Related Manuals for AUMA SA3
Summary of Contents for AUMA SA3
- Page 1 Multi-turn actuators SA3 – SA100 SAR3 - SAR100 with epac controls in SIL version Manual Functional Safety...
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Page 2: Table Of Contents
Manual (Operation and setting) 3.XX NI. • Manual (Device integration Fieldbus) 3.XX NI Profibus. • Technical data on multi-turn actuator and actuator controls. Reference documents can be downloaded from the internet (www.auma.co.in). Table of Contents Sl. No. Content Page No. - Page 3 Multi-turn actuators SA series with Control 3.XX /NI/SIL Redundant system architecture Examples of applications System representation Installation, commissioning and operation 17-19 Installation Commissioning Operation Lifetime Decommissioning Indications on display 20-21 Status indications on SIL functions SIL configuration warning Backlight Signals 22-23 Signals via SIL module SIL fault signal via standard controls display (for troubleshooting support)
- Page 4 Multi-turn actuators SA series with Control 3.XX /NI/SIL 8.4.7 Safe ESD reaction to “Forced torque seating in end position” (torque after limit evaluation): check 8.4.8 Safe ESD reaction for “no seating” (no evaluation of limit and torque): check 8.4.9 Safe STOP function: check 8.4.10 Combination of Safe ESD and Safe STOP function: check Maintenance...
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Page 5: Terminology
Multi-turn actuators SA series with Control 3.XX /NI/SIL Terminology Information sources • IEC 61508-4, Functional safety of electrical/electronic/programmable electronic safety related systems – Part 4: Definitions and abbreviations. • IEC 61511-1, Functional safety - Safety instrumented systems for the process industry sector –... - Page 6 Multi-turn actuators SA series with Control 3.XX /NI/SIL A safety-related system can comprise stand-alone systems dedicated to perform a particular safety function or can be integrated into a plant. Proof test Periodic test is performed to detect dangerous hidden failures in a safety-related system so that, if necessary, a repair can restore the system to an "as new"...
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Page 7: Application And Validity
In applications with requirements on functional safety, only AUMA actuator controls and actuators in SFC or SIL version may be used. AUMA actuator controls and actuators in SIL version can be identified by the letters “SIL” on the nameplate. Figure 1: Example of name plate with “SIL” marking on EPAC. -
Page 8: Architecture, Configuration And Applications
For the Safe STOP function (SS), the overrun of the arrangement (actuator, gearbox, valve) and the reaction time have to be observed. → If the application requires self-locking of the actuator, please consult AUMA. Architecture when using the Safe STOP function Actuators with electromechanical control unit: For end position signaling (limit switching) and torque signaling via the electromechanical control unit are safe signals which may be integrated into a safety-related system. -
Page 9: Configuration (Setting)/Version
Multi-turn actuators SA series with Control 3.XX /NI/SIL Actuators with electronic control unit MWG including limit switches: Information In this version, safe signaling can exclusively be ensured via limit switches. However, this signal is not part of the certification by TÜV Nord. Please refer to the specific safety manual for details regarding this signal. -
Page 10: Protection Against Uncontrolled Operation (Self-Locking/Brake)
Ex approval requirements. Protection against uncontrolled operation (self-locking/brake) For self-locking AUMA actuators, it can be assumed that a load up to nominal torque will not result in uncontrolled valve operation from standstill due to valve torque load. Consequently, in these cases, further protection against uncontrolled operation is not imperatively required. -
Page 11: Operation Mode (Low/High Demand Mode)
Multi-turn actuators SA series with Control 3.XX /NI/SIL Table 8: Overview self-locking for AUMA actuators (at the time of printing of this document) Type Output speed Self-locking 50 Hz 60 Hz SA 3 – SA 100 90 rpm or below... - Page 12 Multi-turn actuators SA series with Control 3.XX /NI/SIL • Enclosure protection test • Corrosion protection test • Ambient temperature • Definition of “cycles” test • Definition of “starts” test • Vibration resistance If the actual ambient temperatures exceed an average of +40 °C, the lambda values have to be incremented by a safety factor.
