Neles SwitchGuard SG9200H. Rev. 1.1 Installation, Maintenance and Operating Instructions

Transcription

1 Neles SwitchGuard SG9200H Rev. 1.1 Installation, Maintenance and Operating Instructions 7 SG92H 70 en 12/2010

2 2 7 SG92H 70 en Table of Contents 1 SG9200H SWITCHGUARD INTELLIGENT ON/OFF CONTROLLER WITH HART COMMUNICATION General Technical description Markings Technical specifications Recycling and disposal Safety precautions TRANSPORTATION, RECEPTION AND STORAGE MOUNTING General Mounting on Metso actuators with VDI/VDE mounting face Mounting on linear actuator with IEC mounting face Piping Electrical connections LOCAL USER INTERFACE (LUI) Measurement monitoring Guided start-up Configuration menu MODE menu Configuration parameters Valve travel calibration Special displays HART write protection MAINTENANCE Opening and closing of the cover Prestage Spool valve Communication circuit board Failsafe errors Alarms Errors Warnings Notifications TROUBLE SHOOTING SG92_/K_, SG92_/I_, SG92_/D_ (WITH LIMIT SWITCHES) Introduction Installing SG92_/K_, SG92_/I_ or SG92_/D_ on a valve controller Electrical connections Adjustment Removal of the limit switches SG92_/K_, SG92_/I_ or SG92_/D for accessing the valve controller Circuit diagrams Maintenance TOOLS ORDERING SPARE PARTS DRAWINGS AND PARTS LISTS Exploded view and parts list, SG9200H Exploded view and parts list,sg9200h/k_, SG9200H/I_, SG9200H/D_ Mounting parts for Metso actuators with VDI/VDE mounting face Mounting parts for old B series actuators Mounting parts for linear actuators Connection diagrams DIMENSIONS CONFIGURATION PARAMETERS EC DECLARATION OF CONFORMITY TYPE CODING READ THESE INSTRUCTIONS FIRST! These instructions provide information about the safe handling and operation of the intelligent on/off controller. If you require additional assistance, please contact the manufacturer or manufacturer's representative. Addresses and phone numbers are printed on the back cover. SAVE THESE INSTRUCTIONS! Subject to change without notice. All trademarks are property of their respective owners.

3 7 SG92H 70 en 3 1 SG9200H SWITCHGUARD INTELLIGENT ON/OFF CONTROLLER WITH HART COMMUNICATION 1.1 General This manual incorporates Installation, Maintenance and Operation Instructions for the Metso s Neles SwitchGuard. The SG9200H may be used with either cylinder or diaphragm type pneumatic actuators for rotary or linear valves. NOTE: The selection and use of the valve controller in a specific application requires close consideration of detailed aspects. Due to the nature of the product, this manual cannot cover all the likely situations that may occur when installing, using or servicing the valve controller. If you are uncertain about the use of the controller or its suitability for your intended use, please contact Metso s Automation business for more information. 1.2 Technical description The SwitchGuard is a 4 20 ma loop-powered microcontroller-based on/off controller. Binary 24 V DC signal can be used via optional U/I converter. The Switch- Guard operates even at 3.6 ma input signal (see restrictions in Section 4.5.3) and communicates via HART. The device contains a Local User Interface enabling local configuration. A PC with FieldCare software can be connected to the SwitchGuard itself or to the control loop. The powerful 32-bit microcontroller controls the valve position. The measurements include: Input signal Valve position with contactless sensor Actuator pressures, 2 independent measurements Supply pressure Device temperature Advanced self-diagnostics guarantees that all measurements operate correctly. Failure of one measurement does not cause the valve to fail if the input signal and position measurements are operating correctly. After connections of electric signal and pneumatic supply the micro controller (µc) reads the input signal, position sensor (α) and pressure sensors (Ps, P1, P2). A difference between setpoint according to stroke curve and position sensor (α) measurement is detected by the control algorithm inside the µc. The µc calculates a new value for prestage (PR) coil current based on this information. Changed current to the PR changes the pilot pressure to the spool valve. Reduced pilot pressure moves the spool and the actuator pressures change accordingly. The spool opens the flow to the driving side of the double-acting actuator (or air side in the sigle acting-actuator) and opens the flow out from the other side of the actuator in case of double-acting. The increasing pressure will move the piston. The actuator and feedback shaft rotate clockwise. Fig Markings The valve controller is equipped with an identification plate sticker (Fig. 2). Fig. 2 The principle of operation Examples of the identification plate Identification plate markings from top to bottom include: Type designation of the on/off controller Revision number Enclosure class Certificate number Hazardous area approval Temperatures classes Input signal and electrical values Supply pressure range Manufacturer CE mark ID code Manufacturing serial number TTYYWWNNNN*) *) Manufacturing serial number explained: TT= device and factory sign YY= year of manufacturing WW = week of manufacturing NNNN = consecutive number Example: PH = controller, year 2011, week 1, consecutive number 1234.

