ARCA 824 series Operating Manual

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1 General data........................................................................................................................... 5 1.1 Validity of the manual.............................................................................................................. 5 1.2 Contact details......................................................................................................................... 5 1.3 Other applicable documents.................................................................................................... 5 1.4 Place of storage of the manual................................................................................................ 5 2 Safety...................................................................................................................................... 6 2.1 Introduction.............................................................................................................................. 6 2.2 General safety information ...................................................................................................... 6 2.3 Explanation of symbols and notices........................................................................................ 6 2.4 Warning symbols on the device .............................................................................................. 7 2.5 Intended use............................................................................................................................ 7 2.6 Improper modifications to the device....................................................................................... 8 2.7 Qualified Personnel................................................................................................................. 8 2.8 Laws and regulations .............................................................................................................. 8 2.9 Liability disclaimer ................................................................................................................... 8 2.10 Conformity to European directives .......................................................................................... 8 3 Transport, storage and packaging .................................................................................... 10 3.1 Transport............................................................................................................................... 10 3.2 Storage.................................................................................................................................. 10 3.3 Packaging.............................................................................................................................. 10 4 Nameplate ............................................................................................................................ 11 5 Type key............................................................................................................................... 12 6 Exploded view ..................................................................................................................... 14 7 Parts list ............................................................................................................................... 15 7.1 Positioner .............................................................................................................................. 15 8 Description........................................................................................................................... 17 8.1 Function and structure........................................................................................................... 17 8.1.1 Cam plate.............................................................................................................................. 18 9 Installation ........................................................................................................................... 19 9.1 Safety instructions for assembly............................................................................................ 19 9.2 Mounting a linear actuator..................................................................................................... 20 9.2.1 Installation according to DIN/IEC 534 T6 (NAMUR).............................................................. 20 9.2.2 Integrated mounting on actuators series 812........................................................................ 22 9.2.3 Integrated mounting on actuators series 813........................................................................ 24 9.3 Installation of the swivel actuator .......................................................................................... 28 9.3.1 Installation according to VDI/VDE 3845 ................................................................................ 28 9.3.2 ARCA mounting on swivel actuator series 840 (external piping) .......................................... 29 9.3.3 Integrated mounting on actuators series 840........................................................................ 29 ARCA Regler GmbH Table of contents Series 824 3 / 46 09.2018 / 1.0

11.1 I/P transducer........................................................................................................................ 32 11.2 Limit value transmitter .......................................................................................................... 32 11.2.1 Normal version (2-wire, N) .................................................................................................... 32 11.2.2 Safe design (2-wire, SN) ....................................................................................................... 32 11.2.3 Direct switching version (3-wire, E2)..................................................................................... 33 11.3 Position feedback.................................................................................................................. 33 11.3.1 Feedback potentiometer........................................................................................................ 33 11.3.2 Position transducer 3-wire..................................................................................................... 33 11.3.3 Position transducer 2-wire..................................................................................................... 33 12 Configuration....................................................................................................................... 34 12.1 Normal / Inversion ................................................................................................................. 34 12.1.1 Changeover switch................................................................................................................ 34 12.1.2 Select cam plate.................................................................................................................... 35 13 Commissioning ................................................................................................................... 36 13.1 Adjustment of zero point and stroke/angle of rotation........................................................... 36 13.2 Limit value transmitter .......................................................................................................... 37 13.3 Position feedback.................................................................................................................. 37 13.3.1 Feedback potentiometer........................................................................................................ 37 13.3.2 Position transducer................................................................................................................ 37 14 Service and maintenance ................................................................................................... 38 15 Retrofit / exchange / repair................................................................................................. 39 15.1 I/P module ............................................................................................................................. 39 15.1.1 Standard................................................................................................................................ 39 15.2 Limit value switch .................................................................................................................. 39 15.3 Feedback potentiometer and measuring transducer............................................................. 40 15.4 Manometer block................................................................................................................... 40 15.5 Spring.................................................................................................................................... 40 15.6 Piston lever............................................................................................................................ 40 15.7 Complete diaphragm chamber.............................................................................................. 41 15.8 Control piston bushing and wire............................................................................................ 41 16 Technical Data..................................................................................................................... 42 16.1 General data.......................................................................................................................... 42 16.2 Data for the basic device....................................................................................................... 42 16.3 Electrical data for options – inductive limit value transmitter................................................. 43 16.4 Electrical data for options – potentiometer and position feedback........................................ 44 17 Disposal and recycling ....................................................................................................... 45 Table of contents ARCA Regler GmbH 4 / 46 Series 824 09.2018 / 1.0

1 General data Series 824 5 / 46 09.2018 / 1.0 1 General data This operating manual contains instructions that enable the product to be safely and properly installed, put into operation and maintained. The target group for this operating manual is exclusively specially trained and authorised technical personnel. Please contact the manufacturer if you encounter problems that cannot be solved with the aid of this operating manual. The product is subject to technical changes at any time. 1.1 Validity of the manual This operating manual applies to the product in the version described in the device pass. 1.2 Contact details Further information about the product can be obtained from: Manufacturer's address ARCA Regler GmbH Kempener Str. 18 D-47918 Tönisvorst Tel.: +49 (0) 2156-7709-0 Fax: +49 (0) 2156-7709-55 E-mail: [email protected] www.arca-valve.com 1.3 Other applicable documents The product can be delivered as part of an actuator and equipped with additional components that are described in their own operating manu- als. The instructions as well as the warning and safety information con- tained therein must also be observed. Furthermore, the following documents apply in addition to this operating manual. ▪Device pass ▪Installation drawing 1.4 Place of storage of the manual The operating manual and all other applicable documents are part of the product. They must be kept in the immediate vicinity of the product and must be accessible to the personnel at all times.

