epac Operation & Spare Parts Manual VERSION: V1.XMP PANEL MOUNTABLE INDEX: I INDEX 1 II INTRODUCTION 2 III ACTUATOR ELECTRONICS 3 BASIC OPERATION OF ACTUATOR ELECTRONICS 4 IV DIGITAL POSITION INDICATOR 7 BASIC OPERATION OF DPI 8 V TROUBLESHOOTING 9 VI SPARE PARTS 11 VII NAME PLATE DETAILS 12 1 INTRODUCTION: Panel mountable modules are designed with the EPAC control (Actuator Electronics) and a Digital Position Indicator for the % indication of valve position, suited to be enclosed with the IP64enclosures which is as shown below; Fig. A: 1.XMP Panel Mountable Module Fig. B: Module within the Enclosure EPAC DPI ABBREVIATIONS: DPI: DIGITAL POSITION IDENTIFIER EPAC: ELECTRONICALLY PROGRAMMABLE ACTUATOR CONTROLLER (ACTUATOR ELECTRONICS) 2 ACTUATOR ELECTRONICS (EPAC): DIP Switch Fig. C: Display Board SYMBOL TYPE DESCRIPTION * Actuator in OPEN direction Torque Switch OPEN * Actuator in CLOSE direction Torque Switch CLOSE Limit Switch OPEN tripped Thermo Switch TRIP Limit Switch CLOSE tripped Actuator in LOCAL mode Common Fault Indication Actuator in REMOTE mode Single Phasing Indication 12V Internal supply 24VDC for Customer’s use available 5V Internal supply FAULT DESCRIPTION TYPE STATUS SYMBOL TOLR TRIP STATUS * Green LED ON (Steady State) – Indicates that the END position is hit by the respective LIMIT Switch * Green LED Blinking ‐ Indicates that the Actuator is running in the respective direction 3 Basic Operation of Actuator Electronics (1.XMP Control Module): 1. Power supply connection is to be made as per the wiring diagram 2. After the power is put ON, check if a. 5V Green LED is ON b. 12V Green LED is ON c. 24V Green LED is ON Now the Actuator is ready for Operation; use the WD to operate it in Local/Remote mode Fig. E: WD‐User end connection for Local & remote operation 3. Set the Selector Switch to Local Mode, the “LOCAL” Green LED will be ON in Display Board indicating that the actuator is ready for local operation 4. Use Open or Close wires to make it run in the respective direction and observe the respective direction Green LED Blinking on the front panel. When the respective end position is reached (Limit Switch is hit) the LED will glow continuously. And also the LED of the respective end position will glow. For OPEN position it is LSO LED and for CLOSE position it is LSC LED 5. In case of a Fault the “FAULT“(RED) LED will glow in the front panel along with the “type of fault” indicator LED. For example if one Mains phase is absent then “SIN‐PH” (RED) LED will glow along with “FAULT” LED. 6. Note: In the case of fault the INFO A will be available and the checking can be done as per the wiring diagram and INFO B will be available as per the requirement for which the wiring diagram is to be referred 7. Now set the EPAC to remote mode, “REMOTE” Green LED will glow in the Display Board indicating that the actuator is ready for remote operation Note: As per the wiring diagram the remote command can be given to the respective terminals and checked for its operation similarly to local mode 4 8. In case when the selector switch is not present, the local/remote mode selection can be done from remote by giving signal at the terminals as per the wiring diagram 9. The DIP switch selection is as follows (Refer Fig. F) Fig. F: DIP switch on the Display Board a. POSITION 1: Setting of the switch towards the left activates the LOCAL inching (INCH‐L) mode. This selection entails operation of the actuator till the push button is kept in pressed condition. Setting of the switch towards the right activates the NON Inching (NON‐IN) mode. Actuator runs continuously till end position as is set, in absence of any fault or tripping of torque switch. b. POSITION 2 & 3: ESD (Emergency Shut Down) Operation ‐ Setting of the switch towards right, enables the ESD feature and towards left, disables the ESD feature Selection of ESD‐OP commands the DIP Switch 2 DIP Switch 3 Function Selected OFF OFF ESD disabled on the depression of emergency switch. ON OFF OPEN Similarly selection of ESD‐CL commands the OFF ON CLOSE ON ON STAY actuator to run in OPEN, till it is fully opened actuator to run in CLOSE, till it is fully closed on the depression of emergency switch. Unselecting of ESD‐OP & ESD‐CL makes the actuator to STOP at its current position on the depression of emergency switch c. POSITION 4: LSO BYPASS (LSO‐BY) – Setting of LSO‐BY, bypasses the feature of tripping by LIMIT switch OPEN. The actuator will trip only by the torque switch OPEN. Enabling this feature, FAULT signal will not be displayed. With the opposite command that is CLOSE given, the CLOSE LIMIT Switch (LSC) is bypassed for the first 3 Seconds. 5 d. POSITION 5 & 6: Inhibit operation: Selecting the Inhibit OPEN (INH‐OP), DIP Switch 5 DIP Switch 6 Function Selected OFF OFF Inhibit disabled command given by remote mode. ON OFF Inhibit OPEN Similarly selecting the Inhibit CLOSE OFF ON Inhibit CLOSE the actuator will not accept the OPEN (INH‐CL), the actuator will not accept the CLOSE command given by remote ON ON Inhibit disabled mode. e.POSITION 7: Selection of REMOTE mode inching (INCH‐R) is done by sliding the switch towards the left. This selection entails the operation of the REMOTE push button till the push button is kept in pressed condition. Similarly selection of REMOTE mode non inching (NON‐IN) is done by sliding the switch towards the right. Actuator runs continuously till end position as is set, in absence of any fault or tripping of torque switch. f. POSITION 8: LSC Bypass – Setting of LSC‐BY, bypasses the feature of tripping by LIMIT switch CLOSE. The actuator will trip only by the torque switch CLOSE. Enabling this feature, FAULT signal will not be displayed. With opposite command that is OPEN given, the OPEN LIMIT Switch (LSO) is bypassed for the first 3 Seconds. 6 DIGITAL POSITION INDICATOR The panel Mountable Digital Position Indicator (DPI) is a stand alone unit which gives the Valve position in percentage. Fig. G: DPI (Front view) Power Supply : 220V AC. In Put : 4‐20mA from RWG mounted in the Norm Actuator. Relay Out Put : R1 to R4 potential free contact for different Valve Position (Acts as intermediate limit switch). Display : 4 Numbers of seven segment LED’s which displays the valve position. Push Buttons : 4 numbers to set the four individual intermediate position of the valve. Dot LED : 1 LED to indicate if the 4‐20mA signal wire is open. ADJ : There are four potentiometers available to adjust the set value at which the respective relay is to be operated. 7 Basic Operation of DPI (Digital Position indicator): 1. Connect RWG 2002 as shown in the WD (No: 17883R1) with a potentiometer of 5 Kilo‐ ohms connected to it. Ensure that when the potentiometer is in one of the end position (end of anti clock wise motion) the RWG produces 4mA and in the other end position (end of clock wise motion) it produces 20mA (this calibration is to be done before connecting it to the circuit). 2. The DPI indication should come ON with some random value depending on the output from the RWG which could be any value between 0 to 100%. If the indication shows negative and I/P OPEN LED is ON this means that the polarity of RWG is to be reversed (terminal connection 9 and 10 is to be reversed). 3. ADJ position setting: The four relays are set to the default values of indication such as 20%, 40%, 60% & 80%, by adjusting the potentiometers either in clockwise (increment) or anticlockwise (decrement) directions. The relay continuity can be checked on terminals 37 to 48 respectively. The relays can also be set as per the user’s choice. 4. When 4mA is fed from RWG the DPI should indicate 00.0% (+/‐ 1) and when 20mA is fed then DPI should indicate 100.0% (+/‐ 1). Procedure to calibrate Digital Position Indicator 1. Adjust Pot P20 (1K) to get 1 volt at pin 44 of U5 (7107). 2. Now feed 4mA at the input and adjust Pot P2 (20K) to get zero at pin 7 of U1 or the display to read zero. 3. Now feed 20mA at the input and adjust Pot P1 (5K) such that the display reads 100.0%. 8 Troubleshooting: A. Actuator Electronics (1.XMP Control Module) Troubleshooting: To identify the problems, check status displayed by the LEDs on the Display Board 1. If power supply indications are not ON (i.e. if any of the 5V Green LED, 12V Green LED or 24V Green LED is not ON): Check the fuses. If fuses are blown, before changing the fuse, check for the SHORT (after the fuse) using a multimeter by disconnecting the MAINS. If there is no dead short, then replace the fuses (FS1 & FS2) and switch on the MAINS. 