Installation Manual OPEN. For Corrosive Service. The ONYX integrates electronic sensors and pneumatic valving into a vapor tight enclosure.

Transcription

1 For Corrosive Service Installation Manual The ONYX integrates electronic sensors and pneumatic valving into a vapor tight enclosure. OPEN StoneL Corporation One StoneL Dr US Hwy 59 Fergus Falls, MN USA Approval Agency Controlled Document. No Changes Authorized Without Prior Agency Approval 2002 StoneL Corporation Telephone: Toll Free: Fax: sales@stonel.com Website:

2 Table of Contents Table Of Contents... Page 2 Mounting & Initial Set-up... Page 3 Maxx Guard & SST Sensors & Wiring... Page 4 Sensor Modules & Wiring Diagrams... Page 5 Communication Modules & Wiring Diagrams... Page 6 Onyx CYCLONE Valve...Page 8 Onyx Integral Solenoid... Page 9 Position Transmitter... Page 10 Intrinsic Safety Installation Diagram... Page 11 Dimensional Data... Page 12 2

3 ONYX Mounting and Initial Set-up Mounting to Actuator 1. Attach slotted mounting plate to monitor using fasteners and lockwashers provided. 2. Attach mounting plate with captured bolts to actuator using fasteners and lockwashers provided. (Skip to step 4. for namur shaft option) 3. Remove coupling spacer and screw with lockwasher. Attach namur coupling directly to shaft and secure with screw and lockwasher. - or - 3a. Remove coupling screw and lockwasher. Attach coupling with additional spacer (if included) to coupling on monitor and secure with screw and lockwasher. 4. Slide monitor mounting plate down over actuator mounting plate until coupling is fully engaged. Namur coupling or Namur Shaft should be bottomed onto actuator shaft. The spring tempered coupling screw head should not contact the actuator. However, the screw head should be within 1/4" (6 mm) from the top of the actuator shaft. 5. Adjust monitor mounting plate front to back and side to side to be fully parallel with actuator mounting surface. Lightly snug adjustment bolts over monitor mounting plate slots. Operate actuator to full open and full closed positions to check for proper coupling alignment. Eccentricity of shaft must be no greater than.01" from centerline. Adjust if necessary and snug-down adjustment bolts tightly. #4 #2 Visual Indicator, #6 Adjustment Ring, #6 Adjustment Screws, #6 Adjust Parallel, #5 #1 Adjust Parallel, #5 Visual Indicator Adjustment 6. Remove cover from unit and loosen two side adjustment screws maximum of one turn. Rotate indicator cover while engaged with adjustment ring into appropriate position. Tighten the adjustment screws. Adjustment may not be achieved if open and closed positions are reversed. To adjust properly, remove entire unit from actuator and remove coupling. Rotate namur coupling or coupling and spacer 90. Reattach coupling and reinstall unit. Touch & Tune Sensor Settings 7. Remove visual indicator from unit and operate valve to closed position. Lift bottom cam and rotate until switch is activated. (Cam highlight will be next to sensor.) Release cam and be sure it slides fully onto spline. 7a. Operate actuator to opposite position, push down on top cam and repeat process. (See SST Touch & Tune Switch Settings on page 4.) 8. Replace visual indicator making sure driver on shaft fits into slot of indicator and tab fits into adjustment ring indentation. Push down firmly on center of indicator to assure proper engagement with drive. Screw cover down hand tight. 3 Namur Shaft, #4 Visual Indicator Driver Top Cam, #7a Bottom Cam, #7 Namur Coupling, #3 - or - Coupling Spacers, #3a Spring-Tempered Coupling, #3a Notes: 1) Watertight Conduit Connections - To properly seal conduit connection use 2 to 3 full turns of teflon tape and tighten conduit to between 35 and 40 ft-lbs of torque. 2) Prevent Switch Overload - Do not install or operate switch without a series load that limits current to values specified on title plate. (Load is typically incorporated in PLC)