4 4 7 SG92H 70 en 1.4 Technical specifications ATEX NOTE: This manual contains technical specifications for several types of the SG9200H valve controller. If in doubt, refer to the type approval certficate of the respective version. The certificate is delivered with the field device and is also available from the manufacturer. SG9200H ON/OFF CONTROLLER General Loop powered, no external power supply required. Suitable for rotary and sliding-stem valves. Actuator connections in accordance with VDI/VDE 3845 and IEC standards. Action: Double or single acting Travel range: Linear: mm Rotary: Measurement range 110 with freely rotating feedback shaft Environmental influence Standard temperature range: -20 to +85 C / -4 to +185 F Optional temperature range: -40 to +60 C / -40 to +140 F Influence of vibration on valve position: under 2g Hz, 1g Hz, 0.5g Hz Open and closed position: no effect Deviation from profile:<10 % Enclosure Material: Anodised aluminium alloy and glass window Protection class: IP66, NEMA 4X Pneumatic ports: SG921_ 1/4 NPT SG9235 1/2 NPT SG NPT (1/2 NPT supply) (single acting only) Conduit entry thread: M20 x 1.5 Weight: SG kg / 6.6 lb SG kg / 10.1 lb SG kg / 11 lb limit switch options plus 1.0 kg / 2.2 lb Mechanical and digital position indicator visible through the main cover Pneumatics Supply pressure: 3 8 bar/ psi Air quality: According to ISO :2001 Solid particles: Class 7 (5 µm filtration is recommended) Humidity: Class 1 (dew point 10 C / 50 F below minimum temperature is recommended) Oil class: 3 (or <1 ppm) Capacity with 4 bar / 60 psi supply: SG Nm 3 /h / 4.1 scfm (Cv =0.06) SG Nm 3 /h / 53 scfm (Cv =0.7) SG Nm 3 /h / 223 scfm (Cv =3.2) SG9237 feed 380 Nm 3 /h / 223 scfm (Cv =3.2) exhaust 700 Nm 3 /h / 412 scfm (Cv =6.4) Consumption with 4 bar / 60 psi supply: actuator pressurized 0.22 Nm 3 /h / 0.13 scfm, actuator vented 0.25 Nm 3 /h / 0.15 scfm Electronics Electrical connections: max. 2.5 mm 2 HART Connections: '+' and '-' Supply power: Loop powered, 4 20 ma Minimum signal: 3.6 ma (see restrictions in 4.5.3) Current max : 23 ma Load voltage: up to 9.5 V DC/20 ma (corresponding 475 Ω.) Voltage: max. 30 V DC Polarity protection: -30 V DC Over current protection: active over 35 ma Max power dissipation: 1.05 W with position transmitter 1.74 W Ex d IIC T5/T6: Ui 30 V Pi 1080 mw Ex ia IIC T4/T5/T6: Ui 28 V Ii 120 ma Pi 1 W Ci 22 nf Li 53 µh Ex na IIC T4/T5/T6:Ui 30 V Ii 152 ma Ex nl IIC T4/T5/T6: Ui 28 V Ii 152 ma Ci 22 nf Li 53 uh Position transmitter (optional) Connections: PT: '+' and '-' Output signal: 4 20 ma (galvanic isolation; 600 V DC) Supply voltage: V Resolution: 16 bit / µa Linearity: <0.05 % FS Temperature effect:<0.35 % FS External load: Ex ia IIC T4/T5/T6: Ui 28 V Ii 120 ma Pi 1 W Ci 22 nf Li 53 µh Ex na IIC T4/T5/T6:Ui 30 V Ii 152 ma Ex nl IIC T4/T5/T6: Ui 28 V Ii 152 ma Ci 22 nf Li 53 uh Ex d IIC T5/T6: Ui 30 V Pi 1080 mw max Ω max Ω for intrinsically safe

5 7 SG92H 70 en 5 Local user interface functions Monitoring of valve position, input signal, temperature, supply and actuator pressure difference Guided start-up function LUI may be locked remotely to prevent unauthorised access Calibration: Automatic Tuning Mode selection: Automatic/Manual Position trigger level Stroke times, stroke profiles Dead angle Maximum speed Positioner fail action, open/close Signal direction: Direct/reverse acting Actuator type: double/single acting Valve type: rotary/linear IEC Language selection: English, German and French Remote user interface functions Configuration and diagnostic information is presented in easily understandable way using FDT/DTM technology, such as Neles FieldCare. APPROVALS Intrinsically safe and non incendive ATEX / IECEx II 1 G Ex ia IIC T4/T5/T6 Ga (EN , EN , EN ) II 2 G Ex ia IIC T4/T5/T6 Gb (EN , EN ) II 3 G Ex na IIC T4/T5/T6 Gc II 3 G Ex nl IIC T4/T5/T6 Gc (EN ) II 1 D Ex td A20 T90 C II 2 D Ex td A21 T90 C II 3 D Ex td A22 T90 C (EN , EN ) FM IS Class I, Division 1, Groups A, B, C, D, T4/T5/T6 IS Class I, Zone 0, AEx ia, IIC T4/T5/T6 NI Class I, Division 1, Groups A, B, C, D, T4/T5/T6 NI Class I, Zone 2, Ex na IIC, T4/T5/T6 Flameproof and explosion proof ATEX ATEX II 2 G Ex d IIC T3/T4 (EN , EN ) Electromagnetic protection Electromagnetic compatibility Emission acc. to EN (2001) and FCC 47 CFR PART 15, SUBPART B, CLASS B (1994) Immunity acc. to EN (2001) CE marking 89/336/EEC Electromagnetic compatibility 94/9/EC ATEX 1.5 Recycling and disposal Most valve controller parts can be recycled if sorted according to material. Most parts have material marking. A material list is supplied with the valve controller. In addition, separate recycling and disposal instructions are available from the manufacturer. A valve controller may also be returned to the manufacturer for recycling and disposal. There will be a charge for this. 1.6 Safety precautions CAUTION: Do not exceed the permitted values! Exceeding the permitted values marked on the valve controller may cause damage to the controller and to equipment attached to the controller and could lead to uncontrolled pressure release in the worst case. Damage to the equipment and personal injury may result. CAUTION: Do not remove or dismantle a pressurized controller! Removing or dismantling a pressurized prestage or spool valve of an SwitchGuard leads to uncontrolled pressure release. Always shut off the supply air and release the pressure from the pipelines and equipment before removing or dismantling the controller. Otherwise personal injury and damage to equipment may result. WARNING: During calibration and tuning the valve operates between open and closed positions. Make sure that the operation does not endanger people or processes! WARNING: Do not operate the device with the cover removed! Electromagnetic immunity is reduced, valve may stroke. ATEX WARNING: The locking screw (part 107) of the cover is essential to explosion protection. The cover has to be locked in place for Ex d protection. The screw grounds the cover to the housing. ATEX WARNING: Spark hazard! Protect the aluminium housing and cover from impacts. ATEX WARNING: Electrostatic charge hazard! The pointer and display windows are non-conductive. Clean with a damp cloth only!

