Badger Meter SRD-SRI Valve Positioners User Manual

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Valve Positioners

RCV SRD991 Intelligent Positioner

POS-UM-00010-EN-03 (August 2014)

User Manual

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Valve Positioners, RCV SRD991 Intelligent Positioner

Page ii August 2014POS-UM-00010-EN-03

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User Manual

CONTENTS

Device Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

With Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Without Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Common Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Unpacking & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Accident Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Summary – Hart and 4-20 mA without Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mounting to Actuator (Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Connection and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Conguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Summary – Foundation Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connection and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Bus Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Summary – Probus-PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mounting to Actuator (Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connection and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Bus Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Summary – FoxCom (Digital) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Mounting to Actuator (Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Connection and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

System conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Method of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Device Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Valve Positioners, RCV SRD991 Intelligent Positioner

In Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Failsafe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Out of Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Simulate (Foundation Fieldbus Version Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Functional Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pneumatic Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Mounting to Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

NAMUR Mounting Linear Actuator, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

NAMUR Mounting Linear Actuator, Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Linear Actuator, Direct Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Mounting to Rotary Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pneumatic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Additional Inputs / Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Built-in Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Setting by Means of Local Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

After Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

In Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operation with Local Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Menu Structure for SRD991 / SRD960 with LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Conguration of 0 and 100% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Description of Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Setting the Travel Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Selecting Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Exchange of Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Service Plug and IrCom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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User Manual

Supply Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Removing the Electronics Unit* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Errors Detected During Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Errors Detected During Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Diagnosis without LED or LCD Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

EMC and CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Explosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

System Conguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

HART Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

FoxCom Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

With Communication PROFIBUS-PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

With Communication FOUNDATION Fieldbus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

System Conguration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Dimensions INOX SRD991 in Stainless Steel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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Valve Positioners, RCV SRD991 Intelligent Positioner

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Device Features

The intelligent positioner SRD991 is designed to operate pneumatic valve actuators and can be operated from control systems, controllers or PC-based configuration and operational tools, such as FDT/DTM Software. The positioner is available with different communication protocols. The multi-lingual full text graphical LCD in connection with the three push-buttons allows a comfortable and easy local configuration and operation as well as the display of valve specific data, and status and diagnostic messages.

DEVICE FEATURES

• Autostart with self-calibration

• Self diagnostics, status and diagnostic messages

• Easy operation with three keys

• Multi-Lingual full text graphical LCD, or LEDs

• VALcare or Valve Monitor DTM for valve diagnostics and predictive maintenance

With Communication

• HART, FOUNDATION Fieldbus H1, PROFIBUS-PA, FoxCom

• Configuration by means of local keys, handheld terminal (HART), PC or I/A Series system or with a infrared interface by means of IRCOM

Without Communication

• Input signal 4…20 mA

Common Features

• Stroke 8…260 mm (0.3…10.2 in.) with standard lever; larger stroke with special lever

• Angle range up to 95° (up to 300° on request)

• Supply air pressure up to 6 bar (90 psig), with spool valve up to 7 bar (105 psig)

• Single or double-acting

• Mounting on linear actuators according to NAMUR

◊ IEC 50534-6-1

◊ VDI/VDE 3847

• Mounting on rotary actuators according to VDI/VDE 3845 or IEC60534-6-2

• Protection class IP 66 and NEMA 4X

• Approved for SIL applications

• Explosion protection: Intrinsic safety according to ATEX and FM/CSA

Repair and maintenance operations must be carried out by qualified personnel!

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Labels

LABELS

A Nameplate B Nameplate C Warning labels, terminal wiring,key and

LED-designation

D Brief description inside cover

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Unpacking & Inspection

UNPACKING & INSPECTION

Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment.

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the

carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

Installation and startup of instrument to be carried out only by qualified personnel, familiar with installation and start-up procedures and operation of this product!

SAFETY INFORMATION

The installation of this product must comply with all applicable federal, state, and local rules, regulations, and codes.

Failure to read and follow these instructions can lead to misapplication or misuse of the product, resulting in personal injury and damage to equipment.

Accident Prevention

The connected instrument contains mechanically moved parts, such as feedback levers, which could cause injuries. The operators have to be instructed accordingly.

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.

• 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 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.

SUMMARY  HART AND 4…20 MA WITHOUT COMMUNICATION

Mounting to Actuator (Valve)

The SRD991 can be mounted to linear or rotary actuators.

Connection and Startup

When connecting the supply air and applying a current source to the input terminals, pay attention to polarity. An initial startup required no additional equipment.

Use the local push-buttons to change basic parameters such as type of actuator, side of installation, valve opens/closes with increasing setpoint value, and characteristics curve of the valve (values set ex-factory: stroke actuator, mounting side: left, valve opens with increasing setpoint value, linear characteristics curve).

Thereafter, an AUTOSTART can be performed during which the SRD991 determines independently the geometric data of the actuator as well as control parameter, to ensure an optimized operation with the attached valve.

HART version:

The positioner can be operated either locally or via handheld terminal or PC (via modem).

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Summary – Hart and 4…20 mA without Communication

System Conguration

Version 4…20 mA without communication: Connection as traditional point-to-point connection according to the known regulations of the measuring & control techniques.

HART version: When using ‘Communication’ (an AC signal which modulates on the 4-20 mA signal), make sure the connected outputs, buffer amplifier and barriers are compatible with the frequency ranges used. In addition to the load, the AC impedance requirements must be met. Therefore, it is recommended that only the specified amplifier, barrier and configuration device be used.

To prevent crosstalk between lines and reduce disturbances through electromagnetic influences, use twisted-pair shielded lines with a diameter of AWG 22…14 (0.3…2.5 mm2) and a maximum capacity of 100 pF/m.

The line capacities and connected devices may not exceed the maximum values listed for a particular HART protocol.

All components that are connected to the SRD in an explosion hazardous area require an Ex-Approval. The applicable limit values must not be exceeded. Comply with the limit values when connecting additional capacitances, inductances, voltage or current sources.

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Summary – Foundation Fieldbus

SUMMARY  FOUNDATION FIELDBUS

Mounting to Actuator (Valve)

The SRD991 can be mounted to linear or rotary actuators.

Connection and Startup

When connecting the supply air and applying a current source to the input terminals, pay attention to polarity. An initial startup required no additional equipment.

Bus Connection

The SRD 991 in the version FOUNDATION Fieldbus is bus compatible, which means that to a 2-core lead, the instruments have to be attached in parallel according to IEC 1158-2. The lead serves as voltage feeder as well as for digital communication.

A FOUNDATION Fieldbus can consist of one or several segments, each with an individual length of up to 1900 meters. An Ex-barrier should not be further than 100 meters from a bus terminal. To a segment up to 32 instruments can be attached. A maximum of up to 240 instruments can be addressed (including repeater = connector of segments). To activate each instrument individually, an individual address has to be entered.

From the factory, the address 29h (41) is always stored. This address can be changed automatically with the NI-Configurator.

System Integration

With the NI-Configurator changes in the configuration of the SRD991 can be carried out. The required files (*.FFO, *.SYM, *.CFF) can be downloaded from the Internet by path http://www.foxboro-eckardt.com/products/srd991_en.html.

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More informations about FOUNDATIONFieldbus seewww.fieldbus.org

Summary – Probus-PA

SUMMARY  PROFIBUSPA

Mounting to Actuator (Valve)

The SRD991 can be mounted to linear or rotary actuators.

Connection and Startup

When connecting the supply air and applying a current source to the input terminals, pay attention to polarity. An initial startup required no additional equipment.

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More informations about PROFIBUS see www.profibus.com

Summary – Probus-PA

Bus Connection

The SRD 991 PROFIBUS-PA version is bus compatible, which means that to a 2-core lead the instruments have to be attached in parallel according to IEC 1158-2. The lead serves as voltage feeder as well as for digital communication. To activate each instrument individually, an individual address has to be entered.

From the factory the address 126 is always stored 1); Since this address cannot be used during operation, a new address has to be entered in every instrument. This can be done via the local keys, with the FDT/DTM software or a commercial configurator.

To a PROFIBUS-PA-segment with a length of up to 1900 meters, up to 32 instruments can be attached. A maximum of up to 126 instruments can be addressed with PROFIBUS.

System Integration

During operation the SRD991 will communicate with a PROFIBUS master class 1. The required GSD-file (“instrument-specific dates”) can be downloaded from the Internet by path http://www.foxboro-eckardt.com/products/srd991_en.html.

as per profile 3.0

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Summary – FoxCom (Digital)

SUMMARY  FOXCOM DIGITAL

Mounting to Actuator (Valve)

The SRD991 can be mounted to linear or rotary actuators.

Connection and Startup

When connecting the supply air and applying a current source to the input terminals, pay attention to polarity. An initial startup required no additional equipment.

FoxCom version:

The positioner can be operated either locally, via PC, or via I/A Series System (FoxCom).

System conguration

When using ‘Communication’ (a digital signal with constant amplitude), make sure the connected outputs, buffer amplifier and barriers are compatible with the frequency ranges used. In addition to the load, the AC impedance requirements must be met. Therefore, use only the specified amplifier, barrier and configuration device.

To prevent crosstalk between lines and reduce disturbances through electromagnetic influences, use twisted-pair shielded lines with a diameter of AWG 22–14 (0.3…2.5 mm2) and a maximum capacity of 100 pF/m.

The line capacities and connected devices may not exceed the maximum values listed for a particular FoxCom protocol.

All components connected to the SRD in an explosion hazardous area require an Ex-Approval. The applicable limit values must not be exceeded. Comply with the limit values when connecting additional capacitances, inductances, voltages and currents.

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Method of Operation

METHOD OF OPERATION

General

The intelligent positioner SRD991 1 and the pneumatic actuator 2 form a control loop with the setpoint value w (from master controller or control system), the output pressure y and the position x of the actuator on valve 3.

Figure 1: Fieldbus version

For the supply air, use a filter regulator.

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sAir supply 1.4... 6 bar (20... 90 psig)

Method of Operation

The positioner can be attached to both linear 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.

HART or FoxCom version:

The positioner can be operated locally by means of local keys or a handheld terminal, or remotely via PC-based configuration or a corresponding control system.

PROFIBUS-PA or FOUNDATION Fieldbus version:

The positioner can be operated locally by means of local keys, remotely via a corresponding control system, or can be operated via PC-based configuration and operating tools.

Block Diagram

Input (w) each acc.to version:

Analog operation

•

4...20mA (+FSK)

• Digital operation

FSK

13...36 VDC

• Bus input

Output pressure to actuator

xPosition

of actuator

Operation

With the intelligent positioner with input signal 4-20 mA or superimposed HART signal, the supply takes place via the power signal adjacent to the input.

By means of voltage converter 7, derivation of the internal supply of the electronics takes place. The power value is measured, in A/D transformer 9 converted, and directed via switch 10 to digital controller 11.

With PROFIBUS-PA or FOUNDATION Fieldbus, the SRD is powered by means of the bus cable. The positioner is operated from a control system by sending a setpoint (setpoint value) to the positioner. The digital signal is directed via the interface component 8 to the digital controller 11. By means of the voltage converter 7 the internal supply of the electronics is established, fed via the bus cable.

With FoxCom digital operation, a DC voltage is provided at input w. On this voltage an FSK signal is modulated. The modulation contains information, such as setpoint value, sent digitally to the control unit 11 across the FSK unit 8.

The output of controller 11 drives the electro-pneumatic converter (IP-module) 12, controlling a pre-amplifier 13, the single acting (or double acting) pneumatic power amplifier 14. The output of the amplifier 14 is the output pressure y to the actuator.

The pneumatic amplifiers are supplied with supply air 1.4…6 bar (20…90 psig).

The position x of the actuator is sent to the control unit 11 by the position sensor (conductive plastic potentiometer) 15.

Optional gauges 16 , pressure sensors 19 , 20 , inputs / outputs 21 (two binary outputs; a 4…20 mA output and alarm; control inputs for ‘Open/Close’ and ‘Hold last value’) enable additional diagnostic indications and possible intervention. The mechanical limit switch 22 (optional) enables independent alarm signals.

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Operating Modes

Adjusting and startup of the positioner, as well as the demand for internal information, can be made using the local keys 17 with indication given by LCD, 18 or LEDs.

OPERATING MODES

Operation of the positioner is divided into individual operating modes. Operating modes may change depending on, for example, key commands or internal calculations. The different operating modes are described in abbreviated form below.

Initialize

Upon powerup or reset (pressing the 3 keys simultaneously), several self-tests are conducted. Individual steps in the self-test process are indicated by the LCD or green LEDs.

If no error occurs, the device moves to OUT OF SERVICE, if it is still in a delivery condition; AUTOSTART has to be performed. If AUTOSTART was done already, the device will go to IN OPERATION.