4 ONYX with Maxx Guard or SST Sensors SST Sensor Setting 2 SPST Maxx-Guard Sensors Set Normally Open Set Normally Closed 1 2 Normally Open Normally Open Ratings: VAC VDC Two year sensor warranty SST Touch & Tune Switch Setting SST Sensors will operate normally open or normally closed by cam adjustment. All adjustments assume you are looking down on top of sensors. Cam metal strip edge will activate sensor. When cam is released be sure it slides fully onto spline. One spline tooth is 3. I. For Normally Open Function**: a. With valve in "Closed" position set bottom cam in middle of sensor target. Set top cam 180 from bottom cam. b. Lift bottom cam and turn counter-clockwise until red LED goes "out" then clockwise again until the red LED just comes "on". (Reverse cam direction if valve opens clockwise.) c. Move valve to opposite position (Open), push down on top cam and rotate counter-clockwise until green LED just comes "on". (Reverse cam direction if the valve opens clockwise.) ** To set NAMUR sensors, follow the same procedure as for Normally Open Function. NOTE: When NAMUR sensor is activated, LED is dim (or off) and current goes to less than 1.0 ma. 2 SPDT Maxx-Guard Sensors Ratings: VAC VDC Minimum of 3.5 volts required for operation Two year sensor warranty Normally Closed Normally Open Normally Closed Normally Open 2 SST Solid State Sensors II. For Normally Closed Function: a. With valve in closed position, set both cams so metal activation strips are aligned with each other and set in middle of sensor targets. b. If valve turns counter-clockwise to open, pull up on the bottom cam and rotate clockwise until red LED goes "out". (If valve turns clock wise to open, rotate bottom cam counter-clockwise until it goes out.) c. Operate valve to opposite position (Open). push down on top cam. If green LED is "off", rotate top cam clockwise until it comes "on". When green LED is "on" turn cam counter-clockwise until green LED just goes "off". 1 2 Normally Open/Normally Closed Normally Open/Normally Closed In normally closed operation, both red and green LEDs will be illuminated during the actuation period. In normally open operation, both LEDs will be off during the actuation period. If optional green "Closed" visual indicator is used colors will be reversed in steps I. and II. 4 Ratings: VAC/VDC 2.0 Amps 125 VAC/VDC (Inrush may be used for solenoid and relay inrush values) Leakage Current: Maximum of 0.15 ma Minimum of 2.0 ma needed for operation in "on " mode Five year sensor warranty

5 Touch & Tune Setting for Dual Modules Notes: All adjustments assume you are looking down on the top of the sensors. The edge of the cam metal strip will be at the edge of the sensor target when activation occurs. When the cam is released be sure it slides fully onto the spline. One spline tooth setting is 3 1/2. I. For Normally Open Function** (See Fig. 1): a. With valve in "Closed" position set bottom cam in middle of sensor target. Set top cam 180 from bottom cam. b. Lift bottom cam and turn counter-clockwise until red LED goes "out" then clockwise again until the red LED just comes "on". (Reverse cam direction if valve opens clockwise.) c. Move valve to opposite position (Open), push down on top cam and rotate counter-clockwise until green LED just comes "on". (Reverse cam direction if the valve opens clockwise.) ** To set NAMUR sensors, follow the same procedure as for Normally Open Function. NOTE: When NAMUR sensor is activated, LED is dim (or off) and current goes to less than 1.0 ma. II. For Normally Closed Function (See Fig. 2): a. With valve in closed position, set both cams so metal activation strips are aligned with each other and set in middle of sensor targets. b. If valve turns counter-clockwise to open, pull up on the bottom cam and rotate clockwise until red LED goes "out". (If valve turns clock wise to open, rotate bottom cam counter-clockwise until it goes out.) c. Operate valve to opposite position (Open). Push down on top cam. If green LED is "off", rotate top cam clockwise until it comes "on". When green LED is "on" turn cam counter-clockwise until green LED just goes "off". In normally closed operation, both red and green LEDs will be illuminated during the actuation period. In normally open operation, both LEDs will be off during the actuation period. If optional green "Closed" visual indicator is used colors will be reversed in steps I. and II. Cams Set for Normally Open Operation Sensor Settings ONYX with Sensor Modules Cams Set for Normally Closed Operation SST Sensor Module (ON33 ) Output: (2) cam selectable N.O. or Hold closed switching outputs Current Rating: VAC/VDC 2.0 Amps 125 VAC/VDC Leakage Current: Maximum of 0.25 ma Minimum of 2.0 ma needed for operation in "on " mode Solenoid 1 Solenoid 2 Solenoid Power 1 Solenoid Power 2 Top Switch NO Top Switch Bottom Switch NO Bottom Switch To Bench Test SST Sensor Module: Use StoneL Light Read Tester. Or use a 24 Vdc or 120 Vac power supply with series load resistor (2K - 6K Ω) SST Sensor Module Wiring Diagram Namur Sensor Module (ON44 ) Output: 2 Namur Sensors (DIN 19234) Target Present: Current <1.0 ma Target Absent: Current >3.0 ma Voltage Range: 6 to 29 VDC Use with intrinsically safe repeater barrier. Namur ratings fully conform to DIN standard To Bench Test Namur Module: Use StoneL Light Read Tester. Or use a 6-29Vdc power supply across + and -. No series resistor needed. Namur Module Wiring Diagram Solenoid 1 Solenoid 2 Solenoid Power 1 Solenoid Power 2 Top Switch + Top Switch - Bottom Switch + Bottom Switch - Fig. 1 Fig. 2 5

