AUMA SQ 05.2 Manual
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AUMA SQ 05.2 Manual

Part-turn actuators
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Part-turn actuators
SQ 05.2
SQ 14.2/SQR 05.2
SQR 14.2
SQEx 05.2
SQEx 14.2/SQREx 05.2
SQREx 14.2
with actuator controls
AC 01.2-SIL/ACExC 01.2-SIL
SIL version
Manual
Functional safety

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Summary of Contents for AUMA SQ 05.2

  • Page 1 Part-turn actuators SQ 05.2 SQ 14.2/SQR 05.2 SQR 14.2 SQEx 05.2 SQEx 14.2/SQREx 05.2 SQREx 14.2 with actuator controls AC 01.2-SIL/ACExC 01.2-SIL SIL version Manual Functional safety...

  • Page 2: Table Of Contents

    Manual (Operation and setting) AC 01.2/ACExC 01.2 actuator controls Manual (Device integration Fieldbus) AC(V) 01.2/AC(V)ExC 01.2 actuator controls Technical data for part-turn actuator and actuator controls. Reference documents are available on the Internet at: http://www.auma.com. Table of contents Page Terminology..........................
  • Page 3 Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Table of contents Signals............................. 7.1. Signals via SIL module 7.2. SIL - fault signal via the standards actuator controls display (for troubleshooting support) 7.3. Status signals via output contacts (digital outputs) of standard actuator controls 7.4.
  • Page 4 Part-turn actuators Table of contents with AC 01.2-SIL/ACExC 01.2-SIL 11.2.9. Safe STOP function irrespective of the selected control unit 11.2.10. Combination of Safe ESD and Safe STOP irrespective of the selected control unit Index............................

  • Page 5: Terminology

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Terminology Terminology IEC 61508-4, Functional safety of electrical/electronic/programmable electronic Information sources safety-related systems Part 4: Definitions and abbreviations IEC 61511-1, Functional safety - Safety instrumented systems for the process industry sector Part 1: Framework, definitions, system, hardware and software requirements 1.1.
  • Page 6 Part-turn actuators Terminology with AC 01.2-SIL/ACExC 01.2-SIL Periodic test performed to detect dangerous hidden failures in a safety-related system Proof test so that, if necessary, a repair can restore the system to an "as new" condition or as close as practical to this condition. Mean time to restoration once a failure has occurred.

  • Page 7: Application And Validity

    Information and actuators in SFC or SIL version may be used. AUMA actuator controls and actuators in SIL version can among others be identified from the letters “SIL” on the name plate. Figure 1: Example of AC name plate with “SIL” marking...

  • 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 ESD function...

  • Page 9: Configuration (Setting)/Version

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Architecture, configuration and applications For “SIL seating” = “no seating” (without end position protection), we recommend: To prevent valve damage during safety operation, we recommend, depending on the stiffness, sizing the valve to 3 5 times the maximum actuator torque.
  • Page 10 Part-turn actuators Architecture, configuration and applications with AC 01.2-SIL/ACExC 01.2-SIL Table 4: For actuators with electromechanical control unit: Configuration Short description Configuration SIL seating type Type of seating Standard controls 1: No seating No seating by limit or torque switches during Freely selectable safety operation 2: Forced torque seating...

  • Page 11: Protection Against Uncontrolled Operation (Self-Locking/Brake)

    3.3. Protection against uncontrolled operation (self-locking/brake) For self-locking AUMA actuators, it can be assumed that a load up to maximum 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 12: Applications (Environmental Conditions)

    Part-turn actuators Architecture, configuration and applications with AC 01.2-SIL/ACExC 01.2-SIL 3.6. Applications (environmental conditions) When specifying and using the actuators within safety instrumented systems, make sure that the permissible service conditions and the EMC requirements by the peripheral devices are met. Service conditions are indicated in the technical data sheet: Enclosure protection Corrosion protection...

  • Page 13: Safety Instrumented Systems And Safety Functions

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Safety instrumented systems and safety functions Safety instrumented systems and safety functions 4.1. 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 3: Typical safety instrumented system Sensors Controls (safety PLC)

  • Page 14: Safe Inputs And Outputs

    Part-turn actuators Safety instrumented systems and safety functions with AC 01.2-SIL/ACExC 01.2-SIL Safe STOP function: Safe STOP An operation command of standard controls (in directions OPEN or CLOSE) will only be executed if an additional enable signal for the operation com- mand is applied.