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Page 13: Safety Instrumented Systems And Safety Functions
Multi-turn actuators SA series with Control 3.XX /NI/SIL Safety instrumented systems and safety functions Safety instrumented system including an actuator Typically, a safety instrumented system including an actuator is composed of the components as shown in the figure. Figure 2: Typical safety instrumented system Sensors Controls (safety PLC) Actuator with actuator controls... -
Page 14: Safe Inputs And Outputs
Multi-turn actuators SA series with Control 3.XX /NI/SIL “Safe end position feedback” is not part of the certification by TÜV Nord and neither part of this safety manual. Please refer to the specific safety manual for details regarding this function. The different configuration options of the safety functions are described in the <Configuration (setting)/version>... -
Page 15: Examples Of Applications
Multi-turn actuators SA series with Control 3.XX /NI/SIL Examples of applications Safe OPENING of a pressure vessel using the Safe ESD function The standard PLC controls the entire system. A system fault occurs if excessive pressure is generated within the system. In this case, the safety PLC immediately opens the valve for safe pressure relief. -
Page 16: System Representation
Multi-turn actuators SA series with Control 3.XX /NI/SIL System representation The representation below shows the simplified design of an epac in SIL version. Figure 7: Simplified system representation... -
Page 17: Installation, Commissioning And Operation
Multi-turn actuators SA series with Control 3.XX /NI/SIL Installation, commissioning and operation Information Installation and commissioning have to be documented by means of an assembly report and an inspection certificate. Installation and commissioning may only be performed by authorised personnel who have been trained on functional safety. The plant operator is responsible for ensuring power supply protection against over-voltage and under-voltage during execution of a safety function. -
Page 18: Commissioning
Multi-turn actuators SA series with Control 3.XX /NI/SIL Signal behavior of SIL ready and SIL failure outputs: • SIL ready/ Absence of fault to be detected by diagnostics: NO (NO contact) output = closed NC (NC contact) output = open Designation Signal Customer connections for... -
Page 19: Operation
In case of possible failures or defects of the safety system, safe function must be guaranteed by introducing alternative actions. Furthermore, a detected fault including fault description has to be sent to AUMA. Autonomous repair work by the plant operator is not permitted. Lifetime Lifetime of actuators is described in the technical data sheets or the operation instructions. -
Page 20: Indications On Display
Multi-turn actuators SA series with Control 3.XX /NI/SIL Indications on display This section contains indications of standard controls only available in SIL version. General indications as well as settings and operation are described in the pertaining operation instructions and in the manual (operation and setting) SA series with epac 3.XX /NI/SIL. Information Indications on the display are not part of a safety function! They must not be integrated in a safety-related system! -
Page 21: Sil Configuration Warning
Multi-turn actuators SA series with Control 3.XX /NI/SIL Not ready REMOTE (S0006) Indication S0006 shows the number of occurring messages which are part of the Not ready REMOTE group. If a safety function is active ( Safe ESD Safe STOP ), the indication is listed in the function active Not ready REMOTE group. -
Page 22: Signals
It might not be possible to execute the Safe ESD and tronics sub-assembly. Safe STOP safety functions. Remedy -- Possible defect at SIL module: Contact AUMA service Fault of redundant wiring of The Safe ESD safety function can be executed. A SIL Safe ESD input. -
Page 23: Status Signals Via Output Contacts (Digital Outputs) Of Standard Controls
Multi-turn actuators SA series with Control 3.XX /NI/SIL Status signals via output contacts (digital outputs) of standard controls Actuator controls offer the possibility of signaling status information on safety-related functions via output contacts (DOUT outputs). Information Status signals via DOUT outputs are not part of a safety function! They may not be used in lieu of safety-related signals within a safety instrumented system. -
Page 24: Tests And Maintenance
Multi-turn actuators SA series with Control 3.XX /NI/SIL Tests and maintenance Test and maintenance tasks may only be performed by authorised personnel who have been trained on functional safety. Test and maintenance equipment has to be calibrated. Information Any test/maintenance must be recorded in a test/maintenance report. Impact of testing/maintenance on relevant devices, equipment or other work must be evaluated. -
Page 25: Proof Test (Verification Of Safe Actuator Function)
Multi-turn actuators SA series with Control 3.XX /NI/SIL Conditions and required settings: − Additional non-interacting end position switches for safe and reliable end position feedback signals are available and wired to the safety PLC. − A digital input of standard controls (galvanically separated from the other inputs) is configured to the following value: −... -
Page 26: Safe Esd Safety Operation "Safe Opening/Closing": Check
If a fault occurs during proof test, safe function has to be ensured introducing alternative actions. Please contact AUMA. The type of proof test to be performed depends on version and configuration of the product. Only the tests applicable have to be performed. -
Page 27: Sil Fault Signal "Actuator Monitoring": Check
Multi-turn actuators SA series with Control 3.XX /NI/SIL Test sequence For “Safe CLOSING” (Safe ESD in direction CLOSE) configuration: Start operation command in direction OPEN. For ““Safe OPENING” (Safe ESD in direction OPEN) configuration: Start operation command in direction CLOSE. Information: For the test, operation commands (in directions OPEN or CLOSE) can be executed both from remote (via DCS) and from Local at the controls (via the push buttons of the local controls). -
Page 28: Safe Esd Reaction To "Limit Seating With Overload Protection" (Limit And/Or Torque Evaluation): Check
Multi-turn actuators SA series with Control 3.XX /NI/SIL The test is performed by simulating the motor protection signal via EPAC local controls: Required user level: Specialist (4) or higher. Simulation value: Thermal test Figure 12: Display indication on local controls The simulation (active/inactive) is activated and deactivated by push button Ok. - Page 29 Multi-turn actuators SA series with Control 3.XX /NI/SIL During Safe ESD operation, the actuator has to stop when reaching the position set via limit switching. Safe ESD operation must also be stopped if the tripping torque set via the MWG.2 is exceeded.
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Page 30: Check Safe Esd Reaction To "Forced Limit Seating In End Position" (Limit Evaluation) - For Actuators With Electromechanical Control Unit
Multi-turn actuators SA series with Control 3.XX /NI/SIL 8.4.5 Check Safe ESD reaction to “Forced limit seating in end position” (limit evaluation) – for actuators with electromechanical control unit Configuration This test is required for the following versions or configurations: •... -
Page 31: Safe Esd Reaction To "Forced Torque Seating In End Position" (Torque After Limit Evaluation): Check
Multi-turn actuators SA series with Control 3.XX /NI/SIL During Safe ESD operation, the actuator has to stop when reaching the position set via limit switching. Test sequence 1. Operate actuator in mid-position or at sufficient distance from the end positions. 2. -
Page 32: Safe Esd Reaction For "No Seating" (No Evaluation Of Limit And Torque): Check
Multi-turn actuators SA series with Control 3.XX /NI/SIL 8.4.8 Safe ESD reaction for “no seating” (no evaluation of limit and torque): check Configuration This test is required for the following versions or configurations: • Actuators with electromechanical control unit or actuator with electronic control unit and limit switches. -
Page 33: Safe Stop Function: Check
Multi-turn actuators SA series with Control 3.XX /NI/SIL 8.4.9 Safe STOP function: check Configuration The test applies to the “SIL function” = “Safe STOP OPEN/CLOSE” (Safe STOP) configuration. The seating configuration is not relevant to the test as it has no impact on the Safe STOP function. - Page 34 Multi-turn actuators SA series with Control 3.XX /NI/SIL → For actuators with “SIL seating” = “no seating”: Interrupt safety operation before reaching the end position (Set Safe ESDa and Safe ESDb input signals to +24 V DC). → For the test, the valve should either be in mid-position or at sufficient distance from the end positions.