6 DeviceNet Module (ON92 ) Communication Protocol: DeviceNet I/O: (2) Discrete Inputs (Sensors) (2) Discrete Outputs (Solenoids) (1) Analog Input (2 Wire Device) 8 bit resolution (0.4%) Default Address: 63 Bit Assignment: Inputs: (3 Bytes) Bit 0 = Input 1 (Red LED; Bottom Sensor) Bit 1 = Input 2 (Green LED; Top Sensor) Bit 4 = Fault Bit (On if both Input 1 and Input 2 are on) Bits 8-15 = Analog Input (Low Byte) Bits = Analog Input (High Byte) Outputs: (1 Byte) Bit 0 = Output 1 (Solenoid 1) Bit 1 = Output 2 (Solenoid 2) I/O Messaging: Polling, Cyclic, Change of State Operating Voltage: 24 VDC via DeviceNet network Baud Rates: 125K, 250K, 500K Output Voltage: 24 VDC Max. Output Current: 160mA, Both Outputs Combined Max. Output Power: 4 Watts, Both Outputs Combined ONYX with Communication Modules Foundation Fieldbus Module (ON93 ) Communication Protocol: Foundation Fieldbus I/O: (2) Discrete Inputs (Sensors) (2) Discrete Outputs (Piezo Valves) Function Blocks: 2 DI, 2 DO Operating Voltage: 9-32 VDC (Foundation Fieldbus Voltage) Max Output Current: 6.5 VDC. Current limited to 2mA (Bus Powered). Suitable for StoneL Piezo Valve Indication: Red LED = Bottom Sensor Green LED = Top Sensor To Bench Test a DeviceNet Module: Use 24 VDC power supply across V + and V -. No series resistor needed. To test communication, a functioning DeviceNet network is required. Do not apply external power to output terminals DeviceNet module Wiring Diagram To Bench Test a Foundation Fieldbus Module: Use 24 VDC power supply across FB + and FB -. No series resistor needed. To test communication, a functioning Foundation Fieldbus network is required. Do not apply external power to output terminals Foundation Fieldbus module Wiring Diagram V + CAN H FB + Shield FB - CAN L OUT 1 + V - Piezo Valve OUT ma Transmitter Ain + Ain - Piezo Valve OUT 2 + OUT 2 - OUT 1-24VDC SIM JMPR SIM JMPR OUT 2-6