6 6 7 SG92H 70 en ATEX WARNING: Electrostatic charge hazard! The paint of the device can enable charging of the metal parts by high voltage sources. Do not install the device in proximity of high voltage sources! Ex i WARNING: Ensure that the complete installation and wiring is intrinsically safe before operating the device! Ex i WARNING: Do not operate the device with electronics cover (39) removed! Electromagnetic immunity is reduced, valve may stroke. Ex i: intrinsic safety may be impaired. Ex i WARNING: For intrinsically safe applications, the equipment must be connected via a certified Zener barrier placed outside the hazardous area! Ex d NOTE: Only persons familiar with Ex d explosion protection are allowed to work with the device. Special attention has to be paid to careful handling and closing of the cover. Ex d WARNING: Do not open the cover when an explosive atmosphere may be present! Ex d WARNING: Use a cable gland with suitable Ex d certification. For ambient temperature over 70 C/158 F use a heat resistant cable and cable gland suitable for at least 90 C/194 F. ELECTRICAL SAFETY WARNING: Use fuses for limit switch installations with 50 V AC/75 V DC or higher. NOTE: Avoid earthing a welding machine in close proximity to an SG9200H valve controller. Damage to the equipment may result. 2 TRANSPORTATION, RECEPTION AND STORAGE The on/off controller is a sophisticated instrument, handle it with care. Check the controller for any damage that may have occurred during transportation. Store the controller preferably indoors, keep it away from rain and dust. Do not unpack the device until installing it. Do not drop or knock the controller. Keep the flow ports and cable glands plugged until installing. Follow instructions elsewhere in this manual. 3 MOUNTING 3.1 General NOTE: The enclosure of SwitchGuard on/off valve controller meets the IP66 protection class according to EN in any position when the cable entry is plugged according to IP66. However, it is not allowed to mount the valve controller in position where cable entry is pointing upwards. Based on good mounting practice, the recommended mounting position is electrical connections placed downwards. This recommendation is shown in our mounting position coding for control valves. If these requirements are not fulfilled, and the cable gland is leaking and the leakage is damaging valve controller or other electrical instrumentation, our warranty is not valid. If the SwitchGuard is supplied with valve and actuator, the tubes are mounted and the SwitchGuard adjusted in accordance with the customer s specifications. If the controller is ordered separately, the mounting parts for the assembly must be ordered at the same time. Sample order: (B1CU13)-Z-SG9235HN The controller is equipped for connection according to VDI/VDE Also the old Neles mounting face is supported (Z beam) but not recommended for high vibration environments. Shaft coupling alternatives for the controller for Metso actuators are shown in Fig. 3. For mounting parts for Metso actuators, see Mounting on Metso actuators with VDI/VDE mounting face figure in Section Mount the H-shaped coupling (47) to the shaft. Apply the thread-locking compound to the screw (48) and tighten firmly. Remove all protective plastic plugs from the pneumatic connections (3 pcs.). BJ and other single acting actuators: mount a metal plug (53) with sealant to the C1 connection. Set the direction arrow of the actuator in the direction of the valve closure member and attach the ear (2) to the indicator cover in the position shown in Section Secure the screw of the ear using e.g. Loctite and tighten firmly. Attach the bracket (1) to the SwitchGuard. Attach the bracket (1) to the actuator. The shaft coupling of the SwitchGuard must fit into the ear (2) so that the pointer is located in the position shown in Fig Mounting on linear actuator with IEC mounting face figure in Section 10.5 Attach the feedback arm with spacer to the controller shaft. Note the position of the pointer on the shaft as in Apply thread locking compound to the screws and tighten firmly. Attach the spring to the feedback arm as shown in Section 10.5.

7 7 SG92H 70 en 7 C2 S C1 Fig. 3 Mounting on Metso actuator with VDI/VDE mounting face Mount the controller mounting bracket loosely to the yoke of the actuator. Remove all plastic plugs from all actuator connections (3 pcs.). Mount the controller loosely to the mounting bracket guiding the pin on the actuator stem to the slot of the feedback arm. 11 The pointer on the coupling must stay in this sector VDI/VDE 3845 mounting Align the bracket and the controller with the actuator stem and adjust their position so that the feedback arm is approximately at a 90 angle to the actuator stem (in the mid-stroke position). Tighten the controller mounting bracket screws. Adjust the distance of the controller to the pin on the actuator stem so that the pin stays in the lever slot at full stroke. Ensure also that the maximum angle of the lever does not exceed 45 in either direction. Maximum allowed travel of the lever is shown in Section Best control performance is achieved when the feedback lever utilises the maximum allowed angle (±45 from horizontal position). The whole range should be at least 45. Make sure that the controller is in right angle and tighten all the mounting bolts. Ensure that the controller complies with previous steps. Check that the actuator pin does not touch the controller case throughout the entire stroke of the actuator. If the actuator pin is too long it may be cut to size. Apply grease (Molykote or equivalent) to the contact surfaces of the actuator pin and the feedback arm to reduce wear. IEC mounting pointer mark on housing pointer mark on housing Fig. 4 Shaft coupling alternatives 3.4 Piping CAUTION: Do not exceed the permitted supply pressure of the SwitchGuard! Table 2 provides the recommended tube sizes in accordance with actuator sizes. Tube sizes are the minimum values allowed. Connect the air supply to S. Connect C1 and C2 to the actuator, see Fig. 5. C1 must be plugged if single-acting actuator. Liquid sealants, such as Loctite 577 are recommended for the pipe threads. CAUTION: It is important to note, that SwitchGuard mounted on a spring actuator MUST be connected only as single-acting. Fig. 5. NOTE: An excess of sealant may result in faulty operation of the controller. Sealing tape is not recommended. Ensure that the air piping is clean. The air supply must be clean, dry and oil-free instrument air, see Section 1.4. Table 1 Spring rates Actuator type Spring rate (bar/psi) B1JK 3/43 B1J 4.2/61 B1JV 5.5/80 Adjust regulator pressure to a level that is max 1 bar (14.5 psi) + spring rate.

