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VAC D500 | OPERATING INSTRUCTION

Digital Positioner for the
positioning of pneumatically
controlled final control elements.

—

D500 Manual

Introduction

The PositionMaster EDP300 has an integral mount
design, features a modular structure and offers an
outstanding price-performance ratio. Fully
automatic determination of the control parameters
and adaptation to the positioner allow for
considerable time savings as well as optimum
control behavior. Due to its characteristics, the
positioner is suited for even the most demanding
operating conditions.

Additional Information

Additional documentation on PositionMaster
EDP300 is available for download free of charge at
www.abb.com/positioners.
Alternatively simply scan this code:

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Summary of Contents for D500

Page 1: ...ce performance ratio Fully automatic determination of the control parameters and adaptation to the positioner allow for considerable time savings as well as optimum control behavior Due to its charact...

Page 2: ...dentification 14 Name plate 14 6 Transport and storage 15 Inspection 15 Transporting the device 15 Storing the device 15 Ambient conditions 15 Returning devices 15 7 Installation 15 Safety instruction...

Page 3: ...2 Menu Display 58 Menu Controller 59 Menu Input Output 62 Menu Communication 68 Menu Diagnosis 69 Menu Device Info 71 Menu Service 72 10 Diagnosis error messages 74 Calling up the error description 74...

Page 4: ...d if expressly permitted by these instructions Information and symbols on the product must be observed These may not be removed and must be fully legible at all times The operating company must strict...

Page 5: ...or any other network as the case may be Operator shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures e...

Page 6: ...ded instructions on different types of protection and installation techniques concerned rules and regulations as well as general principles of zoning The person must possess the appropriate competence...

Page 7: ...ned Only use cable glands which are approved for the type of protection and correspond to IP rating IP 6X Danger due to propagating brush discharge must be avoided Operation in temperature class T6 Du...

Page 8: ...e emergency shutdown function Terminals 85 86 Temperature class T1 T6 Ui 30 V Pi 1 W Ci 5 3 nF Li negligibly small Module for analog feedback AO Terminals 31 32 Temperature class T1 T4 Temperature cla...

Page 9: ...nals 85 86 Electrical values UN 30 V Module for analog feedback AO Terminals 31 32 Electrical values IN 22 mA UN 30 V Module for universal input UAI Terminals 21 22 Electrical values IN 22 mA Umax 30...

Page 10: ...III Div 2 T4 or T6 Class I Zone 2 AEx nA IIC T4 or T6 T4 Ta 40 to 85 C 40 to 185 F T6 Ta 40 to 40 C 40 to 104 F IP64 Mounting The installation commissioning maintenance and repair of devices in areas...

Page 11: ...pagating brush discharge must be avoided Operation in temperature class T6 During operation in temperature class T6 when the equipment is partially or fully depressurized ensure that there is no possi...

Page 12: ...nction Terminals 85 86 Temperature class T1 T6 Ui 30 V Pi 1 W Ci 5 3 nF Li negligibly small Module for analog feedback AO Terminals 31 32 Temperature class T1 T4 Temperature class T6 Ui 30 V Ui 28 V I...

Page 13: ...0 mA Bus connection 2 Digital input 3 Alarm output 4 Supply air 5 Output 1 6 Output 2 7 Analog feedback 8 Digital feedback 9 Emergency shutdown module j Universal input k Pressure sensor l Limit alarm...

Page 14: ...edback output Universal analog input Safety shut down Pressure sensors Electr limit switch Mech limit switch low Mech limit switch high Contactless pos Sensor H Slot1 Slot2 X X X 1 9 j k 3 4 5 6 7 l m...

Page 15: ...der confirmation of the supplier apply Ambient conditions Transport and storage Ambient temperature range 40 85 C 40 185 F Relative humidity 75 annual average Returning devices For the return of devic...

Page 16: ...l connection is carried out as described in chapter EDP300 Remote Sensor Electrical Connection on page 25 Note To connect the EDP300 Remote Sensor a cable with the following specifications needs to be...

Page 17: ...for linear actuators is 45 symmetrically to the longitudinal axis The usable span within the operating range is at least 25 recommended figure 40 The usable span does not necessarily need to run symme...

Page 18: ...l Clamp plates m Follower guide Figure 6 Components of attachment kit M10411 01 1 2 3 4 Figure 7 Attaching a follower guide to the actuator 1 Tighten the screws so that they are hand tight 2 Attach th...

Page 19: ...e operating range is symmetrical lever moves between the arrow marks 4 M10418 01 1 2 3 4 Figure 9 Mounting on a cast iron yoke 1 Attach the mount bracket 2 with screw 4 and washer 3 to the cast iron y...

Page 20: ...range for linear actuators 30 to 30 minimum range 25 Note After mounting check whether the positioner is operating within the sensor range Position of actuator bolt The actuator bolt for moving the p...

Page 21: ...ry actuator For mounting on part turn actuators in accordance with VDI VDE 3845 the following attachment kit is available M10130 01 1 2 3 4 5 6 7 8 9 Figure 16 Components of attachment kit Adapter 1 w...

Page 22: ...of the actuator must be considered when determining the adapter position on axis 1 For this purpose the feedback shaft can be adjusted manually so that the adapter 3 can be attached in the correct pos...

Page 23: ...off the power supply The electrical connection may only be established by authorized specialist personnel Notices on electrical connection in this instruction must be observed otherwise electric safe...

Page 24: ...mns Connections for inputs and outputs Terminal Function comments 11 12 Analog input AI or field bus connection 81 82 Digital input DI 83 84 Digital output DO2 51 52 Limit alarm SW1 Option module 41 4...

Page 25: ...puts Terminal Function comments 1 2 3 EDP300 Control Unit 51 52 Limit switch Limit 1 with proximity switch optional 41 42 Limit switch Limit 2 with proximity switch optional 51 52 53 Limit switch Limi...

Page 26: ...als 31 32 Signal range 4 to 20 mA split ranges can be parameterized Supply voltage two wire technology 24 V DC 10 to 30 V DC Characteristic curve rising or falling configurable Deviation 1 Module for...

Page 27: ...o slots for the option modules Any combination of different option modules is possible However identical option modules cannot be combined Limit switch The limit switch can either be equipped with pro...

Page 28: ...ately 6 mm 0 24 in 2 Connect the wires to the connecting terminals in line with the connection diagram Wire cross sectional areas Basic device Electrical connections 4 to 20 mA input Screw terminals m...

Page 29: ...res 0 14 to 0 75 mm2 AWG26 to AWG20 Flexible with wire end sleeve no plastic sleeve 0 25 to 0 5 mm2 AWG23 to AWG22 Flexible with wire end sleeve with plastic sleeve 0 5 to 1 mm2 AWG21 to AWG18 Limit s...

Page 30: ...ack Digital position feedback Emergency shutdown module Universal input Housing 2 EDP300 Remote Sensor contains the position sensor and is suitable for mounting on linear or rotary actuators If necess...

Page 31: ...ten the screws of the terminals so that they are hand tight Use wire end ferrules when connecting The electrical connections of the EDP300 Control Unit and the optional modules are carried out as desc...

Page 32: ...ctronics and pneumatics along with the following options where applicable Analog position feedback Digital position feedback Emergency shutdown module Universal input Any position sensor 4 to 80 k may...

Page 33: ...the option module so that the plug points to the right 3 Using a small amount of pressure guide the option module into the slot from the side and press it down firmly 4 Secure the option module in the...

Page 34: ...ption modules and remove them from the side 4 If present remove the mechanical position indication and screw off the shaft extension as well as the mechanical alarm signaling unit if applicable 5 Remo...

Page 35: ...the metal tag of proximity switch 2 upper contact on the axis until contact is made i e just before it is inserted in the proximity switch The slot sensor enters proximity switch 2 when the feedback...

Page 36: ...e possibility of this occurring it is recommended to install a pressure compensation valve between the springless chamber and the supply air for these types of applications It enables the increased pr...

Page 37: ...100 55 to 100 8 Commissioning Safety instructions Note The electrical power supply and supply air pressure data indicated on the name plate must be complied with during commissioning Before switching...

Page 38: ...nt end positions 45 0 Pos Ang Check the end positions The angle of rotation is displayed in degrees Recommended range between 30 to 30 for linear actuator between 45 to 45 for rotary actuator Moving t...

Page 39: ...cover open Menu navigation M10145 01 1 2 5 Menu 3 4 5 Exit Select 1 Operating buttons for menu navigation 2 Indication of menu designation 3 Indication of menu number 4 Marking to indicate relative p...

Page 40: ...el Operating modes menu In the operating modes menu the Auto Adjust function can be started for commissioning purposes You can also change the operating modes and switch to the configuration level Con...

