operating instructions fieldit electro-pneumatic …...operating instructions 41/1878 en field...

Operating Instructions41/18�78 EN

Field

Electro-Pneumatic PositionerTZIDC-120

for FOUNDATION FieldbusTM

IT

Software Revision 2.00

PID Block and Enhanced Diagnostic Functions

2 Electro-Pneumatic Positioner TZIDC-120 41/18-78 EN

Product designation:Electro�pneumatic positioner TZIDC�120 for FOUNDATION FieldbusTM

Operating instructions

Item No.: 41/18�78 EN

Date of issue: 02.04

Revision: 04

Manufacturer:

ABB Automation Products GmbH

Schillerstrasse 72

32425 Minden

Germany

Tel. +49 551 905�534

Fax +49 551 905�555

CCC�[email protected]

© Copyright 2004 by ABB Automation Products GmbHWe reserve the right to technical amendments

This document is protected by copyright. Information in this document is intended only to assist the user in safe and efficient operation of the equipment. Its contents are not to be reproduced in full or part without prior approval of legal owner.

NoteMore information, e.g. regarding configuration, operation and ordering details, is available on CD.

Table of contents

1 Safety and precautions .............................................................................................. 5

1.1 Explanation of warning signs and notes ................................................................5

1.2 General safety instructions .....................................................................................5

1.3 Device-specific safety instructions.........................................................................6

1.4 Intended use..............................................................................................................7

1.5 Qualified personnel ..................................................................................................7

2 Manufacturer’s information ...................................................................................... 7

2.1 Delivery......................................................................................................................7

2.2 CE compliance information .....................................................................................7

2.3 Device identification.................................................................................................8

2.3.1 Type plate of the basic device ........................................................................ 8

2.3.2 Type plate indicating the degree of explosion protection................................ 8

3 Installing and commissioning ................................................................................. 9

3.1 Mechanical mounting ...............................................................................................9

3.1.1 General ........................................................................................................... 9

3.1.2 Operating conditions at the installation site ................................................. 10

3.1.3 Mounting the positioner to linear actuators................................................... 10

3.1.4 Mounting the positioner to rotary actuators .................................................. 15

3.2 Pneumatic connection ...........................................................................................18

3.2.1 Safety instructions ........................................................................................ 18

3.2.2 Making the pneumatic connection ................................................................ 19

3.2.3 Mounting the splash guard cap..................................................................... 20

41/18-78 EN Electro-Pneumatic Positioner TZIDC-120 3

3.3 Electrical connection..............................................................................................21

3.3.1 Safety instructions ........................................................................................ 21

3.3.2 Installation instructions ................................................................................. 21

3.3.3 Overview....................................................................................................... 22

3.3.4 Making the electrical connection .................................................................. 23

3.4 Setting jumpers on the motherboard....................................................................24

3.5 Commissioning.......................................................................................................25

3.5.1 Procedure ..................................................................................................... 25

3.5.2 Requesting bus information .......................................................................... 27

3.5.3 Local operation (bus device)......................................................................... 28

3.5.4 Parameter setting example........................................................................... 29

3.6 Functional test / maintenance ...............................................................................31

3.6.1 Functional test of the shutdown module. ...................................................... 31

4 Technical data ............................................................................................................. 32

4.1 Fieldbus specifications ..........................................................................................32

4.2 Basic model.............................................................................................................33

4.3 Options ....................................................................................................................37

5 Certificates.................................................................................................................... 38

Appendix A: Configuration overview ...................................................................... 49


1 Safety and precautions

1.1 Explanation of warning signs and notes

Important information is marked and emphasized in these operating instructions with thefollowing symbols:

1.2 General safety instructions

DangerIndicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

STOP

WarningIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury or serious property damage.!CautionIndicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage. !ImportantIndicates useful hints or other special information which, if not observed, could lead to a decline in operating convenience or affect the functionality.

WarningImportant instructions for your safety! Read and follow these instructions.

Also observe

• the general instructions in this document.

• the relevant safety regulations and standards for the installation and operation of electrical systems, especially the common VDE safety regulations and the accident prevention rules of the Employers Liability Insurance Association.

• the standards, regulations and directives governing explosion protection, when using devices that are protected against explosion hazards. For the electrical installation of explosion-protected devices observe all national regulations, DIN/VDE directives, the directives for explosion protection, especially VDE 0165 or EN 60079-14, and the special requirements for the device (See “Device identification” on page 8 and “Certificates” on page 38 of these operating instructions).

!


Proper and safe operation of the TZIDC-120 positioner requires:

• proper transportation and storage

• installation, electrical and pneumatic connection and commissioning by qualified personnel

• correct operation according to the instructions in these operating instructions

• proper use as intended (see chapter 1.4 on page 7)

• careful maintenance

Only qualified personnel are allowed to work on the device (see chapter 1.5 on page 7).

The regulations, standards and directives referred to in these operating instructions areapplicable in Germany. When using the TZIDC-120 positioner outside the German juris-diction, the relevant regulations, standards and directives applicable in the country wherethe device is used must be observed.

The TZIDC-120 positioner has been designed and tested in accordance with DIN VDE0411 Part 1.