8 8 7 SG92H 70 en Table 2 Piping, stroke times and maximum valve speed (MAXS) parameter selection B1C Actuator SG_12_ Supply 1/4" NPT Actuator 1/4" NPT Stroke vol. NPT Piping Open dm 3 / in 3 (s) / / / / / / / / / B1J B1JA 6 mm or 1/4" 6 mm or 1/4" Stroke vol. NPT Piping Air dm 3 / in 3 (s) / / / / / / : To be defined later Close (s) Spring (s) SG_15_ Supply 1/4" NPT Actuator 1/4" NPT Piping Open (s) Close (s) SG_35_ Supply 1/2" NPT Actuator 1/2" NPT Piping Open (s) Close (s) SG_37_ (Single acting only) Supply 1/2" NPT Actuator 1" NPT Piping Open (s) Close (s) Maximum Valve Speed Parameter FST 6 mm or 1/4" Piping FST FST STD STD STD Air (s) Spring (s) 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" Piping SLO (SG_35) STD (SG_15) SLO SLO SLO SLO SLO SLO SLO SLO Air (s) Spring (s) Piping Air (s) Spring (s) FST FST mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" 16 mm or 5/8" STD 25 mm or 1 25 mm or 1 25 mm or 1" 25 mm or 1" 25 mm or 1" SLO (SG_35) STD (SG_15) SLO SLO SLO SLO CAUTION: Always adjust the maximum valve speed parameter according to Table 2. Erroneous value may cause instability. CAUTION: Extra pneumatics instrumentation (i.e. QEV, VB, etc.) is not allowed with SwitchGuard when opening and closing stroke profiles are used, i.e. when stroking times are set other than 0 s. CAUTION: The air supply system must be of sufficient size and capacity to ensure that at maximum flow during valve movement the pressure at the Switch- Guard must not fall below 3 bar. Also note that if the air supply system allows the pressure at the SwitchGuard to fall below the actuator minimum supply pressure during valve movement the stroke speed will be affected. CAUTION: The stroking times mentioned in Table 2 are trendsetting. They are measured with 5 bar supply air pressure, but may vary significantly due to different factors such as, but not limited to, pressure difference of the valve, the stiction of the actuator, supply air pressure, the capacity of the supply air system and the dimensions of the supply air pipeline.

9 7 SG92H 70 en 9 DOUBLE-ACTING ACTUATOR 1. Increasing input signal to open valve (shown) C2 S C1 Default setting: DIR = OPE ATYP = 2-A PFA = CLO A0 and VTYP according to valve type 2.Increasing input signal to close. valve (not recommended) Default setting: DIR = CLO ATYP = 2-A PFA = CLO A0 and VTYP according to valve type DOUBLE-ACTING ACTUATOR, REVERSED PIPING 3. Increasing input signal to open valve (not recommended) C2 S C1 Default setting: DIR = OPE ATYP = 2-A PFA = OPE A0 and VTYP according to valve type 4.Increasing input signal to close. valve (shown) Default setting: DIR = CLO ATYP = 2-A PFA = OPE A0 and VTYP according to valve type SINGLE-ACTING ACTUATOR, SPRING TO CLOSE 5.Increasing input signal to open valve (shown) C2 S C1 Default setting: DIR = OPE ATYP = 1-A PFA = CLO (must be in the spring direction) A0 and VTYP according to valve type 6.Increasing input signal to close valve (not recommended) Default setting: DIR = CLO ATYP = 1-A PFA = CLO (must be in the spring direction) A0 and VTYP according to valve type SINGLE-ACTING ACTUATOR, SPRING TO OPEN 7.Increasing input signal to close valve (shown) C2 S C1 Default setting: DIR = CLO ATYP = 1-A PFA = OPE (must be in the spring direction) A0 and VTYP according to valve type 8.Increasing input signal to open valve (not recommended) Default setting: DIR = OPE ATYP = 1-A PFA = OPE (must be in the spring direction) A0 and VTYP according to valve type Fig. 5 Operation directions and air connections

10 10 7 SG92H 70 en 3.5 Electrical connections The SG9200H is powered by a standard 4-20 ma current loop that also functions as a carrier to the HART communication. If a 24 V DC (or up to 230 V AC) output from the control system is used, then an U/I converter is needed as shown in Fig. 7 below. typecoding in Section 14 for different converter options. The signal cables are led through M20 x 1.5 cable glands. Cable shall be one or more single-twisted pair shielded or multiple-twisted pair with overall shield. Single and multiple-pair may be combined in a given network provided all current input devices associated with multiple pairs of the same cable shall be located nominally at one end of the multi-pair cable. Unshielded cable may be used if it is demonstrated that ambient noise or crosstalk does not affect communication. Connect the conductors to the terminal strip as shown in Fig. 6. (Connections '+' and '-'). The optional position transmitter is connected to 2-pole terminal PT as shown in Fig. 6. The position transmitter needs an external power supply. The SwitchGuard and NONHAZARDOUS LOCATION the position transmitter circuits are galvanically isolated and withstand a 600 V AC voltage. The earthing of the cables shall be carried out at the DCS end only. NOTE: The SG9200H equals a load of 475 Ω in the current loop. Fig. 6 HART connection Terminals when LUI is removed and position transmitter option is in use. HAZARDOUS LOCATION AI (Analog Input) AO (Analog Output) Control system Uo < Ui Io < Ii Po < Pi Control system Uo < Ui Io < Ii Po < P Position Transmitter Entity Parameters of position transmitter Ui < 28.0 V Rx = 690 Ω Ii < 120 ma Ci < 22 nf Pi < 1.0 W Li < 53 µh SG9200H_T Entity Parameters Ui < 28.0 V Ii < 120 ma Pi < 1.0 W Ci < 22 nf Li < 53 µh NONHAZARDOUS LOCATION HAZARDOUS LOCATION AI (Analog Input) Control system Uo < Ui Io < Ii Po < Pi Position Transmitter Entity Parameters of position transmitter: Ui < 28.0 V Rx = 690 Ω Ii < 120 ma Ci < 22 nf Pi < 1.0 W Li < 53 µh SG9200H_ T DO (Digital Output) Control system Uo < Ui Io < Ii Po < Pi U/I converter Uo < Ui Io < Ii Po < Pi Entity Parameters: Ui < 28.0 V Ii < 120 ma Pi < 1.0 W Ci < 22 nf Li < 53 µh Fig. 7 Control wiring

