actuator The working range for the positioner is between 1 4 10 bar 20 145 psi Connect the connections according to their labeling Designation Pipe connection S...

Page 19: ...ting Mode Auto Adjust O Adaptive O Control O Manual SP O Manual Sensor Configuration Back OK 2 Use or to select the Manual Sensor operating mode 3 Use and to move to the relevant end positions 45 0 Pos Ang Check the end positions The angle of rotation is displayed in degrees Recommended range between 30 30 for linear actuators between 45 45 for part turn actuators 6 2 2 Moving to end positions wit...

Page 20: ...enu 5 Display showing the current functions of the and operating buttons You can use the or operating buttons to browse through the menu or select a number or character within a parameter value Different functions can be assigned to the and operating buttons The function that is currently assigned to them 5 is shown on the LCD display Control button functions Meaning Exit Exit menu Back Go back on...

Page 21: ... that are relevant for the operator The device configuration cannot be changed on this level Operating modes menu In the operating modes menu the Auto Adjust function can be started for commissioning purposes You can also change the operating modes and switch to the configuration level Configuration level The configuration parameterization instruction contains all the parameters required for devic...

Page 22: ...rated in Adaptive Mode the control parameters are automatically optimized to the operating conditions in small increments This is especially helpful if valves and fittings could not be operated with reference conditions while the Auto Adjust function was in progress The self optimization process in Adaptive Mode is affected by several factors that can result in incorrect adjustments in the long te...

Page 23: ...s The position indicator shows the position in angular degrees for the purpose of checking the mounting conditions 1 Press and hold the relevant operating button for the desired direction 2 Additionally press if the device is to be switched to high speed mode CAUTION Risk of crushing If air escapes due to a leakage the position will not be readjusted Configured stroke limit positions and stroke ti...

Page 24: ...Y1 unit Pressure output 2 PY2 unit Differential pressure DP unit Universal input value UIN unit Error messages In the event of an error a message consisting of a symbol and text e g electronics appears at the bottom of the process display The text displayed provides information about the area in which the error has occurred Process display Electronic The error messages are divided into four groups...

Page 25: ...Use to switch to the Operating Mode menu Operating Mode Auto Adjust O Adaptive O Control O Manual SP O Manual Sensor Configuration Back OK 2 Use or to select the Auto Adjust operating mode 3 Use to confirm your selection Press and hold down the control button for at least 4 seconds wait for the time to count down on the top left of the display Auto Adjust Full Auto Adjust Rotary Linear Exit 1 Use ...

Page 26: ...of parameter values Menu Name Parameter Name Actual Value Next Edit 1 Select the parameters you want to set in the menu 2 Use to call up the list of available parameter values The parameter value that is currently set is highlighted Parameter Name Parameter 1 Parameter 2 Parameter 3 Cancel OK 3 Use or to select the required value 4 Use to confirm your selection This concludes the procedure for sel...

Page 27: ...tuator Type Vent Position Shut Off 0 Control at 0 Shut Off 100 Control at 100 Auto Adjust Mode Start Auto Adjust Device Setup 2 Actuator Type Vent Position SETPOINT RANGE SETTINGS END STOP BEHAVE Recalc Position Display 3 ENGINEERING UNITS Display Value Contrast Control 4 Zone Dead Band DB Approach DB Timeout KP Up KP Down TV Up TV Down Y Offset Up Y Offset Down Input Output 5 DIGITAL INPUT DI Fun...

Page 28: ...alue Switch 1 Logic Switch 1 Active Switch 1 Sim SW 1 MASK MAP Alarm Maintenan Alarm OoSpec Alarm Check Fct Alarm Failure SWITCH 2 Switch 2 Funct Switch 2 Value Switch 2 Logic Switch 2 Active Switch 2 Sim SW 2 MASK MAP Alarm Maintenan Alarm OoSpec Alarm Check Fct Alarm Failure UNIVERSAL INPUT UI SP Value Max UI SP Value Min UI Damping UI Charact Curve UI Out Value Min UI Out Value Max Communicatio...

Page 29: ...t Counter Reset Histograms Reset Status Device Info 8 Hardware Rev Software Rev Mounting Date Communication Tag Long Tag HART7 only Device Address Descriptor Device Message Pneumatic Type Stroke Time Up Stroke Time Dn Service 9 Service Mode Factory Setting ADJUST SENSORS Adjust All Adjust Outputs Pneumatic Remote Sensor Sensor Type SENSOR CALIB Sensor Position AO Alarm Current Change from one to t...

Page 30: ...V Ui 28 V Pi 500 mW Pi 400 mW Ci 4 2 nF Li negligibly small Switching output DO terminals 83 84 Temperature class T1 T4 Temperature class T6 Ui 30 V Ui 28 V Pi 500 mW Pi 400 mW Ci 4 2 nF Li negligibly small Shutdown module terminals 41 42 Temperature class T1 T6 Ui 30 V Pi 1 W Ci 5 3 nF Li negligibly small Analog feedback module terminals 31 32 Temperature class T1 T4 Temperature class T6 Ui 30 V ...

Page 31: ...t in type of protection n or device dust ignition protection through housing tb Signal circuit AI terminals 11 12 IN 22 mA Umax 30 V Switching input DI terminals 81 82 UN 30 V Switching output DO terminals 83 84 UN 30 V Shutdown module terminals 41 42 UN 30 V Analog feedback module UAI terminals 31 32 IN 22 mA UN 30 V Universal analog input module terminals 21 22 IN 22 mA Umax 30 V Digital feedbac...

Page 32: ...D500 CI EDP300 EN Rev A 33 ...