Safety Requirements for Electronic Measuring Apparatuses

(based on IEC Publication 348) and has been supplied in a safe condition.

In order to retain the device in a safe condition and to ensure safe operation the instruc-tions given in the sections marked with symbols (see chapter 1.1) must be observed.Otherwise, persons can be endangered or the device itself or other devices or equipmentmay be damaged or fail.

1.3 Device-specific safety instructions

Danger• Do not make any changes on the device! Only the manufacturer or an

expert for explosion protection are authorized to modify the device.

• Before re-using a TZIDC-120 positioner that has already been used in another installation place, always reset the device to the factory setting. Never start the autoadjustment function before having restored the factory setting. Otherwise, hazardous situations may occur.

• Do not use the internal communication interfaces LKS or X5 on the printed circuit board of a TZIDC-120 positioner that is installed and used in the hazardous area.

STOP

Warning• Observe the specifications in chapter 4 "Technical data" for the electrical

wiring.

• Observe the safety instructions for the pneumatic actuator used when mounting and commissioning the positioner. There is danger of injuries caused by the high actuating power of the actuator.

• The (optional) safety shutdown module - if present - must be subject to a functional test every two years at the latest. Follow the instructions in chapter 3.6.1 "Functional test of the shutdown module."

!


1.4 Intended use

The TZIDC-120 positioner is an electro-pneumatic valve positioner for use with pneu-matic linear and rotary actuators.The device may only be used for the applications listedin these operating instructions and in the data sheet 10/18-0.24 EN.

1.5 Qualified personnel

Only those persons familiar with the installation, commissioning, operation and mainte-nance of the TZIDC-120 positioner or similar instruments and who have the requiredqualification are authorized to work on the device.

These persons are:

• Project specialists who are familiar with the security concepts of process automation.

• Commissioning and service personnel, i.e. persons who have been trained ade-quately to mount, commission, put out of service and maintain the TZIDC-120 posi-tioner or similar automation instruments or who are – according to safety standardsand guidelines – permitted to commission electrical circuitry, devices, and systems.

• Operating personnel familiar with handling automation equipment and with the con-tents of these operating instructions.

2 Manufacturer’s information

2.1 Delivery

When receiving the delivery please immediately check items and scope for damages andcompleteness. The scope of delivery is stated in the shipping documents. If ordered, theaccessories (e.g. mounting material, pressure gauge block, filter regulator) are added tothe delivery as individual items. Check items and scope of the delivery by means of thecatalog numbers to see if types and quantities are in accordance with your order.If the positioner is delivered already mounted to the actuator, the positioner, accessories,and actuator are considered as a common delivery item.

A list of catalog numbers and details of the different versions and accessories can befound in data sheet 10/18-0.24 EN.

2.2 CE compliance information

We declare that we are the manufacturer of the TZIDC-120 positioner and that the product conforms with the EMC Directive 89/336/CEE as of May 1989 and meets therequirements of the following standards:

• EN 55022:1998 “Information technology equipment, Radio disturbance characteristics, Limits and methods of measurement”

• EN 61000-6-2:8/2002 ”Electromagnetic compatibility (EMC) — Part 6-2: Generic standards — Immunity for industrial environments

• EN 61000-6-3:3/2000 “Electromagnetic compatibility (EMC) — Part 6-3: Generic standards — Emission standard for residential, commercial and light-industrialenvironments

The TZIDC-120 positioner complies with the EC directive for CE conformity certification.


2.3 Device identification

Your positioner is identifed by two type plates providing the following information:

2.3.1 Type plate of the basic device

Legend:1 Type designation with software revision number, serial number, and supply pressure

2 Input data: input voltage, input current, and failure current

3 Function of the pneumatic output: single acting or double acting

4 Reaction on failure of the electrical power: fail safe or fail freeze

5 Option modules installed: limit switches (electrical or mechanical), position indicator, module for safety shutdown

2.3.2 Type plate indicating the degree of explosion protection

One of the type plates seen in Fig. 2 is attached to your positioner, indicating its degreeof explosion protection and the applicable ATEX certificate. Refer to chapter 5 "Certifica-tes" on page 38 of these operating instructions for details.

Fig. 1 Type plate of the basic device

1

2

3

5

4

Fig. 2 Type plates indicating the degree of explosion protection

WarningAlways observe the specifications and special requirements for your device stated in the applicable ATEX certificate.!


3 Installing and commissioning

3.1 Mechanical mounting

3.1.1 General

The arrow (1) on the feedbackshaft (and thus the lever) musttravel within the area marked withthe small arrows (2).

When mounting,ensure that thetransfer of thestroke or rotationangle for the posi-tion feedback iscorrect. The maxi-mum rotationangle is 60° formounting to linearactuators and120° for mountingto rotary actua-tors. The mini-mum range forboth applicationsis 25°.

Fig. 3 Operating range

1 2

TZID-C

+60°

-60°

+30°

-30°

100%

0%

100%

0%

Sensor range for rotary actuators

Operating range for linear actuators

Operating range for rotary actuators

Sensor range for linear actuators

Fig. 4 Positioner ranges


3.1.2 Operating conditions at the installation site

Ambient temperature: -40 ... +85 °C (-40 ... +185 °F)

Relative humidity 100% (mean annual value), condensation permissible.Observe the specifications for protection class IP65 /NEMA 4X, the mounting instructions for the splash guardcap, see page 20, and the specifications in chapter 4.