11 7 SG92H 70 en 11 4 LOCAL USER INTERFACE (LUI) The local user interface may be used to monitor the device behaviour as well as configuring and commissioning the controller during installation and normal operation. The local user interface consists of two row LCD and four button keypad interface. There are also custom graphical characters for special conditions. Fig. 8 Local user interface (LUI) 4.1 Measurement monitoring When the device is powered, it enters the measurement monitoring view. The following measurements may be viewed from the display. The Table 3 identifies the default unit and also optional unit of the measurement. Table 3 Default / optional units of measurements Measurement Default unit Optional unit valve position Percentage of full scale Angle, where 0 % refers to 0 (angle) current loop setpoint ma Percentage of full scale actuator bar psi pressure difference supply pressure bar psi device temperature Celcius Fahrenheit If the unit selection is altered from the FieldCare software to US units, the pressure default unit will automatically be changed to psi and temperature unit to Fahrenheit. The active unit may be changed by pressing the? key constantly. The display shows the current unit selection on the top row of the display. You may change the selection by pressing + or - while keeping the? key pressed down. When the buttons are released the current selection will be activated. If the device has been idle for 1 hour, and there is no user activity on the local user interface, the measurements will start scrolling on the display. This enables the user to view all the measurements through the window of the main cover. Fig. 9 continuous push brief push Measurement unit change 4.2 Guided start-up Guided startup offers a fast view of the most critical parameters of the SwitchGuard controller, actuator and valve configuration. After verifying the parameters the valve travel calibration is recommended. The guided start-up is entered by pressing the = and? keys simultaneously. The configuration parameters are listed in following order, see explanation from 4.5: Valve type VTYP Actuator type ATYP Maximum Speed MAXS Positioner fail action PFA Valve dead angle A0 Stroke Time Open STOP Stroke Time Close STCL If you modify any of the parameters you will also need to calibrate and tune the device. 4.6 for detailed description.

12 12 7 SG92H 70 en brief push Fig. 10 Guided start-up NOTE: You may cancel any action by pressing the = button. Cancelling of operation returns user interface view one level up in menu hierarchy. 4.3 Configuration menu The local user interface is organised in a menu structure. To enter the menus press + and - simultaneously in the measurement monitoring view panel. To move to the next or previous selection by pressing + or - accordingly. 4.4 MODE menu If the user wants to change the valve operating mode, press the? key at the MODE selection. The mode will start to flash and by pressing + or - you may alter the operation mode selection. User accepts the current selection by pressing the? key. There are two options for the operating mode AUTO During the AUTO mode, the controller controls the valve position according to the incoming setpoint signal from the 4 20 ma signal source. This mode is used during the normal process control service. Fig. 11 Configuration brief push

13 7 SG92H 70 en MAN It is possible to control the valve position from the keyboard in the Manual Mode. To do this, you must return to Measurement Monitoring Menu (main menu). Choose TPOS and press?. In the upper row TPOS starts to blink and in the lower row you can see the current position of the valve. CLO = valve closed OPE = valve open --- = valve is somewhere between open and closed positions. You can control the valve position as follows: + Opens the valve, "---" blinks during movement. - Closes the valve, "---" blinks during movement. Blinking stops when the valve is again fully open or closed. valve travel Linear Slow Starting & Ending Equal Percentage Quick Starting Slow Starting % of stroke time Fig. 13 Stroke profile shapes, opening valve travel Linear Slow Starting & Ending Equal Percentage Quick Starting Slow Starting Fig. 12 Setpoint change in MAN mode 4.5 Configuration parameters When PAR is on the display you may enter the configuration menu by pressing the? key. In this menu the most important configuration and signal modification parameters are viewable. You may view the current value and edit them by pressing the? key at the relevant parameter. The name of the parameter will appear on the upper row of the display and the current value is on the lower row. also table in Section Stroke time and profile, STOP, STCL, SPOP, SPCL Valve open and close profiles can be configured with Neles SwitchGuard with the limitation set by valve assembly. Stroke time performance constraints can be seen from the piping table in Section 3.4. Both stroke directions can be set without any connection to the each other. Opening and closing times can be set with STOP (open) and STCL (close) parameters. Parameter is given in seconds. Used stroke profile shape can be set with parameters SPOP (open) and SPCL (close). Profile can be chosen separately for both direction from one of the five profile shapes: Linear (1), Slow Starting (2), Slow Starting & Ending (3), Equal Percentage (4) and Quick Starting (5). If valve stroke is needed to do as fast as possible, set time stroke time to Fig % of stroke time Stroke profile shapes, closing Trigger level, LEV Input setpoint level to start position transition. A fixed hystereris is applied on this level (trigger level 5 %). Default value is 50.0 % and range is % Signal direction, DIR The opening and closing direction of the valve with raising current loop signal is defined by signal direction parameter DIR. When DIR is displayed press the? key to enter the edit state and DIR starts to blink. Select either the OPE or CLO values by pressing the + and - keys. The value OPE signifies the raising signal 4 20 ma to open the valve and CLO means the raising signal to close the valve. To conclude, press the? key when the desired value is shown on the display. default values in Fig. 5. NOTE: In case of signal direction (DIR) is same than Positioner Fail Action (PFA) 5 ma input signal is recommended as minimum.