2. With 5V LED, 12V LED and 24V LED being ON, if FAULT LED is glowing (ON) then check the following: • “SIN‐PH” LED is ON: o Check the fuse in R (FS1) & B (FS2) phases, whether it is blown. o Ensure the MAINS frequency of operation is as mentioned on the name plate. • “TH‐S” LED is ON: Check the motor thermo switch continuity. • “TOLR” LED is ON: In this case check if the Thermal Over load relay provided along with the contactor is tripped. Reset the TOLR by pressing the RESET switch provided on the TOLR (refer Fig. H). RESET Switch Fig. H: TOLR • “TSO” or “TSC” LED is ON: indicates the tripping of torque in the respective direction. Correct the same by setting the LIMIT switch correctly. For doing this release the valve manually by using the declutch lever available on the actuator and the hand wheel. • “FAULT” LED (alone) is ON: indicates that there is no supply going to space heater / contactor. Check the fuses FS3 & FS4 (1 A fuse). 3. In case of 24V LED off: it represents the failure of the CPU card. Replace the CPU card (K215.213). 4. In case of FAULT LED on & 24V LED off: it represents the failure of the PS card, due to permanent short at the customer end. Before replacing the PS card (K215.214) kindly ensure that there is no short (terminals: +, ‐) at the customer end. 9 5. In case of Remote‐local mode selection option from REMOTE is not happening (optional feature): check for the wiring at the customer end according to the WD. 6. In case of actuator running inadvertently either in OPEN or CLOSE direction check if ESD is activated (wiring mistake) using the WD provided. 7. In case the actuator is not taking command in any particular direction check if INHIBIT feature is enabled (wiring mistake) using the WD provided. 8. During the motor replacement, after changing the MOTOR if the actuator is running in reverse direction for the respective command inputs (Actuator runs in open direction for close command and vice versa): Interchange any 2 wires of the motor. 9. In case the motor is not responding to the OPEN & CLOSE command and OPEN/CLOSE LED is blinking: Check the requisite voltages (110/230V) at the contactor terminals (K, K1 & K, K2 –refer Fig.I). • If the voltages are proper it could be the failure of the contactor; replace the contactor. • If the voltages are not proper, it means relay failure on the PS card; replace the PS card (K215.214). K K K1 K2 Fig. I: CONTACTOR B. DPI Module Troubleshooting: 1. If the negative reading and the “I/P OPEN” LED is ON then the 4‐20mA signal could be disconnected that is wire could be Cut. 2. If the display does not change with the change in 4‐20mA value then replace the front card of the DPI and check. 3. If the relays are not functioning and the respective LED’s are coming ON correctly then replace the DPI bottom card and check. 4. If no display is coming at all then the fuse F4 could have blown replace with a new one and check. 10 Spare Parts: 1.XMP_PANEL CONTROL MODULE SPARE PART DESCRIPTION ARTICLE NO 1.XMP_PANEL DPI MODULE REMARKS 1.XMP_PANEL CONTROL MODULE K215.863 CONTROL MODULE WITH RIGHT ANGLE CONNECTORS 1.XMP_PANEL DPI MODULE K214.891 MODULE FOR POSITION INDICATION Note: For additional details on 1.XMP control module refer to the Manual “EPAC Operation & Spare Parts Manual: Version 1.XMP” 11 EPAC nameplate: Identify the location of the epac name plate on the module which is as shown in the Fig. J EPAC name plate Fig. J: 1.XMP‐PANEL MOUNTABLE EPAC The following relevant details are available on the name plate to ensure our support after supply Fig. K: NAME PLATE Please furnish the above details of the name plate while ordering spare parts/after sales support. Regd. Office & Works: 38A & 39‐B, II Phase, Peenya Industrial Area Bangalore – 560058 Ph: 080‐30412222/28394656 Fax: 080‐28392809 Email: [email protected] Noida Branch: 1310,Tower ‘A’, Corenthum Complex Sector ‐62, Noida ‐201309 Ph: 0120‐3060522 – 26 Fax: 0120‐3060523 Email: [email protected] Kolkatta Branch: Pune Branch: Ph: 09883029170 712,713, Bldg.No. 1, Email: [email protected] “Siddharth towers”, Kothrud, Pune ‐ 411038 Ph: 020‐25410465 Chennai Branch: Fax: 020‐25443186 Ph: 09884119795 Email: [email protected] Email: [email protected] DD/MN‐014 ISSUE 04/2014 12