Handleiding Arcapro 827a Fieldbus 2

ARCAPRO 827A.
E/X - F - -
Electropneumatic Positioner for
Linear and Quarter-turn Actuators
Version with Foundation Fieldbus
Operating Instructions
Reference no.: 827A-FF-BA-09-13_gb
ARCA-Regler GmbH D - 47918 Tnisvorst
Page 1 von 42
Legal information
Warning notice system
This documentation notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety
alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
Indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
With a safety alert symbol, indicates that minor personal injury can result if proper precautions are not
taken.
CAUTION
Without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
Indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device may only be performed by qualified personnel. Within the context of the safety notes in
this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
ARCA-positioner may only be used for the applications described in the relevant technical documentation.
Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to
ensure that the products operate safely and without any problems. The permissible ambient conditions must
be adhered to. The information in the relevant documentation must be observed.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
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Table of Contents
1
2
3
3.1
3.2
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
4
4.1
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.5.1
4.5.2
5
5.1
5.1.1
5.1.2
6
7
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2
7.3
8
8.1
8.2
8.3
9
10
11
Introduction
General safety notes
Description
Function
Structure
Device Components
Motherboard
Electric Connections
Pneumatic Connections
Purging Air Switch
Restrictors
Mounting
Safety notes for mounting
Mounting Linear Actuator
Mounting Kit for "Integrated Fitting Linear Actuator"
Mounting Kit for "Linear Actuator IEC534"
Mounting Kit for "Quarter-turn Actuator VDI/VDE 3845"
Note on the Use of Positioners in Wet Environments
Positioners exposed to strong acceleration forces or vibrations
Slip clutch
Leverage ratio switch
Electrical Connection
Electrical Connection, Basic device
Electrical Connection, Basic device not for explosive regions
Electrical Connection, Basic device for explosive regions
Commissioning
Preparations for Linear Actuators
Automatic Initialization of Linear Actuators
Manual Initialization of Linear Actuators
Preparations for Quarter-turn Actuators
Automatic Initialization of Quarter-turn Actuators
Manual Initialization of Quarter-turn Actuators
Copying Initialization Data (Positioner Exchange)
Overview of Parameters
Parameters 1 to 5
Parameters 6 to 44
Parameters A to P
Fault removal
Service and Maintenance
Technical Data
4
6
8
8
8
9
9
10
10
10
12
12
12
13
13
15
17
19
20
21
21
22
24
24
25
25
26
28
29
30
31
31
32
33
34
34
34
36
37
39
40
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Introduction
This operating instructions contains all information that will be required to connect and to commission the device.
It is aimed at persons who install the device mechanically, connect it electrically and commission it.
Information and tips for projecting, parameterization and service contains the manual that can ordered by us.
This operating instruction is valid for devises from firmware 5.00.00 in not intrinsically safe and intrinsically
safe version.
The content reflects the technical status at the time of printing. We reserve the right to make technical changes
in the course of further development.
Checking the consignment

WARNING
Using a damaged or incomplete device
Danger of explosion
Do not use any damaged or incomplete devices.
Design of the nameplate

2
Stellungsregler 827A.X2-00P-M10-G
II 2 G Ex ia IIC T6/T4 Gb
Ta = -20 50/75C
TV 12 ATEX 085253 X
10
Mat-Nr. XXXXXXX
F-Nr. X XXXXXX
11
1 - Manufacturer
2 Device name
3 - Type
4 - Consult operating instructions
5 - Safety class
6 - Auxiliary power (air supply)
7 - Approval
8 - ATEX marking for hazardous area
9 - Rated signal range
10 - Auxiliary power (voltage)
11 - Manufacturer serial number
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Type key
827A. F
Connection thread
G
N
M
P
R
S
M20x1,5 / G 1/4
1/2 NPT / 1/4 NPT
M20x1,5 / 1/4 NPT
1/2 NPT / G
PROFIBUS plug M12 / G 1/4
PROFIBUS plug M12 / 1/4 NPT
mechanical
actuator
0
2
Standard
without (for external potentiometer)
pneumatic
1
2
single-acting
double-acting ( only stainless housing )
body
M aluminium
E stainless housing
communication
0
H
P
F
without communication 1)
HART 1)
PROFIBUS PA1)
Foundation Fieldbus
binary output
0
B
S
K
without binary outputs 1)

binary module 1)
slot initiator module 1)
contact module 1)
analog - output
0
A
without analog - output

analog module 1) 2)
connection
basic device
2
4
2 - wire
2 / 3 / 4 - wire
Ex - certificate
E
X
not explosion protected

II 2 G Ex ia IIC T6/T4 Gb
electric /
pneumatic
series
Transportation and storage
CAUTION
Insufficient protection during storage
The packaging only provides limited protection against moisture and infiltration.
Provide additional packaging as necessary.
Environmental protection
Devices described in this programming manual can be recycled owing to the low content of noxious substances in their version. Please contact a certified waste disposal company for eco-friendly recycling and to
dispose of your old devices.
1)
The device type is not described in these operating instructions. Please find the specific device characteristics and technical data in the corresponding
separate documentation.
2)
Type 827A.X-A-- only II2G Ex ia IIC T4 Gb
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General safety notes
Requirement for safe use

This device left the factory in good working condition. In order to maintain this status and to ensure safe operation of the device, observe these instructions and all the specifications relevant to safety.
Observe the information and symbols on the device. Do not remove any information or symbols from the device. Always keep the information and symbols in a completely legible state.
Warning symbols on the device
Symbol
Explanation of the warning symbols on the device

Consult operating instructions
Protect the device from shocks (otherwise the degree of protection is not guaranteed)
Laws and directives

Observe the test certification, provisions and laws applicable in your country during connection, assembly and
operation:
IEC 60079-14 (international)
EN 60079-14 (EG)
The working reliability regulation (Germany)
Conformity with European directives
The CE marking on the device shows conformity with the regulations of the following European guidelines:
EMC 2004/108/EG
Directive of the European Parliament and of the Council on the approximation of the
laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC.
ATEX 94/9/EG
Directive of the European Parliament and the Council on the approximation of the laws
of the Member States concerning equipment and protective systems intended for use in
potentially explosive atmospheres. .
LVD 2006/95/EC
Directive of the European Parliament and the Council on the approximation of the laws
of the Member States relating to electrical equipment designed for use within certain
voltage limits.
The applied standards can be found in the EC conformity declaration of the device.
Improver device modifications
WARNING
Improver device modifications
Danger to personnel, system and environment can result from modifications to the device, particularly in
hazardous areas.
Only carry out modifications that are described in the instructions for the device. Failure to observe this
requirement cancels the manufacturer's warranty and the product approvals.
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Use in areas subject to explosion hazard

WARNING
Unsuitable device for the hazardous area
Danger of explosion
Only use equipment that is approved for use in hazardous area and labelled accordingly.
Make sure that the device is suitable for the area of use.
WARNING
Loss of the safety of the device with type of protection "Intrinsic safety Ex i"
If the device has already been operated in non-intrinsically safe circuits or with a higher voltage, the safety of
the device is no longer ensured for use in hazardous areas. There is a danger of explosion.
Connect the device in "intrinsic safety" type of protection solely to an intrinsically safe circuit.
Observe the specifications for the electrical data in the certificate
WARNING
Impermissible accessories and spare parts
Danger of explosion in areas subject to explosion hazard.
Only use original accessories or original spare parts.
Observe all relevant installation and safety instructions described in the instructions for the device or enclosed with the accessory or spare part.
WARNING
Open cable inlet or incorrect cable gland
Close the cable inlets for the electrical connections. Only use cable glands or plugs which are approved
for the relevant type of protection.
WARNING
Exceeded maximum ambient or process media temperature
If the maximum permissible ambient and process media temperatures are exceeded, the temperature class
of the device is no longer valid.
Make sure that the maximum permissible ambient and process media temperatures of the device are not
exceeded.
CAUTION
Electrostatic Sensitive Devices
This device contains electrostatic sensitive devices. Electrostatic sensitive devices may be destroyed by
voltages that are undetectable to a human. Voltages of this kind occur as soon as a component or an assembly is touched by a person who is not grounded against static electricity. The damage to a module as a
result of overvoltage cannot usually be detected immediately. It may only become apparent after a long
period of operation.
Therefore, avoid electrostatic charge.
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Qualified Personnel
Qualified personnel are people who are familiar with the installation, mounting, commissioning, and operation
of the product. These people have the following qualifications:
They are authorized, trained or instructed in operating and maintaining devices and systems according to
the safety regulations for electrical circuits, high pressures and aggressive as well as hazardous media.
For explosion-proof devices: They are authorized, trained, or instructed in carrying out work on electrical
circuits for hazardous systems.
Hey are trained or instructed in maintenance and use of appropriate safety equipment according to the
safety regulations.
Description
3.1
Function
The electro-pneumatic positioner, in combination with the drive, forms a regulation system. The current
position of the drive is detected using a servo potentiometer and is sent back as actual value x. The actual
and target values are simultaneously displayed on the digital display.
The reference variable w is provided digitally through the Feldbus..
The positioner works as a predictive five-point positioner, through whose output value y the integrated
valves can be controlled by pulse length modulation.
These positioning signals cause pressure changes in the drive chamber(s) and thus a repositioning of the
drive until the regulation deviation returns to zero.
Using three buttons and a digital display with the housing cover removed, operation (manual mode) and
configuration (structuring, initialization, and parameterization) can be performed.
Normally the basic device has one binary input (BE1). This can be individually configured, and is particularly provided for blocking the operating levels.
To be able to use the positioner in a variety of mechanically different rotational and linear actuators, it has a
friction clutch and a switchable gear.
3.2
Structure
The following chapters describe the mechanical and electrical structure, components, and principle functionality of the positioner.
The positioner is used to adjust and regulate pneumatic drives. The positioner works electropneumatically,
using compressed air as auxiliary power
The positioner can e.g. regulate valves with:
- Linear actuator (Figure 3-1) or
- Quarter turn actuator VDI/VDE 3845 (Figure 3-2)
For linear actuators, there are various add-on extensions available
- NAMUR or. IEC 534
- integrated addition (ARCA, SAMSON)
- integrated addition according to VDI/VDE 3847
You can mount the positioner on the usual drives and operate it with the usual drives.
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The device is available for single-acting and double-acting actuators and for potentially explosive applications
and applications that are not potentially explosive.
3
2
1
2
3
4
5
Actuator
Positioner, single-acting in metal-housing
Lantern
Manometer block, single-acting
Valve
Figure 3-1 Positioner fitted to a linear actuator