If faults are detected, the code of the faulty self-test will remain. If error occurs again after reset, the device is probably defective and should be sent in for repair.

Device Fault

In the event that the LCD shows a message (or red LED lights up constantly and all green LEDs are off), a device fault is signaled. These faults are detected during cyclical self-test.

The device can no longer be operated. This could be caused by a jammed menu key or defective program memory.

If a device error occurs repeatedly, the device should be sent in for repair.

In Operation

After performing an AUTOSTART, the device moves to IN OPERATION and will always, even after restarting or resetting, move back to the safety position (de-energized valve position) or FAILSAFE. If setpoint values are fed via communication, the SRD will go to IN OPERATION.

Failsafe

With FF H1 and Profibus PA Communication

Positioner carries out actions as configured in menu “failure handling”. Additionally, the cyclical self-diagnosis takes place.

If the instrument is IN OPERATION, but no setpoint values arrive via communication, the SRD will go to FAILSAFE mode, after a defined time period; either with

• maintaining last value

• output pressureless, or

• with predetermined position.

As soon as setpoint values arrive via communication again, the instrument is immediately back IN OPERATION.

Out of Service

The SRD991 as delivered is configured to remain OUT OF SERVICE after powerup until moving to IN OPERATION via the manually initiated function AUTOSTART.

In the device state OUT OF SERVICE, the menu entering mode remains active at all times. If a device has been IN OPERATION already and is removed from an actuator and mounted to another, it is recommended to take the device out of operation via RESET CONFIG (Menu 9.1) prior to disconnecting the device from the first actuator.

This enables the next actuator to be started in the delivered condition (see “Startup”).

Calibrate

During an AUTOSTART function the device is in condition CALIBRATION. The actuator is moved up- and downward several times, and the device could be busy for a few minutes. Subsequently, the device moves to IN OPERATION.

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Operating Modes

Message

The SRD991 continuously supervises important device functions. In the event that limit values are exceeded or operational problems occur, messages are signaled via the LCD or the special LED blinking mode.

The message with the highest priority will be indicated first. With key DOWN additional messages can be called up, with key UP the measuring values can be retrieved. It is possible at all times to reach the menu by pressing the menu keys to possibly eliminate the problem by performing suitable menu functions. Further references may be found in chapter “Troubleshooting”.

Simulate (Foundation Fieldbus Version Only)

During function IN OPERATION, the valve position queried via the communication, can be simulated with a value that has been entered via communication into the instrument during position SIMULATION. Thereby the positioner continues with normal operation and regulates to the ”accurate” set value.

For the SRD, this function has to be additionally released or blocked via menu 10.

LCD description, definition of the LEDs and possible operator interventions are described in “Startup” on page 39.

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FUNCTIONAL DESIGNATIONS

11 12 13 14 15

4) Depending on theversion,the device is equipped with or withoutLEDs

Functional Designations

1a Adapter, eg. 1/2”-14 NPT 1b Cable gland 2 Plug, interchangeable withPos.1 3

Screw terminals1)(11 / 12) for input (w)or

for bus connectionIEC 1158-2

3a Screw terminals1)for additional inputs/outputs 3b Test socketsØ2mm, integrated in terminalblock 4 Ground connection 5 Female threadG)1/4 -18 NPT or outputI(y1) 6 Female threadG)1/4 -18 NPT for air supply (s) 7 Female thread

1/4 -18 NPT or outputII (y2)

8 Direct attachment holefor outputI(y1) 9 Feedback shaft

Connection manifold forattachment to stroke actuators (not withVDI/VDE 3847 version) Connection base forattachment to rotary actuators Travel indicator Key UP Key DOWN Key M (Menu)

16 Status display(1red LED, 4 green LEDs) 16a LCD withtruetext in 3different languages 19 Fixing shaftfor limit switch 20 Coverwith window to 12

Air vent, dust and water protected

21 22 Data label 23 Tipjacks

Ø2mm forcurrent measurement

24 Switch2)for currentmeasurement 25 Tipjacks2)Ø2mm forcommunication 26 Arrow is perpendicular to shaft 9 at angle 0 degree 27 Ball valvefor protection class NEMA 4X 28 High cover withbuilt-in limit switch 29 Plug for service connector

30 IrCom interface

G) With marked letter "G"inthe housing the pneumatic connecting threads

arecut as G1/4 instead of 1/4-18 NPT

1) Alternatively Cageclamps(WAGO) instead of screwterminals

2) Only with FoxCom version

3) Not with FoxCom version

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T LEXG-F1: LEXG-G1: LEXG-H1:

Alternative: Amplifier, (Connection LEXG-X1: LEXG-Y1: LEXG-Z1:

When mounting, check theproper seating of theO-rings

Functional Designations

Pneumatic Accessories

andbolt on theaccessorieswiththe twoM8 bolts. Unused outputs are closed by meansof plastic plugs.

ypes withG-threads instead of standard NPT-threads:

As LEXG-F, however withthread G1/4

As LEXG-G, however withthread G1/4 As LEXG-H, however withthread G1/2

independent of positioner:

from positioner to amplifier with tubes) As LEXG-F1, however externally mounted As LEXG-G1, however externally mounted As LEXG-H1, however externallymounted

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Mounting to Actuators

MOUNTING TO ACTUATORS

NAMUR Mounting Linear Actuator, Left Side

Applicable to actuators with cast yoke or pillar yoke according to NAMUR (DIN IEC 534-6).

Mounting the positioner with pneumatic connections on the left side and electrical connections on the lower right side.

Figure 2: NAMUR mounting, left side

Attachment of the positioner to the actuator is made to the left using the mounting bracket and feedback lever for a NAMUR mount. Use: attachment kit EBZG -H for a cast yoke, or attachment kit EBZG -K for a pillar yoke.

The side outputs I (or I and II) are used. The rear output I is closed by means of a lock screw 522 588 013.

Pneumatic connections: Do not use Teflon tape for sealant. The fine fibers could disturb the function of the SRD. Apply only Loctite® #243 sealant to the male thread.

Screw-type glands for electrical connections are positioned on the lower or right side. Any unused threaded holes are closed by plugs.

If housing cover has an air vent, this air vent must facedown when mounted.

Preparing the Positioner

Rotate the shaft stub of shaft 9 so that the flat on the shaft stub is perpendicular to the arrow 26 on the housing at mid travel range (detail see “Mounting Dimensions for Direct Mounting”). Fasten the feedback lever A to the shaft by means of spring washer and nut M8.

Figure 3: Feedback lever

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Mounting to Actuators

Preparing the Actuator

Screw the carrier bolt to the stem connector and lock it by means of a counter nut.

A carrier bolt with an adjustable length is used to be able to screw on various coupling pieces.

Figure 4: Carrier bolt

It consists of a stud S, which is screwed into the coupling piece K (with 3 mm Allen key) and locked with a lock nut M6. The threaded sleeve H is screwed onto it and locked with a lock nut M6. Make sure that the bolt is adjusted to the right length!

Fasten the mounting bracket to the left side of the yoke. For a cast yoke use a screw M8 x 30, for a pillar yoke use two U-bolts and four nuts.

Mounting of the Positioner

Fasten the positioner to the mounting bracket using two spring washers and two screws M8 x 80.

Note, the carrier bolt B is in the slot of the feedback lever A and the compensating spring F touches the carrier bolt.

Figure 5: Feedback lever

For optimum use of the positioner operating range, it is recommended that the arrangement is adjusted according to the following procedure before fixing. At an actuator position in the middle of travel range, the feedback lever position should be perpendicular to the actuator stem and the angle range should be between −10…10° and −45…45°.

Fasten the positioner to the mounting bracket so that a suitable angle range is selected.

It is recommended that the pneumatic and electrical connections are made after adjusting the position.

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NAMUR Mounting Dimensions – Left Side

LCD orientation canbe changed by means of local push buttons under Menu

9.9.2to„flipped“,to ensure acorrect orientation of the display.

Mounting to Actuators

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Mounting to Actuators

NAMUR Mounting Linear Actuator, Right Side

Right-side mounting is done if left-side mounting is not possible for structural reasons.

Applicable to actuators with cast yoke or pillar yoke according to NAMUR (DIN IEC 534-6).

Mounting the positioner with pneumatic connections on the right side and electrical connections on the left side.

Figure 6: NAMUR mounting, right side

Attachment of the positioner to the actuator is made to the right using the mounting bracket and feedback lever for a NAMUR mount. Use: attachment kit EBZG -H for a cast yoke, or attachment kit EBZG -K for a pillar yoke.

The side outputs I (or I and II) are used. The rear output I is closed by means of a lock screw 522 588 013.

Pneumatic connections: Do not use Teflon tape for sealant. The fine fibres could disturb the function of the SRD. Apply only Loctite® #243 sealant to the male thread.

Screw-type glands for electrical connections are positioned on the left side. Any unused threaded holes are closed by plugs.

If housing cover has an air vent, this air vent must facedown when mounted.

Preparing the Positioner

Rotate the shaft stub of shaft 9 so that the flat on the shaft stub is perpendicular to the arrow 26 on the housing at mid travel range (detail see “NAMUR Mounting Dimensions – Right Side”). Fasten the feedback lever A to the shaft by means of spring washer and nut M8.

Figure 7: Feedback lever

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Mounting to Actuators

Preparing the Actuator

Screw the carrier bolt to the stem connector and lock it by means of a counter nut.

A carrier bolt with an adjustable length is used to be able to screw on various coupling pieces.

Figure 8: Carrier bolt

Fasten the mounting bracket to the left side of the yoke. For a cast yoke use a screw M8 x 30, for a pillar yoke use two U-bolts and four nuts.

Mounting the Positioner

Fasten the positioner to the mounting bracket using two spring washers and two screws M8 x 80.

Note, the carrier bolt B is in the slot of the feedback lever A and the compensating spring F touches the carrier bolt.

Figure 9: Feedback lever

For optimum use of the positioner operating range, it is recommended the arrangement be adjusted according to the following procedure before fixing. At an actuator position in the middle of travel range, the feedback lever position should be perpendicular to the actuator stem and the angle range should be between −10…10° and −45…45°.

Fasten the positioner to the mounting bracket so that a suitable angle range is selected.

It is recommended that the pneumatic and electrical connections are made after adjusting the position.

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Mounting to Actuators

NAMUR Mounting Dimensions – Right Side

Mounting bracket,feedback lever and carrier bolt

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Mounting to Actuators

Linear Actuator, Direct Mounting

Actuators with appropriately prepared yoke (PA200, PA350) enable mounting of the SRD991 directly to the actuator yoke.

Figure 10: Direct mounting

Bolt the positioner directly to the actuator yoke using the feedback lever for a direct mount (with attachment kit EBZG -D).

The rear output I and the side outputs I and II are used as follows:

• Actuator single acting, spring force closes: The rear output I is used (remove lock screw in hole D ). The side output I is closed by means of a lock screw.

• Actuator single acting, spring force opens: The side output I is used. The rear output I is closed by means of a lock screw.

• Actuator double acting: The rear output I and the side output II is used. The side output I is closed by means of a lock screw.

Pneumatic connections: Do not use Teflon tape for sealant. The fine fibers could disturb the function of the SRD. Apply only Loctite® #243 sealant to the male thread.

Screw-type glands for electrical connections are positioned on the side. Any idle female threads are closed by means of plugs.

If housing cover has an air vent, this air vent must facedown when mounted.

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Mounting to Actuators

Preparing the Positioner

Figure 11: Feedback lever

Preparing the Actuator

Screw in the carrier bolt B on the coupling piece K on the drive spindle S at the lower left and lock it by means of a nut M6.

Figure 12: Carrier bolt

Mounting the Positioner

Figure 13: Feedback lever

Fasten the positioner to the upper part of the yoke using 2 spring washers and 2 screws M8 x 80, as shown above. The rear output I of positioner has contact to the air duct R in the yoke.

Note the correct position of the O-ring on the yoke for the rear connection I!

Note, the carrier bolt B is in the slot of the feedback lever A and the compensating spring F touches the carrier bolt.

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Mounting Dimensions for Direct Mounting

Mounting to Actuators

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Mounting to Actuators

Mounting to Rotary Actuators

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 photograph below.

Figure 14: Mounting to rotary actuator

The feedback shaft 9 of the SRD has no mechanical stop, therefore may spin 360°. The permissible rotation angle range is between 50…–50° around the arrow at the housing concerning the flat area of the feedback shaft (also see

“Mounting Dimensions for Direct Mounting” bottom). Since a rotary actuator has a rotary angle of about 90°, the mounting as

described in the following must be carried out very precisely.

