AUMA EPAC Operation & Instruction Manual
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AUMA EPAC Operation & Instruction Manual

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EPAC
Operation Instruction Manual
VERSION: V3.XMP NON- INSTRUSIVE WITH
DATALOGGING (MWG)
(Weather Proof & Explosion Proof)
1

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Summary of Contents for AUMA EPAC

  • Page 1 EPAC Operation Instruction Manual VERSION: V3.XMP NON- INSTRUSIVE WITH DATALOGGING (MWG) (Weather Proof & Explosion Proof)

  • Page 2: Table Of Contents

    4.2.3 4-20 ............................. 27 ALIBRATION 4.2.4 ............................ 29 HANGE ORQUE ALUE 4.2.5 ............................... 30 RESET ORQUE DIAGNOSTIC MODE ..........................35 5. TOPOLOGY CONNECTION 6. REGISTER DETAILS FOR MODBUS COMMUNICATION 7. TROUBLESHOOTING 8. EPAC NAMEPLATE 9. DISPOSAL AND RECYCLING 10. SERVICE...

  • Page 3: Safety Instructions

    Standards/Directives 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.

  • Page 4: Qualification Of Staff

    shown below. Safety Instructions on Actuators: Weather Proof and FlameProof/ExProof Safety instructions FlameProof/ExProof Safety instructions 1.1.3 Qualification of staff 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.

  • Page 5: Protective Measures

    Any device modification requires the consent of the manufacturer. Range of application 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.

  • Page 6: References And Symbols

     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 symbols The following references and symbols are used to provide information of the basic actuator commands to the customer.

  • Page 7: Introduction

    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.

  • Page 8: Event Storage & Datalogging Option

    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.

  • Page 9: Inhibit Option

    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.

  • Page 10: Programmable Relays

    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...

  • Page 11: Power Supply

    upto 20 days to the RTC. 2.14 POWER SUPPLY The Power Supply Card used in this module has several new features. The features are as follows:  Under Voltage Protection  Over Voltage Protection  Short Circuit Protection  Uses Single Transformer with selectable voltage & frequency range ...

  • Page 12: Front Panel Details

    The right half of the first line represents Valve Position (VP) in terms of percentage. The valve position display feature is optional. If required, an appropriate Electronic Position Transmitter (EPT) must be chosen for this feature. Please contact AUMA India for more information.
  • Page 13 If LED is OFF – then actuator is in Mid-Travel. If LED is continuously ON -- Fault Condition If LED is OFF – No fault Condition Default: OFF WHITE/BLUE If LED ON: Paired and Connected with Auma India Utility Software/ Whenever BT is connected...

  • Page 14: Modes Of Operation

    4. MODES OF OPERATION This section describes about the modes available for selection in this module. The options are:  MODE 1 - Program mode  MODE 2 - Calibration mode  MODE 3 - Diagnostic mode There are several options/settings that are available in each of these modes. These are discussed below.
  • Page 15 Program Mode Stop Key Enter Stop Enter Password Stop key to enter digit, Press Stop Key Press open or close key to increment or decrement the digit value Stop Enter Password **** Stop Open General Setting Stop Key Enter Stop Close Open Relay Setting...
  • Page 16 PROGRAM MODE - General Settings Flowchart Local Mode Non-Inching Emergency Behave Stop Close Stop Timer Mode Disable ESD NO/NC Stop Enable Stop Disable ESD Ignore TOLR Enable Emergency Mode Stop Enable Stop ESD Ignore TH Disable Enable Stop Disable ESD Ignore SPH Disable BYPASS OLS Disable...
  • Page 17 TOLR NO/NC Open Starts From VP: 80% FOUR- Stop WIRE Space Heater Open ON Time Disable 5 Sec Stop Stop Valve Position PVST Position Open OFF Time Enable CLOSE 5 Sec Stop Stop PVST PVST PERCENTAGE Close Starts ENABLE From VP: 20% Stop Stop Enable...
  • Page 18 PROGRAM MODE - Remote Settings Flowchart Stop Remote Mode Type Remote Mode Two-Wire Non-Inching Stop FOUR-WIRE Remote TWO-WIRE MODBUS Negative Switching TWO-WIRE Disable Stop Stop Stop Stop Remote TWO-WIRE Remote TWO-WIRE Remote TWO-WIRE 2-WIRE 24V 4-20 MA REG MODBUS Stop Stop Stop Signal Fail...
  • Page 19 The working of each of the different remote operations is described in the 3.XMP Test Procedure Document: 4 - V3.XMP-39305. 4.1.1.3 Relay Settings: There are two main relays available for setting different faults/ actuator status. These are Fault relay and Optional Relay. The default configurations for Fault relay are: 24V supply fail Enable /Disable Control supply fail Enable /Disable...
  • Page 20 Open->FLT Rly Close->OPT Rly F-Rly Opened Opt-Rly Opened YES/NO? YES/NO? F-Rly Closed Opt -Rly Closed YES/NO? YES/NO? Opt -Rly Remote Local Stop F-Rly Remote Local Stop YES/NO? YES/NO? F-Rly Local Stop Opt -Rly Local Stop YES/NO? YES/NO? F-Rly Open torque trip Opt -Rly Open torque trip YES/NO? YES/NO?
  • Page 21 F-Rly Power ON Opt-Rly Power ON YES/NO? YES/NO? F-Rly Program Mode Opt-Rly Program Mode YES/NO? YES/NO? F-Rly SP Reached Opt-Rly SP Reached YES/NO? YES/NO? F-Rly Sel Sw LOCAL Opt-Rly Sel Sw LOCAL YES/NO? YES/NO? F-Rly Sel Sw OFF Opt-Rly Sel Sw OFF YES/NO? YES/NO? F-Rly Sel Sw REMOTE...
  • Page 22 4.1.1.4 Other Settings: There are two different options in other settings RTC Setting Intermediate Position Setting RTC Setting Navigate to “SET RTC” in ‘Other Settings’ inside the Program mode. Press stop key to enter the RTC setting. First setting will be SET Date Press Open or Close key to increase or decrease the date respectively. Press Stop to move to Next setting.