(single-acting)
3.3
1 Positioner, double-acting in plastic housing

2 Quarter-turn actuator
3 Manometer block, double-acting
Figure 3-2
Positioner fitted to a quarter-turn actuator

(double-acting)
Device Components
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1)
Figure 3-3 Structure
2)
Bus cable
Terminal plate on cover
Display
Purging air selector
Output: Actuating pressure Y1
Input: supply air
1)
Output: Actuating pressure Y2
Control buttons
1)
Restrictor Y2
Restrictor
Restrictor Y1
Silencer
leverage ratio switch
Slip clutch adjusting wheel
Connection terminals motherboard
Connection terminals for optional module
2)
Shield support
for double-acting drives

only for plastic housing
3.3.1
Motherboard
The motherboard contains:
- CPU
- Memory
- A/D-converter
- Display
- Operating buttons
- Terminal strips to connect the optional module to the motherboard
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3.3.2
Electric Connections
The connecting terminals for the base device, the optional analog, binary and slot initiator modules are arranged at the front left-hand edge, and are displaced with respect to one another in a stepped pattern.
An assembly cover secures the components against being pulled out, and prevents incorrect assembly.
3.3.3
The pneumatic connections (G1/4) are located on the right-hand side of the positioner
Actuating pressure Y1 in single-acting and double-acting actuators

Feedback shaft
Air supply P z
Actuating pressure Y2 on double-acting actuators
Exhaust air outlet E with silencer on the bottom of the device
Figure 3-4 Pneumatic connections
Connection versions
In addition, the rear of the positioner has pneumatic connections for integrated fitting of single-acting linear
actuators:
- actuating pressure Y1
- exhaust air outlet E
Except in cases of integrated ARCA fitting, these connections are closed by screws. The exhaust air outlet E
can be used to supply the sensing area and the spring chamber with dry, instrumentation-quality air to prevent
corrosion.
Figure 3-6 illustrates the versions of the pneumatic connections for the various types of actuator, the positioning effect and the safety position after failure of the auxiliary power supply.
CAUTION
Before working on the control valve
Note that before working on the control valve, you must first move it to the safety position. Make sure that
the control valve has reached the safety position. If you only interrupt the pneumatic auxiliary power supply
to the positioner, the safety position may in some cases only be attained after a certain delay period.
3.3.4
Purging Air Switch
The purging air switch is accessible when the housing is open above the pneumatic connection strip on the
valve block.
In the IN position the interior of the housing is flushed by very small quantities of clean, dry instrumentationquality air.
In the OUT position, the purging air is fed directly outside.
Purging Air Switch
Pneumatic connection strip
Figure 3-5 Purging air switch on the valve block
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Actuating
pressure
Connection
Safety position following failure of the auxiliary power
Actuator type
electrical
Y1
Closed
pneumatic
Closed
Closed
Open
Open
On rotary actuators,
it is usual to define the
anti-clockwise direction of
rotation seen looking at
the valve's operating
shaft as "OPEN".
Open
Y1
Closed
Open
Y2
Open
Y1
Closed
Closed
Last position
(before failure of
auxiliary power)
Open
Y1
Closed
Y2
Closed
Y1
Open
Open
up
down
down
down
Y1
up
up
up
down
Y2
Y1
up
down
up
up
Last position
(before failure of
auxiliary power)
Y1
Y2
up
down
down
down
Figure 3-6 Pneumatic connection positioning effect
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3.3.5
Restrictors
Note
The exhaust air valve is always open in the de-energized state.
In order to achieve floating times of > 1.5 s on small actuators, it is possible to reduce the air power by
means of the restrictors Y1 and Y2.
By turning to the right, the air power is reduced until it is completely blocked
In order to adjust the restrictors, it is recommended that they are closed and then slowly opened (see initialization RUN3).
In case of double-acting valves, ensure that both restrictors have approximately the same setting.
hexagon socket 2,5 mm
Y1
Y2
Figure 3-7 Restrictors
Mounting
4.1
Safety notes for mounting
CAUTION
Incorrect mounting
The device can be damaged, destroyed or its functionality impaired through improper mounting. .
Before installing ensure there is no visible damage present on the device.
Make sure that process connectors are clean, and suitable gaskets and glands are used.
Mount the device using suitable tools.

CAUTION
Mechanical impact effect

It is essential that the following sequence is observed during assembly in order to avoid injury or mechanical
damage to the positioner/mounting kit:
1. Mechanically mount the positioner
2. Connect the auxiliary electrical power supply
3. Connect the pneumatic auxiliary power
4. Carry out the commissioning procedure
NOTICE
Loss of degree of protection
Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the
nameplate is no longer guaranteed.
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CAUTION
Humid environment/dry compressed air
Install the positioner in a humid environment such that the positioner shaft does not freeze at low ambient
temperatures.
Ensure that water does not seep through an open enclosure or an open gland. Water may seep through if
the positioner is not installed and connected on-site immediately and finally.
As a general rule, the positioner must be operated only with dry compressed air. Therefore, use the customary water separator. An additional dryer is required in extreme cases. The use of dryers is especially important when you operate the positioner at low ambient temperatures. Set the Purge air switch to the "OUT"
position when installing on the pneumatic block, above the pneumatic connections.
4.2
Mounting Linear Actuator
4.2.1
Mounting Kit for "Integrated Fitting Linear Actuator"
Included with the "integrated fitting linear actuator" are (see Figure 4-1 for identifying numbers):
Serial
no.
No. of
items
Name
Note
mounted on lever (2)
Driver pin cpl. with roller
Lever
Washer
B6.4 - DIN 125 - A2
Spring washer
A6 DIN 137A- A2
Lock washer
A6 DIN 127- A2
Cylinder head bolt
M6 x 25 DIN 7984 - A2
Hexagonal nut
M6 - DIN 934 - A4
Square nut
M6 - DIN 557 - A4
Cylinder head bolt
M8 x 65 - DIN 912 - A2
10
Lock washer
A8 - DIN 127 - A2
11
Screw plug
12
O-ring
13 x 2.5
Mounting procedure (see Figure 4-1)

1. Adjust the pin (1) on the previously assembled lever to the value of the stroke range given on the actuator
or, if this is not available as a scale value, at the next largest scale value. In case of uncertainty with regard
to the real actuator stroke (pneumatic actuators often have a travel resource) you always have to choose
the next large scale value. The centre of the pin must be positioned at the scale value. The same value can
later be set during the commissioning under the parameter 3.YWAY, in order to display the displacement in
mm after the initialization.
2. Push the lever to the stop on the controller axis, and fix it with cylinder head screw (6).
3. Open the rear actuating pressure outlet by removing the screw (13) and the O-ring (14).
4. When fitting with spring chamber exhaust air supply open the exhaust air outlet by removing the screw (15)
and the O-ring (16).
5. Seal the actuating pressure outlet with screw plug (11). When fitting with exhaust air supply remove exhaust air silencer and seal.
6. Insert the O-ring (12) in the intermediate bracket recess.
7. Locate the positioner on the actuator in such a way that the roller passes between the pins (17).
8. Align the controller horizontally at the intermediate bracket, and assemble it with the screws (9) and lock
washers (10).
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6
15
5
14
7
13
3
2
1)
16
2)
10
17
12
11
3)
Figure 4-1 Mounting procedure for integrated fitting
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4.2.2
" Mounting Kit for "Linear Actuator IEC534
The "linear actuator IEC 534" mounting kit, stroke 3 35 mm, includes (see Figure 4-3 for identifying numbers):
Serial
no.
No. of
items
Name
Note
NAMUR fitting angle IEC 534
Standardised connecting location for fitting bracket with rib, column

or flat surface
Sensing hoop
Guides the roller with the driver pin and turns the lever arm
Clamping piece
Assembly of the sensing hoop to the actuator's spindle
Driver pin cpl. with roller
NAMUR lever
Mounted on lever (5)