6 / 46 Series 824 09.2018 / 1.0 2 Safety 2.1 Introduction This manual contains all the information you need for the connection and commissioning of the device. It is addressed to people who mechanically mount, electrically connect and commission the device, as well as service and maintenance techni- cians. We expressly state that the contents of this device manual do not form part of or modify a former or existing agreement, assurance or of a legal relationship. All obligations are specified in the particular purchase con- tract which also contains all the applicable warranty regulations. These contractual warranty conditions are neither extended nor restricted by any statements in this document. The contents reflect the technical state at the time of printing. We reserve the right to make technical changes in the course of further development. WARNING Use of a damaged or incomplete device Risk of explosion! ►Do not use damaged or incomplete devices. 2.2 General safety information Requirement for safe use This equipment has been supplied from the factory in a totally safe con- dition. To maintain this condition and to ensure safe operation of the device, follow these instructions and observe all safety-relevant informa- tion. Pay attention to the notices and symbols on the device. Do not remove any notices or symbols from the device. Keep the notices and symbols in a fully legible condition at all times. 2.3 Explanation of symbols and notices This documentation contains notes that you must observe for your own personal safety and for the avoidance of damage to property. Notes con- cerning personal safety are highlighted by a warning triangle; notes con- cerning only damage to property are not marked by a warning triangle. Depending on the danger level, the warning notes are shown in decreas- ing order of severity as follows: DANGER means that death or serious injuries will occur if the corresponding preventive measures are not taken.

2 Safety Series 824 7 / 46 09.2018 / 1.0 WARNING means that death or serious injuries can occur if the corresponding preventive measures are not taken. CAUTION with a warning triangle means that slight injury and/or damage to property can occur if the corresponding preventive measures are not taken. NOTICE indicates an important item of information about the product itself or how the product should be handled, to which special attention should be paid. CAUTION without a warning triangle means that damage to property can occur if the corresponding preventive measures are not taken. ATTENTION indicates that an undesirable event or condition can occur if the corres- ponding instructions are not observed. If several danger levels occur, the warning note for the respectively highest level will always be used. If a warning note with a warning tri- angle warns against personal injury, a warning against damage to prop- erty may be included in the same warning note. 2.4 Warning symbols on the device Symbol Explanation of the warning symbols on the device Observe the operating manual 2.5 Intended use Observe the following: WARNING ARCA positioners may be used only for the applications specified in the associated technical documentation. Proper transport, stor- age, erection, assembly, installation, commissioning, operation and maintenance are required for trouble-free and safe operation. The permissible environmental conditions must be maintained. Notices in the associated documentation must be observed.

8 / 46 Series 824 09.2018 / 1.0 2.6 Improper modifications to the device WARNING Modification to the device Modifications and repairs to the device can result in danger to the per- sonnel, plant and environment! ►Modify or repair the device only as described in the instructions de- livered with the device. The manufacturer's warranty and the product approvals are rendered null and void if this is ignored. 2.7 Qualified Personnel The device may be set up and operated only in conjunction with this documentation. Commissioning and operation may be performed only by qualified personnel. Qualified personnel within the meaning of the safety instructions in this documentation are persons authorised to com- mission, earth and mark devices, systems and circuits according to the safety standards. Qualified persons are those who are familiar with the erection, assembly, commissioning and operation of the product. These persons have the following qualifications: ▪They are authorised and have been trained or instructed to operate and maintain devices and systems in accordance with the safety standards for electrical circuits, high pressures and aggressive and/ or hazardous media. ▪They have been trained or instructed in the care and use of appropri- ate safety equipment in accordance with safety standards. 2.8 Laws and regulations The test certificates, regulations and laws applicable to your country must be observed for the connection, assembly and operation. These are, for example: ▪The Work Health and Safety Regulations 2.9 Liability disclaimer We have checked the contents of this instruction for correspondence to the device described. Nevertheless, deviations cannot be ruled out; therefore we cannot give any guarantee for full correspondence. The specifications are checked regularly and any necessary corrections will be included in subsequent editions. 2.10 Conformity to European directives The CE mark on the device indicates its conformity to the following European directives: 2014/30/EU EMC Directive of the European Parliament and of the Council on the approximation of the Laws of the Member States regarding electromagnetic com- patibility.

2 Safety Series 824 9 / 46 09.2018 / 1.0 2006/42/EC Directive of the European Parliament and of the Council on Machinery (Machinery Directive for short) The applied standards can be found in the EC Declaration of Conformity for the device.

ARCA Regler GmbH 10 / 46 Series 824 09.2018 / 1.0 3 Transport, storage and packaging 3.1 Transport Transport at a temperature lower than -40 °C or higher than +80 °C is not permissible. 3.2 Storage NOTICE Improper storage! There is a danger of the product no longer functioning if it is stored im- properly. ►Storage at a temperature lower than -40 °C or higher than +80 °C is not permissible. ►It must be stored in roofed-over storage places and that are weather- proof. Openings are sealed with suitable means to prevent the ingress of dirt. These should be removed by technical personnel at the place of installa- tion. CAUTION Inadequate protection during storage The packaging offers only limited protection against moisture and infiltra- tion! ►Provide additional packaging if necessary. 3.3 Packaging The product is packed in a PE film inside the outer packaging (card- board box, wooden crate, pallet, lattice box). If the packaging, in particular the PE film, has been opened, the product must be stored immediately in a heated room. The product must be packed in weatherproof or seaworthy packaging for transport by ship, rail or truck.

