AUMA EPAC Guida per l'amministratore

EPAC

Operation Instruction Manual

VERSION: V3.XMP NON- INSTRUSIVE WITH

DATALOGGING (MWG)

(Weather Proof & Explosion Proof)

Table of Contents

1. SAFETY INSTRUCTIONS 3

BASIC INFORMATION ON SAFETY.......................................................................................................................31.1

STANDARDS/DIRECTIVES ......................................................................................................................................31.1.1

SAFETY INSTRUCTIONS/WARNINGS ........................................................................................................................31.1.2

QUALIFICATION OF STAFF .....................................................................................................................................41.1.3

COMMISSIONING ................................................................................................................................................41.1.4

OPERATION........................................................................................................................................................41.1.5

PROTECTIVE MEASURES........................................................................................................................................51.1.6

MAINTENANCE ...................................................................................................................................................51.1.7

RANGE OF APPLICATION .................................................................................................................................51.2

REFERENCES AND SYMBOLS .............................................................................................................................61.3

2. INTRODUCTION 7

2.1 LCD DISPLAY &LED INDICATION................................................................................................................7

2.2 INBUILT FRONT PANEL OPTION SELECTION ................................................................................................7

2.3 INTERFACES..............................................................................................................................................7

2.4 EMERGENCY STOP -ESD............................................................................................................................7

2.5 EVENT STORAGE &DATALOGGING OPTION ...............................................................................................8

2.6 PARTIAL VALVE STROKE TEST (PVST) OPTION............................................................................................. 8

2.7 INHIBIT OPTION........................................................................................................................................9

2.8 REMOTE SELECTOR SWITCH ......................................................................................................................9

2.9 LOCAL CONTROL STATION (LCS) PRIORITY..................................................................................................9

2.10 REMOTE LOCAL STOP..............................................................................................................................9

2.11 TIMER MODE..........................................................................................................................................9

2.12 PROGRAMMABLE RELAYS ..................................................................................................................... 10

2.13 REAL TIME CLOCK (RTC)......................................................................................................................... 10

2.14 POWER SUPPLY .................................................................................................................................... 11

2.15 SURGE PROTECTION AND LIGHTENING ARRESTER.................................................................................. 11

2.16 INBUILT POWER BACKUP DURING POWER OFF ...................................................................................... 11

3. FRONT PANEL DETAILS 12

SELECTOR SWITCH ...................................................................................................................................... 123.1

PUSH BUTTON SWITCHES ............................................................................................................................. 123.2

LCD SCREEN &LEDS .................................................................................................................................. 123.3

4. MODES OF OPERATION 14

PROGRAM MODE ................................................................................................................................... 144.1

EDIT/VIEW OPTION OF PROGRAM MODE .......................................................................................................144.1.1

CALIBRATION MODE............................................................................................................................... 234.2

LIMIT CALIBRATION ......................................................................................................................................254.2.1

DAC CALIBRATION ........................................................................................................................................264.2.2

4-20MACALIBRATION .....................................................................................................................................274.2.3

CHANGE TORQUE VALUE....................................................................................................................................294.2.4

PRESET TORQUE ...............................................................................................................................................304.2.5

DIAGNOSTIC MODE ................................................................................................................................ 354.3

5. TOPOLOGY CONNECTION 37

6. REGISTER DETAILS FOR MODBUS COMMUNICATION 40

7. TROUBLESHOOTING 43

8. EPAC NAMEPLATE 47

9. DISPOSAL AND RECYCLING 49

10. SERVICE 49

1. SAFETY INSTRUCTIONS

Basic information on safety1.1

Standards/Directives1.1.1

AUMA INDIA products are designed and manufactured in compliance with recognized

standards and directives. The list of certifications & agency of certification for Auma India products are

as given below..

All legal requirements, directives, guidelines, national regulations and recommendations with respect

to assembly, electrical connection, commissioning and operation are to be met by the end user or the

contractor at the place of installation. Customer has to follow specified standards for electrical

installations in explosion proof at& other hazardous areas. Modbus RTU application related

configuration guidelines are to be followed.

Safety Instructions/Warnings1.1.2

All personnel working with this device must be well-versed with the safety and warning

instructions in this manual and observe the instructions given. In order to avoid personal injury

or property damage, the safety instructions and warning signs must be observed carefully.

Kindly follow Common Electrical and Electronic related safety instructions according to

industrial standards. The main mechanical safety instructions are fixed on the actuators as

shown below.

Safety Instructions on Actuators:

Weather Proof and FlameProof/ExProof Safety instructions

FlameProof/ExProof Safety instructions

Qualification of staff1.1.3

Assembly, electrical connection, commissioning, operation, and maintenance must be

carried out exclusively by suitably qualified personnel having been authorized by the end

user or contractor of the plant only. Prior to working on this product, the staff must have

thoroughly read and understood these instructions and, furthermore, know and observe

officially recognized rules regarding occupational health and safety.

Work performed in potentially explosive atmospheres is subject to special regulations which

have to be observed. The end user or contractor of the plant is responsible for respect and

control of these regulations, standards, and laws.

Commissioning1.1.4

Prior to commissioning, it is important to check that all settings meet the requirements of the

application. Incorrect settings might present a danger to the application, e.g. cause damage

to the valve or the installation. The manufacturer will not be held liable for any consequential

damage. Such risk lies entirely with the user.

Operation1.1.5

Prerequisites for safe and smooth operation:



Correct transport, proper storage, mounting and installation, as well as careful

commissioning.



Only operate the device if it is in perfect condition while observing these instructions.



Immediately report any faults and damage and allow for corrective measures.



Observe recognized rules for occupational health and safety.



Observe the national regulations.

Protective measures1.1.6

The end user or the contractor is responsible for implementing required protective

measures on site, such as enclosures, barriers, or personal protective equipment for the staff.

Maintenance1.1.7

Auma India multi-turn actuators require very little maintenance but they

need to be tested regularly for its correct functioning. After commissioning, check

actuator for damage to paint finish. Do a thorough touch-up to prevent corrosion. Correct

commissioning is a prerequisite for reliable service. Seals made of elastomers are

subject to aging and must therefore regularly be checked and, if necessary, exchanged.

It is also very important that the O-rings at the covers are placed correctly and cable

glands fastened firmly to prevent ingress of dust or water.

We recommend additionally:

If operated seldom, perform a test run about every 6 months. This ensures that the

actuator is always ready to operate. The version of actuators discussed in this manual

have an option for Partial Valve Stroke Test (PVST) to check if the actuator is healthy.

Approximately six months after commissioning and then every year check bolts

between part-turn actuator and valve for tightness. If required, tighten applying

appropriate torques.

The gear housing is filled with lubricant in the factory. This filling lasts for several years

of service.

Corrosions of paint damage parts must be prevented through touch up.

Any device modification requires the consent of the manufacturer.

Range of application1.2

Auma India actuator controls are exclusively designed for the operation of Auma India

actuators. Other applications require explicit (written) confirmation by the manufacturer. The

following applications are not permitted.

Motor control

Pump control

No liability can be assumed for inappropriate or unintended use.

Observance of these operation instructions is considered as part of the device's designated use.

References and symbols1.3

The following references and symbols are used to provide information of the basic actuator

commands to the customer. They are:

Symbol for CLOSED (valve closed)

Symbol for OPEN (valve open)

Symbol for STOP (valve stop)

2. INTRODUCTION

AUMA INDIA has developed a new range of electric actuators with intelligent

integral starter using microcontrollers for weather proof and explosion proof applications

that has the ability to store events and other upgraded features. As a microcontroller is

used, the actuators support both ON-OFF and Regulating Duty Control. The actuator can

also be run in Inching or Non-Inching mode. The important features of these electric

actuators are as follows:

2.1 LCD DISPLAY & LED INDICATION

Options can be selected by using the selector switches, push buttons based on the

instructions displayed on the LCD screen. Information on faults/statuses can be obtained

from the 4 LEDs next to the LCD. The 4 LEDs are configurable as per user requirement

before-hand. LCD screen facilitates easier understanding of status, operation and

parameter setting details. More information regarding this is described in section 3.

2.2 INBUILT FRONT PANEL OPTION SELECTION

Different features/options of the actuator can be configured using software. This is

done using the selector switches, push buttons based on the instructions displayed on the

LCD screen that is present on the front panel. More information regarding this is described

in section 3.

2.3 INTERFACES

This actuator is capable of supporting different types of interfaces like Remote –4

Wire, Remote -2 Wire Make/Break, 4-20 mA Regulating Duty & MODBUS-RTU.

2.4 EMERGENCY STOP - ESD

ESD feature is default configured to run in Close direction on enabling ESD. One needs to enable

ESD and set its behavior in Program Mode for it to function. An ESD via MODBUS option is also

available that needs to be enabled in Program Mode. ESD Operation can be configured for

OPEN/CLOSE/STAY. One can choose to set ESD on TOLR Ignore, TH Ignore, Space heater Fail Ignore,

OFF Ignore. This means that ESD operation would occur irrespective of these faults. One must enable

ESD on program mode and set its behavior (ESD Open/Close). An ESD NO/NC configuration is also

available that can be configured in Program mode. ESD feature now can be carried out using an

external 24VDc supply also.

2.5 EVENT STORAGE & DATALOGGING OPTION

This range of actuators comes with an option to store events such as faults, statuses, number of

starts (Open in Local/Remote etc. using a Bluetooth module. The events are stored in a flash

memory and can be read via Bluetooth. The data logged will have a real time stamp and can be

downloaded using a user-friendly application called Auma India Utility Software onto a PC/

Laptop with Bluetooth connection. About 43691 events can be stored at a time using this

module. AIUS is also used in assisting commissioning and diagnosing the actuators. Device Tag is

customer configurable. Remote Operation of actuator through Bluetooth is also available.

