MAN-652-OM1. 3 Oct 07 Revision G.R. G.A. 2 Jun 06 Revision A.G. G.A. 1 Feb 06 Revision A.G. G.A. Rev. Date DESCRIPTION Prepared Approved

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1 MAN-652-OM1 3 Oct 07 Revision G.R. G.A. 2 Jun 06 Revision A.G. G.A. 1 Feb 06 Revision A.G. G.A. 0 Sept 2005 First Issue A.G. G.A. Rev. Date DESCRIPTION Prepared Approved Note: Biffi Italia has taken every care in collecting and verifying the documentation contained in this Instruction and Operating Manual. The information herein contained is reserved property of Biffi Italia. 1

2 F02 OM1: I/O ADDITIONAL MODULE INDEX 1. OPTIONAL MODULE 1: I/O ADDITIONAL MODULE MANUFACTURER OM1 CARD FUNCTIONALITY INSTALLATION OM1 CARD SETTING AND CONFIGURATION LOCAL SETTING OF THE OM MONITOR RELAY FUNCTIONALITY AND SETTING OM1 KITS OM1 WIRING DIAGRAM

3 1. OPTIONAL MODULE 1: I/O ADDITIONAL MODULE 1.1 MANUFACTURER Manufacturer with respect to Machinery Directive 98/37: BIFFI ITALIA as specified on the motor label. 1.2 OM1 CARD FUNCTIONALITY The OM1 I/O additional module card is supplied as an option on Biffi F02 actuators. It is possible to have the actuator already equipped with the OM1, ordering it with the basic feature. Alternatively, it is possible to order the OM1 as a separate kit and install it on the basic actuator in the factory or in the field. The OM1 is an optional module suitable to accomplish the following F02 actuator additional functionalities: Positioner with analogue position input 4-20mA or 0-10Vdc Analogue output position transmitter 4-20mA or 0-10Vdc Monitor relay remote signalization for loss of power, torque alarm, high temperature alarm, travel alarm Motor running remote signalization The OM1 module contains 4 additional SPST output contacts to be set independently at 10 points along the stroke. Contacts are configurable (make or brake). Warning: F02 actuator must be electrically isolated before any disassembling or reassembling operation. Before any disassembling or reassembling operation, please follow in detail the relevant paragraph of the basic instruction and operating manual MAN 652 (latest revision available). Warning: The electronic parts of F02 actuators and all the options can be damaged by a discharge of static electricity. Before you start, touch a grounded metal surface to discharge any static electricity. Warning: It is assumed that the installation, setting, commissioning, maintenance and repair works are carried out by qualified personnel and checked by responsible Specialists. Warning: Repair work, other than operations outlined in this manual, is strictly reserved to qualified BIFFI ITALIA personnel or authorized by the Company itself. 3

4 2. INSTALLATION To assemble the OM1 into the F02 actuator, proceed as follows: Ensure that all the parts received with the OM1 are available (OM1 installation kit as shown in figs 1 and 2). Fig.1: OM1 kit for F02 models 63 and 125 Fig.2: OM1 kit for F02 models 250, 500, 1000 and 2000 Gather the right tools for the assembly and for setting the actuator controls; With an Allen wrench unscrew the cover screws (Fig. 3): Fig. 3 Remove the actuator cover (Fig.4): Fig. 4 4

5 Take all the 4 black cables (already included in the basic actuator) (Fig. 5) Remove the local mechanical indicator: Fig. 5 Fig. 6 Connect the flat cable furnished with the OM1 from connector J9 on the OM1 card to connector J8 on the logic card in the basic actuator (figures 7 and 8); Connector J9 Connector J8 Fig. 7 Fig. 8 Connect the 8-pins connector to connector J3 on the OM1 card (figure 9); 8-pin connector Fig. 9 Connect the 4-pin white connector to connector J2 on the OM1 card (figure 10). 5

6 4-pin connector Fig. 10 Connect the 2-pins connector to connector J7 on the OM1 card (figure 11). 2-pin connector Fig. 11 Connect the 3-pins connector to connector J6 on the OM1 card (figure 12); 3-pin connector Fig. 12 Mount the three metal spacers (only for F02 models 63 and 125). Place the OM1 card onto the F02 supports: Fig. 13 6

7 Tighten the four screws shown in the pictures below to fix the OM1 card to the logic card: Fig. 14 Fig. 15 Fig. 16 Fig. 17 Important: Please note that all the connectors provided with the base actuator and all optional cards are different from each other (in terms of design and number of pins). In no way is it possible to make a wrong connection. The OM1 card is now connected. Re-install the local mechanical indicator (figure 18). Fig. 18 Replace the actuator cover and fix it properly. 3. OM1 CARD SETTING and CONFIGURATION For the F02 basic actuator settings, please refer to the basic Instruction Handbook MAN 652. The OM1 optional card can be set once the basic F02 has been completely set. The OM1 configuration can be carried out through the control panel on the optional card itself. In order to get access to the panel, remove the actuator cover and when the setting is completed replace the cover properly. (Please follow instructions in MAN 652.) Warning: Do not electrically operate the F02 when the electrical enclosures are removed. Operating the unit with the electrical enclosures removed could cause personal injury. 3.1 LOCAL SETTING OF THE OM OM1 Card Default General Setting 7