4 Nameplate Series 824 11 / 46 09.2018 / 1.0 4 Nameplate 1 2 3 4 5 7 6 8 9 1 Manufacturer 2 Device name 3 Type 4 Observe the operating manual 5 Protection class 6 Nominal signal range 7 Auxiliary energy (supply air) 8 Auxiliary energy (voltage) 9 Fabrication number Illustration 1: Nameplate

ARCA Regler GmbH 12 / 46 Series 824 09.2018 / 1.0 5 Type key 824. P 0 0 0 - 0 0 0 [1] [2] [3] [4] [5] [6] [7] [8] 1 Series 824. 2 Operating mode P pneumatic E electro-pneumatic, not explosion-proof 3 Output signal 1 single-acting 2 double-acting 4 Input signal 0 0.2 - 1.0 bar 1 4 - 20 mA 2 0 - 20 mA 3 0.2 - 0.6 bar 4 0.6 - 1.0 bar 5 4 - 12 mA 6 12 - 20 mA 7 0 - 10 mA 8 10 - 20 mA 5 For lifting / turning movement 0 Stroke ≥ 20 mm 1 Stroke < 20 mm 3 Angle of rotation 90° 4 Angle of rotation 60° 6 Auxiliary pneumatic equipment 0 without 1 Manometer block 7 Limit switches 0 without 1 inductive, standard design SJ3.5N 2 inductive, safety circuit SJ3.5SN 3 inductive, direct-switching SJ3.5E2 8 Feedback 0 none 1 ./. 2 Potentiometer 3 Position transducer 3-wire 4 Position transducer 2-wire

5 Type key Series 824 13 / 46 09.2018 / 1.0 Example of type designation 824.E110-100 Positioner 824 – electro-pneumatic, not explosion-proof – single-action – input signal 4 - 20 mA – for stroke ≥ 20 mm – with manometer block – without limit value switch – without feedback

ARCA Regler GmbH 14 / 46 Series 824 09.2018 / 1.0 6 Exploded view Illustration 2: Detail drawing

7 Parts list Series 824 15 / 46 09.2018 / 1.0 7 Parts list 7.1 Positioner Item Name 1 Mounting block 2 Control bushing 3 O-ring 4 Plug 5 Bayonet clips 6 Spring 7 Control piston 8 Piston lever 9 Diaphragm chamber 10 Spring suspension 11 Washer 12 Cylinder head bolt 13 Stop screw 14 Washer 15 Hex nut 16 Washer 17 Hex nut 18 Grip ring 19 Cylinder head bolt 20 Shaft 21 Circlip 22 Gear segment 23 Washer 24 Cam plate 25 Position indicator 26 Washer 27 Cylinder head bolt 28 Return plate 29 Return lever 30 Circlip 31 Zero point setting screw 32 Range setting screw 33 Shaft 34 Circlip 35 Ball bearing 36 Washer 37 Circlip 38 Changeover switch 39 O-ring 40 Cylinder head bolt 41 O-ring 42 Sealing plate 43 Cylinder head bolt 44 I/P module (standard) 45 Terminal set 46 Cylinder head bolts 47 Cable gland 48 Cover 49 Spacer screw 50 Spacer screw 51 Cover

ARCA Regler GmbH 16 / 46 Series 824 09.2018 / 1.0 52 Cylinder head bolt 53 Screw plug 54 Earthing block 55 Lug 56 Spring lock washer 57 Cylinder head bolt 58 Earthing block 59 Lug 60 Spring lock washer 61 Cylinder head bolt 62 Control wire 63 Plain bearing 64 Screw plug 65 Screw plug 66 Dirt strainer 80 Limit value transmitter module 81 Cylinder head bolt 82 Cylinder head bolt 83 Washer 84 Cylinder head bolt 85 Limit value transmitter 86 Vane 87 Terminal set 90 Feedback module 91 Potentiometer 92 Position transducer 93 Washer 94 Cylinder head bolt 100 O-ring 101 Manometer block 103 Cylinder head bolt 105 O-ring 106 Mounting block 107 O-ring 108 I/P module (pressure-resistant) 109 Cylinder head bolt 110 O-ring

8 Description Series 824 17 / 46 09.2018 / 1.0 8 Description 8.1 Function and structure ▪The positioner operates in accordance with the force comparison principle and controls the position of actuators proportionally. The signal air pressure at the input is converted into force by a diaphragm in the diaphragm chamber (9) and compared with the return force of the spring (6). At force equilibrium the positioner is in the steady state. If the input pressure increases, the piston lever (8) is deflected upwards so that the piston (7) is also raised. Supply air now flows via the output into the pneumatic actuator, as a result of which it is moved (downwards in the case shown). The pretension of the return spring (6) is thereby increased via the lifting or rotary lever, the cam plate (24) and the return lever (204). This takes place until the spring force and the diaphragm are in equilibrium (steady state). Actuator stroke and input signal pressure are thus correlated in accordance with the cam plate contour. If the input signal falls, this has the re- verse effect on the valve stroke. The piston moves downwards, shuts off the supply air and vents the pneumatic actuator via the vent hole in the piston bushing of the positioner. As a result of this the actuator changes its position towards the original position. ▪The functional sequence is the same with the double-action position- ers, however the piston now controls two outputs. If the piston is de- flected upwards it vents the output y2, while supply air flows in through the output y1. The relationships at the outputs y1 and y2 are the opposite when the piston lever moves downwards. ▪The actuation speed of the cylinder can be regulated in both direc- tions by additionally adjustable throttle check valves in the actuation signal lines Y1 and Y2 to be provided by the customer. As a result of this a more or less strong fixation of the cylinder actuator is also achieved asymmetrically. ▪In the case of the I/P module the impressed DC current I flows through a fixed coil (44.1) as the input signal. This magnetises a magnetically soft yoke (44.2). The field lines of this system exposed at an air gap (44.3) exert a force proportional to the input current on a small magnet (44.4) that is made of a highly coercive alloy. To- gether with a baffle plate (44.5) the small magnet forms the rotary system of the device. The impact plate covers a nozzle (44.6) to a greater or lesser extent, the air from the nozzle exerting a resetting force that is in equilibrium with the force at the magnet. The nozzle is provided via a throttle (44.7) with air from the output of the control part (44.8), which is influenced by the change in pressure in front of the nozzle. Thus a linear correlation between the electrical input sig- nal and the pneumatic output signal exists. ▪Split ranges are used if, for example, two actuators with positioners in different control ranges are to be controlled by one controller. One valve would operate with the input signal range 0.2 – 0.6 bar and the other with the split range 0.6 – 1.0 bar. The split ranges differ by dif- ferent springs, which are marked in colour.