14 14 7 SG92H 70 en Valve type, VTYP To compensate for nonlinearity of the position feedback caused by the actuator linkage mechanism of a linear control valve, the appropriate selection must be made on the VTYP display. After selecting VTYP on the display, press the? key to enter the edit state and the VTYP starts to blink. Select between two values rot or LIn using the + and - keys. The value rot indicates a rotary valve and LIn a linear valve. To conclude press the? key when the desired value is shown on the display Actuator type, ATYP In order to optimise the control performance the device needs to be informed about the actuator type. After selecting ATYP on the display, press the? key to enter the edit state and ATYP starts to blink. Select between two values 2-A or 1-A using the + and - keys. The value 2-A indicates a double acting actuator and 1-A a single acting actuator. To conclude press the? key when the desired value is shown on the display Maximum valve speed, MAXS CAUTION: Stroke times are defined by parameters STOP and STCL. Don t try to adjust the speed with MAXS. Maximum Valve Speed parameter does not adjust the speed of the valve. Parameter describes the pneumatic capacity of SwitchGuard when compared to actuator size. Once MAXS is displayed, press the? key to enter the edit state and the MAXS will start blinking. You may select between three values by pressing the + or - key. For small actuators select FST, medium size actuators STD and large size actuators SLO. Table 2 for correct settings. CAUTION: Always adjust the maximum valve speed parameter according to Table 2. Erroneous value may cause instability. After the desired value is displayed, press the? key to conclude the operation Positioner fail action, PFA This section describes the function of the actuator. Set value according to Fig. 5 for double acting actuators. For single acting actuators set value in the spring direction. This action will also take place when the controller software discovers a fatal device failure. Fig. 5 for correct settings. Once PFA is displayed, press the? key to enter the edit state and the PFA will start blinking. You may select between two values by pressing the + or - key. The CLO value indicates that the valve ought to be closed in fail action situations. The OPE value indicates the valve to be opened in fail action situations. After the desired value is displayed, press the key? to conclude the operation. NOTE: In case of signal direction (DIR) is same than positioner fail action (PFA) 5 ma input signal is recommended as minimum Valve dead angle, A0 The α 0 setting is made for segment and ball valves. This setting takes into account the "dead angle" α 0 of the valves. The entire signal range is then used for effective valve opening 90 - α 0. Use 0 % as the "dead angle" for the valves, which dead angle is not known. Fig. 15 After selecting A0 on the display, press the? key to enter the edit state and A0 starts to blink. The value currently selected appears as a percentage (%) on the display. Modify the parameter value by pressing + or - keys alternately until the desired value appears on the display. Press the? key to make your selection and return to the setting state Language selection, LANG Increasing input signal opens valve Fig POSITION α 0 α INPUT SIGNAL cut-off safety range 2 ± 0.5 % Principle of setting Dead angle Increasing input signal closes valve = Basic setting = α 0 setting Select between three languages EnG, GEr or FrE (English, German or French) using the + and - keys. To conclude press the? key when the desired value is shown on the display.

15 7 SG92H 70 en Valve travel calibration NOTE: Valve travel calibration is possible only when the valve controller is in AUTO mode. Select CAL from the menu by using + or - keys and press the? key. 4.7 Special displays User interface locked In order to prevent unauthorised access, the Local User Interface may be locked. In this mode measurements may be viewed but configurations and calibrations are prohibited. You may lock and unlock the device via HART or by DIP switch (see 4.8. HART write protection). When the Local User Interface is locked the lock symbol will be activated on the display. Fig AUTO CAL calibration function During calibration process a blinking text "CAL run" will be show on the display. If calibration ends successfully, a text "CALIBRATION SUCCESSFUL" will be shown. Calibration can be cancelled with the = key, which will show a text "CALIBRATION CANCELLED". If calibration fails, the reason will be shown, eg. "CALIBRATION START FAILED", "POSITION SENSOR RANGE ERROR", "CALIBRATION TIMEOUT" or "CALIBRATION FAILED". After calibration the device will return to the main menu (measurement monitoring). If the calibration is not finished in 10 minutes, the "calibration timeout" error is shown TUNE Automatic Tuning After selecting this option the number of strokes will be asked: NBR 5. The user is able to change this number between The default value is 5 full strokes (open and close). Calibration selection WARNING: Automatic calibration drives the valve against the mechanical open and closed travel limits of the valve-actuator assembly and a tuning procedure is performed. Make sure that these procedures can be safely executed. During tuning process a blinking text "TUNE run" will be show on the display. If tuning ends successfully, a text "CALIBRATION SUCCESSFUL" will be shown. Tuning can be cancelled with the = key, which will show a text "CALIBRATION CANCELLED". If tuning fails, the reason will be shown, eg. "CALIBRATION START FAILED", "POSITION SENSOR RANGE ERROR", "CALIBRATION TIMEOUT" or "CALIBRATION FAILED". After tuning the device will return to the main menu (measurement monitoring). NOTE: Tuning is only needed if stroke profiles are used, i.e. stroke times are set other than 0 s Fig Online-alarm active If an online alarm has been detected the & symbol is activated. This symbol will disappear after the recovery from online alarm. You may view the reason for the alarm by viewing the latest event while pushing the = and - keys simultaneously or by using FieldCare software where all events may be viewed. Fig HART Communication active When double arrow symbol is indicated, HART communicaton is activated to device. Fig. 20 LUI locked Online alarm message Viewing of latest event scrolling text HART communication activated You may view the latest event by pressing the = and - keys simultaneously in the measurement monitoring view. The message is scrolled on the top row of the display twice. You may stop the scrolling by pressing the? key. By pressing the = key, the message will disappear. For the list of events see Chapter 6.