For stroke range 3 35 mm or (stroke range > 35 130 mm,
order separately, see figure 4-2)
U-bolts
Only far actuators with columns
Hexagonal screw
M8 x 20 DIN 933A2
Hexagonal screw
M8 x 16 DIN 933A2
Lock washer
A8 - DIN 127A2
10
Washer
B 8.4 - DIN 125A2
11
Washer
B 6.4 - DIN 125A2
12
Spring washer
A6 - DIN 137AA2
13
Lock washer
A6 - DIN 127A2
14
Cylinder head bolt
M6 x 25 DIN 7984A2
15
Hexagonal nut
M6 - DIN 934A4
16
Square nut
M6 - DIN 557A4
17
Hexagonal nut
M8 - DIN 934A4
Assembly procedure (see Figure 4-3)

1. Assemble the clamping pieces (3) using the hexagonal screws (14) and lock washers (13) to the actuator
spindle.
2. Push the sensing hoop (2) into the cut-outs in the clamping piece. Adjust to the required length, and tightened the screws so that it is still just possible to push the sensing handle.
3. Adjust the pin (4) on the previously assembled lever to the value of the stroke range given on the actuator
or, if this is not available as a scale value, at the next largest scale value. In case of uncertainty with regard
to the real actuator stroke (pneumatic actuators often have a travel resource) you always have to choose
the next large scale value. The centre of the pin must be positioned at the scale value. The same value can
later be set during the commissioning under the parameter 3.YWAY, in order to display the displacement in
mm after the initialization.
4. Push the lever to the stop on the controller axis, and fix it with cylinder head screw (14).
5. Assemble the fitting angle (1) with two hexagonal screws (8), lock washer (9) and washers (10) to the rear
of the positioner. The choice of the hole row depends on the width of the actuator's intermediate bracket
width. The roller should engage in the sensing hoop (2) as close to the spindle as possible, but must not
touch the clamping piece.
6. Hold the positioner with the fixing angle to the actuator in such a way that the pin (4) passes inside the
sensing hoop (2).
7. Tighten the sensing hoop.
8. Prepare the assembly parts in accordance with the actuator type:
- Actuator with a rib: hexagonal bolt (7), washer (10) and lock washer (9).
- Actuator with a flat surface: four hexagonal bolts (7) with washer (10) and lock washer (9).
- Actuator with columns: two U-bolts (6), four hexagonal nuts (17) with washer (10) and lock washer (9).
9. Attach the positioner with the previously prepared assembly parts to the intermediate bracket. Adjust the
height of the positioner so that the horizontal position of the lever is achieved as close as possible to the
centre of the stroke. The actuator's lever scale provides orientation here. It is essential that the horizontal
lever position is passed through within the range of the stroke.
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90
25
30 35
1
5
33
10
15
90
20
40
50
70
60
90
110 130
Figure 4-2 NAMUR lever 3 ... 35 mm (1), NAMUR lever > 35 130 mm (2)
14
13
11
13
15
16
12
11
5
14
3
1)
2)
10
8
1
10
3)
9
8
F ittin g to la n te rn
w ith fla t s u rfac e
1
7
7
9
10
10
17
6
9
10
F ittin g to la n te rn
w ith c o lum ns
4)
Figure 4-3 Mounting procedure for IEC 534 inear actuator
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4.3
Mounting Kit for Quarter-turn Actuator VDI/VDE 3845"
Included with the "VDI/VDE 3845 quarter-turn actuator" mounting kit are (see Figure 4-4 for identifying numbers):
Serial no.
2
No. of
items
1
Name
Note
Coupling wheel
Fitted to the position feedback shaft of the positioner
Driver pin
Fitted to the actuator's shaft stub
Labels
Display of the actuator position, consisting of: 4.1 and 4.2
4.1
Scale
Various divisions
4.2
Pointer
Reference point for scale
14
Hexagonal screw
DIN 933 - M6 x 12
15
Retaining washer
S6
16
Cylinder head bolt
DIN 84 - M6 x 12
17
Washer
DIN 125 6.4
18
Hexagonal socket bolt
Pre-assembled with coupling wheel
19
Hexagon key
For item 18
Assembly procedure (see Figure 4-4)

1. Attach the VDI/VDE 3845 fitting bracket ((9), actuator-specific, supplied by actuator manufacturer, see Figure 3-8) to the rear of the positioner, and fix it in place with the hexagonal screws (14) and retaining washers (15).
2. Stick the pointer (4.2) on the fitting bracket at the middle of the centring hole.
3. Push the coupling wheel (2) as far as it will go on the positioner axis, pull it back about 1 mm, and tighten
the hexagonal socket bolt (18) with the supplied hexagonal key.
4. Place the driver pin (3) on the actuator's shaft stub and tighten it with cylinder head bolt (16) and washer
(17).
5. Carefully place the positioner with the fitting bracket on the actuator so that the pin of the coupling wheel
engages with the driver pin.
6. Align the positioner / fitting bracket centrally on the actuator, and screw tight (screws are not included with
the supply, but are part of the actuator's fitting bracket!).
7. When commissioning according to chapter 7 has been completed, take the actuator to its end position and
stick the scale (4.1) on to the coupling wheel (2) according to the direction of rotation and the turning range.
The scale is self-adhesive!
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4 .2
15
14
2
18
9
1)
2)
16
17
3
3)
4 .1
2
0% 20
40
60
8 0 10 0 %
4)
5)
Figure 4-4 Mounting procedure for VDI/VDE 3845 quarter-turn actuator
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Section A - B
2
3
4
4.1
4.2
9
10
14
15
16
17
18
18
Positioner
Coupling wheel
Driver pin
Labels
Scale
Pointer
VDI/VDE 3845-fitting bracket
Feedback shaft
Hexagonal screw M6 x 12
Retaining washer S6
Cylinder head boltM6 x 12
Washer
Hexagon key
Quarter-turn actuator
Figure 4-5 Mounted positioner for quarter-turn actuator
Positioner fixing plane
Quarter-turn actuator
a = 4 (0,16)
b = 12 (0,47)
Figure 4-6 Fitting bracket (supplied by actuator manufacturer), dimensions
4.4
Note on the Use of Positioners in Wet Environments

CAUTION
Never clean the positioner with a high pressure cleaner. Protection class IP66 is inadequate for this.
This information provides you with important notes on assembling the positioner in wet environments (frequent
heavy rain and/or persistent tropical condensation) in which protection class IP66 is no longer sufficient, in
particular when there is a risk that the water might freeze.
Avoid the unfavourable mounting positions:
To prevent fluids seeping through during normal operation of the device, e.g. through exhaust air openings.
Otherwise the digital display becomes poorly legible.
Page 19 von 42
Figure 4-7 Favourable and unfavourable installation positions
If local conditions force you to operate the positioner in an unfavourable installation position, you can prevent
the entry of water through additional measures.
Additional measures
The steps necessary to prevent the entry of water depends on the installation position chosen. In certain
cases you may need:
- Threaded joint with sealing rings (e. g. FESTO: CK - -PK-6)
- Plastic hose, approx. 20 to 30 cm (e. g. FESTO: PUN- 8x1,25 SW)
- Cable ties (number and length depend on the local conditions)
Procedure
1. Arrange the pipes in such a way that rainwater or condensation that runs along the length of the pipes can
drop off before reaching the positioner's connection strip.
2. Check that the seals for the electrical connections are correctly seated.
3. Check that the seal of the housing cover is not damaged or soiled. Clean or replace it if necessary.
4. If possible, mount the positioner in such a way that the sintered bronze silencer on the underneath of the
housing is pointing downwards (vertical installation position). If this is not possible, the silencer should be
replaced by a plastic hose using a suitable threaded joint.
Assembling the Threaded Joint with Plastic Hose
1. Unscrew the sintered bronze silencer from the exhaust air opening on the underside of the housing.
2. Screw the threaded joint mentioned above into the outlet opening.
3. Fit the plastic hose mentioned above to the threaded joint and check that it is tightly seated.
4. Use a cable tie to fasten the plastic hose to the fittings in such a way that the opening is pointing downwards.
5. Check that the hose is not kinked, and that the exhaust air can flow out easily.
4.5
Positioners exposed to strong acceleration forces or vibrations
High acceleration forces occur on fittings that are heavily mechanically stressed, such as breakaway flaps,
heavily shaking or vibrating valves or "steam hammer". These forces can be well outside the range specified in
the technical data. In extreme cases this can result in displacement of the slip clutch or the leverage ratio
switch.
In these cases the positioner is fitted as standard with a locking device for the slip clutch with which displacement as a result of the above-mentioned influences is inhibited.
The adjustment function is accessible beneath the black adjusting wheel of the slip clutch and recognisable on
the yellow wheel with slots. The null point setting and slip clutch adjustment functions are marked with symbols
on an auxiliary plate
The clamping piece for the transmission leverage ratio switch is located under the terminals and is also fitted
with a yellow adjusting wheel with slots.
Page 20 von 42
4.5.1
Slip clutch
Procedure
After the positioner has been fitted and fully set into operation, the slip clutch can be locked as follows:
1. Place a commercial screwdriver of about 4 mm wide in a slot in the yellow wheel.
2. Turn the yellow wheel anti-clockwise with the screwdriver until it latches detectably. The slip clutch is
thereby locked.
3. A locked slip clutch is to be recognised by an approximately 1 mm wide gap between the yellow and black
wheel.
4. If a null point setting is necessary, e.g. after a drive change, the locking is released by a clockwise rotation
up to the stop of the yellow wheel. After the null point setting the slip clutch can be fixed again as described
above.
4.5.2
Leverage ratio switch
Starting from the neutral position (as-delivered condition) the leverage ratio switch can be adjusted as follows:
1. Plug a conventional 4 mm wide screwdriver into a slot in the yellow wheel.
2. Then turn the adjustment wheel in accordance to the chosen gearing position (33 or 90) clockwise or anticlockwise until it snaps in audibly.
3. An adjusted fixed leverage ratio switch is recognizable from the asymmetric position of the adjustment
wheel.
4. If you have to switch over the gearing, the adjustment has to be loosen by turning the adjustment wheel into
neutral position first.
Figure 4-8 Locking the slip clutch and leverage ratio switch
slip clutch and
leverage ratio switch
Figure 4-9 Arrester device
External Travel Acquisition