18 / 46 Series 824 09.2018 / 1.0 Illustration 3: Functional description 8.1.1 Cam plate The cam plate (24) of the positioner has three characteristics, which are designed for a 60° angle of rotation equivalent to a 100% stroke or a 90° angle of rotation for a 90° opening angle with rotary valves. For the basic version, the linear curve (no. 1 in fig. 1) is provided normally. The on/off curve (no. 2) and the equal percentage curve (no. 3) are also shown in this diagram. Figs. 1 and 2 show how these curves affect the flow rate of valves with different opening characteristics. The linear curve (no. 1) linearly assigns the valve stroke to the input signal, i.e. the input signal is mapped dir- ectly to the valve stroke so that the effect of the valve's own opening characteristic is retained. The use of the curves (nos. 2 & 3) offers the possibility to change the effect of valve characteristics. Fig. 1 Fig. 2 Fig. 3 Valve characteristics Flow characteristics Flow characteristics depending on the input signal with various cam plates with various cam plates and equal-percentage valve cone depending on the input signal with various cam plates and linear valve cone depending on the input signal

9 Installation Series 824 19 / 46 09.2018 / 1.0 9 Installation Check whether the desired principle of operation - "normal" or "inverted" - is set correctly. To do this, look at the rear side of the positioner and check the setting. If it should be necessary to change the setting, refer to the chapter [12.1] Normal / Inversion "Configuration". 9.1 Safety instructions for assembly CAUTION Improper installation Improper installation can result in damage to the device, its destruction or the impairment of its function. Ascertain that the device shows no visible signs of damage each time before installing it. Ascertain that the process connections are clean and that suitable seals and cable glands are used. Install the device using suitable tools. CAUTION Mechanical impact It is essential that the following sequence is observed during installation in order to avoid injury or mechanical damage to the positioner/mounting kit: ►Mechanically mount the positioner ►Connect the pneumatic auxiliary energy ►Connect the auxiliary electrical energy supply ►Carry out the commissioning procedure ATTENTION The device protection class becoming null and void Damage to the device due to open or improperly closed housing. The protection class specified on the nameplate is no longer guaranteed. CAUTION Humid environment/dry compressed air If the environment is humid, mount the positioner in such a way that there is no chance of the control axis freezing (getting stuck) at low am- bient temperatures. Make sure that water does not enter an open housing or threaded joint. If the positioner cannot be immediately and permanently mounted and connected on site, it is possible for water to enter. In general, only dry compressed air may be used to operate the posi- tioner. Also refer to the chapter [16.2] Data for the basic device. You should therefore make use of the usual water separators. In extreme cases it may be necessary to use an additional dryer. The use of dryers is particularly important if you operate the positioner at low ambient tem- peratures. When mounting on the valve block, set the purging air switch above the pneumatic connections to the "OUT" position.

20 / 46 Series 824 09.2018 / 1.0 9.2 Mounting a linear actuator 9.2.1 Installation according to DIN/IEC 534 T6 (NAMUR) Refer also to fig. 5 "Installation 824/Namur": ▪Seal the actuation pressure output A36 (M8 thread) on the rear side of the positioner with the blanking plug (53). – Also refer to the chapter [10] Pneumatic connection. ▪Mount the spring wire (201) on the drive lever (200) in accordance with fig. 4. – NOTICE! The version ("N" or "I") is visible on the cam plate (24). ▪Mount the drive lever (200) on the stroke indicator using cylinder head bolts (203). ▪Mount the stroke setting screw (205) with the washer (206) on the pivot lever (204) using nut (207). – NOTICE! Observe the stroke scale on the pivot lever (204)! ▪Mount the pivot lever (204) on the positioner using the nut, bolt and spring lock washers (208-210). ▪Bolt the mounting plate (231) to the positioner with the spring lock washers (234) and bolts (235). ▪Position the positioner against the actuator such that the stroke set- ting screw (205) protrudes into the slot of the drive lever (200). – Refer here to fig. 4. ▪Mount the complete positioner with mounting plate (231) on the cast iron or pillar yoke according to fig. 5. Cam plate N (normal) Cam plate I (inverted) Illustration 4: Drive lever

9 Installation Series 824 21 / 46 09.2018 / 1.0 Illustration 5: Installation 824/Namur 200 Drive lever 201 Spring wire 203 Cylinder head bolts 204 Pivot lever 205 Stroke setting screw 206 Washer 207 Hex nut 208 Hex screw 209 Hex nut 210 Washer 230 Stirrup bolts 231 Mounting plate 232 Spring lock washer 233 Hex screw 234 Spring lock washer

22 / 46 Series 824 09.2018 / 1.0 235 Hex screw 236 Spring lock washer 237 Hex nut 9.2.2 Integrated mounting on actuators series 812 Mounting procedure (see illustrations below) ▪Mount the stroke driving pin (225) on the actuator stem and secure with Loctite 601. ▪Seal the actuation pressure output A36 on the positioner with the blanking plug (65). – Remove the blanking plug (53) from the rear side of the device (if fitted). – Also refer to the chapter [10] Pneumatic connection. ▪Mount the stroke adjustment screw (222) on the pivot lever (211) with the washer (217), nut (216), sliding washer (218), conical roller (220) and circlip (221). – NOTICE! Observe the stroke scale on the pivot lever (211)! ▪Mount the pivot lever (211) on the positioner using the nut, bolt and spring lock washers (214-212). ▪Place the O-ring (224) in the groove in the adapter plate (250). ▪Position the positioner against the actuator such that the conical roller (220) engages between the stroke drive pins (225) on the actu- ator stem. ▪Bolt the positioner to the actuator yoke with the bolts (223) and spring lock washers (226).