Page 41: ...l input activated Diagnostic message pending Error pending Maintenance message pending Switching to the information level Operator Menu On the information level the operator menu can be used to displa...

Page 42: ...ing mode results more from the system structure than from the changing behavior of the system meaning that if a stable adaptive operating mode can be obtained over several days of control variations i...

Page 43: ...gh speed mode CAUTION Danger of crushing If air escapes due to a leakage the position will not be readjusted Configured stroke limit positions and stroke times are not effective in manual mode When th...

Page 44: ...e configuration level parameterization The device parameters can be displayed and changed on the configuration level Operating mode Auto Adjust O Adaptive O Control O Manual SP O Manual Sensor Configu...

Page 45: ...ut the area in which the error has occurred Process display Electronic The error messages are divided into four groups in accordance with the NAMUR classification scheme The group assignment can only...

Page 46: ...be visible in it Easy Setup 1 Language Actuator Type Bolt Position Vent Position Tight Shut 0 Control at 0 Tight Shut 100 Control at 100 Autoadjust Mode Start Autoadjust Device Setup 2 Actuator Type...

Page 47: ...back Analog Out Min Analog Out Max Feedbk Charact AO Alarm Mask Alarm Maintenan Alarm OoSpec Alarm Check Fct Alarm Failure AO Simulation Digital Feedback Switch 1 Switch 1 Funct Switch 1 Value Switch...

Page 48: ...input UI SP Value Max UI SP Value Min UI Damping UI Charact UI Out Value Min UI Out Value Max Communication 6 HART Version Find Device Diagnosis 7 Partial Stroke PS Configuration PS Interval PS Start...

Page 49: ...g Date Commun Tag Device Address Descriptor Device Message Pneumatic Type Stroke Time Up Stroke Time Dn Service 9 Service Mode Factory Setting Adjust Sensors Adjust All Adjust Outputs Pneumatic Remote...

Page 50: ...ompletely vented Tight Shut 0 0 0 to 45 0 The shut off value is a percentage of the working range from which the 0 position is approached Once the specified position limit value is reached the actuato...

Page 51: ...tomatic adjustment blocked Note On valves where slip stick effect is significant valve vibration can be reduced by increasing the value of the Zone parameter Start Autoadjust Start The following value...

Page 52: ...r Bolt On Stem actuator bolt on the valve stem Factory setting Bolt On Lever Vent Position Position 0 Position 100 Use this parameter to specify which position is to be shown in the display when outpu...

Page 53: ...ter to set a damping value for the setpoint signal SP Ramp Up Off up to 0 to 200 seconds Here the stroke time for the actuator can be increased A setpoint change is not directly transferred to the pos...

Page 54: ...loop In addition to five predefined characteristic curves you can also select a user configurable characteristic curve which can only be generated and saved in the device via a PC with the appropriate...

Page 55: ...manually rotated old min new max old max new min the device no longer reacts to set point changes A constant process value of 128 flashes on the display Lower Valve Rng 0 0 to 100 0 Normally the valve...

Page 56: ...ent of a power supply failure electric or pneumatic and in manual mode the mechanical end positions are approached Do not reach into the adjustment mechanism Lower Working Rng 0 0 to 100 0 The working...

Page 57: ...s changed the switching points of the binary feedback opposite the valve area which had possibly been previously adjusted will shift Tight Shut 100 55 0 to 100 The shut off value is a percentage of th...

Page 58: ...only be entered in plain text using a DTM EDD Display Value Position Position Setpoint Setpoint mA Deviation Temperature Univ Inp Press Y1 Press Y2 Diff Press Supply Press Use this parameter to select...

Page 59: ...ing compensated This can be prevented by reducing the speed of the dead band approach DB Approach DB Control time 0 to 30 s In some cases it can happen that the valve continues moving slowly after rea...

Page 60: ...alue should be set separately for both positioning directions up down For most actuators satisfactory control behavior is achieved with a KP value between 2 0 and 10 0 Note The control precision is no...

Page 61: ...r stops outside the dead band Y Offset Down 1 to 100 0 Use this parameter to adjust the Y offset for the down positioning direction towards 0 The offset for the set point signal linearizes the behavio...

Page 62: ...Feedbk Charact AO Alarm Mask AO Simulation The current valve position or when the backward calculated characteristics of the valve influence is reported back as a current signal via the analog feedbac...