Explosion protection: Observe the technical data, and the specifications in thecertificates (see the relevant sections of this document).

Mounting position: any orientation allowed, provided that the splash guardcap is in place, see the instructions on page 20.

3.1.3 Mounting the positioner to linear actuators

A special attachment kit is available for mounting the positioner to a linear actuatoraccording to DIN/IEC 534 (lateral mounting to NAMUR) comprising the following parts:

Tools required: Wrench 10 mm/13 mmAllen key 4 mm

• Lever (1.0) w. followerpin, for 10...35 mm or20...100 mm actuatorstroke

• Follower guide (2.0)with two screws (2.1),spring washers (2.2),and clamp plates (2.3)

• Angle bracket (3.0)with two screws (3.1),and two plain wash-ers (3.2)

• Screw (3.4) and plainwasher (3.5) formounting to cast ironyoke

• Two U-bolts (3.7),each with two plainwashers (3.8), andtwo nuts (3.9) formounting to columnaryoke

WarningBefore installing check to ensure that the specifications in terms of safety and control applicable to the TZIDC-120 will not be exceeded.!

3.43.5

3.7

3.9

3.1 3.2

3.0

2.1

2.3

2.0

1.03.8

2.2

Fig. 5 Mounting kit for linear actuators


Follow the procedure (steps 1 - 5) below to mount to a linear actuator:

1. Mount the follower guide to the actuator

2. Assemble the lever (if not yet pre-assembled)

• Fasten the follower guide (1)and the clamp plates (2) withscrews (4) and spring washers(3) to the spindle of the actua-tor; hand-tighten the screws.

• Slip the spring (2) onto the boltwith the follower pin (1).

• Slip the plastic washer (3) ontothe bolt and compress thespring with it.

• Insert the bolt with com-pressed spring into the oblonghole in the lever (4) and fasten itin the desired position using theplain washer (5) and nut (6) atthe lever; the scale on the leverindicates the link point for thestroke range.

• Slip the plain washer (8) ontothe screw (7), insert the screwinto the lever and counter withthe nut (9).

4

2

1

3

Fig. 6 Mounting follower guide to actuator

1

2

3

4

5

6

9

8

7

Fig. 7 Assembling the lever


3. Mount the lever and the angle bracket to the TZIDC-120 positioner

• Attach the lever (1) to the positioner’s feedback shaft (2) (can only be mounted inone position due to the flat on the side of the feedback shaft).

• Check whether the lever travels within the operating range (between the arrows) byobserving the arrow marks (3).

• Hand-tighten the screw (4) at the lever.

• Hold the preassembled TZIDC-120 with the angle bracket (5) still loose in such away against the actuator that the follower pin on the lever introduces into the followerguide, in order to determine the bore holes of the TZIDC-120 to be used for theangle bracket.

• Fasten the angle bracket (5) with screws (6), and plain washers (7) to the corre-sponding bore holes in the TZIDC-120 case; if possible, tighten the screws evenly toensure linearity during operation. Align the angle bracket in the oblong hole toachieve a symmetrical operating range (between the arrow marks (3)).

1

2 34

5

6

7

Fig. 8 Mounting lever and angle bracket to TZIDC-120


4.a Mount the positioner to a cast iron yoke

or

4.b Mount the positioner to a columnar yoke

For information about direct mounting to control valves see the CD.

• Fasten the angle bracket (1)with screw (2), plain washer (3)to the cast iron yoke (4).

• Hold the angle bracket (1) in theappropriate position against thecolumnar yoke (2).

• Insert the U-bolts (3) from theinner side of the columnar yokethrough the holes in the anglebracket.

• Slip on the plain washers (4),and nuts (5). Hand- tighten thenuts evenly.

24

1

3

Positioner

Fig. 9 Mounting to cast iron yoke

5

1

2

3

4

Positioner

Fig. 10 Mounting to columnar yoke

ImportantAdjust the height of the TZIDC-120 positioner at the cast iron yoke or the colum-nar yoke until the lever is horizontal (at visual check) at half valve stroke.

Check the unit for proper mounting after having made the pneumatic and electri-cal connection (see chapter “Commissioning” on page 25 for details).


5. Adjust the stroke

The scale on the lever indicates the relevant points for the various valve stroke ranges.

You can adapt the valve stroke range to the operating range of the position sensor byshifting the bolt with follower pin in the oblong bore hole of the lever. When the linkpoint is shifted to the inside, the position sensor’s rotation angle is increased; shifting tothe outside decreases the angle.

Set the stroke range in such a way that the used rotation angle of the position sensor isas great and as symmetrical around the center position as possible.

Recommended range for linear actuators: between -28° and +28° Minimum angle: 25°

decreaseincrease

Fig. 11 Positioner linkage

ImportantAfter mounting, check whether the positioner operates within the sensor range.

After having made the pneumatic and electrical connection (see chapter “Com-missioning” on page 25 for details) check the unit for proper mounting.