24 / 46 Series 824 09.2018 / 1.0 Illustration 7: Assembly 824/812 side view 211 Pivot lever 212 Spring lock washer 213 Hex screw 214 Hex nut 216 Hex nut 217 Washer 218 Sliding washer 219 Spring 220 Conical roller 221 Circlip 222 Stroke setting screw 223 Cylinder head bolt 224 O-ring 225 Stroke driving pin 226 Spring lock washer Illustration 8: Assembly 824/812 standard top view 9.2.3 Integrated mounting on actuators series 813 Mounting procedure (see illustrations below) ▪Mount the stroke driving pins (258) on the bracket (257) and secure with Loctite 601. ▪Mount the bracket (257) on the actuator stem with the nut (259).

9 Installation Series 824 25 / 46 09.2018 / 1.0 ▪Seal the actuation pressure output A36 on the positioner with the blanking plug (65). – Remove the blanking plug (53) from the rear side of the device (if fitted). – Also refer to the chapter [10] Pneumatic connection. ▪Mount the adapter (252) on the positioner with the grub screw (253). ▪Mount the adapter plate (250) and O-ring (254) on the positioner with the screws (251). ▪Mount the stroke adjustment screw (222) on the pivot lever (211) with the washer (217), nut (216), sliding washer (218), conical roller (220) and circlip (221). – NOTICE! Observe the stroke scale on the pivot lever (211)! ▪Mount the pivot lever (211) on the positioner using the nut, bolt and spring lock washers (214-212). ▪Place the O-ring (255) in the nut in the actuator yoke. ▪Position the positioner against the actuator such that the conical roller (220) engages between the stroke drive pins (258) on the actu- ator stem. ▪Bolt the positioner to the actuator yoke with the bolts (256).

26 / 46 Series 824 09.2018 / 1.0 Illustration 9: Adapter plate / pivot lever

9 Installation Series 824 27 / 46 09.2018 / 1.0 Illustration 10: Assembly 824/813 side view 211 Pivot lever 212 Spring lock washer 213 Hex screw 214 Hex nut 216 Hex nut 217 Washer 218 Sliding washer 219 Spring 220 Conical roller 221 Circlip 222 Stroke setting screw 250 Adapter plate 251 Cylinder head bolt 252 Adapter 253 Grub screw 254 O-ring 255 O-ring 256 Cylinder head bolt 257 Bracket 258 Stroke driving pin 259 Hex nut Illustration 11: Installation 824/813 top view

28 / 46 Series 824 09.2018 / 1.0 Illustration 12: Photo - assembly 824/813 9.3 Installation of the swivel actuator 9.3.1 Installation according to VDI/VDE 3845 ▪Insert the coupling (265) into the actuator adapter (264) (not included in the scope of delivery) and secure with the screw (266). – Secure the screw (266) with Loctite 601! ▪Mount the yoke (260) (not included in the scope of delivery) on the actuator with the screws (261). ▪Mount the adapter plate (268) on the positioner with the screws (267). – Secure the screw (267) with Loctite 601! ▪Mount the positioner on the yoke (260) with the screws (263) and spring lock washers (262). Illustration 13: Installation 824/VDI-VDE 3845 top view 261 Cylinder head bolt 262 Spring lock washer

9 Installation Series 824 29 / 46 09.2018 / 1.0 263 Cylinder head bolt 265 Coupling 266 Cylinder head bolt 267 Cylinder head bolt 268 Adapter plate 260 Yoke 264 Actuator adapter Items 260 and 264 are part of the scope of delivery only when mounting on an ARCA actuator from the series 840. In the case of third-party actu- ators the yoke (260) can be supplied on request! 9.3.2 ARCA mounting on swivel actuator series 840 (external piping) ▪Insert the coupling (271) into the actuator hub. – NOTICE! Observe the positioning of the groove for the positioner, danger of destruction! ▪Mount the yoke (272) on the actuator with the bolts (273). ▪In the case of the 844 actuator, additionally place the adapter plate (270) between the yoke (272) and the actuator. ▪Mount the positioner on the yoke (272) with the screws (274). Illustration 14: Assembly 824/840 side view 270 Adapter plate 271 Coupling 272 Yoke 273 Cylinder head bolt 274 Cylinder head bolt 9.3.3 Integrated mounting on actuators series 840 ▪Insert the coupling (282) into the actuator hub. – NOTICE! Observe the positioning of the groove! ▪Mount the mounting plate (280) and O-ring (281) on the actuator with the screws (283). – Omitted with actuator sizes 841 and 842. ▪Mount the transfer plate (285) and O-ring (284) on the actuator or on the mounting plate (280) with the screws (286).