External travel acquisition is a possibility for those cases in which the measures described above are not sufficient, such as when vibration is heavy and persistent, at particularly high or low ambient temperatures, or in
the presence of nuclear radiation. In this case the special positioner (see Type Code) is used at a distance
from the fitting.
More information contains the appendix to the manual 827.EDP.
Page 21 von 42
Electrical connection
Basic safety instructions

WARNING
Improper power supply
Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using alternating current
instead of direct current.
Connect the device in accordance with the specified power supply and signal circuits. The relevant specifications can be found in the certificates or on the nameplate.
WARNING
Unsafe extra-low voltage
Danger of explosion in areas subject to explosion hazard due to voltage flashover
Connect the device to an extra-low voltage with safe isolation

WARNING
Connecting device in energized state

Connect devices in hazardous areas only in a de-energized state.
Exception:
Circuits of limited energy may also be connected in the energized state in hazardous areas.
WARNING
Lack of equipotential bonding
Danger of explosion through compensating currents or ignition currents through lack of equipotential bonding.
Ensure that the device is potentially equalized.
Exception:
It may be permissible to omit connection of the equipotential bonding for devices with type of protection "Intrinsic safety Ex i".
WARNING
Unprotected cable ends
Danger of explosion through unprotected cable ends in hazardous areas.
Protect unused cable ends in accordance with IEC/EN 60079-14
WARNING
Improper laying of shielded cables
Danger of explosion through compensating currents between hazardous area and the non-hazardous area.
Only ground shielded cables that run into the hazardous area at one end.
If grounding is required at both ends, use an equipotential bonding conductor.
Page 22 von 42
WARNING
Unsuitable cables and/or cable glands
Danger of explosion in areas subject to explosion hazard if cables and/or cable glands are connected which
do not match one another or comply with the technical requirements.
Before taking the device into operation let the device adapt for several hours in the new environment.
Tighten the cable glands in accordance with the torques specified
When replacing cable glands use only cable glands of the same type.
After installations check that the cables are seated firmly.
CAUTION
Condensation in the device
Damage to device through formation of condensation if the temperature difference between transportation or
storage and the mounting location exceeds 20 C
Before taking the device into operation let the device adapt for several hours in the new environment.
CAUTION
Ambient temperature too high
Damage to cable sheath
At an ambient temperature 60 C, use heat-resistant cables suitable for an ambient temperature at
least 20 C higher.
CAUTION
Connection of voltage source to current input
Device damage if a voltage source is connected to the current input Iw (terminals 6 and 7).
Never connect the current input Iw to a voltage source, otherwise the positioner may be destroyed.
Always use a voltage source with a maximum output current of I = 20 mA.
WARNING
Version Ex i
As auxiliary power, control, and signal circuits, only certified intrinsically safe circuits may be connected.
NOTICE
Dissipation of glitch impulses/equipotential bonding
In order to dissipate glitch impulses, the positioner must be connected to a potential equalizing cable (earth
potential) using a low resistance.
The positioner have a corresponding terminal on the outer side of the enclosure. This terminal must also be
connected to the potential equalizing cable.
For applications in hazardous areas, ensure an adequately suitable equipotential bonding between the hazardous and non-hazardous areas.
Owing the reasons pertaining to tightness (IP enclosure rating) and the required tensile strength, only use the
cables having a diameter 8 mm for standard M20x1.5 cable gland, or use a suitable seal insert in case of
smaller diameters.
In the NPT version, the positioner is delivered with a coupling. When inserting a counter piece in the coupling,
ensure that the maximum permissible torque of 10 Nm is not exceeded.
Page 23 von 42
5.1
Electrical connection, basic device
If the bus shield is fully effective, the interference immunity and the interference emission conform to the specifications. The following measures ensure that the bus shield is fully effective:
The shields have been connected to the metallic connections of the positioner.
The shields have been laid up to the terminal boxes, the distributor and the transceiver.
Safety shutdown
The positioner is equipped with an additional input (terminal 81 and terminal 82) for driving to the safety position. After activating this function this input must be supplied with uninterrupted, to allow normal positioning
operation.
If this power supply is switched off or drops out, the air exhaust valve is automatically opened and the drive will
move to the pre-arranged safety position, so that the drive cannot be activated using the keys on the control
unit or by means of the master switch.
This function is activated by the coding bridge on the motherboard. This is accessible after removing the module cover and must be moved from the right position (as delivered) to the left position
Installing the bus cable
1.
2.
3.
4.
5.
Isolate the buscable as shown in figure 5-2.

Open the positioner housing by undoing the four cover screws.
Feed the prepared bus cable through the screw-type cable gland.
Secure the shield with the cable clip and the two screws to the housing
Tighten the screw-type cable gland
6. Connect the red and green wires as shown in figure 5-3 to terminals 6 and 7 of the mother board (the polarity is immaterial)
5.1.1
Electrical connection, basic device not for explosive regions
30 V
32 V
F o unda tio n F ieldbus
81
82
I nput: Sa fe p ositio n
Po sitioner
7
8
9
10
Inpu t: S im u la tion s e nab le
Figure 5-1 Electrical connection for basic device, not for explosive regions
Bus cable
Cabler shield
Figure 5-2 Preparing the bus cable
Page 24 von 42
Bus cable
Cable clip
Basic PCB
Module cover
cable glands
Grounding cable
Ground potential
Terminals
Label
Figure 5-3 Connection the bus cable
5.1.2
Electrical connection, basic device for explosive regions
Intrinsically safe power sources
30 V
EEx
24 V
Foundation Fieldbus
EEx
81
82
Positioner
7
8
9
10
Region of no explosive hazard
Input: Safe position
Input: Simulations enable
Region of explosive Zone 1 or Zone 2
Figure 5-4 Electrical connection of basic device, for explosive regions
WARNING
For reasons of safety, the auxiliary pneumatic energy should only be connected after assembly when, in the
presence of an electrical signal, the positioner is switched to the P-manual operating level (delivery status,
see leaflet Concise operating notes).
NOTICE
Ensure correct air-quality! Oil-free, instrument quality air with no water or dust, solid material content
max. 1 mg/m3 (standard atmospheric conditions), max. particle size 1 m, oil content max. 0.1 mg/m3
(standard atmospheric conditions), pressurised dew point 20 K below the lowest ambient temperature.
When working on the compressed air system ensure that any contamination present such as water, oil,
swarf, soldering material residues etc. are expelled by blowing out
Page 25 von 42
Procedure
- If appropriate, connect manometer block for air supply and actuating pressure.
- Connection via internal thread G 1/4 DIN 45141
PZ
Air supply 1,4 to 7 bar
Y1
Actuating pressure 1 for single-acting and double-acting actuators
Y2
Actuating pressure 2 for double-acting actuators
E
Exhaust air output (remove silencer if necessary)
- Safety position at failure of auxiliary electrical power:
Single-acting: Y1
vented
Double-acting: Y1
max. actuating pressure (supply pressure)
Y2
vented
- Connect actuating pressure Y1 or Y2 (only on double-acting actuators) according to the desired safety position.
- Connect air supply to PZ.
Note
So that spring-loaded pneumatic actuators can reliably exploit the maximum possible travel, it is necessary
that the supply pressure exceeds the maximum required final pressure of the actuator by a sufficient margin.
After installing the pneumatic connections, check the tightness of the entire control valve. Besides continuous
air consumption, the positioner may try to compensate the position deviation due to leakage. This will lead to
premature wear in the entire control unit.
Commissioning
(see leaflet "Concise operating notes")