3.1.4 Mounting the positioner to rotary actuators

The following mounting kit is available for mounting to a rotary actuator according to VDI/VDE 3845 :

Tools required: Wrench 10 mm/13 mmAllen key 3 mm

• Namur feedbackshaft adapter (1.0)with spring (1.4)

• Four screws, M6(1.1), four springwashers (1.2), andfour plain washers(1.3) for fasteningthe mountingbracket (2.0) to thepositioner

• Mounting bracket(2.0)

• Four screws, M5(2.1), four springwashers (2.2), andfour plain washers(2.3) for fasteningthe mountingbracket to the actua-tor

1.3

1.0

1.1

2.0

2.1

2.2

2.3

1.2

1.4

Fig. 12 Mounting kit for rotary actuators


Follow the procedure (steps 1 - 3) below to mount to a rotary actuator:

1. Mount the adapter to the positioner

2. Attach the mounting bracket (1) to the positioner

• Determine the mounting position (in parallelto the actuator or shifted by 90°).

• Determine the direction of rotation of theactuator (clockwise or counterclockwise).

• Move rotary actuator to its home position.

• On the basis of the mounting position, thehome position, as well as the direction ofrotation it must be determined in whichposition the feedback shaft (1) of the posi-tioner must be pre-adjusted and in whichposition the adapter (2) must be placed, toenable the positioner to travel within theproper range (the arrow on the rear of thedevice must travel within the admissiblerange, see Fig. 3 on page 9).

• Pre-adjust the feedback shaft.

• Place the adapter on the feedback shaft inthe appropriate position and fix it by set-screws (3); ensure that one of the set-screws is engaged on the side of thefeedback shaft with the flat.

1

2

3

Fig. 13 Mounting the adapter

1

M6 Screws

Fig. 14 Attaching the mounting bracket to the positioner


3. Attach the TZIDC-120 positioner to the actuator

M5 Screws

Fig. 15 Attaching the positioner to the actuator

ImportantAfter mounting, check whether the actuator’s operating range is in accordance with the positioner’s sensor range.

After having made the pneumatic and electrical connection (see chapter “Com-missioning” on page 25 for details) check the unit for proper mounting.


3.2 Pneumatic connection

3.2.1 Safety instructions

Warning• Observe the accident prevention rules of the Employers Liability Insurance

Association.

• Observe the safety instructions for the pneumatic actuator used. There is danger of injuries caused by the high actuating power of the actuator.

• Do not exceed the maximum operating pressure of the actuator.

!

Caution• Take suitable measures to ensure that even in case of malfunctions the

positioner’s max. admissible operating pressure of 6 bar (90 psi) is not exceeded. Otherwise, the positioner and/or the actuator can be damaged.

• The positioner must be supplied with instrument air that is free of oil, water and dust according to DIN/ISO 8573-1, Class 3

Purity max. particle size: 5 �mmax. particle density:5 mg/m3

Oil contentsmax. concentration:1 mg/m3

Pressure dew pointMaximum value:10 K below operating temperature

Before connecting the air pipes, remove dust, splinters and other particles by blowing them out of the pipes.

!


3.2.2 Making the pneumatic connection

All pneumatic piping connections are located at the right-hand side of the device (seeFig. 16).

The threaded bores G 1/4 or 1/4-18 NPT, respectively, are provided. The correspondingscrewed pipe connections have to be supplied by the customer. We recommend pipeswith the dimension 6 x 1 mm for the pneumatic piping.

The amount of supply pressure has to be matched to the working pressure necessaryfor the actuation. The operating range of the positioner is between 1.4 and 6 bar.

The connections have to be arranged, according to their marks, in the following way:

Mark Connection piping

- Air supply, pressure 1.4...6 bar(20...90 psi)

OUT1 Output pressure, to actuator

OUT2 Output pressure, to actuator (for double-acting actuators)

Filt

er

OUT

1OU

T 2

NPT

¼M

12x1

G ¼

Pneumatic outputs

Air supply

Filter screw plug

Fig. 16 Pneumatic connections


3.2.3 Mounting the splash guard cap

Screw the splash guard cap delivered with your positioner into the appropriate hole in thebottom plate of the case, as seen in the illustration below. Do not use a screw driver forthis purpose! Make sure that the splash guard cap is always in place during operation.

CautionProtection class IP 65 / NEMA 4X is only achieved when the splash guard cap is mounted! Do not use the positioner without this cap!!

Fig. 17 Mounting the splash guard cap


3.3 Electrical connection

3.3.1 Safety instructions

3.3.2 Installation instructions

Warning• Observe the common VDE safety regulations and the accident prevention

rules of the Employers Liability Insurance Association relevant for the electrical installation.

• Observe the common standards/safety regulations for the installation and operation of electrical systems.

• Observe the additional standards, regulations and guidelines for the set-up and the operation of explosion-proof installations, if explosion-proof devices are used.

!

CautionObserve all of the following instructions. They are essential to proper operation and functionality of the device.

General

• When connecting a device make sure that the electrical specifications in chapter 4 "Technical data" are observed.

Power supply

• The basic device is bus-powered via the Fieldbus connected to the bus terminals +(11) and -(12). The option modules have to be supplied separately.