30 / 46 Series 824 09.2018 / 1.0 ▪Seal the actuation pressure output A36 on the positioner with the blanking plug (63). – Remove the blanking plug (53) from the rear side of the device (if fitted). – Also refer to the chapter [10] Pneumatic connection. ▪Mount the mounting strip (298) and O-ring (288) on the positioner with the screws (299). ▪Mount the positioner with the mounting strip (298) installed on the transfer plate (285) with the O-ring (287) and screws (300). Illustration 15: Assembly 824/840, pipeless, side view 280 Mounting plate 281 O-ring 282 Coupling 283 Cylinder head bolt 284 O-ring 285 Transfer plate 286 Cylinder head bolt 287 O-ring 288 O-ring 298 Mounting strip 299 Cylinder head bolt 300 Cylinder head bolt

10 Pneumatic connection Series 824 31 / 46 09.2018 / 1.0 10 Pneumatic connection The assignment of the pneumatic connections is done in accordance with the designation of the connection sign affixed to the side or affixed inside the cover (51). Commercially available screw connections for cop- per and stainless steel pipe or plastic hoses can be used. In the case of versions with manometer block, the connections are loc- ated on the manometer block. ▪With all electro-pneumatic versions the input E26 is to be sealed with the blanking plug (64). ▪In the case of integrated positioner mounting (refer also to the chapters [9.2.2] Integrated mounting on actuators series 812, [9.2.3] Integrated mounting on actuators series 813 and [9.3.3] Integrated mounting on actuators series 840) the output A36 is to be sealed with a plug. The blanking plug (53) on the rear side of the positioner (illus- tration: Rear side) is to be unscrewed and removed. Rear side single-acting double-acting Illustration 16: Pneumatic connection

ARCA Regler GmbH 32 / 46 Series 824 09.2018 / 1.0 11 Electrical connection The electrical work is to be carried out under careful observation of the safety instructions in the chapter [2] Safety. Refer to the chapter [16] Technical Data for the individual electrical op- tions! ▪Undo the screws (52) and remove the cover (51). ▪Feed the cable through the cable gland. ▪Connect in accordance with the terminal diagram or the details inside the cover (51). – NOTICE! Make sure the polarity is correct. ▪Activate the strain relief by tightening the cable glands (47). ▪The max. permissible connection data for the individual electrical components are shown on the nameplate and must be observed! 11.1 I/P transducer Illustration 17: IP transducer 11.2 Limit value transmitter The limit value transmitter is equipped with two inductive proximity switches (slot-type proximity switches), which are actuated by the infin- itely adjustable vanes. The proximity switches can be supplied in three different basic versions. 11.2.1 Normal version (2-wire, N) The proximity switches according to EN 60947-5-6 (NAMUR) are 2-wire inductive sensors whose signals only need to be amplified by down- stream switching amplifiers (provided by the customer). Normally closed (N) types are generally used. Illustration 18: Limit value transmitter 2-wire N+SN 11.2.2 Safe design (2-wire, SN) These proximity switches correspond to the normal version, but with an additional function:

11 Electrical connection Series 824 33 / 46 09.2018 / 1.0 In the event of an error message for the proximity switch, the switching amplifier or the connecting cable, the output automatically enters the safe "off" state (= logic 0). Normally closed (SN) types are generally used. Illustration 19: Limit value transmitter 2-wire N+SN 11.2.3 Direct switching version (3-wire, E2) These proximity switches already contain an output amplifier and have separate connections for the power supply and for the load. Plus-switch- ing (E2) normally-open types are generally used. Illustration 20: Limit value transmitter 3-wire E2 11.3 Position feedback 11.3.1 Feedback potentiometer 11.3.2 Position transducer 3-wire 11.3.3 Position transducer 2-wire

34 / 46 Series 824 09.2018 / 1.0 12 Configuration 12.1 Normal / Inversion ▪Determine the required switch position and cam plate characteristic from fig. 20. – Refer also to the chapter [8.1.1] Cam plate. Illustration 21: Table: Mode of operation Check the configuration of the positioner and if necessary perform the steps listed in the chapters [12.1.1] Changeover switch and [12.1.2] Select cam plate. ▪Depressurise the positioner and switch it off! 12.1.1 Changeover switch ▪Loosen the screws (40) and remove the changeover switch (38) with the O-ring (39). ▪Mount the changeover switch (38) in the desired position. Changeover switch position "normal" Changeover switch position "in- verted" (Rear side of device) (Rear side of device) Illustration 22: Changeover switch

12 Configuration Series 824 35 / 46 09.2018 / 1.0 12.1.2 Select cam plate ▪Unhook the spring (6) from the return lever (29). ▪Loosen the screw (27). ▪Remove the position indicator (25) (versions for swivel actuators only) and the cam plate (24) and mount in the desired position. ▪Hook the spring (6) into the return lever (29). Illustration 23: Curve "1" normal

36 / 46 Series 824 09.2018 / 1.0 13 Commissioning 13.1 Adjustment of zero point and stroke/angle of rotation ▪The adjustment is done in accordance with the flow chart below. ▪Measure the stroke or angle of rotation with a dial gauge or angle of rotation measuring instrument respectively! ▪The equations produce the recommended values of the input vari- ables E1 and E2. – E1 = E (0%) ± (E (0%) x 1.05), max. 5% of control range – E2 = E (100%) ± (E (100%) x 1.05), max. 5% of control range Illustration 24: Zero point and stroke/angle of rotation adjustment chart

13 Commissioning Series 824 37 / 46 09.2018 / 1.0 13.2 Limit value transmitter The limit contacts are normally adjusted so that a signal is present in each of the end positions (open/closed). Both vanes can be infinitely ro- tated so that intermediate positions can also be signalled. To ensure reli- able switching, the switching point should be set approx. 2% before the mechanical stop (open/closed). We recommend the valve position "closed" for the limit value transmitter "A" and the valve position "open" for the limit value transmitter "B", whose setting is described below for a normally closed valve. ▪Loosen the screws (81). ▪Position the limit value transmitter (85) in the centre of the slots. ▪Tighten the screws (81). ▪Loosen the screw (82). ▪Coarse adjustment of the two vanes (86) with input signal at 0% and 100%. ▪Tighten the screws (82). ▪Apply a 2% input signal. ▪Loosen the screw (81) on the limit value transmitter "A". ▪Adjust vane "A" so that a signal is present at the limit value transmit- ter "A". ▪Tighten the screws (81). ▪Apply a 98% input signal. ▪Loosen the screw (81) on the limit value transmitter "B". ▪Adjust the vane so that a signal is present at the limit value transmit- ter "B". ▪Tighten the screws (81). 13.3 Position feedback 13.3.1 Feedback potentiometer The rotary movement of the positioner shaft is transmitted to the poten- tiometer (91) via a gear unit. The zero point and range setting must be done on the downstream devices (not included in the scope of delivery). 13.3.2 Position transducer The built-in position transducer (R/I) measures the change in resistance of the feedback potentiometer and converts the input signal into the out- put signal (0/4 - 20 mA). The zero point and range setting is done using the screws provided for this purpose on the position transducer (92).