8 Please refer to the last column on table 1 below OM1 Card Setting If the application requires a different actuator setting than by default, please proceed as described in this chapter. Important: Please note that the OM1 module setting does not require to be done in succession as indicated in the following pages. Each parameter can be set independently. The setting of the actuator parameters is made through the following tools: - three selector switches SW8, SW7 and SW9 for functionalities settings; - input and output voltage/current selection (through switches SW1, SW6, SW3 and SW5); - monitor relay contact type (through the welding pin J1); - ENTER pushbutton SW2 (confirmation pushbutton); - dip switch SW4 (enable configuration mode); - red led for ENTER action confirmation (switch on when setting is confirmed). SW2 Red LED SW8 SW7 SW9 SW4 Fig Enter set up configuration: move SW4 switch to position ON (configuration mode) 8

9 2. Set the requested parameters and functionalities accordingly to the following table: Table 1: OM1 setting table FUNCTION SW8 SW7 SW9 SW2 ENTER Default Values Pushbutton Relay AUX1 0 0 to 9 - push 0% Relay AUX2 1 0 to 9 - push 25% Relay AUX3 2 0 to 9 - push 75% Relay AUX4 3 0 to 9 - push 100% Set 0% push 4 ma Set 100% push 20 ma Request position failure 5 0 (stay-put) 1 (fully open) 2 (fully closed) - push Stay-put Dead band 6 0 to 9 - push 0.5% Relays AUX1-7 0 = brake - AUX3 1 = make push Brake Relays AUX2-8 0 = brake - AUX4 1 = make push Make Blinker Local selector (OM3) 9 0 = OFF 1 = Blinker 2 = Local interface (OM3) selector in local 0 push OFF Retransmission (direct or reverse) 9 0 = dir. 1 = rev. Set direct/reverse 9 0 = dir. 1 = rev. Position control 9 0 = OFF 1 = ON 1 push Direct 2 push Direct 3 push OFF 3. Confirm each setting by pushing ENTER pushbutton SW2. 4. When pushing SW5, the red led switches on for confirmation 5. Exit configuration mode (move SW4 from position ON). 6. Testing previously set functions: in order to check how the various functions are set, proceed as follows: a. Move SW4 to position 1/OFF b. Move SW8 to the position relevant to the function to be checked c. Push SW2 (Enter) button d. Move SW7 around until the red LED goes on: the red LED indicates the previous setting ma / 0-10 Vdc Input and Output Setting Input 4-20mA Impedance = 250 Ohm Input 0-10Vdc Impedance = 200 kohm Output 4-20mA Impedance = 250 Ohm Output 0-10Vdc Impedance = 2 k Ohm 9

10 SW2 Table 2: 4-20 ma /0-10 Vdc Input & Output Setting* FUNCTION SW8 SW7 SW9 SW2 SW3/1 SW3/2 SW5 SW6 SW1/1 SW1/2 SW1/3 SW1/4 Retransmission push OFF ON OFF OFF ON current Retransmission push ON OFF ON ON OFF tension Set 4-20mA 9 0=Off 4 push OFF ON ON 1=On Set 0-10Vdc 9 0=Off 1=On 5 push ON OFF OFF * see Figs Default values are set in-house as follows: Retransmission 4-20 ma: Current Position request (set): 4-20 ma SW5 Red LED SW3 SW8 SW7 SW9 SW4 Fig

11 SW1 SW6 Fig Relays Aux1, Aux2, Aux3 and Aux4 Please find here below the tables reporting the settings of each relays Aux1, Aux2, Aux3 and Aux4 - Relay AUX1 Setting: Relay 3 SW8 SW7 Set action 0 0 Inactive 0 1 0% % % % % % % % % - Relay Aux3 Setting: Relay 5 SW8 SW7 Set action 2 0 Inactive 2 1 0% % % % % % % % % - Relay AUX2 Setting: Relay 4 SW8 SW7 Set action 1 0 Inactive 1 1 0% % % % % % % % % - Relay Aux4 Setting: Relay 5 SW8 SW7 Set action 3 0 Inactive 3 1 0% % % % % % % % % 11

12 Dead band settings Please find here below the table with the setting of the Dead band: Dead band SW8 SW7 Set action Additional Bluetooth TM Optional Card It is possible to receive the Bluetooth TM Card as option, to be added to the OM1 card. Pin J1 Fig. 22 and 23: Additional Bluetooth TM Optional Card After installing the Bluetooth TM Card it is necessary to turn off then on the actuator in order to restore the settings. For any further information please refer to MAN 652 OM4 Non intrusive configuration tool Instruction and Operating Manual. 12

13 4. MONITOR RELAY FUNCTIONALITY AND SETTING The monitor relay indicates the following failures: Table 2: Monitor relay functionality 1 Missing input 4-20mA 2 Stop by torque out of the limits 3 Directions 4 Temperature too high 5 Position sensor 6 Local control panel with selector in local position 7 Valve jammed 8 Hardware malfunction 9 Alarm on the local control panel (if present) 10 Stroke 11 Bluetooth TM failure (if present) The monitor relay contacts can be set as closed or open by changing the welding of pin J1. As a default setting, pins 2 and 3 are welded together, and the monitor relay contact operates as follows: - contact closed in normal condition with relay energized, and open in case of malfunction (relay is de-energized). In case of request, if contact must be open in normal condition and closed in case of malfunction, the contacts of Pin J1 must be modified by welding Pins 1 and 2 together. 13

14 5. OM1 KITS The OM1 option kit consists of the following parts: - OM1 modulating input/output module - 3pcs metal spacers - 4pcs screws - 1pc flat cable with connectors There are two versions available. One is specifically for F02 models 63 and 125. The other for F02 models 250, 500, 1000 an Both kits are indicated in figures 1 and 2. 14

15 6. OM1 WIRING DIAGRAM 15

16 Biffi Italia s.r.l. Headquarters, Sales department: Fiorenzuola d'arda Italy Tel fax Website: 16