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 fibers could disturb the function of the SRD. Apply only Loctite® #243 sealant to the male thread.

Screw-type glands for electrical connections are used as needed. Any unused threaded holes are closed by plugs.

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.

Preparing the Positioner

Valve must be in failsafe position 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 spring 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 double-acting actuator (without spring reset) both air chambers are basically equal. Failsafe position can be either “open” or “close”. Therefore, indication of the failsafe position has to be determined by engineering. Then the direction of rotation may be determined by manual feeding of compressed air.

Bolt 2 is screwed into actuator drive shaft 1 for subsequent centering of the rotary adaptor 3. The attachment console is mounted to the stroke actuator (see illustration).

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Figure 15: Attachment diagram for bracket

Mounting to Actuators

Figure 16: Rotary adaptor

Preparing the Actuator

Prepare the rotary adapter:

• For attachment to a counter-clockwise or left turning actuator, secure the stud screw 4 in the threaded hole “L” of the rotary adaptor; hole “R” remains open.

• For attachment to a clockwise or right turning actuator secure the stud screw 4 in the threaded hole “R” of the rotary adaptor; hole “L” remains open. Stud screw should always be tightened into the flat on the on the feedback shaft 9.

Place the rotary adaptor 3 with two washers 5 on the feedback shaft 9 of the positioner against the stop.

OTE:N When the product temperature rises, the drive shaft 1 becomes longer. Therefore, mount the rotary adaptor 3 with

approximately 1 mm (0.04 in.) of clearance between the drive shaft 1 and the rotary adaptor 3. Add washers 5 on the feedback shaft stub 9 before attaching the rotary adaptor. Two washers should result in a clearance of 1 mm.

Screw and tighten the bolt in the coupling against the flat part of the feedback shaft (do not screw against thread!).

Turn the feedback shaft so that the arrow of the coupling points to the arrow of the SRD housing. Beginning and end positions of the actuator drive shaft 1 and feedback shaft 9 are marked by arrows for the respective direction of rotation.

The feedback shaft is now in the normal position corresponding to the failsafe position of the actuator.

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Mounting to Actuators

Mounting the Positioner

SRD and actuator are in failsafe position.

Attach the SRD 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 positioner to the bracket by means of 4 lock washers and 4 screws M6 x 12.

SRD

Direction

of rotation

0 → 100 %

of feedback

shaft

SRD

Direction

of rotation

0 → 100 %

of actuator

Rotary actuator

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shaft

Rotary actuator

Page 33

PNEUMATIC CONNECTIONS

FRS923 filter regulator.

Supply

Supply air pressure .......1.4 to 6bar (20 to 90 psig)

Air supply ...............accordingto ISO 8573-1

- Solid particle size and density class2

-Oil rate ..............class3

- Pressure dew point 10 K under ambient temperature

For air supply, we recommend the FOXBORO ECKARDT

Pneumatic Connections

W ARNING

To avoid anypersonal injury resulting from burstingofparts,do not exceedmaximum supply pressure of positionerand actuator. To avoid anypersonal injury or propertydamage fromsuddenor fast movement, during airconnection: Do not put your fingerorother part at anytime insidethe valveor in anymoving part of theactuator. Do not put your fingerorother part at anytimeinthe feedback levermechanism. Do nottouchthe rear part of thepositioneratany time.Connect airsupply only after connection Y1 andY2 (fordoubleacting)are done.

Following alignment and mounting of thepositioner to the valve, pneumatic tubing has to be provided.

Explanationofabbreviatons:

s Supply air y1-d Output 1for direct mounting,depressurizedat

currentless electronics.When using this output has to be closed by meansofhex.screw.

y1 Output1,depressurized at currentlesselectronics.

When usingthisoutput, means of sealing screw and O-ring.

y2 Output2fordouble-actingactuator. Full pressure at

currentless electronics. Closedatsingle-acting actuator.

n1 Hex. Screw with NPTthread

Part No.522 588 013 (stainless steel) Part No.556 446 016 (plastic)

n2 Sealingscrew with O-ring

Unused pneumatic connectionsmust be closed off.

FAIL SAFE POSITION FOR DOUBLE ACTING

Fail safe position of the double acting valveis given by the fail safe action of the pneumaticofthe positione ritself. In case positioner is de-energized: Output Y1 is 0 Output Y2 is 100% of airsupply pressure

Thereforedopneumatic piping of Y2 to the chamber of the actuator that should be pressurized to do the requested fail safe. In any caseput air supply only when theoutput Y2 is connected.

y1-d has to be closed by

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Electrical Connection

ELECTRICAL CONNECTION

TO AVOID ANY ELECTRICAL SHOCK, RESPECT THE MAXIMUM INPUT SUPPLY VOLTAGE FOR THE DEVICE AND OPTIONS. TO AVOID ANY PERSONAL INJURY OR PROPERTY DAMAGE FROM SUDDEN OR FAST MOVEMENT, DURING ELECTRICAL CONNECTION: DO NOT PUT YOUR FINGER OR OTHER PART AT ANY TIME INSIDE THE VALVE OR IN ANY MOVING PART OF THE ACTUATOR. DO NOT PUT YOUR FINGER OR OTHER PART AT ANY TIME IN THE FEEDBACK LEVER MECHANISM. DO NOT TOUCH THE REAR PART OF THE POSITIONER AT ANY TIME.

Unused cable glands should be closed off.

Feed in the bus cable through the gland 1. The gland is suitable for cable diameters of 6…12 mm (0.24…0.47 in). Observe the tightness of the cable entry.

Make the electrical connection of the input line at the screw terminals 3b, whereby with fieldbus devices no polarity has to be observed. The terminals are suitable for wire cross-sections of 0.3…2.5 mm2 (22 -14 AWG).

The shield of the bus connection is

• with conductive cable glands (recommended) directly connected with the housing

• with non-conductive cable glands to be placed onto the inner screw terminal 4. OTE:N When connecting shielded cable, connect the cable shield on both sides (on the positioner as well as on the system

side). For selection of cable, see recommendation for cable types according to IEC 1158-2.

For connection to a local ground, use the internal and external ground terminal 4.

Test sockets for measuring purposes are integrated into the connecting terminals. With version HART or FoxCom at clamps 11+ and 12– a handheld terminal or modem for communication can be attached.

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Electrical Connection

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Options

OPTIONS

Limit Switch

TO AVOID ANY PERSONAL INJURY DO NOT TOUCH CONTROL VANES DURING OPERATION.

Remove three screws A including tooth lock washer from plastic cover.

Attach limit indicator B 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 longer screws C and washers.

Test: the coupling 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 C 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 28 (or standard cover with insert frame) on housing.

Figure 17: Limit switch

Figure 18: Switch functions

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, the control vanes can be adjusted relatively to the angle rate, so that, for example, one vane dives into and another dives out of the sensor (see illustration).

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Setting Limit Switch Trigger Points

First loosen screw S until disc D is no longer blocked by bolt B. Then turn disc by 90°, until set screws 1 and 2 are accessible.

Set trigger point switch GW1: Turn screw 1 at mark (•), until desired switch behavior is reached.

Set trigger point switch GW2: Turn screw 2 at mark (• •), until desired switch behavior is reached.

To fix switch points turn disc again by 90°, until the bolt catches, then fasten tight the center screw S.

Figure 19: Levels of control vanes (illustration without cover)

Additional Inputs / Outputs

General

All versions of the SRD991 are prepared to retrofit this option.

Take current off SRD and turn off the supply air. Unscrew cover and remove electronics unit 40.

Attach option board 8 to connection ledge (observe orientation, see illustration). Refasten electronics unit 40.

After initialization, acknowledge message 10 by simultaneous pressing keys UP + DOWN.

Options

Option “Position Feedback and Alarm”

The analog output for position feedback indicates the valve position 0…100% as current signal 4…20 mA 1). Signal range is

3.8…20.5 mA, at fault approx. 0.5 mA.

The direction of action of the position response message is set: valve position 0% = 4 mA; valve position 100% = 20 mA

The binary output for Alarm will be activated in the following cases (see “Messages”):

• Calibration error (for example due to break-up of calibration) Message 3

• Output outside of limits determined during Autostart (Check mounting of feedback lever) Message 5

• Circuit to potentiometer is disturbed (cable plugged?) Message 5

• Circuit to IP module is disturbed (cable plugged?) Message 6

• No actuator movement; Message 7

• Remaining control deviation (packing is too tight?) Message 11

Signal range: 1 mA resp. 4…6 mA, at fault < 50 A.

In the event of disturbances in the electronics of the SRD, the Watchdog circuit is activated. The binary output for alarm signalizes this as “cable failure”.

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Options

Figure 20:

Option “Two Binary Outputs”

Both binary outputs AB1 resp. AB2 switch to high current as soon as the valve position is below resp. exceeds the associated limit value. If the binary outputs AB1 resp. AB2 are to be inverted (higher current no alarm, lower current alarm), the association upper/ lower alarm have to be exchanged.

Signal range 1 mA resp. 5…6 mA, at fault < 50 A.

Option “Binary Inputs”

The binary inputs EB1 and EB2 for two external switches resp. sensors initiate the following actions:

EB1 EB2 Action

closed closed IN SERVICE

open closed Position to be operated

full power to 0%

closed open Position to be operated

full power to 100 %

open open Hold last value

Factory setting. Via communication actions may be turned off or used otherwise. EB1 and EB2 can thus also be used as

diagnostics inputs.

An input not used is to be short-circuited (wire bridge between + and –).

Attention: Even if opening limit or closing limit are set: these actions are superimposed, and the actuator actually moves to 0 % resp. 100%.

Built-in Pressure Sensors

The pressure sensors 50 are part of the electronics 40 , therefore, the electronics has to be exchanged for conversion to this option.

Disconnect electric power and air supply. Remove cover and electronic unit 40.

Remove, if present, the M3 bolts with sealing washers from both chimneys 52. Press in a sealing plug 51 Part No. 534 346 013 into the top of each chimney 52 until the collar makes contact. DO NOT GREASE!

To install an electronics unit with pressure sensors, carefully guide the tubes 50 of the pressure sensors vertically into the sealing plugs 51. Do not twist or tilt the unit. Fasten screws on the electronics unit.

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Startup

Figure 21: Pressure sensors

STARTUP

TO AVOID ANY PERSONAL INJURY OR PROPERTY DAMAGE FROM SUDDEN OR FAST MOVEMENT, DURING CONFIGURATION AND AUTOSTART:

DO NOT PUT YOUR FINGER OR OTHER PART AT ANY TIME INSIDE THE VALVE OR IN ANY MOVING PART OF THE ACTUATOR. DO NOT PUT YOUR FINGER OR OTHER PART AT ANY TIME IN THE FEEDBACK LEVER MECHANISM. DO NOT TOUCH THE REAR PART OF THE POSITIONER AT ANY TIME.

ENSURE YOU THAT PNEUMATIC CONNECTION IS MADE ACCORDING TO “PNEUMATIC CONNECTIONS”.

General

Check the nameplate with respect to indications referring to Ex / non- Ex, input signal, communication, output signal, single / double acting, additional inputs / outputs.

Setting by Means of Local Keys

The SRD991 can be adjusted by means of a local keypad when the cover is off.

M (Menu) start menu / end menu

UP / DOWN counting up/down of menu numbers resp. parameter numbers

UP + DOWN simultaneously: confirm at start, or when entering, storing, or verifying

M + UP + DOWN simultaneously: Reset = new start of SRD, thereafter initialization

The stored data of the positioner is not affected, and remains unchanged.

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MDOWN UP

M1 234

1c ¼f ¾f ½f –OFF

Operation

Indication with LCD

In totally intuitive text:

Before starting the positioner, mount the SRD to the actuator; connect power and air supply. The supply air connection must have sufficient capacity and pressure of 1.4…6 bar (20…90 psig) and should not exceed the maximum operating pressure of the actuator.

OTE:N Configuration using local keys or the communication interface may interfere with operation of the actual process!

During configuration it is recommended that there is no flow through the valve.

Figure 22: Local keys

If there is no response using the local keypad (message 1 appears), make sure that the Write Protection is not set. Remove the write protection using the FDT/DTM configuration software.

Indication with LEDs

The LEDs serve as indication in the following methods:

½½ ---Mand LED1flash

onstant light,ON lashing: shortON, long OFF lashing: long ON,short OFF lashing: ON andOFF same duration

OPERATION

After Power ON

INIT: After power on of the input signal, or after reset, the SRD initializes, and the various components of the electronics are checked and started. (The stored data of the positioner not affected, and remains unchanged).