16 16 7 SG92H 70 en Fail-safe active When the SwitchGuard detects serious device failure (setpoint, valve position and control signals) it enters failsafe mode, which drives the control valve into the position defined in the parameter controller fail action (PFA). Fail-safe mode is indicated by the display as seen in Fig 21. The error message is displayed until the cause of error is eliminated and the SwitchGuard unit is restarted, i.e. the power loop is momentarily disconnected. Fig HART write protection The SG9200H is delivered from the factory with the default set as HART write protection OFF. Reading and changing parameters is allowed. HART protection may be enabled with a switch (DIP1) located on the communication circuit board under the Local User Interface module, Fig. 22. Changes that may influence the valve position cannot be made using the FieldCare software or HART hand held when switch no. 1 (on the left-hand side of the switch block) is ON. Fig. 22 Failsafe display ON 1 2 HART write protection 5 MAINTENANCE scrolling text Ex d NOTE: Maintenance of the parts of the flameproof enclosure is not allowed! Device type SG9200H_E1_: Housing (2), Cover (100), Shaft assembly (11), Limit switch housing (300). The maintenance requirements of the SwitchGuard valve controller depend on the service conditions, for instance, the quality of instrument air. Under normal service conditions there is no requirement for regular maintenance. When maintaining the SwitchGuard ensure that the supply air is shut off and pressure is released. In the following text the numbers in brackets ( ) correspond to the part numbers in the exploded view as shown in Chapter 11, unless otherwise stated. The Switchguard SG9200H includes the following modules: prestage unit (120), spool valve (420), communication circuit board with optional position transmitter (215) and controller circuit board with position and pressure sensors (210). The spool valve is located on the bottom side of the device while the other modules are located below the cover 100. In the event of failure the whole module must be changed. The module retrofit must be assembled in a clean, dry environment. On reassembly apply a thread-locking compound (for instance, Loctite 243) and tighten the screws firmly. NOTE: Whenever any maintenance operations have been done for the SG9200H, the device should be calibrated and tuned. 5.1 Opening and closing of the cover Open SG9000H cover (100) by opening the M4 screw (107) first until it is not anymore attached to the housing (2). Then turn the cover counterclockwise until it can be removed. Close the cover (100) in reverse order. Mount it first on top of the housing (2) and then turn it clockwise until threads are tight and the screw (107) is facing the spring (111) in the housing (2). Tighten the M4 screw (107). 5.2 Prestage NOTE: The prestage must be handled carefully. In particular the moving parts of the prestage should not be touched when the inner cover (39) is not in place Removal Loosen the M8 stop screw (110) in the position indicator (109) and turn the position indicator from the shaft (11). Remove the inner cover (39) attached with M3 screws (42, 3 pcs.). Unplug the prestage wire connector from the connector board (182). Unscrew the M4 screws (139, 2 pcs.) and lift up the prestage unit (120). Remove the O-ring (140) Installation Place a new O-ring (140) into the groove in the prestage mounting plate (400) and press the prestage into place. Make sure the nozzle is guided into the O-ring properly. The screws guide the prestage body into the correct position. Tighten the screws (139) evenly.

17 7 SG92H 70 en 17 Push the prestage 2-pole wire connector into the socket on the connector board (182). The wire connector can only be fitted in the correct position. Replace the inner cover (39) and tighten the M3 screws 5.3 Spool valve NOTE: Spool valve cannot be changed in the field. NOTE: If the maintenance operations are needed for the spool valve, it is advised to replace the whole spool valve assembly with a spare unit Restricted and standard Restricted and standard capacity means the spool valve options 12 and 15 in SG9212 and SG9215 respectively. type coding in the machine plate for details Removal For spool valve removal it is usually necessary to unmount the valve controller from the actuator. Working from the bottom side of the valve controller, unscrew the M5 screws (4 pcs.). Remove the spool valve (420) with gasket. The spool valve may be opened and cleaned if special attention is paid to a clean environment and proper procedure. Clean the spool and the bore of the body with care. Do not leave any fibres from cleaning materials in the bore or on the spool. Do not scratch the mating surfaces of the spool and body. NOTE: Each spool valve body has an individual corresponding spool which cannot be replaced by any other spool. Never alter the orientation of the spool, see Fig High capacity High capacity spool valve means the spool valve options 35 or 37 in SG9235 or SG9237. type coding in the machine plate for details Removal Unscrew the M5 screws (4 pcs.). Remove the spool valve (420) with gasket from the mounting block (421). The spool valve may be opened and cleaned if special attention is paid to a clean environment and proper procedure. Clean the spool and the bore of the body with care. Do not leave any fibres from cleaning materials in the bore or on the spool. Do not scratch the mating surfaces of the spool and body. NOTE: Each spool valve body has an individual corresponding spool which cannot be replaced by any other spool. Never alter the orientation of the spool, see Fig Installation Fig. 23 Ensure that the gasket (63) is properly located in the grooves in the bottom of the spool valve. Mount the spool valve (420) to the mounting block (421), and tighten the four M5 screws evenly. Required torque is 4.5 Nm. Spool valve assembly Installation Ensure that the gasket (174) is properly located in the grooves on the bottom of the housing. Mount the spool valve mounting plate (421) and the spool valve (420) to the housing, and tighten the four M5 screws evenly. Required torque is 4.5 Nm. The spool valve mounting plate (421) can be exchanged to convert capacity between resctricted (SG9212) and normal (SG9215). NOTE: If the maintenance operations have been done for the spool valve assembly, the device must always be calibrated and tuned.