7 Modbus Module (ON95 ) Communication Protocol: Modbus I/O: (2) Discrete Inputs (Sensors) (2) Discrete Outputs (Solenoids) (1) Analog Input (2 Wire Device) 10 bit resolution (0.1%) Default Address: 03 Bit Assignment: Inputs: 10001= Input 1 (Red LED; Bottom Sensor) = Input 2 (Green LED; Top Sensor) Analog Input: Outputs: = Output 1 (Solenoid 1) = Output 2 (Solenoid 2) Operating Voltage: 24 VDC via Modbus network Baud Rates: 9.6K, 19.2K, 38.4K Output Voltage: 24 VDC Max. Output Current: 160mA, Both Outputs Combined Max. Output Power: 4 Watts, Both Outputs Combined ONYX with Communication Modules AS-i Module (ON96 )* Communication Protocol: AS- Interface (AS-i) Configuration: (2) Discrete Inputs (Sensors) (2) Auxiliary Discrete Inputs (2) Discrete Outputs (Solenoids) Default Address: 00 AS-Interface ID/IO Code: F4 Bit Assignment: Inputs: Bit 1 = Auxilliary Input 1 Bit 2 = Auxilliary Input 2 Bit 3 = (Green LED; Top Sensor) Bit 4 = (Red LED; Bottom Sensor) Outputs: Bit 1 = Not Used Bit 2 = Not Used Bit 3 = Output 1 (Solenoid 1) Bit 4 = Output 2 (Solenoid 2) Voltage: VDC (AS-i Voltage) Output Voltage: 24 VDC Max. Output Current: 160mA, Both Outputs Combined Max. Output Power: 4 Watts, Both Outputs Combined *For version ON91 specifications, please consult factory. To Bench Test a Modbus Module: Use 24 VDC power supply across V + and V -. No series resistor needed. To test communication, a functioning Modbus network is required. Do not apply external power to output terminals Modbus module Wiring Diagram To Bench Test AS-i Module: Use 24 VDC power supply across AS-i + and AS-i -. No series resistor needed. To test communication, a functioning AS-i network is required. Do not apply external power to output terminals AS-i module Wiring Diagram V + BUS + BUS - V - ASI + ASI - Aux IN + Aux IN1-4-20mA Transmitter Ain + Ain - Aux IN2-3 wire RTN OUT 1 + OUT 2 + OUT 1 - OUT 2 - OUT 2 + OUT 1 + OUT 2 - OUT 1-7

8 Description The Onyx CYCLONE valve is a pilot operated 5-way spring return which may be used for single and doubleacting actuators. It features a direct-acting solenoid with manual overide for the pilot. The porting is sized to tolerate contaminants up to 40 microns in size which may be found in conventional pneumatic systems. The Onyx CYCLONE valve is O-ring sealed on the Lexan enclosure to maintain it's temporary submersibility rating. ONYX CYCLONE Valve Solenoid Pilot Valve Manual Override Valve Body O-ring Seal Specifications 120 V AC (With burn-out proof coil) Power Watts Inrush Amps Holding Amps 24V DC Power Watts Current draw Amps Temperature C to +50 C Filtration Requirements Microns Pressure Range PSI to 120 PSI Cv V DC Intrinsically Safe (Use 24VDC Supply and I.S. Barrier) Vmax VDC Ci... 0 Li... 0 Power Watts Current draw Amps Temperature... 0 C to +50 C Piezo Pilot Current draw... Temperature C to +60 C Filtration Requirements Microns Pressure Range to 120 PSI Cv (10.7 Kv) Other Information Dual Coil Options: 1. Blocked Center (3 Position) 2. Shuttle Piston (2 Position) Manual Overrides: One internal momentary and One external locking. Variable Speed Adjustment: Each cylinder port is internally ported to a unique exhaust port (EA for exhaust of port A and EB for exhaust of port B). To vary actuator speed flow restrictors may be added to EA or EB to reduce exhaust flow and actuator speed in either direction. Single-Acting Vent to Atmosphere or Refresh: Exhaust (EA or EB) and secondary ports (A or B) may be blocked for single-acting operation with the actuator venting directly to atmosphere. Alternatively, the secondary port may be plumbed to the actuator supplying air to the spring side of the actuator and preventing it from ingesting atmospheric contaminants. 8 Lexan Enclosure Pneumatic Porting P A P - Pressure Port (1/4 " NPT) A - Cylinder Port (1/4" NPT) B - Cylinder Port (1/4" NPT) E(A) - Exhaust for Cylinder Port A (1/4" NPT) E(B) - Exhaust for Cylinder Port B (1/4" NPT) Single Coil: 5 way with Pneumatic pilot E(A) Schematics Dual Coil: Blocked Center with 2 Pneumatic Pilots (3 Position valve with Spring to Center) Dual Coil: Shuttle Piston with 2 Pneumatic pilots (2 Position Valve with position detent Latching Manual Override B A P B A P E A P EA EB B E B P E(B)