The available events are as follows:

Number of Starts (Open and close in specified duration)

Open and close Command with Selector Switch Position

Tripping Torque Profile (Non-Intrusive)

Faults.

oLoss of Phase

o24 V Fail

oThermal Switch Trip.

oTorque Switch Trip

oControl Supply Failure

oTOLR

Selector Switch Change.

End Position

ESD

More details of this feature is available in AIUS User Manual ( Doc. No.: 4-AIUS-MANUAL-39396).

2.6 PARTIAL VALVE STROKE TEST (PVST) OPTION

This feature is used in checking correct functioning of valves which are not operated for a

long period. When PVST is triggered the valve moves to particular percentage and come

back to the same end position and gives PVST result. The features are:

PVST can be triggered externally through a switch or via MODBUS.

PVST command can be given through MODBUS using dedicated registers.

PVST Position can be configured in the following two ways.

From Open End

From Close End

PVST Percentage can be set to any of the three options.

5%, 10%, 15%

PVST Failure : This failure occurs when the PVST command doesn’t take place after a specified time

(that is specific to actuators based on its RPM and No. of Turns). This failure is indicated by using

any one of the programmable relays present in your module.

2.7 INHIBIT OPTION

Inhibit is an interlock for open close operations. Inhibit Operation can be Enabled or Disabled in

Software (Program Mode). In this module, separate terminals for Inhibit Open and Inhibit Close are

available. Based on this, Open/Close Commands can be inhibited.

2.8 REMOTE SELECTOR SWITCH

This option allows the user to create a selector switch for the actuator in Remote mode. It is mainly

used to lock/unlock the Local operation of the actuator using push buttons through a Remote

command. This is serves as a software lock.

2.9 LOCAL CONTROL STATION (LCS) PRIORITY

When this feature is enabled, the user can control the actuator in remote 4 –wire mode of operation

even when in 4-20mA or MODBUS mode of Operation.

2.10 REMOTE LOCAL STOP

This option is also software configurable and can be enabled in Program Mode. The actuator

should stop running in Remote Mode when STOP key is pressed in the Actuator Front Panel. No

commands should be accepted by the actuator until it is reset.

2.11 TIMER MODE

Timer mode is used to control the valve movement. This mode allows us to open or close the valve

slowly towards the end position after reaching a certain distance with continuous operation.

Configurable Options

Open timer start Valve Position: The user has to set the valve position at which this Timer

mode should go on for Open Command.

Open ON time : This parameter decides the amount of time (in s) the actuator runs in Open

direction before shutting off for Open OFF time (in s). This continues to happen until the

respective limit switch is hit (unless the switch is bypassed).

Open OFF time: This parameter decides the amount of time (in s) the actuator shuts off

before running in open direction for Open ON time (in s). This continues to happen until the

respective limit switch is hit (unless the switch is bypassed).

Close timer start Valve Position : The user has to set the valve position at which this Timer

mode should go on for Close command.

Close ON time : This parameter decides the amount of time (in s) the actuator runs in Close

direction before shutting off for Close OFF time (in s). This continues to happen until the

respective limit switch is hit (unless the switch is bypassed).

Close OFF time : This parameter decides the amount of time (in s) the actuator shuts off

before running in open direction for Open ON time (in s). This continues to happen until the

respective limit switch is hit (unless the switch is bypassed).



2.12 PROGRAMMABLE RELAYS

As per standard two relays are given for customer end information - Fault Relay & Optional Relay 1.

There are about 6-8 more additional relays that have been added along with this module. Each of

these relays can be configured for the following 27 faults/statues as given below.

List of available relays

o Fault Relay

o Optional Relay ( 3 relays)

o Additional Relay(2 Latching relays)

Available Programmable options are:

oOpened (Open Limit Trip)

oClosed (Close Limit Trip)

oRemote Local stop

oLocal Stop

oOpen Torque Trip

oClose Torque Trip

oLoss of Phase

oTH-Trip

oTOLR Trip

oControl Supply Fail

oPhase reversal

oJammed Valve

oPower ON

oProgram Mode Indication

oSP Reached ( via DAC/MODBUS)

oSelector SW LOCAL

oSelector SW OFF

oSelector SW REMOTE

oESD Pressed

o24V DC Fail

oSpace Heater Fail

oRunning Open

oRunning Close

oRemote Selector SW EN

oPVST Fail

oIntermediate Pos

o4-20mA Signal Fail

2.13 REAL TIME CLOCK (RTC)

This module has a Real time clock that is used to obtain the time-stamp for Event logging. The RTC

can be configured by Auma Utility Software or by manually setting the RTC in Program Mode

settings. The RTC is powered by a Super Capacitor when the power is off which is another added

feature of this module. The Super Capacitor takes about 2 hours to charge and can supply power

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