WARNING
Improper commissioning in hazardous areas
Device failure or danger of explosion in hazardous areas
Do not commission the device until it has been mounted completely and connected.
Before commissioning take the effect on other devices in the system into account.
WARNING
Loss of explosion protection
Danger of explosion in hazardous areas if the device is open or not properly closed. .
WARNING
Opening device in energized state
Only open the device in a de-energized state.
Check prior to commissioning that the cover, cover locks, and cable inlets are assembled in accordance
with the directives.
Exception: Devices having the type of protection "Intrinsic safety Ex i" may also be opened in energized
state in hazardous areas.
Page 26 von 42
WARNING
Water in compressed air line
Device damage and possibly loss of type of protection. The factory setting for the purging air selector is "IN".
In the "IN" position, water from the compressed air line may enter the device from the pneumatics during
initial commissioning.
Before commissioning, make sure that no water is present in the compressed air line.
If you cannot be sure that there is no water in the compressed air line:
Set the purging air selector to "OUT". In this way, you prevent water from the compressed air line from
penetrating the device.
Only set the purging air selector to "IN" again when all water has been discharged from the compressed
air line.
NOTICE
Loss of degree of protection
Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the
nameplate is no longer guaranteed.
Make sure that the device is securely closed.
WARNING
Commissioning and operation with pending error
If an error message appears, correct operation in the process is no longer guaranteed.
Check the gravity of the error
Correct the error
If the device is faulty:
- Take the device out of operation.
- Prevent renewed commissioning.
NOTICE
During the initialization process, the operating pressure must be at least one bar more than that required
to close or open the valve. However, the operating pressure should not be greater than the maximum
permissible operating pressure for the actuator.
The leverage ratio switch can be set only when the positioner is open. Therefore, check this setting before
closing the enclosure.
Safety notes for operation with natural gas

For operation with natural gases actuator medium an electric connection acc to explosion protection ia category 2G is needed. More information and safety notes see for manual 827A-GHB-natural gas
General Information
After installing the positioner on a pneumatic actuator, you must supply electric and pneumatic auxiliary power
to it.
The positioner is in the "P manual mode" before initialization. At the same time, "NOINI" blinks in the lower line
of the digital display.
Adjust the positioner as per the respective actuator with the help of the initialization process and by setting the
parameters. If required, use the "PRST" parameter to cancel the adjustment of the positioner on the actuator.
The positioner is again in the "P manual mode" after this process.
Page 27 von 42
Types of initialization
-
Automatic initialization
The initialization takes place automatically. In this case, the positioner determines, one after another, the
effective working direction, the travel distance or rotation angle and the actuator's adjustment times and
adjusts the control parameters to match the dynamic behaviour of the actuator.
Manual initialization
The travel distance or rotation angle of the actuator can be set manually. The other parameters are
automatically determined, just as in the case of automatic initialization. This function is useful on actuators with soft end stops

In devices with HART functionality, the initialization data of one positioner can be read and copied into
another positioner. This allows a faulty device to be exchanged, without having to interrupt a running
process in order to carry out initialization.
You have to define a few parameters for the positioner before initialization. Owing to the preset values, you
cannot adjust further parameters for initialization.
You can use a suitably configured and activated binary input to protect the configured settings against accidental adjustment.
7.1
Preparations for Linear Actuators
1. Assemble the positioner with the appropriate mounting kit

The position of the leverage ratio switch in the positioner is particularly important here.
Stroke
lever
Position leverage ratio switch
5 to 20 mm
short
33 (i.e. down)
25 to 35 mm
short
90 (i.e. up)
40 to 130 mm
long
90 (i.e. up n)
2. Connect a suitable source of current or voltage
3. Connect the actuator and the positioner to the pneumatic lines, and activate the positioner's auxiliary
pneumatic power.
4. The positioner is now in the Pmanual" operating mode. The top line of the display now shows the current
potentiometer voltage (P) in percent, e.g.: P37.5, while "NOINI" flashes on the bottom line:
5. Check that the mechanics can move freely over the entire active range by moving the actuator with the
and
buttons as far as the end positions. The value P5.0 may not be fallen below and P95.0 may not be
exceeded. The difference of the two values must be greater than 25.0
You can move the actuator rapidly by pressing the button for the opposite direction as well while continuing
to hold down the first direction button.
6. Now move the actuator so that the lever is horizontal. The display should show a value between P48.0 and
P52.0. If this is not the case, make appropriate adjustments to the slip clutch. The closer you can get to the
"P50.0" value, the more accurately the positioner can determine the travel.
Page 28 von 42
7.1.1
Automatic Initialization of Linear Actuators
When you can move the actuator correctly, leave it in a central position and start the automatic initialization:
button pressed for longer than 5 s. This will bring you to the configuration mode
1. Hold the
Display:
2. Switch to the second parameter by pressing the

Display:
or
button briefly.
It is essential that this value matches the setting of the leverage ratio switch (33 or 90))
button to move on to the following display:
3. Use the
You only have to set this parameter if you want to have the total stroke determined displayed in mm at the
end of the initialization phase. To do this, you select the value in the display at which you have set the
driver pin on the scale at the lever.
4. Use the
5. Start the initialization by pressing the

Display:
button for longer than 5 s.
"RUN1" to "RUN5" appear in sequence in the lower display during the initialization process.
Depending on the actuator, the initialization process can take up to 15 min and it is completed when the following display appears:
The first line also contains the stroke that has been determined, in mm, if the lever length has been given
with the 3.YWAY parameter.
button:
The following display appears after briefly pressing the
button for longer than 5 s. The software status will be disTo leave the Configuration mode, press the
button is released, the device will be in manual operation mode.
played after about 5 s. When the
button. Your previous setYou can interrupt an initialization that is in progress at any time by pressing the
tings will be retained. The parameters will only be returned to the factory settings if you have carried out a
"Preset".
After successful initialization slipping clutch and leverage ratio switch can be adjusted if necessary
Page 29 von 42
7.1.2
Manual Initialization of Linear Actuators
With this function the positioner can be initialized without having to move the actuator hard against the end
stops. The start and end positions of the travel are set manually.
When you can move the actuator correctly, leave it in a central position and start the manual initialization. The
other initialization steps (optimisation and control parameters) are carried out in the same way as under automatic initialization.
1. Hold the
button pressed for longer than 5 s. This will bring you to the configuration mode
Display:

Display:
or
button briefly.
It is essential that this value matches the setting of the leverage ratio switch (33 or 90))
3. Use the
You only have to set this parameter if you want to have the total stroke determined displayed in mm at the
end of the initialization phase. To do this, you select the value in the display at which you have set the
driver pin on the scale at the lever.
4. Press the
button twice to move on to the following display:

Display:
6. After 5 s the display changes to:
(The potentiometer settings shown here and below are only illustrative examples.)
and
buttons to move the actuator to the position that you wish to define as the first of the
Now use the
two end positions. Then press the
button. This will register the current position as end position 1, and will
move on to the next step.
If the message "RANGE" appears on the lower line, the selected end position is outside the permitted
measurement range. There are a number of ways to correct this error:
- adjust the slip clutch until "OK" appears, then press the
button again, or
and
buttons to move to a different end position, or
- use the
button. You must then change to P-manual operation and
- interrupt the initialization by pressing the
correct the travel and the displacement accession in accordance with chapter 7.1
7. When Step 6 has been successfully completed, the following display appears:
and
buttons to move the actuator to the position that you wish to define as the second
Now use the
button. This will cause the current position to be registered as end position
end position. Then press the
2.
If the message "RANGE" appears on the lower line, the selected end position is outside the permitted
measurement range. There are a number of ways to correct this error:
- adjust the slip clutch until "OK" appears, then press the operating mode switch again, or
- use the
and
buttons to move to a different end position, or
Page 30 von 42
interrupt the initialization by pressing the

button. You must then change to P-manual operation and
correct the travel and the displacement accession in accordance with chapter 7.1
If the message "Set Middl" appears, the lever arm must be moved to a horizontal position with the aid of the
and
buttons, and the
button then pressed. This will set the reference point for the sine correction
on linear actuators.
8. The rest of the initialization will now proceed automatically. "RUN1" to "RUN5" will appear in sequence on
the lower line of the display. The following display appears when the initialization has been completed successfully:
The first line also contains the stroke that has been determined, in mm, if the lever length has been given
with the 3.YWAY parameter.
button the lower line will again show 5.INITM. You are then once more in the
After briefly pressing the
Configuration operating mode
After successful initialization slipping clutch and leverage ratio switch can be adjusted if necessary.
7.2
Preparations for Quarter-turn Actuators
In the positioner, place the leverage ratio switch in the 90 position (the usual adjustment angle for quarter-turn
actuators).
1. Assemble the positioner with the appropriate mounting kit.
2. Connect a suitable source of current or voltage.
3. Connect the actuator and the positioner to the pneumatic lines, and activate the positioner's auxiliary
pneumatic power
4. The positioner is now in the P-manual .The top line of the display now shows the current potentiometer
voltage (P) in percent, e. g.: P37.5 while NOINI flashes on the bottom line
5. Check that the mechanics can move freely over the entire active range by moving the actuator with the
and
buttons as far as the end positions. The value P5.0 may not be fallen below and P95.0 may not be
exceeded. The difference of the two values must be greater than 25.0.
You can move the actuator rapidly by pressing the button for the opposite direction as well while continuing to
hold down the first direction button.
7.2.1
Automatic Initialization of Quarter-turn Actuators
When you can move the actuator correctly through its range, leave it in a central position and start the automatic initialization:
1. Hold the
button pressed for longer than 5 s. This will bring you to the configuration mode.
Display:
2. Hold the
Display:

Display:
button briefly. This has automatically been set to 90.
It is essential that this value matches the setting of the leverage ratio switch (33 or 90)
Page 31 von 42
4. Use the

Display:
"RUN1" to "RUN5" appear in sequence in the lower display during the initialization process.
Depending on the actuator, the initialization process can take up to 15 min and it is completed when the following display appears:
The upper value gives the actuator's full turning angle (e.g. 93.5). The following display appears after
button:
briefly pressing the
button. Your previous setYou can interrupt an initialization that is in progress at any time by pressing the
tings will be retained. The parameters will only be returned to the factory settings if you have carried out a
"Preset".
7.2.2
Manual Initialization of Quarter-turn Actuators
With this function the positioner can be initialized without having to move the actuator hard against the end
stops. The start and end positions of the travel are set manually
When you can move the actuator correctly, leave it in a central position and start the manual initialization. The
other initialization steps (optimisation and control parameters) are carried out in the same way as under automatic initialization.
1. Hold the
Display:
2. Use the
Display:
button to set the YFCT parameter to "turn"

Display:
button briefly.
Ensure that the leverage ratio switch is in the 90 position.

button twice to move on to the following display:
4. Press the
The following steps are identical to steps 5) to 8) in the initialization of linear actuators.
Following successful initialization, the pivoting range that has been determined is shown on the upper display
in degrees
After briefly pressing the
button the lower line will again show 5.INITM. You are then once more in the Configuration operating mode.
Page 32 von 42
To leave the Configuration mode, press the

button for longer than 5 s. The software status will be displayed
after about 5 s. When the
7.3
Electropneumatic positioners can be replaced in a running system without interrupting the process.
By copying and transferring the device and initialization data, it is possible to commission a replacement
positioner without needing to initialize it.
An electropneumatic positioner uses the communication interface to transfer data.
The following steps are required to exchange a positioner:
1. Prerequisite is that the positioner to be replaced and all ist parameters is in the project database. The
replacement instrument should be online on the bus.
2. Fix the actuator in its current position (mechanically or pneumatically).
3. Read and note the current position value from the display of the positioner that is being replaced. If the
electronics are faulty, find the current position by measurement at the actuator or valve
4. Dismount the positioner. Fit the lever arm of the positioner to the replacement device. Mount the replacement device to the fittings. Put the leverage ratio switch in the same position as on the faulty device.
Download the device data and initialization dat.
5. Now transfer all parameters from the projected positioner to the new positioner. With the NI Configurator
this can be done by right clicking the appropriate blocks in the function block application window, chosing
Replace With ... and selecting the new blocks. Do this also with the Transducer Block. In order to transfer
the parameter INIT_VALUES (Initialization parameters), you have to set SERVICE_UPDATE (Save/Reset)
to 9 (Enable Write INIT--Values), then click Write changes and set SERVICE_UPDATE to 3 (Set device to
state INIT). Now the positioner is initilisid with the same parameters as the old one
6. If the actual value displayed does not accord with the value noted from the faulty positioner, set the correct
value with the slip clutch.
7. The positioner is now ready for operation.
The accuracy and the dynamic behaviour may not be as good as they would be following a proper initialization.
In particular the position of the hard end stops and the associated servicing data may be inaccurate. An initialization must therefore be carried out at the next opportunity.
NOTICE
Deferred initialization
Initialize the replacement positioner as soon as possible. The following properties can be ensured only after
initializing:
Optimum adjustment of the positioner as per the mechanical and dynamic properties of the actuator.
Unrestricted accuracy and dynamic behaviour of the positioner
Deviation-free position of the hard end stops
Correctness of the maintenance data
Page 33 von 42
Overview of Parameters
8.1
Parameters 1 to 5
Parameters 1 to 5 are the same for all versions of positioner. These parameters are used to adjust the positioner to the actuator. Normally the parameter setup is sufficient to be able to operate the positioner on an actuator.
If you want to get to know the positioner in detail, gradually try out the effects of the remaining parameters by
systematic testing.
Parameter
Function
Parameter values
(bold = factory setting)
Unit
1.YFCT
Type of position actuator
2.YAGL
turn (quarter-turn actuator)

WAY (linear actuator)
LWAY (linear actuator without sine correction)
ncSt (quarter-turn actuator with NCS)
-ncSt (quarter-turn actuator with NCS, inverse direction
of action
ncSL (linear actuator with NCS)
ncSLL (linear actuator with NCS and lever)
Nominal angle of rotation of the feedback message (
- Parameter does not appear if 1.YFCT = turn, LWAY or ncS_ has been selected.
- Set the leverage ratio switch accordingly)
33
90
3.YWAY
Range of stroke (optional setting)

- The parameter only appears for "WAY" and for "ncSLL".
- When used the value must correspond with the set range of stroke on the actuator. Carriers must be scaled to the
actuator's stroke value, or if this is not scaled they then must be set to the next largest scaled value.
4.INITA
5.INITM
8.2
OFF
5 | 10 | 15 | 20 (short lever 33)
25 | 30 | 35 (short lever 90)
40 | 50 | 60 | 70 | 90 | 110 | 130 (long lever 90)
NOINI | no / ###.# | Strt
NOINI | no / ###.# | Strt
Initialization (automatic)
Initialization (manual)
mm
Parameters 6 to 44
These parameters are used to configure the following additional functions of the positioner:
Target value preparation
Actual value preparation
Binary signal processing
Tight closing function
Boundary value detection
Parameter
Function
6.TSUP
7.TSDO
8.SFCT
Setpoint ramp OPEN

Setpoint ramp CLOSED
Setpoint function
Linear
Equal percentage
Parameter values
Auto / 0 ... 400
0 ... 400
Inverse equal percentage
9.SL0 ... 29.SL20

9SL0
10SL1 ....
28.SL19
29.SL20
30.DEBA
31.YA
1 : 25
1 : 33
1 : 50
25 : 1
33 : 1
50 : 1
%
%
Lin
1 - 25
1 - 33
1 - 50
n1 - 25
n1 - 33
n1 - 50
FrEE
Freely adjustable
Setpoint turning point (Interpolation points appear only upon selection of 12.SFCT = "FrEE")
at
0%
5 % ...
0.0 ... 100.0
95 %
100 %
Dead zone of closed-loop controller
Auto / 0.1 ... 10.0
Start of the manipulated variable limit
0.0 ... 100.0
Unit
%
%
%
Page 34 von 42
Parameter
Function
32.YE
33.YNRM
End of the manipulated variable limit

Manipulated variable scaling
Mechanical
On flow
Lower value for tight closing
Upper value for tight closing
Function of BE1
34.YCDO
35.YCUP
36.BIN1
Parameter values
0.0 ... 100.0
Unit
%
MPOS
FLOW
0.0 ... 100
0.0 ... 100
%
%
Normally open
Normally closed
(Action on switch closed or

High-Level)
(Action on switch open or LowLevel)
37.AFCT
None
Message only
Block configuration
Block configuration and manual
Move valve to position YE
Move valve to position YA
Block movement
Partial-Stroke-Test
Alarm function
38.A1
39.A2
40. FCT
without
A1 = Min, A2 = Max
A1 = Min, A2 = Min
A1 = Max, A2 = Max
Trigger threshold, alarm 1
Trigger threshold, alarm 2
Function for fault message output
Normal
Inverted
(+ means: Logical OR combination)
(High level without fault)
(Low level without fault)
OFF
on
bloc1
bloc2
uP
doWn
StoP
PST
Normal
-on
-uP
-doWn
-StoP
-PST
Inverted
(High level without fault)
41. TIM
42. LIM
43.PRST
44.XDIAG
Fault
Fault + not automatic
Fault + not automatic + BE
Monitoring time for setting of fault message
"regulation deviation"
Response threshold for fault message "regulation deviation"
Preset (factory setting) results in "NOINI"!
no
Nothing activated
Strt Start of factory setting
oCAY Display after pushing button for 5 s
Activation of extended diagnostics
Off
Single-level message
Two-level message
Three-level message
(Low level without fault)
OFF
0.0 ... 10.0 ... 100