9 Description The integral solenoid valve is a 5-way spring return which may be used for single and double-acting actuators. It features a MAC direct acting solenoid with poppet style spool. The porting is designed to tolerate contaminants found in conventional pneumatic systems. However, should the poppet spool hang-up, the solenoid coil features a unique burn-out proof mechanism to prevent continued inrush current when used on AC systems. The valve is ported to an external stainless steel or brass manifold which is gasket sealed on the Lexan enclosure. Specifications 24 VDC Coil: Power Watts Current draw Amps ONYX Standard EA Manual Override Stainless Steel or Brass Lexan Enclosure 120 VAC Coil: Inrush Current... Holding Current Amps 0.06 Amps Pneumatic Porting Temperature to 35 C (0 to 120 F) Filtration Requirements Microns Pressure Range... Vacuum to 120PSI (Vacuum to 8.2 Bar) Cv Other Information Manual Override: To operate the pneumatic valve the manual override must be depressed and held. Releasing will return valve to deactuate mode. EA A P B P - Pressure Port (1/4 " NPT) A - Cylinder Port (1/4" NPT) B - Cylinder Port (1/4" NPT) EA - Exhaust for Cylinder Port A (1/8" NPT) EB - Exhaust for Cylinder Port B (1/8" NPT) EB Variable Speed Adjustment: Each cylinder port is internally ported to a unique exhaust port (EA for exhaust of port A and EB for exhaust of port B). To vary actuator speed flow restrictors may be added to EA or EB to reduce exhaust flow and actuator speed in either direction. Direct Acting Solenoid Schematic B A Single-Acting Vent to Atmosphere or Refresh: Exhaust (EA or EB) and secondary ports (A or B) may be blocked for single-acting operation with the actuator venting directly to atmosphere. Or the secondary port may be plumbed to the actuator supplying air to the spring side of the actuator and preventing it from ingesting atmospheric contaminants. Manual Override P EA EB 9

10 Description The Position Transmitter is a two wire, loop powered device that provides a 4-20 ma signal based on valve position. Voltage Range Span Temp. Range Maximum Error Maximum Load Specifications VDC; 24VDC Nominal Standard Span is from Consult factory for other ranges. -40 F to +185 F (±0.35 for HP-7) 24VDC See Load Curve ONYX Position Transmitter Potentiometer "Zero" Adjustment Operate Position,#3 Lift Pot. & Rotate Gear Adjust Position,#3 Installation & Adjustment 1. Attach ONYX to actuator or valve and set switches if included. Connect the plug as shown for either clockwise or counter clockwise operation (as viewed from top). 2. Operate actuator to desired "zero" position. With power disconnected, connect an ohm meter across pins 2 & 3 of the potentiometer for counter clockwise rotation. For clockwise rotation, connect the ohm meter across pins 1 & 2 of the potentiometer. 3. Lift the end of the potentiometer to disengage the gears and rotate until the ohm meter reads between 400W - 600W. Lower the potentiometer and engage the gears. 4. Disconnect the ohm meter and connect DC power to the + and - terminals (see electrical schematic). 5. Adjust the screw on the zero trimpot for a 4mA output. 6. Operate actuator to the "100%" position. 7. Adjust the screw on the span trimpot for a 20mA output. Zero and Span adjustments are non interactive. Electrical Schematic 55% Circuit Board Adjustments & Rotation Settings Zero Adjustment, #5 Connector Plug, #1 (Set in Counter Clockwise Position) Span Adjustment,#7 Wiring Diagram Connector Plug, #1 (Set in Clockwise Position) 4-20 ma Readout Loop Resistance (Ohms) StoneL Onyx Position Transmitter Load Curve Voltage Supply _ + Normally Open/Normally Closed Normally Open/Normally Closed Operatingı Region Region Power Supply Voltage Voltage 10