  • Page 15: Examples Of Applications

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Safety instrumented systems and safety functions Figure 4: Redundant system with Safe ESD for Safe CLOSING Figure 5: Redundant system with Safe ESD for Safe OPENING 4.5. Examples of applications Safe OPENING of a pressure vessel using the Safe ESD function The standard PLC controls the entire system.
  • Page 16 Part-turn actuators Safety instrumented systems and safety functions with AC 01.2-SIL/ACExC 01.2-SIL Figure 6: Application example: Pressure vessel Safe stop of locks to prevent destruction using the Safe STOP function. Operation safety (preventing hazards to persons and systems) is of utmost importance for locks.

  • Page 17: System Representation

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Safety instrumented systems and safety functions Figure 7: Application example: Lock 4.6. System representation The representation below shows the simplified design of an AC 01.2/ACExC 01.2 in SIL version. Figure 8: Simplified system representation...

  • Page 18: Installation, Commissioning And Operation

    Part-turn actuators Installation, commissioning and operation with AC 01.2-SIL/ACExC 01.2-SIL Installation, commissioning and operation Installation and commissioning have to be documented by means of an assembly Information 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 overvoltage and undervoltage during execution of a safety function.
  • Page 19 Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Installation, commissioning and operation The Safe STOP OPEN and Safe STOP CLOSE inputs are two independent inputs Information with independent functions: If Safe STOP OPEN = low level, the safety function inhibits operation in direction OPEN (exception ESD OPEN) If Safe STOP CLOSE = low level, the safety function inhibits operation in direc- tion CLOSE (exception ESD CLOSE)

  • Page 20: Commissioning

    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 Riester GmbH & Co. KG. Autonomous repair work by the plant operator is not permitted.

  • Page 21: Lifetime

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Installation, commissioning and operation 5.4. Lifetime Lifetime of actuators is described in the technical data sheets or the operation instructions. Safety-related figures are valid for the cycles or modulating steps defined in the technical data specifications for typical periods of up to 10 years (the criterion achieved first is valid).

  • Page 22: Indications On Display

    Part-turn actuators Indications on display with AC 01.2-SIL/ACExC 01.2-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) AC 01.2/ACExC 01.2.

  • Page 23: Sil Configuration Warning

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Indications on display Figure 12: Signal: Safety function active As soon as a safety function is active (SIL function active indication), the actuator is Information controlled via the safety PLC and the SIL module. For “standard control ” (standard PLC), controls are therefore “Not ready REMOTE”.

  • Page 24: Signals

    Possibly defect at actuator Remedy mechanics. → Verify reduction gearing settings within the actuator. → In case of possible defect at the actuator: Contact AUMA service Phase fault One phase of power supply is The Safe ESD safety function cannot be executed.

  • Page 25: Status Signals Via Output Contacts (Digital Outputs) Of Standard Actuator Controls

    Actuator locked during manual Remedy operation. → In case of possible defect at the actuator: Contact AUMA service Possible defect at actuator. Fault of redundant wiring of The Safe ESD safety function can be executed. A SIL fault is indic- Safe ESD input.

  • Page 26: Signals Via Fieldbus Of Standard Actuator Controls

    Part-turn actuators Signals with AC 01.2-SIL/ACExC 01.2-SIL Default values: Signal DOUT 5 = SIL function active Signal DOUT 6 = SIL fault 7.4. Signals via fieldbus of standard actuator controls For actuator controls in fieldbus interface version, status information on the safety-related functions is provided in the process representation.

  • Page 27: Tests And Maintenance

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Tests and maintenance 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. Any test/maintenance must be recorded in a test/maintenance report. Information Impact of testing/maintenance on relevant devices, equipment or other work must be evaluated.
  • Page 28 <Proof test> chapter. Note: “Safe end position feedback” includes the end position switches which are directly wired to the customer output and assessed by AUMA within the framework of a Declaration of Incorporation for functional safety (SFC). These switches are not part of the TÜV certification.

  • Page 29: Proof Test (Verification Of Safe Actuator Function)

    If a fault occurs during proof test, safe function has to be ensured introducing alternative actions. Please contact AUMA Riester GmbH & Co. KG. The type of proof test to be performed depends on version and configuration of the product.

  • Page 30: Preliminary Test

    Part-turn actuators Tests and maintenance with AC 01.2-SIL/ACExC 01.2-SIL 8.4.1. Preliminary test The actuator system has to be subjected following inspections first: Visual inspection: Test procedure Visual inspection for external damage and corrosion. Check electrical and mechanical connections. Function check Operate actuator at least once from CLOSED to OPEN and back (or vice versa).