0.0 ... 90.0 ... 100
%
%
Auto / 0 ... 100
Auto / 0 ... 100
no
Strt
oCAY
OFF
On1
On2
On3
Page 35 von 42
8.3
Parameters A to P
These parameters are used to set the extended diagnostic functions of the positioner.
Note
Parameters A to P and their sub-parameters are only displayed when the extended diagnostics has been activated using parameter "XDIAG" with parameter value "On1", "On2" or "On3".
Parameter
Function
A. PST
A1.STPOS
A2.STTOL
A3.STEP
A4.STEPD
A5.INTRV
A6.PSTIN
A7.FACT1
A8.FACT2
A9.FACT3
b. DEVI
b1.TIM
b2.LIMIT
b3.FACT1
b4.FACT2
b5.FACT3
C. LEAK
C1.LIMIT
C2.FACT1
C3.FACT2
C4.FACT3
d. STIC
d1.LIMIT
d2.FACT1
d3.FACT2
d4.FACT3
E. DEBA
E1.LEVEL3
F. ZERO
F1.LEVEL1
F2.LEVEL2
F3.LEVEL3
G. OPEN
G1.LEVEL1
G2.LEVEL2
G3.LEVEL3
H. TMIN
H1.TUNIT
H2.LEVEL1
H3.LEVEL2
H4.LEVEL3
J. TMAX
J1.TUNIT
J2.LEVEL1
J3.LEVEL2
J4.LEVEL3
L. STRK
L1. LIMIT
L2.FACT1
L3.FACT2
L4.FACT3
O. DCHG
O1.LIMIT
O2.FACT1
O3.FACT2
O4.FACT3
P. PAVG
P1.TBASE
P2.STATE
P3.LEVEL1
P4.LEVEL2
P5.LEVEL3
Partial-Stroke-Test with the following parameters:

Starting position
0.0 ... 100.0
Starting tolerance
0.1 ... 2.0 ... 10.0
Step height
0.1 ... 10.0 ... 100.0
Step direction
uP / do / uP do
Test interval
OFF / 1 ... 365
Partial-Stroke-Test reference step time
NOINI / (C)##.# / Fdini / rEAL
Factor 1
0.1 ... 1.5 ... 100.0
Factor 2
0.1 ... 3.0 ... 100.0
Factor 3
0.1 ... 5.0 ... 100.0
General control valve fault with the following parameters:
Time constant
Auto / 1 ... 400
Limit
0.1 ... 1.0 ... 100.0
Factor 1
0.1 ... 5.0 ... 100.0
Factor 2
0.1 ... 10.0 ... 100.0
Factor 3
0.1 ... 15.0 ... 100.0
Pneumatic leakage with the following parameters:
Limit
0.1 ... 30.0 ... 100.0
Factor 1
0.1 ... 1.0 ... 100.0
Factor 2
0.1 ... 1.5 ... 100.0
Factor 3
0.1 ... 2.0 ... 100.0
Friction (slip-stick effect) with the following parameters:
Limit
0.1 ... 1.0 ... 100.0
Factor 1
0.1 ... 2.0 ... 100.0
Factor 2
0.1 ... 5.0 ... 100.0
Factor 3
0.1 ... 10.0 ... 100.0
Dead zone monitoring with the following parameters:
Threshold
0.1 ... 2.0 ... 10.0
Zero point monitoring with the following parameters:
Threshold 1
0.1 ... 1.0 ... 10.0
Threshold 2
0.1 ... 2.0 ... 10.0
Threshold 3
0.1 ... 4.0 ... 10.0
Displacement of the upper stop with the following parameters:
Threshold 1
0.1 ... 1.0 ... 10.0
Threshold 2
0.1 ... 2.0 ... 10.0
Threshold 3
0.1 ... 4.0 ... 10.0
Monitoring of the lower limit temperature with the following parameters:
Temperature unit
C
F
Threshold 1
-40 ... -25 ... 90
-40 ... 194
Threshold 2
-40 ... -30 ... 90
-40 ... 194
Threshold 3
-40 ... 90
-40 ... 194
Monitoring of the upper limit temperature with the following parameters:
Temperature unit
C
F
Threshold 1
-40 ... 75 ... 90
-40 ... 194
Threshold 2
-40 ... 80 ... 90
-40 ... 194
Threshold 3
-40 ... 90
-40 ... 194
Monitoring the path integral with the following parameters:
Limit for the number of changes of direction
1 ... 1E6 ... 1E8
Factor 1
0.1 ... 1.0 ... 40.0
Factor 2
0.1 ... 2.0 ... 40.0
Factor 3
0.1 ... 5.0... 40.0
Monitoring the changes in direction with the following parameters::
Limit for the number of changes of direction
1 ... 1E6 ... 1E8
Factor 1
0.1 ... 1.0 ... 40.0
Factor 2
0.1 ... 2.0 ... 40.0
Factor 3
0.1 ... 5.0... 40.0
Position mean value calculation with the following parameters:
Time base of the mean value generation
0.5h / 8h / 5d / 60d / 2.5y
State of the position mean value calculation
IdLE / rEF / ###.# / Strt
Threshold 1
0.1 ... 2.0 ... 100.0
Threshold 2
0.1 ... 5.0 ... 100.0
Threshold 3
0.1 ... 10.0 ... 100.0
Parameter values
Unit
%
%
%
d
s
s
%
%
%
%
%
%
%
%
C/F
C/F
%
%
%
Page 36 von 42
Fault removal
Diagnostic guide
See Table
In which operating mode does the fault appear?
-
Initialization
Manual operation and automatic operation
In what environment and under what boundary conditions does the fault
appear?
-
Wet environment (e.g. severe rain or constant condensation)
Vibrating (oscillating) fittings
Impact or shock loading (e.g. steam hammer or breakaway flaps)
Damp (wet) compressed air
Dirty compressed air (contaminated with solid particles)
When does the fault appear?

-
Regularly (reproducible)
Sporadically (not reproducible)
Mostly after a certain length of time of operation
Table 1
Fault symptoms
Possible cause(s)
Positioner remains in RUN 1

mode.
Initialization from end position

started and
Failure to wait for reaction time of max.

1 min.
Mains pressure not connected or too
low.

mode.
Leverage ratio switch and Parameter 2 (YAGL) and also actual stroke
are not in agreement.
Stroke on lever incorrectly adjusted.
Piezo valve(s) are not switching

(see Table 2)

mode.
Actuator travel time too long

mode, does not get to FINISH
(waiting time > 5 min)
Slack (play) in the positioner

actuator fitting
Remedial measures
-
Up to 1 min waiting time is required
Do not start initialization from end

position
Check mains pressure
Check settings: Leverage ratio

switch (10 in fig.1) and parameter 2
Check stroke on lever
see Table 2
Open restrictor completely and/or

set PZ pressure to highest permissible value.
If necessary use booster
Quarter-turn actuator: Check that

grub screw on the coupling wheel is
tight
Linear actuator: Check that lever on

the positioner shaft is tight
Remove any other play between

actuator and fitting.
Page 37 von 42
Table 2
Fault symptoms
Possible cause(s)
CPU test flashes in the display (approx. every 2 s)
Water in the valve block (caused by

wet compressed air)
Piezo valve(s) are not switching.
Actuator will not move at all or

only in one direction in both
manual and automatic operating
modes.
Dampness in the valve block

(also no soft clicking audible if
or - button depressed in
manual operating mode).
Remedial measures
-
In its early stages the fault can be

removed by subsequent operation
with dry air (if necessary in the dryer
at 50 to 70C).
Otherwise repair
Screw between cover and valve

block not screwed tight or cover
jammed.
Tighten screw, if necessary remove

cause of jam.
Dirt (chips, particles) in valve block
Repair or new unit
Deposits on contacts between electronics board and valve block; these

can occur as a result of abrasion
from long-term loading caused by
severe vibration..
Clean all contact surfaces with spirit,

if necessary bend valve block contact
springs a little.
Table 3
Fault symptoms
Possible cause(s)
Remedial measures
Actuator does not move
Compressed air < 1.4 bar
Set incoming air pressure to > 1.4

bar.

(however soft clicking audible
or
button depressed in
if
manual operating mode).
Restrictor valve(s) closed (screw(s)

at the right-hand stop)
Open restrictor screw(s) by turning to

the left
Dirt in the valve block
Repair or new unit
In steady-state automatic operating mode (constant setpoint)

and in manual operating mode
one Piezo valve is constantly
switching.
Pneumatic leakage in the positioner actuator system. Begin

leakage test in RUN 3 (initialization)
Remove source of leakage in actuator and/or feed
In the case where actuator is intact

and feed is fully sealed: Repair or
new unit
Dirt in the valve block (see above)
Repair or new unit
Table 4
Fault symptoms
-
Possible cause(s)
In steady-state automatic operating mode (constant setpoint)

and in manual operating mode
both Piezo valves are constantly switching alternately; actuator
oscillates about a mean value.
Positioner does not drive fitting

up to the stop (with a 100% input signal)
Remedial measures
Static friction in the stuffing box of

fitting or actuator too large.
Reduce static friction or increase

dead zone (parameter DEBA) until
the oscillating movement stops
Slack (play) in the positioner - actuator - fitting system
Quarter-turn actuator: Check that

grub screw on the coupling wheel is
tight
Linear actuator: Check that lever on

the positioner shaft is tight
Remove any other play between

actuator and fitting.
Increase travel times by means of

restrictor screws.
If fast travel time is necessary, increase dead zone (parameter DEBA)

until the oscillating movement stops.
Increase supply pressure
Actuator too fast
Supply pressure too low
Page 38 von 42
Table 5
Fault symptoms
-
Null point moves about sporadically (> 3 %)
Possible cause(s)
-
Equipment functionality completely fails: also no indication in

the display
-
10
Remedial measures
As a result of impact or shock loading accelerations occur that are so high

that the slip clutch is displaced (e.g.
by steam hammer in steam pipework)
Remove causes of shock loading.
Electrical auxiliary power source

inadequate ( 3,6 mA)
Control electrical auxiliary power

source
Tighten screws and secure with

sealant
Repair
As a preventative measure mount

positioner on rubber-metal mounts
Re-initialise positioner, lock slip

clutch (see chapter 4.1.2)
With very high long-term loading

caused by vibration (oscillations)::
-
Screws on the electrical connecting terminals can work

loose.
Electrical connecting terminals

and/or electronic components
can be shaken loose
Service and maintenance

WARNING
Impermissible repair of the device
Repair must be carried out by authorized personnel only.
WARNING
Impermissible accessories and spare parts
Only use original accessories or original spare parts.
Observe all relevant installation and safety instructions described in the instructions for the device or enclosed with the accessory or spare part.
WARNING
Improper connection after maintenance
Connect the device correctly after maintenance.
Close the device after maintenance work.
CAUTION
Penetration of moisture into the device
Device damage
Make sure when carrying out cleaning and maintenance work that no moisture penetrates the inside of
the device.
Page 39 von 42
CAUTION
Releasing key lock
Improper modification of parameters could influence process safety.
Make sure that only authorized personnel may cancel the key locking of devices for safety-related applications.
WARNING
Electrostatic charge
Danger of explosion in hazardous areas if electrostatic charges develop e.g. when cleaning plastic enclosures with a drycloth.
Prevent electrostatic charging in hazardous areas.
WARNING
Enclosure open
Danger of explosion in hazardous areas as a result of hot components and/or charged capacitors inside the
device.
Isolate the device from power, before open the device in a hazardous area.
Exception Devices having the type of protection "Intrinsic safety Ex i" may also be opened in an energized
state in hazardous areas.
WARNING
Dust layers above 5 mm
Danger of explosion in hazardous areas. Device may overheat due to dust build up.
Remove any dust layers in excess of 5 mm.
The positioner requires almost no maintenance. Filters are fitted to the pneumatic connections to protect the
positioner against large particles of dirt. Dirt present in the input air can collect on the filter and then adversely
affect the operation of the positioner (increased travel time). In such a case, the filters can be cleaned as follows:
1.
2.
3.
4.
11
Switch off the auxiliary pneumatic energy and disconnect the hose lines.
Carefully remove the metal filters from the holes and clean them (e.g. with compressed air).
Insert the filters
Connect the hose lines again and turn on the auxiliary pneumatic power.
Technical Data
General data for the base device

Degree of protection
IP66 to EN60529
Climatic class in accordance with IEC 721

Storage
1K5 but -40 C + 80 C
1)
Transport
2K4 but -40 C + 80 C
1)
Operation
without purging air
3K3 but -30 C 3) + 80 C
2)
with purging air
4K3 but -30 C 3) + 80 C
2)
Shock resistance
10 g to 100 Hz
recommended continuous operating range of the entire
fitting 30 m/s2
Page 40 von 42
Applicable directives and standards see declaration of conformity

Any, although in wet environments the pneumatic connections
and exhaust opening must not face upwards
CE marking
Fitting orientation
Connections
electrical
Screw terminals 2,5 AWG28-12

Cable feed through M 20x1.5 or
(cable feed through 14 NPT on request)
pneumatic
Internal thread G 1/4 DIN 45141

(Internal thread 1/4 18 NPT on request)
1)
If commissioning at 0 C it is important that the valves are flushed for long enough with a dry medium.
See the electrical data for devices protected against explosion hazard.
3)
Reduced refresh rate in on the LCD display below -10 C.
Pneumatic data for the base device

Auxiliary power (air supply)
Medium
Instrument quality air meeting DIN ISO 8573-1, class 2
Pressure
1,4 7 bar
Electrical data for the base device

Type 827A.E
Type 827A.X
Ignition protection type according to EN 50014 and EN 50020
II2G Ex ia IIC T4/T6 Gb
Ambient temperature
- 30 + 80 C
T4
- 20 + 75 C
T6
- 20 + 50 C
Electrical connection
See Figure 5-1
Communication
H1 communication to specification of the Fieldbus Foundation, group 3, class 31

PS (Publisher/Subscriber)
1 resource block (RB2), 1 analog output function block (AO), 1 PID function block
(PID), 1 transducer block (standard advanced positioner valve)
Physical layer profile
123, 511
Block execution times
Analog output function block 60 ms; PID function block 80 ms
Power supply
Bus-powered
Bus-powered
Bus voltage
DC 9 ... 32 V
DC 9 ... 24 V
Current consumption
10.5 mA 10 %
10.5 mA 10 %
Fault current
For connection to
See Figure 5-4
circuits with certified FISCO power

supply with max.
Ui = 17,5 V
Ii = 380 mA
Pi = 5,32 W
circuits with certified barrier with max.
Ui = 17,5 V
Ii = 380 mA
Pi = 5,32 W
Internal capacitance
Negligible small
Internal inductance
8 H
Page 41 von 42
Type 827A.E
Type 827A.X
Input resistance
> 20 k
> 20 k
Signal status 0: active
DC 0 ... 4.5 V
DC 0 ... 4.5 V
Signal status 1: inactive
DC 13 ... 30 V
DC 13 ... 30 V
For connection to
certified intrinsically safe circuits with

max.
Ui = 30 V
Ii = 100 mA
Pi = 1 W
Internal capacitance
Negligible small
Internal inductance
Negligible small
Binary input BE1
Suitable for dry contact, max. contact load 5 A at 3 V
Electrical isolation
Bus connection and safety shutdown

electrically isolated, Bus connection and
BE1 electrically connected
Safety shutdown
Bus connection and safety shutdown

electrically isolated, Bus connection
and BE1 electrically connected
ARCA-REGLER GmbH
D-47913 Tnisvorst
Phone: +49-(0)2156/7709-0
Fax:
+49-(0)2156/7709-50...55
E-Mail sale@arca-valve.com
The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be
liable for damages. All rights created by the granting of patents or registration of a design are reserved. Technical data subject to change
without notice.
Page 42 von 42

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ARCAPRO 827A.

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Checking the consignment

Design of the nameplate

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

without binary outputs 1)

without analog - output

not explosion protected

Type 827A.X-A-- only II2G Ex ia IIC T4 Gb

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

General safety notes

Requirement for safe use

Explanation of the warning symbols on the device

Laws and directives

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Use in areas subject to explosion hazard

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Figure 3-1 Positioner fitted to a linear actuator

1 Positioner, double-acting in plastic housing

Positioner fitted to a quarter-turn actuator

Figure 3-3 Structure

for double-acting drives

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Actuating pressure Y1 in single-acting and double-acting actuators

Exhaust air outlet E with silencer on the bottom of the device

Figure 3-4 Pneumatic connections

Purging Air Switch

Pneumatic connection strip

Figure 3-5 Purging air switch on the valve block

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Safety position following failure of the auxiliary power

Figure 3-6 Pneumatic connection positioning effect

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

hexagon socket 2,5 mm

Figure 3-7 Restrictors

Safety notes for mounting

Mount the device using suitable tools.

Mechanical impact effect

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Mounting Linear Actuator

Mounting Kit for "Integrated Fitting Linear Actuator"

Driver pin cpl. with roller

B6.4 - DIN 125 - A2

Cylinder head bolt

Cylinder head bolt

Mounting procedure (see Figure 4-1)

Reference no.: 827A-FF-BA-09-13_gb

ARCA-Regler GmbH D - 47918 Tnisvorst

Reference no.: 827A-FF-BA-09-13_gb