• When connecting a power source for test purposes without establishing a bus communication (e.g. when executing the Autoadjust function), a supply voltage between 9.0 V DC and a maximum of 32 V DC can be applied.

Electromagnetic interference

• Do not run bus/signal lines close to power lines. Power lines produce interference in their near vicinity which may affect the electrical capabilities of the bus/signal lines.

• In order to ensure electromagnetic compatibility (EMC), always use shielded cables conforming to the standards for the bus lines. When running the device with the option modules (proximity switches, microswitches, shutdown module) use shielded cables for these modules as well. All cable shields must be kept as short as possible and have to be connected to protective ground on both sides (use the grounding screw in the TZIDC-120 connection compartment on the device side).

• Keep the case closed. When the case is open, the positioning action may be affected through electromagnetic interference. This may result in a permanent positioning error, especially when the Autoadjust function is performed with the case open.

!


3.3.3 Overview

Two threaded holes PG 13.5,1/2 - 14 NPT or M20 x 1.5 areavailable on the left hand sideas the cable entry into thecase (see Fig. 18). One isequipped with a cable glandand in the other a dummy plugis mounted.

The screw terminals inside the case are assigned as follows (see Fig. 19):

1 Not used

2 Service switch for shut-down module

3 Terminals for the plug-in module for the shutdown function

4 Kit for digital position feedback, either proximity switches or 24 V microswitch (first connector), terminals designed for wire sizes up to 1.0 mm2

5 same as 4

6 Bus terminals, designed for wire sizes up to 2.5 mm2

7 Grounding screw

Cable gland

Dummy plug

Fig. 18 Cable entry

+41

-42

Lim

it 2

Lim

it 1

+85-

86

+51

-52

+-

(11)

(12)

1

2

4

6

7

5

3

OnOff2

Off1

Fig. 19 Screw terminals


3.3.4 Making the electrical connection

Proceed as follows:

• Remove approximately 6 mm of the cable insulation

• When connecting the bus lines, shutdown module, proximity switches ormicroswitches, insert the wire ends from the left into the appropriate screw terminaland hand-tighten the screws (access from above). When connecting a plug-in mod-ule, insert the wire ends from the top into the corresponding screw terminal andhand-tighten the screws (access from the side).

CautionDo not expose the terminals to strain. !

Lim

it 2

Lim

it 1

NC

NO

NC

NO+4

1 -4

2

Lim

it 2

Proximity switchesSupply 5…11VDC

Signal L 1mA, H 2 mA< >

Fieldbus,bus powered

9…32V

Op

tio

n 1

:Po

siti

on

sw

itch

esO

pti

on

2

Microswitchesmax. 24V, max. 2A

41

42

4351

52

53

Keep cable shields as shortas possible and connectto ground on both sides

Shutdown module24V (20V…30V)

Lim

it 1

+51

-52

+11

-12

+85

-86

Fig. 20 Wiring diagram


3.4 Setting jumpers on the motherboard

Two jumpers can be set on the motherboard to enable/disable simulation or write access.Set the jumpers according to your needs as seen in the illustration below:

SimulationWrite-access

Disabled

Enabled

Default setting (acc. to Fieldbus Foundation standard):

Simulation disabled

Write-access enabled

Fig. 21 Jumper setting


3.5 Commissioning

3.5.1 Procedure

1. Turn on the air supply to the positioner.

2. Connect the bus with arbitrary polarity (or auxiliary power 9 V DC ... 32 V DC) to the bus terminals.

is displayed.

3. Check for proper mounting:

- Press and hold MODE and ENTER simultaneously. Wait until the countdown has run down from 3 to 0, then release MODE and ENTER. The operating level (mode 1.x) is reached and indicated.

- Press and hold MODE.

- Additionally briefly press or until mode 1.3 (manual adjustment within the sensor range) is displayed.

- Release MODE.

- Press or to move the actuator to its mechanical limit stops in both directions, and note the values. The angle of rotation is indicated in degrees.

4. Return to the remote level.

- Press and hold MODE and ENTER.

- Wait until the countdown has run down from 3 to 0, then release MODE and ENTER.

is displayed.

ImportantThe prerequisite for proper operation of the TZIDC-120 positioner on the bus is that the Transducer Block can change over to AUTO mode. This requires that that the operating range of both the positioner and the valve be matched to each other (as described in step 5 of the procedure below). If this auto-adjust-ment should fail or cannot be performed for any reason, the Transducer Block remains in “Out of Service” mode and the configuration bit in the “BLOCK-ERR Parameter” is “active”.

conf

mA%

C°

Recommended range:between -28° and +28° for linear actuatorsbetween -57° and +57° for rotary actuatorsMinimum angle: 25°

ImportantThe positioner should be mounted/adjusted in such a way that the portions of the sensor’s operating range above and below the center point are nearly identical. Make sure to use the rotation angle of the position sensor in the positioner to its utmost extent. Refer to chapter 3.1 "Mechanical mounting" for details about how to readjust/correct if required.

conf

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C°


5. Run the standard Autoadjustment function.

- Make sure that the remote level is activated.

a) For linear actuators:

- Press and hold MODE. Wait until the countdown has run down from 5 to 0, then release MODE.