ARCA Regler GmbH 38 / 46 Series 824 09.2018 / 1.0 14 Service and maintenance Basic safety instructions WARNING Impermissible repair of the device Repairs may be carried out only by authorised personnel. WARNING Impermissible accessories and impermissible spare parts Damage to the device ►Use exclusively original accessories and original spare parts. ►Observe all relevant installation and safety instructions described in the manuals for the device, accessories and spare parts. WARNING Improper connection following maintenance Damage to the device ►Connect the device correctly following maintenance. ►Close the device after maintenance. CAUTION Penetration of moisture into the device Damage to the device ▪Make sure that no moisture gets into the device during cleaning and maintenance work.

15 Retrofit / exchange / repair Series 824 39 / 46 09.2018 / 1.0 15 Retrofit / exchange / repair A new nameplate must be requested following any modifications. Some modules cannot be installed together in the positioner. Therefore it is es- sential that you read the chapter [16] Technical Data for the individual modules. 15.1 I/P module 15.1.1 Standard ▪Release the cables of the I/P module (44) from the terminals (45). – if existent. ▪Loosen the screws (53). ▪Remove the I/P module (44) or sealing plate (41). ▪Insert the dirt strainers (66). – if not existent. ▪Attach new I/P module (44). ▪The cable must be routed between the base plate (1) and the I/P module (44)! ▪Tighten the screws (43). ▪Mount the terminal set (45). – if not existent. ▪Insert the blanking plug (64). – if not existent. ▪For the electrical connection see [11] Electrical connection. ▪For commissioning see [13] Commissioning. 15.2 Limit value switch ▪Release the cable of the limit value switch (85) from the terminals (87). – if existent. ▪Mount the gear segment wheel (22) if not already existing. – Dismount the cam plate (24) in accordance with the chapter [12.1.2] Select cam plate. – Remove the disc (23). – Attach the gear segment (22). – Mount the cam plate (24) in accordance with the chapter [12.1.2] Select cam plate. ▪Unscrew the spacer screw (50). ▪Attach the limit value module (80). ▪Tighten the spacer screw (50) and screw (84) with washer (83). – NOTICE! The gear wheels must intermesh without play after- wards! ▪For the electrical connection see [11] Electrical connection.

ARCA Regler GmbH 40 / 46 Series 824 09.2018 / 1.0 ▪For commissioning see [13] Commissioning. 15.3 Feedback potentiometer and measuring transducer ▪Release the cables of the feedback potentiometer (91) and the measuring transducer (92) from the terminals (45). – if existent. ▪Mount the gear segment wheel (22) if not already existing. – Dismount the cam plate (24) in accordance with the section [12.1.2] Select cam plate. – Remove the disc (23). – Attach the gear segment (22). – Mount the cam plate (24) in accordance with the section [12.1.2] Select cam plate. – Attach the feedback potentiometer and measuring transducer module (90). ▪Tighten the screws (94) with washers (93). – NOTICE! The gear wheels must intermesh without play after- wards! ▪Mount the terminal set (45). – if not existent. ▪For the electrical connection see [11] Electrical connection. ▪For commissioning see [13] Commissioning. 15.4 Manometer block ▪Loosen the pneumatic connections. – if already mounted. ▪Unscrew the manometer block (101) if existent. ▪Mount the new manometer block (101). ▪Tighten the screws (103). ▪For pneumatic connection see [10] Pneumatic connection. ▪For the electrical connection see [11] Electrical connection. ▪For commissioning see [13] Commissioning. 15.5 Spring ▪Unhook the spring (6) from the return lever (29). ▪Unhook the spring (6) from the spring suspension (10). ▪Hook in the new spring (6). ▪For commissioning see [13] Commissioning. 15.6 Piston lever ▪Dismount the spring (6) in accordance with the chapter [15.5] Spring. ▪Loosen the nuts (16 & 17).

15 Retrofit / exchange / repair Series 824 41 / 46 09.2018 / 1.0 ▪Remove the circlip (18). ▪Loosen the screws (19). ▪Remove the piston lever (8). ▪Mount the new piston lever (8). ▪Further installation in the reverse order. ▪For commissioning see [13] Commissioning. 15.7 Complete diaphragm chamber ▪Dismount the piston lever (8) in accordance with the chapter [15.6] Piston lever. ▪Loosen the screws (12). ▪Remove the diaphragm chamber (9). ▪Mount the new diaphragm chamber (9). ▪Further installation in the reverse order. ▪For commissioning see [13] Commissioning. 15.8 Control piston bushing and wire ▪Dismount the diaphragm chamber (9) in accordance with the chapter [15.7] Complete diaphragm chamber. ▪Pull out the control piston (7). ▪Remove the bayonet clip (5) and protective cap (4). ▪Pull the control bushing downwards (2). ▪Mount the new control bushing (2) and new control piston (7) with a new control wire (62). ▪Further installation in the reverse order. ▪For commissioning see [13] Commissioning.