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Page 35: Maintenance
<Safety equipment: check> and <Proof test (verification of safe actuator function)> chapters. In case a fault is detected during maintenance, this must be reported to AUMA India Private Limited. Information AUMA actuators prioritize motor operation to manual operation. -
Page 36: Safety-Related Figures
60% and <90 % according to table 2 of IEC 61508-2 for SIL 2 (subsystems with a hardware fault tolerance of 0). Figure 16: Non-normative failure distribution assumed by AUMA Information System power supply has not been considered for calculating the figures for actuator and actuator controls. -
Page 37: Specific Figures For Sa Series With Epac Controls 3.Xx/Ni In Sil Version With Actuators
• MTTR_STOP = 72 hours The following formula can be used for the calculation of the PFD values: Table 10: SA series with EPAC controls in SIL version SA3 to SA100 Switchgear version: Contactors Safety function Safe ESD CLOSE Safe ESD OPEN Safe STOP λ... -
Page 38: Sil Certificate
Multi-turn actuators SA series with Control 3.XX /NI/SIL SIL Certificate... -
Page 39: Checklists
Multi-turn actuators SA series with Control 3.XX /NI/SIL Checklists 11.1 Commissioning checklist Information Table 16: Commissioning checklist 11.2 Proof test checklists If the proof test is performed according to proof test checklists, the pertaining NOTICES contained in the <Tests and maintenance> chapter have to be observed. 11.2.1 Safe ESD safety operation (Safe OPENING/CLOSING) Information... -
Page 40: Safe Esd Reaction For "Motor Protection (Thermal Fault)" Signal
Multi-turn actuators SA series with Control 3.XX /NI/SIL Table 18: Proof test checklist 11.2.3 Safe ESD reaction for “Motor protection (thermal fault)” signal Information Proof test checklist for version or configuration: • Safe ESD function “Safe CLOSING” (Safe ESD in direction CLOSE) •... -
Page 41: Safe Esd Reaction To "Limit Seating With Overload Protection" (Limit And/Or Torque Evaluation)
Multi-turn actuators SA series with Control 3.XX /NI/SIL 11.2.4 Safe ESD reaction to “Limit seating with overload protection” (limit and/or torque evaluation) Proof test checklist for version or configuration: • Actuator with electromechanical control unit • One of the following safety functions: Safe ESD function “Safe CLOSING”... -
Page 42: Safe Esd Reaction To "Forced Limit Seating In End Position" (Limit Evaluation) - For Actuators With Electromechanical Control Unit
Multi-turn actuators SA series with Control 3.XX /NI/SIL 11.2.5 Safe ESD reaction to “Forced limit seating in end position” (limit evaluation) – for actuators with electromechanical control unit Proof test checklist for version or configuration: • Actuator with electromechanical control unit •... -
Page 43: Safe Esd Reaction To "Forced Torque Seating In End Position" (Torque After Limit Evaluation)
Multi-turn actuators SA series with Control 3.XX /NI/SIL Table 22: Proof test checklist 11.2.7 Safe ESD reaction to "Forced torque seating in end position" (torque after limit evaluation) Proof test checklist for version or configuration: • Actuator with electromechanical control unit •... -
Page 44: Safe Esd Reaction To "No Seating
Multi-turn actuators SA series with Control 3.XX /NI/SIL 11.2.8 Safe ESD reaction to “no seating” Proof test checklist for version or configuration: • Actuators with electromechanical control unit or actuator with electronic control unit and limit switches. • One of the following safety functions: - Safe ESD function “Safe CLOSING”... -
Page 45: Safe Stop Function
Multi-turn actuators SA series with Control 3.XX /NI/SIL 11.2.9 Safe STOP function Proof test checklist for version or configuration: “SIL function” = “Safe STOP OPEN/CLOSE” (safe stop) configuration. Also, valid for combination of Safe ESD with Safe STOP. Table 25: Proof test checklist 11.2.10 Combination of Safe ESD and Safe STOP Safety function... - Page 46 Multi-turn actuators SA series with Control 3.XX /NI/SIL Table 26: Proof test checklist...
- Page 47 Multi-turn actuators SA series with Control 3.XX /NI/SIL...
- Page 48 We reserve the right to alter the data according to the changes made. The product features and technical data provided do not express or imply any warranty. For the latest information on AUMA products, please visit www.auma.co.in DD/MN.038/ISSUE 10/2020 REV1...