18 18 7 SG92H 70 en 5.4 Communication circuit board Removal Loosen the M8 stop screw (110) in the position indicator (109) and turn the position indicator from the shaft (11). Remove the inner cover (39) attached with M3 screws (42, 3 pcs.). Remove the M3 screws (217, 4 pcs.). Hold the sides of the circuit board and lift it directly upwards and outwards. Handle the board carefully, touching only the sides. NOTE: Ground yourself on the body of the device before touching the circuit board Installation Mount the new communication circuit board carefully. Locate the pins with the matching connector on the board. Tighten the M3 screws (217) evenly. Install the inner cover (39). Mount the position indicator (109) on the shaft and tighten the M8 stop screw (110) temporarily. The final orientation and locking of the position indicator should be done after installation of the valve controller to the actuator. ATEX WARNING: Grounding of the circuit board is essential to explosion protection. The board is grounded to the housing by the mounting screw next to the terminal blocks. Fig Communication board ERROR MESSAGES NOTE: Parameter limits can only be changed via HART. DTM manual for setting the parameter limits. 5.5 Failsafe errors Display message CONTINUED INTERNAL BOOT FAILSAFE ACTIVATED PARAMETERS DATABASE ERROR PRESTAGE SHORTCUT ERROR SETPOINT SENSOR ERROR SUPPLY PRESSURE FAILSAFE ACTIVATED 5.6 Alarms Description Too many consecutive internal resets have been generated Device is in failsafe state Parameter database initialization failed Prestage coil shortcut has been detected Setpoint sensor defect has been detected Supply pressure has dropped below user defined alarm limit. This causes the device to go to the failsafe state Display message Description PNEUMATICS PROBLEM Actuator pressure difference has not changed even it should have been. Spool valve may be jammed TOO FAST VALVE CLOSING Valve was closed faster than ALARM was determined by alarm limit parameter TOO FAST VALVE OPENING Valve was opened faster than ALARM was determined by alarm limit parameter TOO SLOW VALVE CLOSING Valve was closed slower than ALARM was determined by alarm limit parameter TOO SLOW VALVE OPENING Valve was opened slower ALARM than was determined by alarm limit parameter UNINTENDED VALVE Valve position has changed MOVEMENT ALARM but setpoint is still in open or close position VALVE CLOSE STUCK Over 5 % difference between ALARM setpoint and valve position. Valve may be jammed at close position. Difference is a user configurable parameter VALVE INTERMEDIATE Over 5 % difference between STUCK ALARM setpoint and valve position. Valve may be stuck between open and close positions. Difference is a user configurable parameter VALVE OPEN STUCK ALARM Over 5 % difference between setpoint and valve position. Valve may be jammed at open position. Difference is a user configurable parameter

19 7 SG92H 70 en Errors 5.8 Warnings Display message Description CALIBRATION FAILED Calibration process has failed CALIBRATION START FAILED Calibration process could not be started CALIBRATION TIMEOUT Calibration process has taken too long time FACTORY SETTINGS CREATE FAIL Factory settings creation failed FACTORY SETTINGS Factory settings restoration RESTORE FAIL failed, i.e. current parameter set could not be loaded with factory settings INTERNAL BOOT RESET Software has lost the control and internal watchdog generated reset POSITION SENSOR FAILURE Position sensor defect has been detected POSITION SENSOR RANGE Too narrow position sensor ERROR range was detected in position calibration process PRESSURE SENSOR 1 FAILURE Pressure sensor #1 defect has been detected PRESSURE SENSOR 2 FAILURE Pressure sensor #2 defect has been detected PRESSURE SENSOR 3 FAILURE Pressure sensor #3 defect has been detected PRESTAGE CUT ERROR Prestage coil cut has been detected PRESTAGE SHORTCUT ERROR Prestage coil shortcut has been detected PT COMMUNICATION ERROR Communication with position transmitter was lost STATISTICS DATABASE ERROR Error occurred when writing statistics to database TEMPERATURE SENSOR FAILURE Temperature sensor defect has been detected Display message ACTUATOR FULL STROKES WARNING CLOSE STROKE DEVIATION WARNING OPEN STROKE DEVIATION WARNING REDUCED PERFORMANCE ACTIVATED SPOOL REACTION TIME CLOSE WARNING SPOOL REACTION TIME OPEN WARNING SUPPLY PRESSURE OUT OF LIMITS SUPPLY PRESSURE TREND WARNING TEMPERATURE OUT OF LIMITS TEMPERATURE TREND WARNING TOTAL OPERATION TIME WARNING VALVE FULL STROKES WARNING VALVE REACTION TIME CLOSE WARNING VALVE REACTION TIME OPEN WARNING 5.9 Notifications Display message CALIBRATION CANCELLED CALIBRATION SUCCESSFUL EXTERNAL RESET FACTORY DEFAULTS ACTIVATED REDUCED PERFORMANCE DEACTIVATED Description Actuator full stroke counter has exceeded the warning limit Valve close stroke deviation time trend has exceeded the warning limit Valve open stroke deviation time trend has exceeded the warning limit Controller can not perform boosting due to pressure sensor failure. Also, position sensor failure cause device to act like any normal solenoid device: position can not be controlled Spool valve reaction time close trend has exceeded the warning limit Spool valve reaction time open trend has exceeded the warning limit Supply pressure is out of warning limits Supply pressure trend value has exceeded the warning limits Temperature is out of warning limits Temperature trend value has exceeded the warning limits Total operating time has exceeded the warning limit Valve full stroke count has exceeded the warning limit Valve reaction time close trend has exceeded the warning limit Valve reaction time open trend has exceeded the warning limit Description Calibration process has been cancelled Calibration process has ended successfully Device has been booted, i.e. power-up reset Device parameters were changed to factory settings Recovery for reduced performance activation