ARCA Regler GmbH 42 / 46 Series 824 09.2018 / 1.0 16 Technical Data 16.1 General data Installation on thrust actuators ARCA-integrated or according to IEC 534-6 (NAMUR) Stroke range 10 to 120 mm on swivel actuators ARCA-integrated or according to VDI/VDE 3845 Angle of rotation 90° Housing material Cast aluminium / plastic Protection class IP 54 Mounting position arbitrary Climate class Operation 4K3, but -20 to +80 °C, Low temperature version -40 to +80 °C Storage 1K5, but -40 to +80 °C Transport 2K4, but -40 to +80 °C Vibration resistance < 10g according to DIN 89011, recommended con- tinuous operation range of the complete valve ≤ 3 g CE mark Conformity according to EU EMC directive 2014/30- EU and Machinery Directive 2006/42/EC Controller data Gain max. 100 Hysteresis < 0.7 % of the control range Response threshold < 0.5 % of the control range Linearity error < 2 % of the control range Draught dependence < 0.2 % / 0.1 bar, type 824.P < 0.1 % / 0.1 bar Dimensions see data sheet Weight Type 824.P approx. 1.8 kg Type 824.E approx. 2.0 kg Manometer block approx. 0.5 kg Connections electrical 0 to 2 cable glands M20 x 1.5 depending on the ver- sion pneumatically externally piped Y and Z: laterally G ¼ DIN 45141, Special version ¼" NPT pneumatically internally piped Z: laterally G ¼ DIN 45141, Y: at rear G 1/8 16.2 Data for the basic device Pneumatic data Supply air pres- sure 1.4 to 6 barg Air quality Solids Class 2 ISO 8573-1 (particle size ≤ 1 μm, particle density ≤ 10 mg/m3 in the normal state) Dew point Class 2 ISO 8573-1 (-40 °C, at least 20 K below ambient temperature, low temperature version < -50 °C) Oil content Class 2 ISO 8573-1 (≤ 0.1 mg/m3 at standard atmospheric conditions)

16 Technical Data Series 824 43 / 46 09.2018 / 1.0 Air consumption < 0.6 m3/h in the normal state, type 824.P < 0.5 m3/h in the normal state in stationary operation Flow rate 6 m3/h in the normal state at 1.4 barg Electrical / pneumatic data for the base device pneumatic not explosion proof Electrical connection [11.1] I/P transducer Input signal 0.2 to 1 bar 0/4 to 20 mA Split ranges 0.2 to 0.6 to 1 bar 0/4 to 10 / 12 to 20 mA Load resistor 170 Ώ Required load voltage 3.4 V 16.3 Electrical data for options – inductive limit value transmitter Limit value transmitter N 824.P/Exxx-x1x Normal version 2-wire technology in accordance with DIN 19234 (NAMUR), for downstream switching amplifiers 2 slot-type initiators Type SJ 3.5 N Function NC, normally closed Switching difference < 1 % Control circuit see downstream switching amplifier EMC according to EN 60947-5-2 and DIN 19234 Electrical connection [11.2.1] Normal version (2-wire, N) Limit value transmitter SN 824.P/Exxx-x2x Safe design 2-wire technology according to DIN 19234 (NAMUR) for customer provided switching amplifier in safe design 2 slot-type initiators Type SJ 3.5 SN Function NC, normally closed Switching difference < 1 % Control circuit see downstream switching amplifier EMC according to EN 60947-5-2 and DIN 19234 Electrical connection [11.2.2] Safe design (2-wire, SN) Limit value transmitter E2 824.P/Exxx-x3x Direct-switching 3-wire technology with integrated switching amplifier for direct switching 2 slot-type initiators Type SB 3.5 E2 Function NO, normally open Switching difference < 1 % Operating voltage 10 to 30 V DC perm. load current 100 mA Electrical connection [11.2.3] Direct switching version (3-wire, E2)

ARCA Regler GmbH 44 / 46 Series 824 09.2018 / 1.0 16.4 Electrical data for options – potentiometer and position feedback Potentiometer 824.P/Exxx-xx2 Resistance 200, 500 or 1000 Ohm 4) Characteristic deviation < 2 % 5) Internal capacitance Ci 3.5 pF Internal inductance Li 10 mH Electrical connection [11.3.1] Feedback potentiometer Position transducer 3L 824.P/Exxx-xx3 3-wire circuit RWG, type 4522 Operating voltage 15 to 24 V DC Output 4(0) - 20 mA, short-circuit proof Current limitation at approx. 28 mA Load Ri 0 - 400 Ohm Characteristic deviation < 2 % 5) Electrical connection [11.3.2] Position transducer 3-wire Position transducer 2L 824.P/Exxx-xx4 2-wire circuit RWG, type TMT 136R Supply voltage DC 8.5 ... 36 V Output 4 - 20 mA, short-circuit proof Current limitation at approx. 36 mA Load Ri 1300 Ohm at 36 V DC Characteristic deviation < 2 % 5) Electrical connection [11.3.3] Position transducer 2-wire 1) Permissible ambient temperature for other circuits on enquiry. 2) Special version down to -40 °C (pressure dew point < -50 °C). 3) Special version NPT ¼". 4) Zero point and range setting must be done on the receiving device. 5) A deviation of up to 5% is possible, depending on the method of mounting the positioner or the stroke range.

17 Disposal and recycling Series 824 45 / 46 09.2018 / 1.0 17 Disposal and recycling WARNING Operating media and auxiliary materials that are hazardous to health Danger to people and the environment! ►Wear suitable protective equipment ►If applicable, collect and dispose of rinsing medium or residual me- dium. Particular attention is to be paid to dead spaces (pressure compensation, bellows, etc.) ►Observe the legal regulations for the disposal of media that are haz- ardous to health ARCA products are modularly constructed and can be sorted by material into the following components. ▪Electronic components ▪Metals ▪Plastics ▪Greases and oils ▪Packaging material The general rules are: ▪greases and oils are usually water pollutants and must not be al- lowed to escape into the environment ▪Dispose of dismantled materials properly or recycle the separate ma- terials ▪Observe national disposal regulations