- Press and hold MODE again until the countdown has run down from 3 to 0, then release MODE.

Autoadjustment is started automatically, and the progress is displayed.

b) For rotary actuators

- Press and hold ENTER.

- is displayed.

- Wait until the display has changed to

- Release ENTER.

- Press and hold ENTER again until the countdown has run down from 3 to 0.

- Release ENTER.

Autoadjustment is started automatically, and the progress is displayed.

When Autoadjustment has completed successfully, the determined parameters aresaved automatically, and the remote level is activated again.

If, however, an error should occur during Autoadjustment, error code 255 is briefly indi-cated. The device then automatically changes over to parameter P1.1 Autoadjust (cus-tom autoadjustment) at the configuration level.


- Additionally, briefly press or several times until.

- is displayed.

- Release MODE. CANCEL is displayed. If not, briefly press or .

- Press and hold ENTER until the countdown has run down from 3 to 0.

The positioner automatically returns to the operating level. Briefly press twice to reachoperating mode 1.3 “Manual adjustment within the sensor range” and then check thepositioner-actuator assembly for proper mounting. Re-adjust if required (see chapter3.1.3 or chapter 3.1.4 for details) and then start standard Autoadjustment again.

conf

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C°

conf

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C°

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C°


3.5.2 Requesting bus information

Additional information about the bus can be called up for display by briefly pressing thebuttons shown in the table when bus mode is active (i.e. the following display is seen):

Buttons pressed Command/Action

Show setpoint value and state.The display shows the last valid setpoint value (SP_VALUE) andstate (SP_STATE) from the transducer block for two seconds,each. Then the REMOTE display is seen again.The setpoint value is indiated as a percentage.The setpoint state is indicated as a code number, meaning thefollowing:

Code Meaning (Status, sub-status, details)28 Bad, OutOfService, NotLimited73 Uncertain, SubstituteValue, LowLimited74 Uncertain, SubstituteValue, HighLimited75 Uncertain, SubstituteValue, Constant79 Uncertain, InitialValue, Constant192 GoodCascade, NonSpecific, NotLimited224 GoodCascade, InitiateFaultState, NotLimited

Show current block mode.The display shows the current mode of the AO function blockand the transducer block for approximately two seconds, each.Then the REMOTE display is seen again.

The AO function block may have the following modes:OOS_AO AO block out of serviceIMAN_AO Initialization Manual of AO blockAUTO_AO Automatic AO blockMAN_AO Manual AO blockCAS_AO Cascade AO blockLO_AO Local Override AO block RCAS_AO Remote Cascade AO blockROUT_AO Remote Output AO block

The transducer block may have the following modes: OOS_TB TB out of serviceAUTO_TB Automatic TB

Show software revision level and device type

conf

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C°

ENTER


3.5.3 Local operation (bus device)

Procedure for mode selection from operating level:

• Press and hold MODE.

• Additionally briefly press as often as required. The selected operating mode is indicated.

• Release MODE.• The position is indicated as a percentage or rotation angle.

Overview

*) Positioning not active

**) For quick motion: Press and together.

Mode Mode display Position display

1.1Positioning with fixed setpoint.Setpoint can be adjusted by pressing

or .

1.2Manual adjustment* within the operating range. Press or to adjust.**

1.3Manual adjustment* within the sensor range.Press or to adjust.**

conf

mA%

C°

conf

mA%

C°

conf

mA%

C°

conf

mA%

C°

conf

mA%

C°

conf

mA%

C°


3.5.4 Parameter setting example

"Changing zero position (of the LCD) from clockwise to counter-clockwise"

Starting situation: the positioner is operating remote-controlled.

1. Cange over from the remote level to the operating level:

- Press and hold MODE and ENTER simultaneously.

- Wait until the countdown has run down from 3 to 0.

- Release MODE and ENTER. Mode 1.1 is reached and indicated.

2. Change over to the configuration level:

- Simultaneously press and hold and .

- In addition, briefly press ENTER.

- Wait until countdown from 3 to 0 has run down.

- Release and .

- is displayed.

3. Change over to parameter group 3._:

- Simultaneously press and hold MODE and ENTER.

- In addition 2 x briefly press .

- is displayed.

- Release MODE and ENTER.

- is displayed.

4. Select parameter 3.2 "Zero position”:


- In addition, 2 x briefly press .

- is displayed.

- Release MODE.

5. Change parameter setting:

- Briefly press to select "CTCLOCKW".

conf

mA%

C°

conf

mA%

C°

conf

mA%

C°

conf

mA%

C°


6. Change over to parameter 3.3 "EXIT" and save the new setting:


- In addition, 1 x briefly press .

- is displayed.

- Release MODE.

- Briefly press to select "NV_SAVE.

- Press and hold ENTER until the displayed countdown from 3 to 0 has run down.

The positioner saves the new settings and automatically returns to the operating level.

7. Return to the remote level.

- Press and hold MODE and ENTER.

- Wait until the countdown has run down from 3 to 0.

- Release MODE and ENTER.

is displayed (percentage is an example)

conf

mA%

C°

conf

mA%

C°

Refer to Appendix A for an overview of the parameters that can be set via the front panel keys of the TZIDC-120 positioner.


