Badger Meter SRD-SRI Valve Positioners User Manual

Valve Positioners

RCV SRD991 Intelligent Positioner

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

User Manual

Valve Positioners, RCV SRD991 Intelligent Positioner

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

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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