11 ONYX Intrinsic Safety Hazardous Location Installation Diagram HAZARDOUS (CLASSIFIED) LOCATION StoneL Enclosure Terminal Strip Identifiers Intrinsic Safety Barrier (Associated Apparatus) NON-HAZARDOUS (SAFE AREA) LOCATION 2 Class I, II, III; Division 1 Groups A,B,C,D,E,F,G TOP SWITCH C NO/NC 3 Control Equipment SST Switches 7 9 Seperate Shields BOTTOM SWITCH C NO/NC Intrinsically Safe Ground FM INSTALLATION NOTES: SST Entity Parameters: Vmax = 40 Vdc Imax = 120 ma Ci = 11 nf Li = 0.46 mh Voc or Vt < Vmax, Isc or It < Imax, Ca > Ci + Ccable, La > Li + Lcable. 2. For Class II and III, Division 1 installations, where conduit is not used, use Listed dust-tight cable-gland fittings. 3. Control equipment connected to intrinsic safety barrier must not use or generate more than 250 Vrms or Vdc. 4. Installation should be in accordance with ANSI/ISA RPA12.6 "Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations" and the National Electrical Code (ANSI/NFPA 70). 5. The configuration of the intrinsic safety barrier for each SST wiring pair must be FMRC Approved. 6. Intrinsic safety barrier manufacturer's installation drawing must be followed when installing this equipment. 7. To maintain intrinsic safety, wiring associated with each SST must be run in separate cables or separate shields connected to intrinsically safe (associated apparatus) ground. 8. To maintain Onyx enclosure sealing properties for Class II and III hazardous locations and NEMA 4, 4X, and 6 applications, seal conduit entries with 2-to-3 turns of teflon tape and tighten conduit to between 35 to 40 ft-lbs. of torque. 9. Conduit Grounding - Upon installation verify electrical continuity between conduit and ground terminal. CSA INSTALLATION NOTES: CSA-Certified 28 Volt (Max.), 300 Ohm(Min.) Intrinsic Safety barriers. 2. For Class II and III, Division 1 installations, where conduit is not used, use CSA-Certified dust-tight cable-gland fittings. 3. Control equipment connected to Intrinsic Safety barriers must not use or generate more than 250 VRMS or VDC. 4. Install in accordance with the Canadian Electrical Code. 5. The configuration of intrinsic safety barriers for each SST wiring pair must be CSA-Certified. 6. Intrinsic safety barrier manufacturer's installation drawing must be followed when installing this equipment. 7. To maintain intrinsic safety, wiring associated with each SST must be ran in seperate cables or separate shields connected to intrinsically safe barrier ground. 8. To maintain Onyx enclosure sealing properties or class II or III Hazardous locations and type 4, 4x, and 6 applications, seal conduit entries with 2 to 3 turns of teflon tape and tighten conduit or cable-gland fittings to between 35 to 40 ft-lbs of torque. 9. Conduit Grounding - Upon installation verify electrical continuity between conduit and ground terminal. 11

12 ONYX Overall Specifications & Dimensional Data Namur Shaft with Cyclone Valve S Shaft with Standard Manifold Approval Agency Controlled Document. No Changes Authorized Without Prior Agency Approval 12 StoneL Corporation One StoneL Dr US Hwy 59 Fergus Falls, MN USA Telephone: Toll Free: Fax: StoneL Corporation sales@stonel.com Website: