Biffi IS2000
Biffi IS2000
Biffi IS2000
INDEX
CHAPTER 1 General Description and Accessories page 3 Storage and Pre-Installation page 7 Installation page 7 Setting of Accessories page 8 Maintenance page 13 Trouble-Shooting page 14 Recommended Spare Parts page 15
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
CHAPTER 7
IMPORTANT: this manual must be used together with the manual relevant to the actuator to which the IS 2000 is fitted.
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
BIFFC-0031-EN-9602
NOTES: BIFFI Italia has taken every care in collecting and verifying the documentation contained in this instruction and operating manual. Nevertheless Biffi Italia does not provide any guarantees for this instruction manual. BIFFI Italia will not be responsible for any mistakes contained in it or for any damage either accidental or due to the use of this manual. The information herein contained is reserved property of BIFFI Italia and is subject to being modified without notice.
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
BIFFC-0031-EN-9602
2 3 4 5 6 7A
10 6 8 7B 2 8 5 1 3 4
14 15
10 9 6 7
18
17
16 Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
BIFFC-0031-EN-9602
2 - General Description
The Integral Starter IS 2000 is a new concept and design starter unit used coupled with Base electric actuators. The reversing function is realised by two electrically and mechanically interlocked contactors. The logic and local control standard functions are realised using two separate printed circuit boards connected to each other. - pushbutton card (PBC): DE 1891 - multi-function card (MFC): DE 1890 Three main versions are foreseen: - three-phase - single-phase - direct current. Additional cards with optional functions can be added to the existing standard cards.
Green ON/Amber ON: the actuator is stopped in mid-travel position Red FLASHING: incorrect connection of phase in the 3-Ph systems when alarm mode is selected No LED illuminated: power failure. 3.2) REMOTE CONTROLS AND INDICATIONS 3.2.1) Remote controls Available by a 24 VDC or 115 VAC with external or internal power supply. They are active when the local selector is in REMOTE position: - Open, Close, Stop remote controls with 4 wires: three contacts will provide open, close and stop signals to the control with either latched or momentary action selected by link on the terminal board - Open, Close remote controls with 3 wires: two contacts will provide open and close signals with either latched or momentary action selected by link on the terminal board. 3.2.2) Remote indications 3.2.2.1) Monitor relay (Normally Open free-voltage contact ) The contact is open when one of the followings faults occurs: - loss of one phase - loss of power - local Stop activated - selector switch in Local or Off - motor thermostat tripped - alarm for incorrect connection of phases (for 3Ph systems). When remote controls are available, the contact makes a circuit. 3.2.2.2) Motor running indication Normally open (NO) free-voltage contact, which closes when one of the two contactors is energised.
BIFFC-0031-EN-9602
3.2.2.3) Local selector status Two independent, free voltage contacts, which indicate the status (Local/Remote) of the local selector. 3.3) EMERGENCY SHUT DOWN (ESD) In an emergency situation, the ESD external signal coming from the remote control overrides the thermostat and any other existing signal to drive the valve to its security position (open or closed) according to the preselected connection of the ESD contact on the terminal board. 3.4) AUTO-PHASE CORRECTION (FOR 3PH SYSTEMS ONLY) This feature controls the phase sense of rotation, available with two options selectable on a dip-switch mounted on the DE 1890 card. 3.4.1) Automatic phase rotation correction mode: correction of the motor rotation, independently of the field phase rotation, by automatically selecting the appropriate power contactor. 3.4.2) Alarm mode: block of the control circuit with alarm indications, locally through a red flashing LED, remotely through the monitor relay. 3.5) POWER FAIL DETECTION The loss of one phase to the motor power supply is detected: the control is stopped and a remote alarm is set. 3.6) MOTOR THERMOSTAT The temperature of the motor windings is detected: when the max acceptable temperature is reached the control is stopped and a remote alarm is set.
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
Antidisturb Filter
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BIFFC-0031-EN-9602
The timer allows the actuator to operate step-by-step in order to vary the stroking time on a large scale independently for both opening and closing operations. Function modes: three different modes can be selected through links on the main terminal board: - timer operation for both opening and closing directions - timer operation only for closing direction - timer operation only for opening direction. 4.3) TWO-WIRE CONTROL TWC (DE 2184 CARD) The two-wire function allows the actuator to be controlled by means of a single pair of wires and a remote contact located in the control room. Modes of operations are: energise to close/de-energise
to open or vice versa. The selection is carried out by means of a dip-switch on card DE 2184. 4.4) 4-POSITIONS LOCAL SELECTOR
4-Position Label The fourth position (Local-Remote) in addition to the standard functions (Local / Off / Remote) can be obtained by a link on the pushbutton card.
BIFFC-0031-EN-9602 Contents may change without notice.
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
2 - Storage Procedure
The IS 2000 unit is subject to the same procedures applicable to the actuator it is fitted to, already described in the relevant Instruction and operating manual.
CHAPTER 3 Installation
IMPORTANT: - be sure that the terminal board is positioned with the cable entries in the lowest position, to avoid any water infiltration through the line cables - if the connection is made by rigid conduits, we suggest to place a flexible pipe connection between the conduit and the terminal board. All the instructions of the actuator manual relevant to the installation are also valid for the IS 2000.
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
BIFFC-0031-EN-9602
INDEX
1) IS 2000/ESD: setting of ESD function and phase discrimination 2) IS 2000/RBS: calibration of the electronic cards 3) IS 2000/TMR and IS 2000/TWC: calibration of the electronic card 4) 4-position local selector
A B
may be selected by means of dip-switches: - stay-put of the actuator (standard) - the actuator reaches the open position (on request) - the actuator reaches the closing position (on request). The setting of the dip-switches is carried out in the factory. Setpoint signals 4-20 mA or 1-5 V-type may be accepted by means of a wire jump. The selection of the type of setpoint signal is carried out in the factory (4-20 mA standard, 1-5 V on request). A 4-20 mA type retransmission signal of the valve position is available for an external user. The maximum value of load resistance is 500 ohm. The RBS 2264 position controller/servodrive consists of two cards: - DE 2037 card: position servo amplifier - DE 2038 card: 4-20 mA position transmitter (resistive potentiometer) and dead band adjustment. Card DE 2038 must be calibrated on site by the user, while card DE 2037 is normally calibrated in the factory and no operation must be carried out by the final user.
DE 1890/1 Card
The proper dip-switch 1 can be selected in these two functions: - position A: automatic correction of phase-rotation - position B: block of the control circuit function with alarm indication: locally through a red flashing LED, remotely through the monitor relay.
ESD
2.1) OPERATING PRINCIPLE: The RBS 2264 position controller is only active when the local selector of the actuator is in the AUTOMATIC position. In this case, the POSITION SETPOINT (which comes from a process controller) is compared with the position value (POSITION FEEDBACK) of the actuator. If the difference between the two signals (POSITION ERROR) is higher than the value of the DEAD BAND, the close or open output line is activated: this energises the closing or opening contactor until the position error becomes lower than the dead band. One of the following actions - which are carried out by the actuator if there is no setpoint or feedback BIFFC-0031-EN-9602
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
2.2) INSTRUCTIONS FOR THE CALIBRATION OF CARDS DE 2038 AND DE 2996 (4-20 mA POSITION TRANSMITTER AND DEAD BAND ADJUSTMENT)
2.2.1) DE 2038 Card: calibration of the position signal of the actuator: - close the valve until the electric position limit switch trips
CN1
CN1
R2
Span
R3
Zero
R3
Zero
operation, check that the voltage value indicated by the multimeter rises without reaching the discontinuity zone of the potentiometer - calibrate trimmer R2 (span) until the voltage value indicated by the multimeter is 5V (position 100%, corresponding to the fully open valve position) - repeat the previous operations in automatic mode until the 1V and 5V values correspond to the open and close actuator positions. 2.2.2) DE 2996 Card: calibration of the position signal of the actuator: - connect a multimeter between test points E positive and A - move the valve at 50% of the stroke. Check the position on the mechanical indicator of the actuator - rotate the potentiometer shaft until the multimeter indicates 1.25V - connect the multimeter between test points C and A - open the valve until the electric position limit switch trips. Adjust trimmer R1 until the multimeter indicates 5V - close the valve. Adjust R3 until the multimeter indicates 1V - repeat the previous operations in automatic mode until the 1V and 5V values correspond to the open and close actuator position. 2.2.3) Calibration of the dead band signal: the dead band value of the position controller can be calibrated by means of trimmer R5. A clockwise rotation decreases the dead band and its value is available in volts between test points D and A. The dead band can be calibrated from a minimum of 0.8% full scale corresponding to about 0.15V, to a maximum of 9% full scale corresponding to about 3.2 V, and must be calibrated according to: - the speed of the actuator
BIFFC-0031-EN-9602
R5
Dead band
R5
Dead band
B A D
B A D R1
Span
The calibration is performed by means of four trimmers operating on the following values: - zero/span of the internal feedback - dead band - max value of the output (20mA).
CN1 Connector
4 3 2 1
- disconnect plug CN1 - rotate the shaft of the resistive type potentiometer (position transducer) until its resistive value (measured between pins 2 and 3 of the CN1 connector) is at a minimum, without entering the discontinuity zone of the potentiometer. The suggested value is between 20 and 50 ohm - reconnect plug CN1 - calibrate trimmer R3 (zero) until the multimeter connected between test points C and A indicates 1V (position 0%, corresponding to the fully closed valve position) - open the actuator until the opening electric limit switch trips. During the opening
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
- the necessary positioning accuracy - the allowable number of cycles per hour. 2.2.4) Calibration of the end travel indication lamps signaling: after completing the calibration explained at points 2.2.1), 2.2.2) and 2.2.3) check that the indication lamps at both end travel positions are on. If they are flashing, proceed as follows: Step A) A.1. connect a 4-20 mA (or 1- 5V) signal generator to terminals 43 and 44 of the actuator A.2. connect a multimeter between test points C and A of DE 2038 card A.3. switch the local selector to Automatic operation A.4. set the signal generator to 4 mA (or 1V) A.5. when the actuator is in fully closed position, check the closing lamp: - if it is on, go to the step B - if it flashes, decrease the value measured by the multimeter of 20 mV, by means of trimmer R3 A.6. set the signal generator to 12 mA (or 3V): the actuator must open A.7. restart from point A.4. Step B) B.1. set the signal generator to 20 mA (or 5V) B.2. when the actuator is in fully open position, check the opening lamp: - if it is on, go to step C - if it flashes, increase the value measured by the multimeter of 20 mV, by means of: trimmer R2 for DE 2038 card trimmer R1 for DE 2996 card B.3. set the signal generator to 12 mA (or 3V): the actuator must close. B.4. Restart from point B.1.
Step C) C.1. repeat step A and step B until the open and closed lamps are on, when the actuator reaches the end travel positions. 2.2.5) Test of the retransmission signal of the 4-20 mA valve position: - open the valve until it automatically stops - connect a multimeter between test points C and A: the measured value should be 5V - connect a milliammeter between test points B and A - the indication of the milliammeter will be 20 mA (max load resistance = 500 ohm). 2.3) INSTRUCTIONS FOR THE CALIBRATION OF CARD DE 2037/1 (position servo amplifier) These operations are normally carried out in the factory.
2.3.1) Selection of the type of position setpoint: - if the set is a 4-20 mA type, the JP1 jumper must be plugged in - if the set is a 1-5V type, the JP1 jumper must be removed.
J1
T3 T2 T1
JP1
U1 U2
DE 2037/1 Card
10
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BIFFC-0031-EN-9602
2.3.2) Selection of the type of action carried out by the actuator if there is no set point or feedback: - stay-put: dip-switches S5, S6, S7 and S8 in the OFF position - opening: dip-switches S5 and S7 in the OFF position; S6 and S8 in the ON position - closing: dip-switches S5 and S7 in the ON position; S6 and S8 in the OFF position.
2.3.3) Calibration of position error: - place dip-switches S1 and S3 in ON; S2 and S4 in OFF position - send a 12 mA (or 3 V) position set according to the type of programming carried out in step 1) - calibrate trimmer T1 until a multimeter connected between pin 14 of the U1 integrated circuit and pin 4 of the J1 connector indicates 0V - set dip-switches S1 and S4 in ON; S2 and S3 in OFF position. 2.3.4) Balancing the dead band signal - rotate trimmer R5 on card DE 2038 to the minimum value - measure the voltage value between pin 1 of U2 and 4 of J1 (on card DE 2037/1) - calibrate trimmer T3 (on card DE 2037/1) until the value between pin 7 of U2 and 4 of J 1 is equal to the value previously read, but negative - rotate trimmer R5 on card DE 2038 until the dead band is 2.5 V - measure the voltage value between pin 1 of U2 and 4 of J1 (on card DE 2037/1) - calibrate trimmer T2 (on card DE 2037/1) until the value between pin 7 of U2 and 4 of J1 is equal to the value previously read, but negative - repeat the previous operations as the calibrations of the two trimmers T2 and T3 influence each other.
DE 2037/1 Card
J1
7 4 3
6 2
5 1
8 9 10 11 12 13 14 8 9 10 11 12 13
7
5
U2
6 4
1
7
6 5 4 3 1 2
14 U1
DE 2037/1 Card
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BIFFC-0031-EN-9602
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A B
SWIR
JP1
JP2
Trimmers
{
DE 2184 Card The closing contact of an auxiliary electric switch of the actuator is used to start the timer mode during the opening or closing operation of the actuator. If timer operation is required in both directions (opening and closing), two auxiliary switches (one for each direction) are needed to start the timer mode. The timer function remains active until the position limit switch is operated. If the actuator moves in the opposite direction the function is reset and can only be restarted by the corresponding auxiliary switch.
3.1.2)Setting and calibration Four terminals are available on the actuator terminal board to enable timer operations of the actuator by means of links. These links are generally made in-house according to the customers specifications. You can anyway change in field the original configuration by means of the following information: - link 51- 60 to activate timer in closing direction - link 2-47 to activate timer in opening direction. Terminal board connections:
2 43 47
51 5 60
Timer in Opening
Timer in Closing
The timer and two-wire functions are both performed by electronic card DE 2184. The selection of one function or the other is possible by means of jumpers JP1 and JP2 (see figure): - both JP1 and JP2 plugged-in: timer function activated - both JP1 and JP2 removed: two-wire function activated. 3.1) IS 2000/TMR 3.1.1) Operating principle The timer function allows changing the actuator strokingtime. When the function is active the electric motor is driven by pulses; the ON and OFF duration can be adjusted by means of 4 trimmers, independently for both opening and closing directions.
2 43 47
51 5 60
The timer is active all along the stroke. If the timer has to be activated from a certain point until the end of the stroke, auxiliary switches operated by sector cams must be foreseen (for closing or opening directions, or for both). During the timer period the cam will maintain the relevant auxiliary switch tripped.
Contents may change without notice.
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BIFFC-0031-EN-9602
To recognise the position of the selector for the Local-Remote function, proceed as follows:
7 35 36
Off - Opening
54
62
Terminal Board Remote Control Room
On - Closing
The calibration of the On/Off cycle (contactor energised/deenergised) can be adjusted independently for both opening and closing directions within the following ranges, by means of four trimmers mounted on card DE 2184: - ON: from 1 to 10 seconds - OFF: from 10 to 100 seconds. The adjustment range of trimmers from 0 to 10 is clearly marked on their housing. An arrow on the rotor trimmer indicates the slider position. The value of the ON or OFF time is increased by a clockwise rotation of the trimmer.
3.2.2) Selection of the operational mode Dip-switch SWIR, located on the card, allows the selection of one of the following two possibilities (see previous figure): - position A: the remote open contact opens the actuator - position B: the remote closed contact closes the actuator.
3-Position Label
- rotate the selector switch to the OFF position keeping the Remote indication on the left.
16 17
1 12 13 25
3.2) IS 2000/TWC
3.2.1)Operating principle The two-wire function allows the actuator to be controlled by means of a single pair of wires and a remote contact located inthe control room. Modes of operations are: energise to close/de-energise to open or viceversa. Disconnect the link 35-36 (if existing). Link terminals 36-54. The drawing below shows the diagram of an actuator controlled by two wires.
4-Position Label
This accessory is generally supplied in phase of order and the proper label is fitted in the factory. If this feature has to be added on field, after making the necessary links on the internal pushbutton card between pins 16 and 17 of the Molex connector, it is necessary to modify the selector label as is shown below.
- mark this new position on the label as Local-Remote by means of a permanent marker.
CHAPTER 5 Maintenance
All the instructions of the actuator manual relevant to the maintenance are also valid for the IS 2000.
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BIFFC-0031-EN-9602
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- the presence of the position retransmission signal, by connecting a milliammeter between terminals 19 and 20 (by disconnecting all eventually connected wires). In lack of this signal verify the correct operation of the position transmitter placed on the control group and/or the correct working of the 4-20 mA card (DE 2038), which is also placed on the control group - that the driven valve closes in clockwise direction and the setpoint signal is 4-20 mA with 4 mA at closed valve.
Contents may change without notice.
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Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
2.4) For IS 2000/TMR or IS 2000/TWC verify: - the correct voltage at terminals 62 and 44 - the three secondary control fuses. If the above is correct, there is a fault in card DE 2184.
replace them if necessary. Always check the cause of this malfunction. 3.2) If one or both position LEDs are on, verify: - the surface temperature of the motor: if it is very hot wait until the motor cools down to enable the automatic reset of the thermal switch or of other thermal relays which may be present in the power supply circuit - the three secondary control fuses: replace them if necessary. Always check the cause of this malfunction.
3.3) For IS 2000/RBS verify that the selector switch is in manual mode. 3.4) At completely open or closed valve position the LED keeps on blinking. Check the valve position settings values and re-set them a described in this manual.
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BIFFC-0031-EN-9602
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BIFFI ITALIA s.r.l. - Loc. Caselle S. Pietro - 29017 Fiorenzuola dArda - Piacenza - ITALY - Tel. (0523) 944411 - Fax (0523) 941885 - Telex 530107 - 531447
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
BIFFC-0031-EN-9602
A.C./Grafiche Malvezzi/2.000/05.96
E-IM/IS-E Rev. 2