Page 63: ...matic outputs Partial Stroke Test Start Partial Stroke Test Service Required Issue diagnosis bit via binary feedback Safety Position Approach safety position Conf Locked Block local configuration Pane...

Page 64: ...mA However the current range must not be smaller than 10 1 6 mA Analog Out Max 5 6 to 20 0 mA Use this parameter to specify the upper current range limit for the analog feedback The current range corr...

Page 65: ...Switch 2 simulation SW 2 Mask Map Alarm Maintenan Alarm OoSpec Alarm Check Fct Alarm Failure Switch 2 Sim The function of switch 2 MASK MAP is configured in this parameter group SW 2 Mask Map Switch 2...

Page 66: ...arm Check Fct Alarm Failure Switch 1 Sim Use this parameter to simulate the switch function Off Simulation deactivated Menu SW 2 Mask Map Menu parameter Value range Description Input Output Digital Fe...

Page 67: ...Universal input UI SP Value Max 4 0 to 20 0 mA Use this parameter to specify the upper current range limit for the universal input UI SP Value Min 4 0 to 20 0 mA Use this parameter to specify the low...

Page 68: ...ted In the event of a switch from HART 7 to HART 5 if write protection has been activated via HART 7 it is deactivated when the device is restarted When switching from HART 5 to HART 7 device addresse...

Page 69: ...an individual bar graph The valve ranges are divided up as follows 0 0 10 10 20 20 30 30 40 40 50 50 60 60 70 70 80 80 90 90 100 100 The histograms support valve diagnostics and allow conclusions to b...

Page 70: ...is automatically determined by Auto Adjust only in Auto Adjust mode Valve Ranges Full Dead Time Use this parameter dead time to set the time in which the valve should have moved out of the end positi...

Page 71: ...he device information is displayed here The description can only be entered and changed using a PC DTM EDD Pneumatic Type Single Safe Single Freeze Double Safe Double Freeze The type of pneumatics tha...

Page 72: ...s the device triggers a sequence to vent the outputs The end points of the valve are approached without the brakes being applied Do not reach into the adjustment mechanism Supply Pressure Supply air p...

Page 73: ...tered values are accepted by using Confirm Sensor Position 0 Position Use this parameter to set the fine adjustment of the 0 position after a sensor replacement The current position of the sensor rang...

Page 74: ...n Information Back Exit The error message is shown on the display according to priority The first line shows the area in which the error has occurred The second line shows the unique error number It i...

Page 75: ...unction deactivated X 13 53 Stroke counter limit exceeded Many valve strokes Valve requires maintenance X 14 54 Travel counter limit exceeded Many valve strokes or vibrating valve Valve requires maint...

Page 76: ...tuator 32 41 Y Offset Up exceeded Excessive dynamic friction Valve requires maintenance X Actuator 33 42 Y Offset Down exceeded Excessive friction Valve requires maintenance X Actuator 34 61 Friction...

Page 77: ...Special Requirements 48 81 Pressure measurement defect Print option optional module defective Replace Print option optional module X Electronics 202 Extern access Communication with the device is perf...

Page 78: ...ng hazardous materials the owner of hazardous waste is responsible for its disposal or must observe the following regulations for shipping purposes All devices delivered to ABB must be free from any h...

Page 79: ...n data and contributing factors Output Y1 Increasing set point signal 0 to 100 Increasing pressure at output Decreasing set point signal 0 to 100 Decreasing pressure at output Action set point signal...

Page 80: ...he positioner can be fitted with a contactless position sensor Pressure option The pressure option comprises 3 absolute pressure sensors which facilitate pressure based valve diagnostics valve signatu...

Page 81: ...e Fax Email Device details Type Serial no Reason for the return description of the defect Was this device used in conjunction with substances which pose a threat or risk to health F Yes F No If yes wh...

Page 82: ...82 17 Appendix Control Drawing 901305...

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Page 84: ...84 17 Appendix Control Drawing 901305...

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Page 86: ...86 17 Appendix Control Drawing 901305...

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Page 88: ...turer ABB Automation Products GmbH Process Automation Schillerstr 72 32425 Minden Germany Tel 49 571 830 0 Fax 49 571 830 1806 Customer service center Tel 49 180 5 222 580 Mail automation service de a...

Page 89: ...VALVE ACCESSORIES CONTROLS 200 Jade Park Chelsea AL 35043 TEL 205 678 0507 info vacaccessories com...

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