  • Page 23: Calibration Mode

    CALIBRATION MODE In this mode, the following three key parameters can be calibrated: Limit Calibration Position Feedback (E2: DAC Output Calibration (“DAC Cal Mode”) III. Command signal Input(E1: 4 – 20 mA Calibration (“4-20mA Cal Mode”) The following options are also available: 1) Preset Torque 2) Change Torque Value To enter into the Calibration Mode follow the below steps:...
  • Page 24 Calibration Mode Stop Key Enter Stop Enter Password Press Stop Key Stop Enter Password **** Stop Open TOR Cal MODE Stop Key Enter Stop Close DAC Cal Mode Open Stop Key Enter Stop Close Open Close 4_20MA Cal Mode Stop Key Enter Stop Limit Cal Mode Stop Key Enter...

  • Page 25: Limit Calibration

    4.2.1 LIMIT CALIBRATION The flowchart for this calibration is as given below. The procedure is as discussed below. Stop Limit Open Mode Stop Key Enter Stop Press Open key to run in open Limit Open Set xxxxx (Position Value) Direction and Close key to Stop. Press Stop key to Store.

  • Page 26: Dac Calibration

    Press STOP key to accept the Close Limit Value. ** Note: Please ensure Limit Close Set and Limit Open Set (xxxx) are in the range 8000 - 25000. Please contact AUMA Service for any further assistance. 4.2.2 DAC CALIBRATION...

  • Page 27: M A Calibration

    below DAC Cal Mode Press Stop Key c. Press STOP push button to select and enter into the DAC calibration mode d. Now connect the multi meter/current reading meter (ammeter) to IO+ and IO- points. The following messages are displayed on the screen DAC 4mA Set DAC 4mASet Until……………4mA...
  • Page 28 The flowchart for 4-20mA Calibration is as shown above and the procedure is discussed below. In the Calibration mode, use the below steps to enter into 4-20mA calibration a. Press STOP key when the following screen appears on LCD Calibration Mode Press Stop Key b.

  • Page 29: Change Torque Value

    4.2.4 Change Torque Value Stop Change Torque Value Stop Key Enter Stop Press Open/Close to change and Set Open Tripping Torque Stop to Store xxx Nm Stop Press Open/Close to change and Set Close Tripping Torque Stop to Store xxx Nm a) Press STOP key when the following screen appears on LCD Calibration Mode Press Stop Key...

  • Page 30: Preset Torque

    Stop Preset Torque Yes/No ** Note : For Details regarding Preset Torque please contact AUMA Service Team. 4.2.6 SSR Tuning for Regulating Duty Solid state relays can be used in place of contactor in 3.XMP module for better precision. To identify if the actuator is Solid State Relay based check the firmware version.
  • Page 31 P band: in this the cycle time will vary depending on the error value i.e. SV-PV Start H– BAND = ±0.5% (SP) Start P – BAND SP = 50% PV Process Value OPEN LIMIT CLOSE LIMIT Fig.1: Example for Close to open direction with Set Point 50% P –...
  • Page 32 The above values are optimally set for the actuator as default settings. They can be changed if required for the following conditions:  The P band is to be increased in case the PV (process value/ valve position) increases the SV (set valve) and the actuators goes into hunting between Open and close and settles at the SV (set value).
  • Page 33 PROGRAM MODE Stop Key to Enter Press Open Key to move into Menu General Setting Stop Key to Enter Press Open Key to move to Remote Setting Remote Setting Stop Key to Enter Press Stop Key to enter into Remote mode Remote Mode Non-Inching Press Stop Key to move...
  • Page 34 Press Stop Key to move next CLOSE H-BAND Press Open / Close 0.1% Key change Value Press Stop Key to move next CLOSE CT 001 Sec Press Open / Close Key change Value Sample Tuning Values: SL.NO ACTUATOR PARAMETER OPEN SIDE CLOSE SIDE P band SA 12...

  • Page 35: Diagnostic Mode

    PHASE, OUT-PHASE and LOSS OF PHASE detection can be verified. A factory reset to set the system into default settings according to the customer specifications can be carried out. Besides this, this module has a Factory settings option that only under the scope of Auma India Employees that has several software configurable options.
  • Page 36 Version Reading Close Open VER: I2018-03-21 Works Number Stop to Enter NOTE: Flow-Control L of Factory Settings under Stop Diagnostic Mode is in the scope of Auma India Close Open Works Number Engineers only. 1818ID00025 RTC Reading Stop to Enter...

  • Page 37: Topology Connection

    5. TOPOLOGY CONNECTION Topology is a pattern in which DCS/AIMS and several actuators are connected in a network. The figures below show the two main topologies – Line and Loop - used to connect our actuators for MODBUS communication. The figures below represent the same. This configuration for Line and Loop is decided by the DIP switch settings in the new IF card.
  • Page 38 : Refer to the Wiring Diagrams for Terminal numbers present at customer end connection Use the repeaters if the NOTE distance between the active adjacent participants exceeds 1.2km In case of line/redundant line topology, use repeaters after 32 participants...
  • Page 39 DIP SWITCH SETTING The table for DIP switches selection is as given below. If termination is required for Channel A/Channel B in line topology, then dip switch 1/ 2 should be on respectively. All the dip switch should be put on for LOOP topology.

  • Page 40: Register Details For Modbus Communication

    Modbus is a two-wire serial communication protocol that is used for information exchange between DCS/AIMS and our actuators. The details needed for the Modbus communication such as Function Code, Address, Data to be written is listed below. Function Code Details (as implemented by AUMA): DESCRIPTION VALUE 1.
  • Page 41 Function Code 2: The register details associated with the function code 2 (Read Input Status) are as below. DESCRIPTION ADDRESS IN HEX OPEN POSITION 0x0000 CLOSE POSITION 0x0001 SET POINT REACHED 0x0002 RUNNING OPEN 0x0004 RUNNING CLOSE 0x0005 THERMAL FAULT 0x0008 REMOTE SW POSITION 0x000A...
  • Page 42 Function Code 3, 7 & 8: The holding register details for read & write operations associated with the function codes 3, 7 & 8 (holding registers) are as below; ADDRESS DATA RANGE DESCRIPTION VALUE STD. VALUE NOTE (MEANING) (MIN-MAX) OPEN CLOSE REMOTE CONTROL 0x3E8...

  • Page 43: Troubleshooting

    7. TROUBLESHOOTING The RED LED in the LED card indicates the FAULT. To identify the fault, check the status displayed on the LCD/relay status. Following are the typical displays of the FAULT condition and the trouble shooting methods to resolve those issues. DISPLAY-“24V supply fail”...
  • Page 44 DISPLAY- “TOLR Trip” TROUBLESHOOTING: a. Disconnect the supply to actuator and check whether TOLR is tripped; if yes then reset TOLR using reset switch as shown in figure D below. RESET Switch RESET SWITCH Fig. 6.1: TOLR Fig. D: TOLR Trip b.
  • Page 45 DISPLAY- “Control supply fail” TROUBLESHOOTING: a. Check whether Fuse-F3 is blown; If yes, replace with good fuse of 150mA, 250V rating. b. With the help of multimeter measure the Control Supply Voltage (AC voltage between Orange and Black wires of J2 on Power Supply card), which is to be 220VAC/110VAC as per the customer requirement.
  • Page 46 b) If the voltages are not proper, it means relay failure on the PS card. Replace the PS card. Fig. O: CONTACTOR Fig. E: Contactor XIII. 4-20mA Signal Fail: TROUBLESHOOT: heck if 4-20mA values in Diagnostic Mode are less than 30 or greater than 2000. Under Remote-regulating duty mode we have to give 4-20mA DC Current from external DC source to the respective terminals (as per WD) named with ferrule “II+”...

  • Page 47: Epac Nameplate

    Actuator RPM Wiring Diagram Number Material Code Works Number: Gives EPAC Version The Works Number mentioned in this name plate gives other details besides giving the EPAC Version. The actuator type gives the maximum torque, RPM of the actuator, weather...
  • Page 48 Explosion Proof Name Plates: Actuator Nameplate: This plate contains the actuator specifications. Commission Number of the Actuator Actuator Type EPAC Nameplate : This gives the complete information of the EPAC version and Wiring diagram used. Commission Number of the Actuator Wiring Diagram Number...

  • Page 49: Disposal And Recycling

    Ensure observation of the national regulations for waste disposal. 10. SERVICE AUMA offers extensive services such as maintenance and inspection for actuators. The contact details are given below. For Spare parts related details, please refer to 3.XMP WITH DATALOGGING OEM SPARES LIST (This document will be available on Auma India Website –...

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