The current status is stated on the LCD in clear text or indicated as LED code.

Initialization after positioner startup takes approx. 3 sec, then the SRD goes

• Into operation (Autostart has already been done) or

• To configuration, Menu 9.9 (with LCD, select the text language).

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...

Select with keys

(together)

½=ON and OFF flashing same duration

UP or DOWN and confirm with UP+DOWN

and the display orientation is selected ...

then automatically continued to configuration:

Configuration

MENU: The various specifications for configuration are arranged in menus:

LEDsflash

red green

M 1234

½½ 1

½½ 2

Description

Actuator system, mounting side

Autostart, ShortAutostart

Operation

½½3

½½4

½½½ 5

½½ ½ 6

½½ ½ 7

½½½ 8

½½½9

½½½ 10

Versions without LCD: This menu can be configured only with version HART or version “without communication”.

Valve function

Characteristic of setpoint

Limits and Alarms

Parameterfor position controller

Manual setting of pneumatic output

Manual setting of valve position

Calibrationfunctions for workshop

PROFIBUS-PA:BusAddress FOUNDATION F.:Simulate

In Operation

After an autostart, the SRD automatically goes IN OPERATION. (Additional parameters can be configured by pressing the menu key M.)

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Operation

87.5 %

On the LCD display the process variable is indicated.

(With LED version, all LEDs are off during operation.)

Through pressing of keys UP or DOWN, additional information can be retrieved from the SRD:

(Certain data is available only with the corresponding options.)

Manual Operation

Press UP+DOWN together to put the SRD into manual operation mode, where the valve position can be set manually. Press M twice to exit the menu.

Diagnostics During Operation

If the diagnostics determines an occurrence, this is indicated in

87.5 %

MESSAGE: The SRD recognizes an occurrence which the user must eliminate by taking suitable steps in order to continue with operation. This can be e.g. a wrong configuration or missing supply air.

ERROR: During self-testing the SRD recognized an error and is no longer operable.

the bottom line: (resp. blinking code with LEDs).

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Operation with Local Keys

Operation

With LCD

• Press M to enter the Menu mode. Menu 1 appears.

• Press UP or DOWN to select the desired Menu item Each press of the key moves one menu item forward (or back).

• Press UP+DOWN together to confirm the selected menu item and enter the Parameter change mode for the selected menu item.

• To exit the Menu mode, press M again. If the device remains in the Menu mode, it still is OUT OF SERVICE and AUTOSTART has to be initiated. If the device is IN OPERATION, the display with the valve position appears. If you select a menu but press no other keys for a few moments, the SRD switches automatically back to operation.

With LED

• Press M to enter the Menu mode. The red LED flashes alternately with the green LED1, which indicates the Menu item 1.

• Press UP or DOW to select the desired Menu item Each press of the key moves one menu item forward (or back). The flashing green LEDs indicate the selected menu item. LED test before configuration: Move from menu item 1 to 4 and inspect that each LED lights.

• Press UP+DOWN together to confirm the selected menu item and enter the Parameter change mode for the selected menu item. The red LED goes off and the remaining green LED indicates the parameter or state to be set.

• To exit the Menu mode, press M again. Red and green LEDs extinguish when device is IN SERVICE. If device remains in Menu mode, it still is OUT OF SERVICE and AUTOSTART has to be initiated. If you select a menu but press no other keys for a few moments, the SRD switches automatically back to operation.

Exception in Menu 6 (and at PROFIBUS Menu 10). No parameter indicated at rst, but ashing rhythm with long green and short red phases. This points to a sub-menu. Then entry

into parameter selection as described.

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Operation

Menu Structure for SRD991 / SRD960 with LCD

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Additional Parameters

The following parameters are accessible via communication only:

Control difference limit value 5% Control difference response time 1 min

Parameter write protectio Alarm limit fortotal strokes 90 Mio. Alarm limit fortotal cycles 90 Mio. Dead band for valve cycles 1% Set value source: Model CodexFxx digital Set value source: all others analog

Hysteresis for position alarms 0.5%

For the complete parameter list, see the FDT/DTM Software.

Operation

yrotcafxeretemaraP

%5.0siseretsyhgnilaeS

FFOnoitkA-efasliaF

ECIVRESNInoitcapu-rewoP

%001mrala-erpreppU %0mrala-erprewoL

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Operation

Conguration of 0 and 100%

Valid for single and double acting

Configuration requested

MENU 1:

"Mounting"

1.11.2 1.31.4 3.1 3.2

MENU3:

"Valve Action"

Configuration of0and 100%

Input Signal

Range

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

Linear

Left

Linear

Right

Rot

cclockw

Rot

clockwise

Direct Reverse

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

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Valid for single and double acting

Configuration requested

MENU 1:

"Mounting"

1.11.2 1.3 1.4 3.

Operation

MENU 3:

"Valve Action"

Configuration of 0and 100% Request Action

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

Linear

Left

Linear

Right

cclockw

Rot

clockwise

Direct Reverse

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

4mA=0%

20 mA = 100%

4mA=100%

20 mA =0%

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Confirm

Operation

Description of Menus

Menu 1: Actuator System, Mounting Side

withkeys UP+DOWN

W ARNING

To avoid anypersonalinjuryorpropertydamagefromsuddenor fast movement, during configuration: Do not put your finger or otherpartatany time inside thevalve or in anymoving part of the actuator.Do not putyourfinger or otherpart at anytimeinthe feedback lever mechanism. Do nottouch therear part of thepositioneratany time.

M 1234

½½ ---Mand LED1flash

Foranoptimal actuator adaptation theSRD hastobeconfigured whether it isarotaryoralinear actuator.

The positioner of the rotary actuator can work directly with thelinearposition sensorvalue. In case of a stroke actuator an error tan(α )arises due to the angle of theresultingin1%non-linearityattravelof 30°. The SRD is able to correct thetravel viathe tanfunction and thus avoid bigger linearity errors.

The rotationdirectionofthe adaptershaft forthe tapchangesdepending on the mountingsideofthe stroke actuator. “Valve closed” in one case means “Valve open” in another one.

There are rotary actuator typesopening in thecounter clockwise direction and othersopening in theclockwise direction. This also has to be signaled to theSRD so that 0% “Valve closed” and100% “Valve open” arecorrectly assigned.

(Further with UP key:)

-1--- LED 1lightsup

Forstroke actuators mountedleft of thespindle resp. directly mounted.

--1-- LED 2lightsup

For stroke actuators mountedright of thespindle.

---1- LED 3lightsup

For rotaryactuators opening thevalve during counter clockwise (left)rotation.

----1 LED4lightsup

For rotaryactuators openingthe valve during clockwise (right)rotation.

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Menu 2: Autostart

M123 4

Selection betweendifferent Autostart modes (change withkey UP or DOWN):

Autostart:

To automatically adapt the positioner to the valve. Geometric dataofthe actuator is determined and optimally assignedtocontrol parameters. If the "Standard" Autostart does not resultinstableregulation, another Autostart mode-depending upon actuator-shouldbeselected. At initialstart-up, an Autostart should always be performed.

2.2 Ready for"Standard"Autostart:

With keyUPorDOWN to other Autostart modes:

2.1 Ready for "End points" Autostart: Serves for automatic adjustment of the SRD to the mechanicalend points.

2.3 Ready for "Enhanced" Autostart: To the optimizationofthe controllerparametersinrelationtostandard mode:

2.4 Ready for "Smoothresponse" Autostart: Extended, damped controllerparameters fore.g. smaller drives

2.5 Ready for "Fastresponse" Autostart: Extended, undamped controllerparameters fore.g.largerdrives

Operation

½-½- -MandLED 2flash

Attention:Autostart overwrites previouscontrol parameters!

-1--1 LED1andLED 4lightsup

--11-LED 2 and LED 3lightsup

- -1-1LED 2and LED4lights up

-1-1-LED 1and LED3lights up

-11--LED 1 and LED 2lightsup

W ARNING

To avoidany personalinjuryorpropertydamage from sudden or fast movement, duringautostart: Do not put your fingerorother part at anytimeinside the valve or in anymovingpart of theactuator. Do not put your fingerorother part at anytimeinthe feedback lever mechanism. Do not touchthe rear part of the positioneratany time.

After selection andstart taking severalminutes canbefollowedatLCD or thegreen LEDs . Durationonavalve positioncan take some time depending on actuator volume, air supply,pressure, etc.

-1--- LED1lights up

Moving direction, mechanical startingand ending positions are determined by one or several passagesofvalve position range.

- -1- -LED 2lightsup

Ramps areentered and controlsystemparameter is determined(ratio position/valvesize).

---1-LED 3lightsup

Jumps are entered for determination of control parameters.

----1LED 4lightsup

Determinationof positioning speeds.

----- AllLEDs are off

Determined values aresaved;previous valuesare superscribed. The SRD is IN SERVICE againwiththe detected new parameters.

(bypressing theUP+DOWN keys)the function

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M1 234

Operation

Menu 3: Mode of Action of SRD and Additional Position Feedback

½- -½-MandLED3flash

Function of the positioner is setat: It will set themodeof actionofthe positioner and theoptionally present feedback. Without thecard“position feedback”, themenuitem“Feedback” is not displayed.

3.1Select “SRD”:

¼¾ ---Mshort flash, LED1long flash

-1--- LED1lights up

3.1.1“Normal”if increasing inputsignal is to initiateincreasing output signal.

----1 LED4lightsup

3.1.2“Reverse”ifincreasing input signal is to initiatedecreasing output signal.

3.2Select “Feedback”: (if present)

¼-¾- -Mshortflash,LED 2 longflash

-1--- LED1lights up

3.2.1“Normal”for increasing current with increasing valve position.

----1 LED4lightsup

3.2.2“Reverse”for decreasing current with increasing valve position.

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Menu 4: Characteristic of Setpoint

M 1234

½- --½MandLED4flash

A relationship between theinput signal and valveposition is set.

-1--- LED 1lightsup

4.1 “Linear”.See Fig. 4.1

--1-- LED 2lightsup

4.2 “Equalpercentage”: Resultsinanequal percentage characteristicline withaposition ratio of 1:50 foravalveoflinear characteristic. See Fig. 4.2

---1- LED 3lightsup

4.3“Inverse equal perc.”:Resultsinaninverselyequal percentagecharac teristic line with a positionratio of 50:1for a valve of linear characteristic. See Fig. 4.3

Operation

----1LED 4light sup

“User definedcharacteristic”: Acharacteristic line entered via communication (not via local keys) with 2to22supportingpoints)isactivated. A linear characteristic is factoryset.

3.4.giF2.4.giF1.4.giF

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Note:

inversely equal percentage characteristic

Operation

Menu 5: Limit and Alarms of Valve

With versionswithLCD,the values canbeadjusted stepwiselocallyin “clear text” withkeysUPorDOWN. With versionswithLED andHARTor“withoutcommunication”, the corresponding currentofthe valveisrated via analog output and entered with keys UP+DOWN. With versionsLED andfieldbus, thevalues can be entered only via communication. With versionswithcommunication, thevaluescan be configured also with corresponding software.

Sealing tightly, linear charcteristic line

Opening limit x

, Closing limit xz, linear characteristic

Sealing tightly, inversely equal percentage

Openinglimit xa,Closing limitxz,

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5.1SettingLower limit (”closinglimit“)

-1--- LED 1lightsup

Thepositionerprovides that IN SERVICEthe valve position doesnot close anyfurtherthan definedbythe closing limit.Ifthe setpoint valueislower than this limit,message 12 is produced.

By pressing of UP or DOWN keys,the valueisadjusted and confirmedwithkeysUP+DOWN. Thekeys haveAutorepeat:By pressing and holding of akey UP or DOWN,the valueis counted upward,aftersome time in largersteps.

Example: Lowerlimit is setto2%.

5.2SettingCutofflow (”0% seal-tightpoint“)

--1--LED 2lightsup

If a0%seal-tight point is given, in case thesetpoint is deviated lower(e.g. 3 %), theSRD provides thepneumaticoutputto press thevalve into its seat with full forceinordertotightlyseal valve. As soon as thecommandvalue is 1%* higher than this seal-tightvalue,the position again follows thecommand value.

*This istthe “Seal-tighthysteresis” factoryset at 1%.The value may be changed via

communication.

5.3SettingCutoffhigh(“100%seal-tight point”)

---1- LED3lightsup

If a 100%seal-tight pointispre-set andincaseacertainset valueisexceeded (e.g.97 %), theSRD provides that thepneumatic outputpresses thevalve 100% intoits seat with full force. This functionmakes sense for3-way valves. Also bothseal-tight pointscan be used in order to tightlyclosethe respective shut-offpathduring partial operation.

Example: Cutoff high is setto97%.

Operation

5.4 Setting Upperlimit (”opening limit“)

----1 LED4lights up

TheSRD provides that IN SERVICEthe valve position does not open any further than defined by theopeninglimit.Ifthe setvalue is exceeded, message13is produced.

Definitions

Stroke, strokerange of the membrane actuatoris definedfor rotary actuator as angle, angle range.

0%position is the mechanical impact at actually closedvalve (cautionif usinghandwheel andmechanically adjust-

100%position is the mechanical impact at actually open valve.

Closing limit is a lower limit setvia software. In normal operation the valvewill not close morethanset here.

Opening limit is a upper limit set via software. In normal operationthe valvewill not close morethan sethere.

Normal operation (= IN SERVICE)means that the position is controlled to the4–20mA input signal.

able stroke limitation!)

Attention:Inthe event of failureofthe auxiliaryenergy no controlling is possible,therefore thesprings in the actuator will move thevalveintosafety position(forsingle-actingactuator).

Attention:Inthe event of failureofthe auxiliaryenergy no controlling is possible,therefore thesprings in

the actuator will move the valveintosafety position(forsingle-acting actuator).

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Operation

Split Range

Split-Range, PV_Scale Splitting

Split Range 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.

With conventional positioners, this function is realized through serial connection of the instruments and allocation of individual regulating ranges (see drawing). With SRD with analog setpoint value (version HART or “without communication”), this can be adjusted with menus 5.5 and 5.6.

The other versions of the SRD receive the set value via digital means; the input data signal cannot be split. The function can be realized either in the primary control system, in which setpoint values are calculated for each valve, or via the variables PV_SCALE. With PV_Scale the digital input setpoint value can be assigned to the valve span.

Example: At low current, only the smaller valve positions; from approx. 40% the large valve is added

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SRD991 with HART or without Communication

(Withthe other versionsofthe SRD, thesemenus cannotbeselected.)

Operation

5.5 Split Range0%

-1-1- LED1 andLED3lightsup

LED:The value that wasadjustede.g.withaloop calibrator at theinputof theSRD,is entered with confirmation of keysUP+DOWN as 0%value. LCD:By pressingofkeysUPorDOWNthe valueisadjustedand confirmed withkeysUP+DOWN.

5.6 Split Range 100%

---11LED 3and LED4lightsup

LED: Thevaluethat was adjusted e.g. with an loop calibratoratthe input of theSRD,is entered with confirmation of keys UP+DOWNas 0%value. LCD:By pressingofkeysUPorDOWNthe valueisadjustedand confirmed withkeysUP+DOWN.

Thekeys have Autorepeat:Bypressing and holding of akey UP or DOWN,the value is counted upward, after sometimein larger steps.

Example:Aninput currentof10.4mAhas to correspond toavalve position of 100 %.

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5.7Setting LowerAlarm

Operation

-11--LED 1and LED2lightsup

When falling below theset value underneaththe entered alarm limit, an alarmisactivated. Message 12 is generated. To switch offthe alarmsetting, enter thevalue –10%.

5.8Setting UpperAlarm

- -1-1LED 2and LED4light sup

When surpassingthe setvalue above theentered alarm limit, an alarmis activated. Message 13 is generated. To switch offthe alarmsetting, enter thevalue +110%.

By pressing of keys UP or DOWN,the valueisadjustedand with keys UP+DOWN confirmed. ThekeyshaveAutorepeat:Bypressing and holding of akeyUP or DOWN,the valueiscounted

upward,aftersometime in largersteps.

Example: UpperAlarmset to 91.3%.

5.9Valve Limits (Not with versions FF/PB/FoxCom with LED display) At Autostartthe SRD determines thereal limits of theactuator (which generally arealittle largerthenspecified on the specification sheet). An actuator with 30 mm stroke, could display a real strokeof33 mm. In order to produceaprecise relationshipbetweenthe input signal andthe stroke, thetolerances of theactuator can be compensated with menus5.9 and

5.10. At unchanged0%,the actuator could be moved until exactly30mm are reached. Through executionoffunction 5.10, thecurrent positioncan be declared as 100%and at asetpoint valueof50%,the actuator will run on exactly15 mm. For new configuration of the strokes at 0% or 100%, thevalve must be run in thecorresponding position and then must be confirmed.

5.9Setting Valve0%

-11-1LED 1, LED2and LED4lightsup

Theactual positionofthe actuator is declaredas0%.

5.10 Setting Valve 100 %

--111LED 2, LED3and LED4lightsup

Theactual positionofthe actuator is declaredas100 %.

By pressing of keys UP or DOWN,the valueisadjustedand with keys UP+DOWN confirmed. ThekeyshaveAutorepeat:Bypressing and holding of akeyUP or DOWN,the valueiscounted

upward,aftersometime in largersteps.

Example:The actual valve position 98.4%is to be countedas 100 %.

5.11 Setting Stroke with stroke actuators (onlywith LCD)

--11-(LED2and LED3lightsup

TheSRD measures with itsfeedbacklever always onlyan angle and by means of itstangentfunction, a linear stroke of 0to 100 %iscalculated therefrom.In order to indicateas wellarealstrokein mm, thefull strokeat 100%can be entered in this menu. The LCD display will then indicatethe actual positioninmm (or inch). (Changingofdisplay to “inch” viacommunication.)

By pressing of keys UP or DOWN,the valueisadjustedand with keys UP+DOWN confirmed. ThekeyshaveAutorepeat:Bypressing and holding of akeyUP or DOWN,the valueiscounted

upward,aftersometime in largersteps.

Example:Stroke range of valveistobe30 mm.

5.12 Temperature unit (only with LCD) Selection of temperature indicationin°Cor°F.

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Menu 6: Parameter for Position controller

Along with thedetermination of theactuatorgeometry and control

Operation

parameters the suitable setting parameters forthe position controller are determined via function AUTO- STARTinMenu2.Assessmentofa control behavior generallyisvery subjective.Partiallyaquickresponseis requested withoutconsiderationofthe overshootwidth, partiallyavery smoothswinging is requested with minor overshoot.

We basically recommend to first performthe execution of theautomatic setting via AUTOSTART in Menu 2inorder to achieve a stable control behavior. Corrections maythenbemadefromthe determined values. In rare cases AUTOSTART cannot find theoptimal setting forthe respective application.See “Remarks forcontroller optimization” following table 4.

For small actuators an improvement of thecontrol behaviorcan be achieved also by increasing damping at the pneumatic output. Afurther optimizationmay followby repeating AUTOSTART.

M 1234

½½ -½-M, LED 1and LED3flash

Seven controlparametersare combined in Menu 6each availing of asubmenu. 15 different values maybeselectedineachoftheseand pressing of UP+DOWN be enteredinthe position controller as constant. Controller type is aPIcontroller.

etc.

ParameterDesignation

Proportionate amplification

Integration time constant

Positioning time Dead band for

control diff.

Valveis

opening

Valve is

closing

Unit

P P -

T63

Tn sec

T63 sec

GAPGAP %of span

The dead band prevents(at theexpense of accuracy) that the valve in the controlled condition constantly moves around the setpoint. This reduces harm to themechanical partsofthe actuator and, in particular, the valve packing.

Selectionofsub-menus:

M 1234

¼-¾- -M,LED2flash: P

¼¾¾ --M, LED 1and LED2flash: P

¼- -¾-M,LED3flash:Tn

¼¾ -¾-M, LED 1and LED3flash: Tn

¼ ---¾M,LED4flash:T63

¼¾ --¾M, LED 1and LED4flash: T63

¼-¾¾ -M, LED 2and LED3flash: GAP

Followingselection of thesub-menu thecodesfor the parameter values (table 4) can be selected by pressing UP+DOWN:

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Table 4: Allocationofthe parameter values to coding:

50 50

52 32

Operation

In LCD shown values: [inMenuNr.]

[6.2]

LEDs

Code

1234 1 1000 210. 2 0100 2.66 1.33 0.15 0.12 3 1100 3.50 1.75 0.25 0.16 4 0010 4.72.4 0.35 0.22 5 1010 6.33.2 0. 6 0110 8.44.2 0.75 0.4 7 1110 11.2 5.61.1 8 0001 15 7.51.7 9 1001 20 10 2.

10 0 101 26.6 13.33.9 1.25 11 1 101 35.5 17.85.9 1.67 12 0 011 47.3 23.78.8 13 1 011 63.1 31.613. 14 0 111 84.2 42.12 15 1 111 112.2-off- 30 5.3

[6.1]

Tn Tn

[6.4] [6.3]

(sec)

T63 T63

(sec)

[6.6] [6.5]

Dead band

[6.7]

(%)

.53 .7 .94

.22 .96 .95

Remarks to Controller Tuning

If AUTOSTART does not find the optimum setting the following may be the result:

A) slow response to setpoint, long positioning time or long neutral time

B) continuous oscillation following setpoint jump

C) wide and high overshoot

For the assessment of the control 12.5 % jumps in both directions may be performed in Menu 8. The valve dynamics may be observed at LCD or the mechanical indicator.

Prior to changing parameters for valve dynamics a number of items are to be checked, see below. The pneumatic output can be operated directly without controller via Menu 7 and the valve movement may be assessed.

In case of behavior A) check:

1. Is the Proportionate gain P (Menu 6.1) or P (Menu 6.2) too small? Remedy: Increase parameters according to chart 4.

2. Is the air pressure high enough to possibly overcome the actuator spring force and friction? Remedy through increasing air pressure.

3. Is the actuator volume high, possibly requiring an increased air capacity for fast valve movement? Remedy: through booster, see accessories, or spool valve option.

4. Was AUTOSTART performed in Menu 2 and did messages 8 resp. 9 occur (messages, see table)? Remedy: “AUTOSTART” in Menu 2 resp. observe information in table.

5. Has the parameter for the positioning time been set at a value too high? Remedy: decrease both parameters “T63" in Menu 6.5 or 6.6.

6. Is valve packing too tight resulting in a very high friction?

7. Is the supply air lter blocked? Remedy - see “Supply Filter Replacement”.

8. Has the supply air been contaminated by small oil drops, particulate or are pneumatic parts possibly blocked? Remedy: exchange pneumatic parts; possibly use a suitable air supply station.

Behaviors B) and C) check:

1. Is the air capacity possibly too high, e.g. through spool valve or booster? Remedy: Work, if necessary, without booster or use version without spool valve.

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Page 59

Operation

2. Is the air achievement throttle too far open with a small drive, with high supply air pressure? Remedy: damping screw, to more signicant throttling.

3. Has the air supply pressure been set too high? Remedy: reduce pressure install pressure reducer.

Changing valve dynamics during behavior A):

If valve has a high friction (for example, often the case in small rotary actuators due to low air supply pressure or due to a valve seat packing which is too tight) then the valve position gets stuck after a setpoint jump and possibly is recontrolled via the resetting time Tn, possibly after quite some time has elapsed.

Basically, the following is possible:

a) to accept a remaining deviation

b) to accept some response procedures (such as remaining in over-response for a short time, and remaining below setpoint and trailing).

When deciding a), “Tn” should become ineffective, table value (15). Compensating “P(kp)” should be increased until the setpoint jumps reach the setpoint within a short period of time and without significant over-response (adapt to both movement directions).

When deciding b) start as in a) above. Thereafter “Tn” is re-switched and decreased until the setpoint deviation has been re-controlled within a short period of time and without long after-response (adapt in both movement directions). It is recommended to maintain the Tn’s for both directions about the same.

If a post oscillation occurs after a setpoint jump, “Tn” is selected too small, possibly “P(kp)“ was selected too large.

The positioning time “T63”, also called valve damping, does not have an effect during AUTOSTART in Menu 2, however, setpoint jumps in Menu 8 reach the position controller in a damped condition which then is not easily stimulated to oscillation. This behavior is also true for the setpoint input. This enables setting the controller to higher “P(kp)“ values without producing oscillations in the process. On one side this helps the position control to level disturbances due to friction, changes in load or air supply pressure changes faster. On the other hand it helps the superimposed valve control circuit that neutral times in the valve control route do no have such a big effect (stability in valve control circuit).

Changing valve dynamics during behavior B):

Increase “Tn” for both movement directions, possibly turnoff and proceed as described in behavior A) alternative b).

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Page 60

setpoint is automatically restarted.

W ARNING

Operation

Menu 7: Pneumatic Output for Troubleshooting

To avoid any personal injury or propertydamagefrom sudden or fast movement,during use of Menu 7

pneumatic output: Do not put your fingeror other part at anytimeinside thevalve or in anymoving part of theactuator. Do not

put your fingerorother part at anytimeinthe feedback lever mechanism. Do nottouchthe rear part of the positioneratany time.

etc.