3.6 Functional test / maintenance

The TZIDC-120 positioner is virtually maintenance-free.

To ensure error-free and maintenance-free operation, the positioner must be operatedwith instrumen air that is free of oil, water and dust according to DIN/ISO 8573-1 (purityand oil content should meet the requirements acording to class 3, pressure dew point10 K below the operating temperature).

We recommend to check the integrated air filter and to replace it if it becomes pluggedwith dirt.

The control position should be checked regularly for conformity with the tolerance limit.

3.6.1 Functional test of the shutdown module.

Proceed as described below:

• Remove the cover.

• Alternately set the slide switch (see Fig. 19 on page 22) from the "On" position in themiddle to the top and bottom position ("Off1" and "Off2") to check whether or not theactuator is depressurized properly.

• Set the slide switch to the "On" position in the middle again.

• Replace the cover.

DangerDo not make any changes on devices with explosion protection.STOP

ImportantAlthough positioners without explosion protection may be modified by the user to a certain extent, the electronics must not be changed at all. You should be aware of the fact that the positioner warranty will expire immediately in case of user modifications of the electronics.

WarningIf the optional shutdown-module is used, it must be subject to a functional test every two years at the latest to ensure full operational reliability in com-pliance with DIN V 19250. Note that, otherwise, the AK 4 approval will lapse.

!


4 Technical data

4.1 Fieldbus specifications

PhysicalSpecification FOUNDATION FieldbusTM Revision 1.5Physical layer, profile class Device type 113, 121 (IEC 61158-2)Communication speed 31.25 Kbit/secondCurrent rating 11.5 mAFault current 15 mA (11.5 mA + 3.5 mA)Operating voltage Bus-powered: 9.0 V DC to 32.0 V DCMax. withstand voltage 35 V DCATEX-certified for FISCO YesPolarity-sensitiveness Not sensitive to polarity reversal

CommunicationsClass LM profile 32L, 31PSNumber of free VCRs 23 (No. of VCRs of which the application can be changed,

except for the VCR used for management)User layerFunction blocks provided 1 AO Function Block, 1 PID BlockExecution time AO Block: 40 ms; PID Block: 50 msBlock class AO Block: standard; PID Block: enhanced

Resource Block: enhanced; Transducer Block: customNumber of linkage objects 22Minimum cycle time 50 msDevice description (DD) Rev. No. 1 (file name: 0201.ffo, 0201.sym)Common file format file provided Yes (file name: 020101.cff)FF Certification Registered with ITK 4.51, Dec. 2003

IT Camp. Number ITO23200Documentation Configuration and parameter setting instructions,

45/18-78 ENSupport of “Incremental DD” NoCalibration and diagnostic Yesinformation defined in DD

Support of self-tuning Supports self-tuning of the valve. Control loop “self-tuning” through the PID function block is not supported.

Delivery state The positioner is delievered in an unadjusted state. The standard autoadjustment function has to be run to adapt the working range and control parameters. Otherwise the transducer block will remain in “Out of service” mode.

Diagnostic capabilities Self-diagnostic of positioner hardware and software. Basic valve diagnostics incl. extended alarm handling


4.2 Basic model

Name

Device tagABB POSITIONER TZIDC-120 xxxxxx

Device ID0003200028______TZIDC-120 xxxxxx

Device addressBetween 10 and 247, default node address 23

Output

Range0...6 bar (0...90 psi)

Air capacityat supply pressure of 1.4 bar (20 psi)

5.0 kg/h = 3.9 Nm3/h = 2.3 scfmat supply pressure of 6 bar (90 psi)

13 kg/h = 10 Nm3/h = 6.0 scfm (Booster, for increasing air capacity, on request)

Functionfor single or double acting actuators, air is vented from actuator or actuator is blocked in case of an electrical power failure

Shut-off functionWhen the setpoint exceeds or falls below the defined limit value,the actuator immediately moves to the 0 % or 100 % position.

Travel

Angle of rotationUsed range 25...120 ° (rotary actuators, optionally 270°)

25...60 ° (linear actuators)Travel time prolongation

Range 0...200 seconds, individually configurable for each direction

Air supply

Instrument airfree of oil, water and dust to DIN/ISO 8573-1pollution and oil contents according to Class 3(Purity: max. particle size 5 �m, max. particle density 5mg/m3; Oil content: max. concentration 1 mg/m3; Dew point at least 10 °C below operating temperature)

Supply pressure1.4...6 bar (20...90 psi)Caution: Do not exceed the max. operating pressure of the actuator!