  • Page 31: Check Sil Fault Signal Actuator Monitoring

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Tests and maintenance 8.4.3. Check SIL fault signal Actuator monitoring” Configuration This test is required for the following versions or configurations: Safe ESD function “Safe CLOSING” (Safe ESD in direction CLOSE) Safe ESD function “Safe OPENING” (Safe ESD in direction OPEN) If the motor does rotate within a defined time once safety operation was triggered, Test procedure a SIL fault must be signalled.

  • Page 32: Check Safe Esd Reaction To Limit Seating With Overload Protection

    Part-turn actuators Tests and maintenance with AC 01.2-SIL/ACExC 01.2-SIL Set selector switch to position 0 (OFF). Change to main menu and select the Thermal test simulation value via the Proof test (motor prot.) parameter M1021 (Do not yet activate simulation: white dot).

  • Page 33: Check Safe Esd Reaction To "Forced Limit Seating In End Position" (Limit Evaluation)

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Tests and maintenance Open the switch compartment Initiate safety operation: Safe ESDa Safe ESDb input signals to 0 V (low). Check seating via limit switches: Operate limit switches until test is complete: For “Safe CLOSING” (Safe ESD in direction CLOSE) configuration: Turn test button [1] in direction of the LSC arrow.
  • Page 34 Part-turn actuators Tests and maintenance with AC 01.2-SIL/ACExC 01.2-SIL Figure 15: Electromechanical control unit Turn test button [1] in direction of the LSC arrow: Limit switch CLOSE trips. Turn test button [2] in direction of the LSO arrow: Limit switch OPEN trips. Test sequence Operate actuator in mid-position or at sufficient distance from the end positions.

  • Page 35: Check Safe Esd Reaction To "Forced Torque Seating In End Position

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Tests and maintenance 8.4.8. Check Safe ESD reaction to Forced torque seating in end position” (torque after limit evaluation) Configuration This test is required for the following versions or configurations: Actuator with electromechanical control unit One of the following safety functions: Safe ESD function “Safe CLOSING”...
  • Page 36 Part-turn actuators Tests and maintenance with AC 01.2-SIL/ACExC 01.2-SIL Configuration of “SIL seating” = “no seating” (Safe OPENING or CLOSING without responding to any protective equipment) For Safe ESD operation, the actuator has to perform the safety operation without Test procedure interruption.

  • Page 37: Check Safe Stop Function

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Tests and maintenance Operate torque switches: For “Safe CLOSING” (Safe ESD in direction CLOSE) configuration: Turn test button [1] in direction of the TSC arrow. For "“Safe OPENING” (Safe ESD in direction OPEN) configuration: Turn test button [2] in direction of the TSO arrow: The safety function reaction to the torque switch signals is correct if: Safety operation is not stopped.

  • Page 38: Maintenance

    27, Safety equipment: check page 29, Proof test (verification of safe actuator function) In case a fault is detected during maintenance, this must be reported to AUMA Riester GmbH & Co. KG. AUMA actuators prioritise motor operation to manual operation. This means that the Information actuator automatically switches to motor operation if requested.

  • Page 39: 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 17: Non-normative failure distribution assumed by AUMA System power supply has not been considered for calculating the figures for actuator Information and actuator controls.

  • Page 40: Specific Parameters For Ac 01.2 Actuator Controls In Sil Version With Actuators Of Sq

    (Safe STOP OPEN/CLOSE) must be applied for the assessment. Table 9: SQ .2/SQEx .2 type range with AC 01.2/ACExC 01.2 actuator controls in SIL version SQ 05.2 – SQ 12.2 / SQEx 05.2 – SQEx 12.2 Switchgear version: Contactors Safety function...
  • Page 41 Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Safety-related figures SQ 05.2 – SQ 12.2 / SQEx 05.2 – SQEx 12.2 Switchgear version: Contactors Safety function Safe ESD Safe STOP OPEN or Safe STOP CLOSE = 1 Jahr (1001) 2.15 x 10 2.26 x 10...
  • Page 42 ) (failures in diagnostic function) Table 15: SQ .2/SQEx .2 type range with AC 01.2/ACExC 01.2 actuator controls in SIL version, with heating system SQ 05.2 – SQ 12.2 / SQEx 05.2 – SQEx 12.2 Switchgear version: Contactors Safety function...
  • Page 43 Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Safety-related figures SQ 05.2 – SQ 12.2 / SQEx 05.2 – SQEx 12.2 Switchgear version: Contactors Safety function Safe ESD Safe STOP OPEN or Safe STOP CLOSE = 1 Jahr (1001) 2.20 x 10 2.28 x 10...
  • Page 44 Part-turn actuators Safety-related figures with AC 01.2-SIL/ACExC 01.2-SIL SQ 14.2 / SQR 14 Switchgear version: Thyristors Safety function Safe ESD Safe STOP OPEN or Safe STOP CLOSE = 1 Jahr (1001) 2.72 x 10 2.18 x 10 Proof = 1 Jahr (1002) 2.60 x 10 2.23 x 10 Proof...

  • Page 45: Sil Certificate

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL SIL Certificate SIL Certificate...

  • Page 46: Checklists

    Part-turn actuators Checklists with AC 01.2-SIL/ACExC 01.2-SIL Checklists 11.1. Commissioning checklist Table 21: Checklist 1 1. Actuator and actuator controls are correctly wired? ⎕ ✓ 2. Limit and torque switching set? ⎕ ✓ 3. Safety function (depending on the configuration) checked in accordance with the ⎕...

  • Page 47: Safe Esd Reaction For "Motor Protection (Thermal Fault)" Signals Irrespective Of The

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Checklists Table 23: Checklist 3 ✎ ✎ Configuration Configuration Safe CLOSING (Safe ESD in direction CLOSE) Safe OPENING (Safe ESD in direction OPEN) 1. Is actuator in mid-position or at sufficient distance ⎕ ✓ 1.

  • Page 48: Safe Esd Reaction To "Limit Seating With Overload Protection

    Part-turn actuators Checklists with AC 01.2-SIL/ACExC 01.2-SIL 11.2.4. Safe ESD reaction to Limit seating with overload protection” (limit and/or torque evaluation) – for actuators with electromechanical control unit Proof test checklist for version or configuration: Actuator with electromechanical control unit One of the following safety functions: Safe ESD function “Safe CLOSING”...

  • Page 49: Safe Esd Reaction To "Forced Limit Seating In End Position" (Limit Evaluation) For Actu

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Checklists Actuator with electromechanical control unit One of the following safety functions: Safe ESD function “Safe CLOSING” (Safe ESD in direction CLOSE) Safe ESD function “Safe OPENING” (Safe ESD in direction OPEN) Configuration of “SIL seating” = “Forced limit seating in end position”...

  • Page 50: Safe Esd Reaction To Forced Torque Seating In End Position (Limit Evaluation) For Actu

    Part-turn actuators Checklists with AC 01.2-SIL/ACExC 01.2-SIL Table 27: Checklist 7 Configuration ✎ Configuration ✎ Safe CLOSING (Safe ESD in direction CLOSE) Safe OPENING (Safe ESD in direction OPEN) 1. Is actuator in mid-position or at sufficient distance ⎕ ✓ 1.

  • Page 51: Safe Stop Function Irrespective Of The Selected Control Unit

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Checklists 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” (Safe ESD in direction CLOSE) Safe ESD function “Safe OPENING” (Safe ESD in direction OPEN) Configuration of “SIL seating”...

  • Page 52: 11.2.10. Combination Of Safe Esd And Safe Stop - Irrespective Of The Selected Control Unit

    Part-turn actuators Checklists with AC 01.2-SIL/ACExC 01.2-SIL Table 30: Checklist 10 Safe stop in direction OPEN ✎ Safe stop in direction CLOSE ✎ Safe STOP OPEN Safe STOP CLOSE 1. Is actuator in mid-position or at sufficient distance ⎕ ✓ 1.
  • Page 53 Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL...
  • Page 54 Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL...

  • Page 55: Index

    Part-turn actuators with AC 01.2-SIL/ACExC 01.2-SIL Index Index Partial Valve Stroke Test (PVST) Actuator monitoring internal PFD for actuator Actuator sizing Probability of failure Ambient conditions Proof test 6, 29, 29 Architecture Proof test checklists Brake Range of application Certificate Safe failure fraction (SFF) 5, 40 Checklists...
  • Page 56 AUMA Riester GmbH & Co. KG P.O. Box 1362 DE 79373 Muellheim Tel +49 7631 809 - 0 Fax +49 7631 809 - 1250 info@auma.com www.auma.com Y006.433/003/en/1.22 For detailed information on AUMA products, refer to the Internet: www.auma.com...

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