M1 234

½½ --½M,LED1and LED4flash

Serves to checkthe pneumatic partsofthe positioner andthe right valve piping by directly applying currenttothe IP module withthe UP and DOWN

keys (no control; softwarelimit values such as “strokelimits”or“tight closing” are ignored).

The currentofthe IP module is increased by about 3% in 32 steps. By measuringthe output pressure generally thefollowingcharacteristic line of theIP moduleisachieved. Theramp also may be more steeporflat depending on theair supply pressure.

The pneumatic worksprecisely, if theactuator begins movement in section II and runs latest in sectionIVintothe endposition.

If no reactionis shown, check:

- does air supply exist? -isplugconnected to IP module? If these itemsare okay, possibly the electronics or apneumaticpartis defective. After leavingthis menu (by pressing theMkeyor UP+DOWN)the actual

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Menu 8: Manual Setting of Valve Position

W ARNING

To avoid any personal injury or propertydamagefrom sudden or fast movement,during use of Menu 8

manual setting of valve position: Do not put your fingerorother part at anytimeinside the valve or in anymoving part

of the actuator. Do not put your fingerorother part at anytimeinthe feedback levermechanism.Donot touchthe

rear part of the positioner at anytime.

M1 234

½-½½ -M,LED2and LED3flash

Forthe purposeofchecking the control reactionofthe actuatortoasetpoint jump canbeobserved viathe indicator. As farasthe device is IN SERVICE theUP/DOWN keyscan initiatejumpsof12.5%(or 1%)each. Thestarting valuefor Menu 8is alwaysthe current setpoint value.

If thecontrolbehavioristobeimproved, this canbereached by performing a completeAutostart (see Menu 2) or throughmanual tuning (see Menu 6).

After leavingthis menu theexistingsetpointvalueatthe input is automatically restarted.

This menu pointcan alsobecalled up under normal operating conditions, by twice pressing of key M.

Operation

etc.

8.3DoPST

With this function,the PartialStroke Test is started, withthe given parameters by DTM. If thetestispassed back to themenu. If the PST is not passed,the error message "PST error"appears on LCD.

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M 1234

keys

The must p

Operation

Menu 9: Calibration Functions for Workshop

½-½-½M, LED 2 and LED4flash

Factorycalibrationsare carried out with sufficient accuracyand remain unchanged during lifetime. However, an alignment may become necessary in some cases afterservicing hardwarecomponents.

9.1Reset Configuration to “exfactory” settings

-1--- LED1lightsup

It is possible to restorethe configuration existingattimeofdeliveryvia this function. This may become necessary if it is unclear what had been changed per menu or in the eventthat a positioner was taken from one actuator and mounted to another actuator. Following this functionthe device is turned to conditionOUT OF SERVICE. This has to be followed by Autostartfor thepurposeof adaptingthe calibration to the actuator andtostart IN SERVICE. The parametersofthe factory setting are listed in tableMenuStructure.

following calibration functions

only be performed by trained

ersonnel.

RD991 with HART or

“Without Communication”

Thecalibrationofthe input current or position sensor makes sense, if after exchange of theelectronics,the valve position is inaccurately displayed.

Calibrationofinputcurrent (OnlywithSRD with analog setpoint; does notapply to fieldbusinstruments.) Serves to equalizepossible inaccuraciesinthe completecurrent loop.

9.2 Calibrationofinput currentto4mA

--1--LED2lights up

Thepresent input current valueistaken over as “4 mA”when pressing UP+DOWN.

9.2 Calibrationofinput currentto20mA

-11--LED1and LED2lightsup

Thepresent input current valueistaken over as “20mA” when pressing keys UP+DOWN.

Calibration of position sensor (angle calibration) Theangle pertaining to thevertical tap position (arrow mark)isfactory calibrated forthe positiontap. If the positionsensor or the electronics board is exchanged the mechanicaland electric tolerances havetobe aligned through recalibration. See Service Instruction manual.

9.4 Calibrationofposition sensorvalue to –45°

---1- LED3lightsup

Thepresent positionvalue is takenoverasangle –45° when pressing keys UP+DOWN.

9.5 Calibrationofposition sensorvalue to +45°

-1-1-LED1and LED 3lightsup

Thepresent positionvalue is takenoverasangle +45° when pressing keys UP+DOWN.

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9.6 ResettingofConfigurationand Calibrationto“ex factory” settings

thefirsttimetothe electrical supply.

Configuration

Forthe exchange of the electronics the devicemustbeconfigured whetherthe pneumatic output is single-acting or double-actingsothatthe controller shows thecorrect behavior duringthe nextstart-up.

Caution: Thecurrent calibration for inputs and outputs, the anglecalibration and all other calibrations are reset to theirfactory definedcondition!

9.6 ResettingofConfiguration andCalibration to “exfactory” settings –for single-acting pneumatic output

----1 LED4lights up

Thefactory calibration forsingle-acting pneumatic output is restoredwhen pressing UP+DOWN keys simultaneously.

9.7 ResettingofConfiguration andCalibration to “exfactory” settings –for double-acting output

-1--1LED 1and LED4lights up

Thefactory calibration fordouble-acting pneumatic output is restored when pressing UP+DOWN keys simultaneously.

9.8GoOnlinewithoutAutostart

In principle, thefirst startup runs an Autostart in which the SRD is optimally adaptedtothe actuator,thenthe SRD goes online and beginstoregulate.

This service functionsetsthe SRD directly online, without an Autostart.

Only fortest purposes. Not recommendedfor regularuse.

functions for allSRD versions with LCD

9.9 Selection of menu language

Oneofthree of the programmed languagescan be selected (only with version with LCD display)

Ex-factorythe active language is always English. Changing to one of the other two languages,can alsotake place during operation.

Thethird menu languagecan be selected and was already programmed in thefactory according to customer order. If adifferent third menu language is desired,thenthe language file canbe downloadedfrom our website:

http://www.foxboro-eckardt.eu/download/PLFselector.html

Thereafter downloadthe file from thePCvia FDT/DTM-Software ontothe SRD. See also references on the internet page.

Operation

9.10 LCDOrientation

Display normalorturned by 180°.

9.11 Calibration of Option "PositionFeedback 4-20 mA"

Connect24VDC to theterminalsofthis optionand insert a precise ampmeter intothis loop.

Selecting "Cal.4mA" should result acurrent of 4 mA. CalibratewithkeysUPorDOWN. ConfirmwithkeysUP+DOWN.

Selecting "Cal.20mA" shouldresultacurrent of 20 mA. CalibratewithkeysUPorDOWN. ConfirmwithkeysUP+DOWN.

1) Themenus 9.8and 9.9 appear automatically at initial start-up,i.e.ifthe SRDis connected

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Page 64

M123 4

Operation

SRD991 with PROFIBUS PA—Menu 10: Bus Address

½- -½½M, LED 3and LED4 flash

Here the bus addressofthe SRD canbeindicatedand changed.The bus address is in thevalue rangeof0to 127;for thedisplay7bits arerequired. Each bit hasaspecificvalue(bit1=1,bit 2=2, bit3=4, bit 4=8, bit 5=16,bit 6=32, bit 7=64). Thebus addressisthenthe totalofthe individual values.

To displaythis with4LEDs, selection must be made between thelower and upper 4bits(wherebythe highestbit 8 has no usage and is always 0).

10.1 Selection of lower 4bits:

¼¾ --- Mshort flash, LED1long flash

With UP or DOWN keytoselection of upper 4bits:

10.2 Selection of upper4bits:

¼ ---¾Mshortflash, LED4longflash

Upon selection, the bitsare displayed. When pressing UP or DOWN keys, thevalue is alwayschanged by 1. Pressingkeys UP+DOWN, the newly entered address willbeactivated.

Thebus address is thetotal of theindividualvalues:

Valuesofthe lower 4 bitsand the upper 4 bits:

–[1] [2][4] [8]Value of thebits–[16] [32] [64]– Valueofthe bits

----- 0----- 0

-1--- 1-1--- 16

- -1--2 --1--32

-11--3 -11--48

---1- 4---1- 64

-1-1- 5 -1-1-80

--11-6 --11-96

-111-7 -111- 112

----1 8

-1--1 9

--1-110

-11-111

---11 12

-1-1113

--111 14

- 111115

Note: Addresses 0 and 127shouldnot be used. Address 126 (deliverycondition)is not permittedfor cyclical operation. Forfurther information seeTI EVE0105P.

In theversion with LCD indicator, theaddress is displayedin decimal and hexadecimalnumbersystem.

10.3Address

With LCD indicator,thisfunctionis recommended, whereby theaddress can be completely entered,withoutseparation in LSB andMSB. Thekeys haveAutorepeat:By pressing andholding of akey UP or DOWN, the value is counted upward,aftersometime in larger steps.

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Page 65

SRD991 with FOUNDATION Fieldbus—Menu 10: FF Configuration

as analog value4to 20 mA.

M 1234

½- -½½M,LED 3and LED4 flash

Special settingsfor Foundation Fieldbus device.

10.1Simulate enable /disable

¼¾ --- Mshort flash,LED 1longflash

TheSRD991 sends duringnormaloperationits actual Position-Actual-

back to thecontrolsystem.

Value If, however,“Simulate”isreleasedinthe SRD and in additionvia communication Simulateisactivated,thenasimulationvaluecoming from thecontrol system is sent back as an actual valuetothe controlsystem. In this way within thecontrol system, e.g. thereactiontospecificvalve adjustments can be tested withouthavingtoadjustthe valve–the SRDregulates toward the ”accurate”setpoint value. Forfurther informationabout theSimulatesee TI EVE0105Q.

10.1.1Simulate Disabled

-1--- LED1lightsup

Disablesimulate. Therealvalve positionwillbeindicated.

Operation

10.1.2Simulate Enabled

----1 LED4lightsup

Releasesimulate.

10.2 Foundation Fieldbus Profile:Activate LinkMaster

¼-¾- -Mshortflash,LED 2long flash

10.2.1 Link Master active

-1--- LED 1lightsup

This SRD becomes theLinkMasterif Control Systemisdown.

10.2.2 Basicdevice

----1 LED4lightsup

This SRD becomes not theLinkMasterifControl System is down.

By using theUPorDOWN keys the desired condition canbeselected and entered throughpressing keysUP+DOWN.

1) With theoption ”Position Feedback”,the position-actual-value willbedisplayed,as before,

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Decommissioning

Setting the Travel Indicator

The mechanical travel indicator is coupled to the feedback shaft of the positioner by a gear. The gear has two selectable ratios1) 1 : 2 and 1 : 6.

The values are rounded for making easier calculations. The exact ratios are 1 : 1.83 and 1 : 6.28.

Selecting 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.

For linear actuators the rotation angle is determined by travel span and feedback lever length. In this case, an exact 180° display angle can only be achieved for a 30° rotation angle using a 1 : 6 gear ratio. If any other rotation angle results, either the closed or full open position can be set to be indicated at, for example 0° or 180°. However, if the closed position is chosen for display, then the full open display position angle is dependent on travel span, feedback lever length and gear ratio. If the full open position is chosen for display, then the closed position angle becomes dependent.

Setting Gear Ratio

Remove the travel indicator 12. Pull out the 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 the pin 12b against the stop. See illustration.

Figure 23:

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.

DECOMMISSIONING

Before decommissioning the unit, disconnect the supply air and the electrical input signal.

After disconnecting the electrical input signal the last confirmed configuration of the positioner is preserved in the memory.

Exchange of Device

If a temporary decommissioning of the SRD and a later mounting to another actuator has to be carried out, before disconnecting, we recommend to Reset Configuration in Menu 9.1. So the default settings ”Ex-Factory” are reactivated. This facilitates a later recommissioning.

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Maintenance

MAINTENANCE

General

The SRD991 requires no periodical maintenance. When replacing components during repair work, “Safety Requirements” must be observed!

Service Plug and IrCom

All basic instruments of the SRD991 are equipped with a service plug. There via RS232 a PC with FDT/DTM Software can be connected via modem EDC82 (galv. separated, not Ex).

This universal interface, together with the PC software, allows the configuration of all SRD991 versions independent of the protocol. Thus, versions HART, FOUNDATION Fieldbus, PROFIBUS PA, FoxCom and also the version “without communication” can be configured from the PC, without having to acquire expensive modems. For details see TI to EDC82.

The service plug (IDC connector) is accessible, if the cover A is pushed to the side.

The connector links EDC82 modem with SRD, and from EDC82 a 9 pole subD cable links to RS232 interface of PC.

Figure 24: Service plug

If the SRD is equipped with option “IrCom” B , communication can take place contactless via infrared with the positioner (even with closed cover!). Modem “IR Interface” (not Ex) is connected via RS232 to a PC (for practical reasons a notebook) with FDT/ DTM software in a range of approx. 1 m. (If the notebook has an IrDa interface, this cannot be used, despite similar technique. The IrDa instruction set has no communication instructions for positioners.-)

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.

Removing the Electronics Unit*

* On SRD991 with ‘pressure sensors’ option, see “Built-in Pressure Sensors”

TO AVOID ANY PERSONAL INJURY RESULTING FROM BURSTING OF PARTS, TAKE OFF AIR SUPPLY BEFORE ANY REMOVAL OF ELECTRONIC BOARD.

Pull off the travel indicator 12. To remove the electronics unit 40, loosen the 7 screws on the front.

Lift the electronic vertically upward.

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Troubleshooting Guide

Disconnect the plugs 41 and 42 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.

Figure 25: Removing the electronic unit

Connect the plugs 41 and 42 to the new electronics unit 40 and attach the new unit by using the 7 screws on the front (attention with the cables).

TROUBLESHOOTING GUIDE

The components of the positioner are under constant surveillance by the installed micro controller. Errors detected are displayed in LCD or indicated by the LEDs.

Certain conditions (such as “Stroke limitation active”) are displayed in LCD or indicated by the LEDs as message.

Errors Detected During Initialization

After startup or reset, several initialization phases are passed through which are shown in LCD or in the green LEDs. If this phase stops, an error was detected.

If after renewed reset 1) the indicator stops at an error code, the device is probably defective and should be sent to the manufacturer for repair. Stating the error code be helpful to the Repair and Service Dept.

Execute reset by simultaneously pressing M+UP+DOWN keys, or by turn-off and restart of input signal

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LED Error Codes (with LCD in true text)

LEDs

1=LED constant light

After start /reset:(XXXX=error code) M1

D M1 1-

¾x xxxflashing: messages. 11.4

1=LEDconstantlight

red green

M1234

-1111Micro controller functional test

-111 - Micro controllerRAM test

-11-1Micro controller ROMtest

-11- -initialize operating system

-1-11 initialize monitor

-1-1-initialize interfaces

-1--1 initialize timer

-1---initialize EEPROM

--111initialize data

--11 - initialize ADC

--1-1initialize communication

--1- - initialize local operation

---11start background process

---1-check options and start

----1start operating system

Description

Troubleshooting Guide

LED indication for diagnosis, errors.

The following combinations are possible:

Errors Detected During Self-Test

During cyclical self-test, certain components of the SRD are under constant surveillance. At trouble detection in the electronics, output y1 becomes pressureless (‘fail safe position’).

If after reset 1) the display shows the error again, the device is probably defective and should be sent to manufacturer for repair.

234

-XXXXError detectedduring Init s. 11.

evice in normal operation:

234

---Cyclical self-testdetects errorss. 11.

---diagnosis without LED informs. 11.

LEDs

redgreen

M1234

1----

Red LED lightsupconst. RAM/EPROMfault Actuate“Reset”; senddeviceto manufactureriferror reappears

Description

Execute reset by simultaneously pressing M+UP+DOWN keys, or by turn-off and restart of input signal

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Troubleshooting Guide

Diagnosis without LED or LCD Information

Fault Possible Cause Solution

Positioner not operational using key pads

Autostart not completed (> 45 min)

Actuator does not react to a change in the input signal

Actuator does not attain the closed or opened position

No input signal at 11, 12 Connect input signal

Local operation blocked (write protection)

No automatic power up (Reset)

A key got jammed Release cover screws, check menu functions, retighten cover

Failure in the positioner Send device to manufacturer

Actuator volume too large Stop Autostart and carry out extended Autostart, see

Failure in the positioner, otherwise Message 8, 9

Autostart remains stagnant for a longer time (>10 min) in step 1 or 2 (LED 1 or 2 lights up), otherwise message 8

Autostart remains stagnant for a longer time (>10 min) in step 3 (LCD: shows”Control params“) (LED: #3 lights up)

No Autostart performed. Perform Autostart.

Positioner is not IN OPERATION

Setpoint source is configured wrong

Autostart not carried out Carry out Autostart

Supply pressure too low Check supply air pressure

Travel limit is set Message 12, 13

Angle position linearization, positioner action or characteristic curve is set incorrectly (e.g. ‘Custom’, but values are missing)

Remove blockage via communication

Reset SRD with keys

“Menu 2: Autostart” or apply booster

Carry out Autostart again, see “Setting by Means of Local Keys” and

“Menu 2: Autostart”

Carry out Reset configuration

Send device to manufacturer

Feedback lever (at stroke actuator) incorrectly mounted. Verify installation of feedback lever, see “Mounting to Actuators”; flat part points to arrow on housing

Coupling piece (at rotary actuator) incorrectly turned (R and L mixed up): Verify direction of rotation, see “Mounting to Actuators”; flat part points to arrow on housing

At large volume actuators the Autostart can possibly remain stagnant for a longer time (>10 min) in step 3, prior to continuing in step 4

Switch positioner IN OPERATION, see “Operation” resp. Autostartor via Configurator

Correct configuration via configurator

Check settings, see “Menu 5: Limit and Alarms of Valve”

Check settings, see “Menu 1: Actuator System, Mounting Side”,

“Menu 3: Mode of Action of SRD and Additional Position Feedback”, “Menu 4: Characteristic of Setpoint”

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Fault Possible Cause Solution

Troubleshooting Guide

Unstable behavior, position control circuit oscillates

Autostart incomplete, therefore, control parameters not suitable

Small actuator volume but high air capacity

Carry out complete Autostart, see “Menu 2: Autostart”

Increase damping at pneumatic output, see

“Menu 6: Parameter for Position controller” reduce gain (P

parameters)

Friction on valve packing

Loosen packing gland slightly or replace

too great

IP module or Pneumatic

Change module, pneumatic amp

amplifier defective

Actuator leakage Check the actuator and repoint

Actuator reacts too sluggishly

Air capacity insufficient Attach booster

Gain set too low Increase damping at pneumatic output, see

“Menu 6: Parameter for Position controller”

No communication possible

Positioning time T63 set too high

Input voltage too low Eliminate voltage drop

Faulty protocol,

Reduce positioning time, see

“Menu 6: Parameter for Position controller”

Check configuration of devices communicator and device type do not match

Wrong electronics unit Change device

For tuning controller parameters see “Menu 6: Parameter for Position controller”.

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Troubleshooting Guide

Messages

In the SRD with the “Built-in pressure sensors” option, flashing is superimposed by a flickering.

LEDs Description of message/LCD text Remedy

M 1234

¾¼ ---

Message1: write protection

M 1234

¾-¼- -

Message2: Parameter

M 1234

¾¼¼ --

Message3: Calibration

M 1234

¾- -¼-

Message4: Input current outside of operating range

M 1234

¾¼ -¼-

Message5: Position sensor

Positioner already calibrated, dismonted and supply. If you supply (4-20 mA or withafieldbus) apositioner not mounted and bring the potentiometer out of range, the message will apear and remain till the potentiometer goes again in range and the error is validate

with push button.

M 1234

¾-¼¼ -

Message6: I/P-converter output

M 1234

¾¼¼¼ -

Message7: Air supply / pneumatic error

Parameter andfunctions arewrite-protectedCan be changedvia Configurator,FDT/DTM Soft-

ware or Profile3.0 (PROFIBUS)

Invalid, undefined parameter values Reset of configuration to factorysetting in Menu

9.1

Incomplete calibration or entering value resp.

Repeat calibrations in Menus9.2 ... 9.5 calibration value outside of permissibletolerance range

Check nameplate(INPUT) for correct version Message appears at :

Analog or HART: input current under approx. 3.8

check supply voltage (Analog) or

checkBus voltage (Fieldbus),

exchange SRDif necessary mA or above approx.22mA

Fieldbus or FoxCom: input current under approx.

9mAor above approx.12mA

Position sensor input recognizes errorcheck 3-pole plug at electronic board

check cabletosensor check sensor (Potentiometer:5k +20% –0%)

Position notwithinpermissible rotation angle range. Lower deviation of the original 0% and exceeding

Checkfeedback lever mounting (flat area pointsto

arrow on housing) of the original 100%, which have beendetermined by Autostart.

During Autostartachangeofthe direction of mo-

AcknowledgewithUP+DOWNkeys, then o.k. vement wasfound

Checkfurther possible reasons:

valve seat worn-out;spindlelock out-of-line; carrier

unit on spindle lock is damaged(fordeterminationof

valve position).

Connection I/P converter to electronic board faulty check 2-pole plug at electronic board

checkcable to theI/P converter

checkI/P converter to detectshort circuitor inter-

ruption

Detection: spring closes:w>2%, but position <1% spring opens: w<98 %, but position >99% without spring: no actuator change in direction of position signal

checkair supplypressure

lead cableseparated

possibly poor control parametersare set

pneumatic parts blocked

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Page 73

LEDs Description of message/LCDtextRemedy

M123 4

¾ ---¼

Message 8: AUTOSTART defective

Feedback lever (linear actuator)orCoupling (rotary actuator) incorrectly linked. Potentiometer moves out of operating rangeof±47%of0° position

Coupling (rotary actuator) incorrectlylinked (R andLinterchanged)

Pneumatic output to actuator closed or untight/ When direct mounting ontoFlowToporFlowPak, the screw plug y1-d is not removed.

Mechanical stops not determinable Checkspringmovementofactuator/

When using a boosteror spool valve, no control parameters canbe determined, sinceair capacity is toohigh.

Control parameter too high sinceair capacityistoo high (in general, oscillation in valve movement )

Possibly incomprehensible configurationdataReset configuration, seeMenu9.1

M123 4

¾¼ --¼

Message 9: AUTOSTART

Configurationto single-acting instead of double-acting actuator

defective

M123 4

¾-¼-¼

Message 10: Disturbances at Option board

M123 4

Configured status of theSRD deviatesfrom existing version (e.g.Optionboard hasbeen inserted subsequently.

¾¼¼ -¼

Message 11:

Actuator problems (highfrictionor blocked)Check actuator Remaining control deviation

Insufficient parametesfor position controls,

forexample, amplification too small

IP module or pneumatic amplifier defect Check in Menu 7; replaceifnecessary

M123 4

¾- -¼¼

Message 12: configurated

If this is desired, the message may be ignored, of

course. closing limit has been reached

M123 4

¾¼ -¼¼

Message 13: configurated

If this is desired, the message may be ignored, of

course. opening limit has been reached

Troubleshooting Guide

ylppusriakcehCwolootylppusriA

Checkmounting. Flat area points to arrow on housing

Checkmounting

Checkpneumatic connections

check air supply/Check mounting

Device version is notsuitablefor this actuator;select version with smallerair capacityorremove booster.

Use abooster or theversion with spoolvalve. Reduce control parameterprop.-gain (Menu 6.1and

6.2) to Code 10 =value 26.6.

Initialize factorycalibration fordouble-acting in Menu 9.7

Check if correctoptionboard hasbeenconnected Confirmmessage andthereby newinstrument version.

degnahcretnislanimretotsnoitcennoCtcatnocdaB Check connections Tightenelectronics

draobnoitpoegnahcxEevitcefeD

retlifria/ylppusriakcehCylppusriatneiciffusnI

Check control paramter, checkpneumatic components

If not, thesetting has to be checkedinMenu5.1 or viacommunication

If not, thesetting has to be checkedinMenu5.4 or viacommunication

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Page 74

Safety Requirements

LEDs Description of message / LCD text Remedy

M 1234

¾-¼¼¼

Message 14: Maintenance required

M 1234

¾¼¼¼¼

Message 15: Not defined

Operating pointof controller is outside of permissibletolerance

Pneumatic componentshavetobecheckedand if necessary readjusted.Filters arepossiblyblocked and have to be replaced

SAFETY REQUIREMENTS

EMC and CE

For notes regarding Electromagnetic compatibility EMC and CE labels, see the product data sheet.

In order to ensure EMC protection, the black electronic cover made of conductive plastic has to be screwed to the housing.

Explosion Protection

(Only if ordered)

Technical data for explosion protection see Product Specifications Sheet PSS EVE0105 A or Certificates of Conformity EX EVE0105 A.

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.

MPORTANTI

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.

SYSTEM CONFIGURATION

The safety requirements (see above) must be observed!

HART Communication

When using the ‘communication’ (an alternating current signal, which is modulated onto the 4-20 mA signal), it must be observed that the connected outputs are suitable for the used frequency ranges. Apart from the load, also the alternating current impedances have to be observed. It is recommended therefore, to use only suitable instruments.

To eliminate crosstalk between leads and to reduce disturbances through electromagnetic influences, it is recommended to use twisted paired shielded leads (0.3…2.5 mm2, max. 100 pF/m).

The capacities of the leads and the connected instruments must not exceed the maximum values for HART.

All components which are connected to the SRD in an explosion hazardous area, require an Ex-Approval. The applicable limit values must not be exceeded. These limit values also have to be adhered to when connecting additional capacitances, inductances, voltages and currents.

Measuring HART Communication Signal

If a reliable communication signal cannot be received, it is advisable to check the level with an oscilloscope. The first data block always comes from the configurator and the second block is the reply from the SRD.

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Page 75

System Conguration

HART measured at

configurator:

Configurator transmits

SRD991 transmits

at least

350 mVpp

at least

120 mVpp

measured at

SRD:

at least

120 mVpp

at least

400 mVpp

FoxCom Communication

When using the ‘communication’ (a rectangular signal which is modulated onto the constant current signal), make sure the connected outputs are suitable for the used frequency ranges. The supply instrument must be a voltage source with an impedance of 250…500 Ohm. The total of all instrument and lead capacities must be <60 nF. It is recommended therefore, to use only suitable instruments.

To eliminate crosstalk between leads and to reduce disturbances through electromagnetic influences, use twisted paired shielded leads (0.3…2.5 mm2, max. 100 pF/m).

The capacities of the leads and the connected instruments must not exceed the maximum values for FoxCom.

All components which are connected to the SRD in an explosion hazardous area, require an Ex-Approval. The applicable limit values must not be exceeded in any case. These limit values also have to be adhered to when connecting additional capacitances, inductances, voltages and currents.

Measuring FoxCom Communication Signal

FOXCOMmeasured at

configurator:

Configurator transmits (Request)

SRDtransmits (Acknowledge)

at least

350 mVpp

at least

75 mVpp

measured at

SRD:

at least

75 mVpp

at least

350mVpp

With Communication PROFIBUS-PA

The operation of the positioner takes place digitally, as per PROFIBUS-PA Profile Class B according to EN 50170 and DIN 19245 part 4. Data transmission via bit synchronous current modulation with a speed of 31250 bits via twisted and shielded two-wire connections according to IEC 1158-2, with cable shields on both sides and bus terminators according to recommendation IEC 1158-2.

The positioner has to be connected to a segment coupler, which has to be conforming to IEC 1158-2. For operation in explosion hazardous areas, a segment coupler in explosion proof version has to be used. Supply as well as communication takes place via the bus.

All components which are connected to the SRD in an explosion hazardous area, require an Ex-Approval. The applicable limit values must not be exceeded in any event. These limit values also have to be adhered to when connecting additional capacitances, inductances, voltages and currents. The FISCO model is thereby used as a basis.

Further information for observance: ”Technical Guide for PROFIBUS-Connection Technique” PROFIBUS-User Organization, Order no. 2.141

With Communication FOUNDATION Fieldbus

The operation of the positioner takes place digitally, as per FOUNDATION Fieldbus Specification Rev. 1.4. Data transmission via bit synchronous current modulation with a speed of 31250 bits of via twisted and shielded two-wire connections according to IEC 1158-2, with cable shields on both sides and bus terminators according to recommendation IEC 1158-2.

The positioner has to be connected to components which are conforming to IEC 1158-2. For operation in explosion hazardous areas, an Ex-separator has to be used. Supply as well as communication takes place via the bus.

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Page 76

Electrical connection

Connection

Electrical in

Connection values

)

on nameplateresp. certificateofconformity, have to be observed!

System Conguration

Further information for observance: “Wiring and Installation 31.25 kBit/s, Voltage Mode, Wire Medium Application Guide” by FOUNDATION fieldbus

System Conguration

compartment see “ELECTRICAL CONNECTION”

connection forSRD991

intrinsic safe (EEx i) version

Non hazardous Hazardous

erminals:

Input signal /Setpoint value HART/FoxCom/ 4-20mA Fieldbus acc. to IEC 1158-2 Options /Additonal In-/Outputs Position feedback Binary output Binary input Limit signal switch Potentiometer Sensor

any Polarity

)ixEE(noitacolaera

Input Options

11 12 ABCD

11+ 12–

11** 12**

81+ 82– 31+ 32–

81+ 82– 83+ 84– 13+ 14– 15+ 16– 41+ 42– 51+ 52–

HART /4-20mA

Terminals...............11+/12-

Signal range ............4... 20 mA

Input voltage ............DC12 ... 36 V (nonloaded

FOUNDATIONFieldbus

Terminals...............11 /12

Busconnection ..........Fieldbus interfaceacc.to

IEC1158-2

Supplyvoltage ...........DC9... 32 V

max. Supply voltage.......DC36V

Operatingcurrent . ........10.5mA±0.5mA

PROFIBUS-PA

Terminals...............11 /12

Busconnection ..........Fieldbus interfaceacc.to

IEC1158-2

Supplyvoltage ...........DC9... 32 V

max. Supply voltage.......DC36V

Operatingcurrent . ........10.5mA±0.5mA

FoxCom - digital (IT2)

Terminals...............11+/12–

Supplyvoltage ...........DC13 ... 36 V

max. Supply voltage.......DC36V

Operatingcurrent . ........~9mAatDC24V

FoxCom - analog (IT1)

Terminals...............11+/12–

Signal range ............4... 20 mA

Supplyvoltage ...........DC13 ... 36 V

*) In preparation

2) When used in Ex-hazardous areas, themax. supply voltages,etc.

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Page 77

Communication HART an

Electrical

(Electronic Conformity

see

Type

Temperatur

Certificat For ally Input U Li

A T T

Explosion

It t In be the values.

Type

(Electronics Cl. hazardous NEMA

Type

(Electronics Cl. hazardous NEMA

Type

(Electronics Class hazardous

2) National requirements must be observed

Communication PROFIBUS-PA

reference

System Conguration

dATEX Certification

classification

sfamily AI 638 perEC- Certificate of

PTB 00 ATEX 2128)

Certificates of ConformityEX EVE0105 A

of protection ATEX “intrinsicsafety”

.................II2GEEx ia IIB/IIC,

eclasses

Type AI638 HH ......T4, Model Code EA4

Type AI638 GH ......T6/T4,Model Code EAA

eof Conformity ....PTB 00 ATEX 2128

use in hazardous areasin circuits certifiedas intrinsic-

safe with the following maximum values:

circuit:

i=30V,Ii=130 mA, Pi = 0.9 W

=5µH,Ci=1.3nF (5.3nFto earth)

mbient temperature ranges:

emperature class T4:......–40 °C to +80°C

emperature class T6:......–40 °C to +55°C

protection Zone2

is recommended to use the positioner with explosion pro-

ection “intrinsically safe” (consider temperature class).

theFederal Republic of Germany these positioners may

operated in Zone2with non-intrinsically safe circuitsif

operating values do not exceedthe maximum reference

of protection FM “intrinsic safety”

family per BIM638 (GH))

I, Div 1, Gp ABCD; Cl. II, Div 1, Gp EFG; Cl. III, Div 1

locations indoor and outdoor, T6/T4,

Type 4X

of protection FM “non-incendive”

family per BIM638 (GH))

I, Div 2, Gp ABCD; Cl. II, Div 2, Gp FG; Cl. III, Div2

locations indoor and outdoor, T6/T4,

Type 4X

of protection CSA“intrinsic safety”*)

family per CSA xxx)

I, Div. 1, Groups A, B, C, D;

locations indoor and outdoor, NEMAType4X*)

In preparation With appropriateorder only

1) 2)

II 2GEExib IIB/IIC

andFOUNDATION Fieldbus H1

Electrical classification

(Electronics family AI 638 perEC- Certificateof Conformity PTB 00 ATEX 2128)

seeCertificatesofConformityEXEVE0105 A

Type of protection ATEX “intrinsic safety”

.................II 2GEExiaIIB/IIC,

Temperatureclasses

Type AI 638 GP/GQ, Rev2.0,T6/T4,Model Code EAA

CertificateofConformity....PTB 00 ATEX 2128

Foruse in hazardous areas in circuits certifiedasintrinsically safe withthe followingmaximum values: Input circuit: Ui =24V,Ii=380mA, Pi =5.32W Li =5µH,Ci=1.3nF (5.3nFtoearth)

Ambient temperatureranges:

Temperature classT4: ......–40°Cto+80 °C

Temperature classT6: ......–40°Cto+55 °C

Explosion protection Zone2

It is recommended to use thepositioner with explosion protection “intrinsicallysafe” (considertemperature class). In theFederal RepublicofGermany these positioners may be operatedinZone2with non-intrinsicallysafecircuitsif theoperating valuesdonot exceed themaximum values.

Type of protection FM “intrinsicsafety”

(Electronics family per BIM 638(GP/GQ,Rev.2.0)) Cl.I, Div 1, Gp ABCD; Cl. II, Div 1, Gp EFG; Cl. III, Div1 hazardouslocationsindoor and outdoor, T6/T4, NEMA Type4X

Type of protection FM “non-incendive”

(Electronics family per BIM 638(GP/GQ,Rev.2.0)) Cl.I, Div 2, Gp ABCD; Cl. II, Div 2, Gp FG; Cl.III,Div 2 hazardouslocationsindoor and outdoor, T6/T4, NEMA Type4X

Type of protection CSA“intrinsic safety” *)

(Electronics family per CSAxxx) ClassI,Div.1,Groups A, B, C, D; hazardous locations indoor and outdoor, NEMA Type 4X *)

1) 2)

II 2GEExib IIB/IIC

Page 77 August 2014 POS-UM-00010-EN-03

Page 78

4-20 mA Intelligent without Communication (

Electrical

(Electronic Conformity

see

Type

Temperatur

Certificat For ally Input U Li

A T

Explosion

It t In be the values.

Type

(Electronics Cl. hazardous NEMA

Type

(Electronics Cl. hazardous NEMA

Type

(Electronics Class hazardous

2) National requirements must be observed

System Conguration

replaces SRD992) andATEX Certification

classification

sfamily AI 638 perEC- Certificate of

PTB 00 ATEX 2128)

Certificates of ConformityEX EVE0105 A

1) 2)

of protection ATEX “intrinsicsafety”

.................II2GEEx ia IIB/IIC,

II 2GEExib IIB/IIC

eclasses

TypeAI 638 HI .......T4, Model Code EA4

eof Conformity ....PTB 00 ATEX 2128

use in hazardous areasin circuits certifiedas intrinsicsafe with the following maximum values:

circuit:

i=30V,Ii=130 mA, Pi = 0.9 W

=5µH,Ci=1.3nF (5.3nFto earth)

mbient temperature range:

emperature class T4:......–40 °C to +80°C

protection Zone2

is recommended to use the positionerwith explosion pro-

ection “intrinsically safe” (consider temperature class).

theFederal Republic of Germany these positioners may

operated in Zone2with non-intrinsically safe circuitsif

operating values do not exceedthe maximum reference

of protection FM “intrinsic safety”

I, Div 1, Gp ABCD; Cl. II, Div 1, Gp EFG; Cl. III, Div 1

I, Div 2, Gp ABCD; Cl. II, Div 2, Gp FG; Cl. III, Div2

family per BIM638 (GI, Rev 2.0))

locations indoor and outdoor,T6/T4,

Type 4X

of protection FM “non-incendive”

family per BIM638 (GI, Rev 2.0))

locations indoor and outdoor,T6/T4,

Type 4X

of protection CSA “intrinsic safety”

family per CSA xxx)

I, Div. 1, Groups A, B, C, D;

locations indoor and outdoor, NEMAType4X

With appropriateorder only

Page 78 August 2014POS-UM-00010-EN-03

Page 79

DIMENSIONS

Dimensions

*) Dimension with high cover

with option “built-in limit switch”

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Page 80

Dimensions

Dimensions INOX SRD991 in Stainless Steel Housing

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Page 81

INTENTIONAL BLANK PAGE

User Manual

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Page 82

Valve Positioners, RCV SRD991 Intelligent Positioner

INTENTIONAL BLANK PAGE

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Page 83

INTENTIONAL BLANK PAGE

User Manual

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Page 84

Valve Positioners, RCV SRD991 Intelligent Positioner

Control. Manage. Optimize.

RCV is a registered trademark of Badger Meter, Inc. Other trademarks appearing in this document are the property of their respective entities. Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists. © 2014 Badger Meter, Inc. All rights reserved.

www.badgermeter.com