Air consumption< 0.03 kg/h (0.08 scfm) (independent of supply pressure)


Transmission data and influencesAction (output signal or pressure in the actuator)

Direct: Increasing signal 0...100 % Increas. pressure at the output OUT1

Reverse: Increasing signal 0...100 % Decreas. pressure at the output OUT1

Characteristic deviation< 0.5%

Tolerance band 0.3...10%, adjustable

Dead band 0.1 % ... 5.0 %, adjustable

Resolution (A/D conversion)> 16,000 steps

Sample rate20 ms

Influence of ambient temperature< 0.5% for every 10 °C change in temperature

Influence of vibration� +/-1% up to 10g and 80 Hz

Seismic requirementsMeets requirements of DIN/IEC 68-3-3 Class III for strong and strongest earthquakes

Influence of mounting positionNo effect

Meets the following requirementsEMC Directive 89/336/CEE as of May 1989EC Directive for the CE conformity marking

Environmental capabilities

Ambient temperature- 40 to + 85 °C (- 40 to + 185 °F)for operation, storage and transport

Relative humidityOperational (with closed housing and air supply switched on):100 %, condensation permissibleTransport and storage:75 % (annual average), non-condensing


Case

Material/ProtectionAluminum, protection class IP 65 (NEMA 4X)

Surface/colorElectrostatic dipping varnish with epoxy resin, stove-enamelledBottom part of case varnished black, RAL 9005, matt,Cover white aluminum, RAL 9006

Electrical connectionsScrew terminals: max. 1.0 mm2 for options, max. 2.5 mm2 for bus connectionCaution: Do not expose the terminals to strain!Cable entry2 threads Pg. 13.5, 1/2-14 NPT or M20x1.5for cable diameter 6...12 mm1 with cable gland and 1 with pipe plug

Pneumatic connectionsThreads G 1/4 or 1/4-18 NPT

Weight1.7 kg

Mounting orientationany orientation allowed

Dimensionssee dimensional drawings in data sheet 10/18-0.24 EN


Explosion protection

FM/CSA (pending)

ATEX II 2G EEx ia II C T6Type examination certificate TÜV 02 ATEX 1834 XType: Intrinsically safe equipmentDevice class: II 2G (EEx ia IIC)Temperature class: T4, T5, T6Permissible ambient temperature: T4: -40 °C � Tamb � 85 °C

T5: -40 °C � Tamb � 55 °CT6: -40 °C � Tamb � 40 °C

ATEX II 3G EEx n A II T6Type examination certificate TÜV 02 ATEX 1943 XType: Explosion-proof equipment for zone 2Device class: II 3G (EEx n A II)Temperature class: T4, T5, T6Permissible ambient temperature: T4: -40 °C � Tamb � 85 °C

T5: -40 °C � Tamb �� 65 °CT6: -40 °C � Tamb � 50 °C

Signal current circuit for FOUNDATION FieldbusTM, only for connection to a certified in-trinsically safe circuit (e.g. FISCO power unit oder barrier) with the following max. values:

FISCOia/ibfor groupIIB/IIC

FISCOia/ibfor group IIB/IIC

Barrier or power supply unitia/ibfor group IIB/IIC

Vi = 17.5 V Vi = 17.5 V Vi = 24 V

Ii = 380 mA Ii = 360 mA Ii = 250 mA

Pi = 5.32 W Pi = 2.52 W Pi = 1.2 W

rectangular trapezoidal linear

WarningThe values indicated here have been taken out of the approval certificate. Always observe the specifications and supplements in the ATEX certificate (see chapter 5 on page 38).

!


4.3 Options

Module for the shutdown function

Supply voltage Vmin = 20 V, Vmax = 30 V DCSafe position is activated when V < 5 VAK approval AK 4 to DIN V 19250Test report No. 101/S01/148Explosion protection see certificates

In case of a 24 V DC power failure, the positioner can let the valve move to the safe positionby depressurizing the actuator independently of the processor. To achieve this, the I/P mod-ule power supply is separated by an optocoupler. Both the communication and feedback arestill active, since the positioner is powered via the bus line. The shutdown input is electricallyisolated from the control signal.

Due to the shutdown function no additional solenoid valves are required. It has a safety cer-tificate from TÜV Rheinland in accordance with AK4. The plug-in module also has an Ex cer-tificate for use in intrinsically safe current circuits.

Digital position feedback with proximity switches

2 proximity switches for min. and max. position(position adjustable within range of 0...100%)

Current circuit to DIN 19234Supply voltage 5...11 V DCControl current < 1 mA = switching state logical "0"

> 2 mA = switching state logical "1"

Direction of action (logical state):

Digital position feedback with 24 V microswitches

Two 24 V DC/AC microswitches for independent position signalling.Switching points adjustable between 0 and 100 %Not approved for use in hazardous areas !

Voltage max. 24 V AC / DC

Current load max. 2 A

Contact surface 10 µm gold (AU)

Proximity switchPosition

< min. > min. < max. > max.

SJ2-SN (NC) 0 1 1 0

SJ2-S1N (NO) 1 0 0 1



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The IndustrialIT wordmark and all mentioned product names in the form XXXXXXIT are registered or pending trademarks of ABB.

ABB has Sales & Customer Supportexpertise in over 100 countries worldwide.

www.abb.com

The Company’s policy is one of continuous productimprovement and the right is reserved to modify the

information contained herein without notice.

Printed in the Fed. Rep. of Germany (02.04)

© ABB 2004

41/1

8�78

EN

R

ev. 0

4

ABB Ltd.Salterbeck Trading EstateWorkington, CumbriaCA14 5DSUKTel: +44 (0)1946 830 611Fax: +44 (0)1946 832 661

ABB Inc.125 E. County Line RoadWarminster, PA 18974 USATel: +1 215 674 6000Fax +1 215 674 7183

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