Neles ValvGuard™ VG9200F - Documents

Neles ValvGuard™ VG9200F - Documents
Neles ValvGuard™
VG9200F
Rev. 1.1
Installation, Maintenance and
Operating Instructions
7 VG92F 70 en • 11/2010
2
7 VG92F 70 en
Table of Contents
1
2
3
4
5
6
7
VG9200F VALVGUARD
INTELLIGENT SAFETY VALVE CONTROLLER
WITH FOUNDATION FIELDBUS
COMMUNICATION.......................................... 3
1.1 General .................................................. 3
1.2 Technical description ............................. 3
1.3 Markings ................................................ 3
1.4 Technical specifications ......................... 4
1.5 Recycling and disposal .......................... 5
1.6 Safety precautions ................................. 5
TRANSPORTATION, RECEPTION AND
STORAGE ....................................................... 6
MOUNTING...................................................... 6
3.1 General .................................................. 6
3.2 Mounting on Metso actuators with VDI/VDE
mounting face ........................................ 6
3.3 Mounting on linear actuator with
IEC 60534 mounting face ...................... 7
3.4 Piping ..................................................... 8
3.5 Electrical connections .......................... 10
LOCAL USER INTERFACE (LUI) ................. 11
4.1 Measurement monitoring ..................... 11
4.2 Guided start-up .................................... 12
4.3 Configuration menu.............................. 12
4.4 Configuration parameters .................... 12
4.5 Valve travel calibration......................... 15
4.6 Testing ................................................. 15
4.7 Limit Switch LS status.......................... 16
4.8 Advance parameters............................ 16
4.9 Special displays ................................... 17
MAINTENANCE............................................. 18
5.1 Prestage .............................................. 18
5.2 Spool valve .......................................... 18
5.3 Communication circuit board ............... 19
MESSAGES................................................... 20
TROUBLE SHOOTING.................................. 21
8
9
10
11
12
13
14
15
VG92_/K_, VG92_/I_, VG92_/D_
(WITH LIMIT SWITCHES) ............................. 22
8.1 Introduction .......................................... 22
8.2 Installing VG92_F/K_, VG92_F/I_ or
VG92_F/D_ on a valve controller ......... 24
8.3 Electrical connections .......................... 24
8.4 Adjustment ........................................... 24
8.5 Removal of the limit switches VG92_F/K_,
VG92_F/I_ or VG92_F/D for accessing
the valve controller............................... 24
8.6 Circuit diagrams ................................... 25
8.7 Maintenance ........................................ 25
TOOLS........................................................... 25
ORDERING SPARE PARTS ......................... 25
DRAWINGS AND PARTS LISTS .................. 26
11.1 Exploded view and parts list, VG92_J.. 26
11.2 Exploded view and parts list,
VG92_/_, VG92_J/__ ........................... 28
11.3 Mounting parts for Metso actuators
with VDI/VDE mounting face................ 30
11.4 Mounting parts for Quadra-Powr®
actuators .............................................. 30
11.5 Mounting parts for linear actuators ...... 31
11.6 Connection diagrams ........................... 32
DIMENSIONS ................................................ 37
CONFIGURATION PARAMETERS............... 40
EC DECLARATION OF CONFORMITY ........ 41
TYPE CODING .............................................. 42
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about the safe handling and operation of the intelligent safety valve 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.
7 VG92F 70 en
1
1.1
VG9200F VALVGUARD
INTELLIGENT SAFETY VALVE
CONTROLLER WITH FOUNDATION
FIELDBUS COMMUNICATION
General
This manual incorporates Installation, Maintenance and
Operation Instructions for the Metso’s Neles ValvGuard
safety valve controller. The VG9200F may be used with
either cylinder or diaphragm type pneumatic actuators
for rotary or linear valves.
3
reads the input signal, position sensor (α) and pressure
sensors (Ps, P1, P2 and P3). This information is used to
run the partial stroke tests and other tests. .
NOTE:
Micro controller is only able to control the prestage if
safety signal is present (24 V DC). Micro controller can
never prevent the safety action to happen since safety
action is the same as there’s no voltage in the safety
signal line.
1.2
PIPING FOR DOUBLE-ACTING ACTUATORS ONLY
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.
Technical description
Neles ValvGuard VG9000F is a microcontroller-based
safety valve controller and partial stroke test device
with FOUNDATION fieldbus communication. Addition to
FOUNDATION fieldbus there is also a separate binary
24 V DC signal needed. It is isolated from the fieldbus
and powers the safety part.
Main components of ValvGuard are spool valve (SV),
prestage unit (PR) and micro controller (µC). Spool
valve and prestage unit are the only components,
which takes part of the safety action. Spool valve controls the main airflow between supply-, actuator- and
exhaust connections. The spool is operated by spring
force to fail safe position and by pneumatic force generated by the prestage valve to the normal position. The
prestage valve is coil operated flapper valve (normally
open). Coil of the prestage is energized with the safety
signal (24 V DC) and controlled by the micro controller.
Micro controller cannot prevent the safety action. Pressure sensors (Px) and position sensor (α) are used to
getting the measurements for controlling the PST and
other tests. Measurements from the sensors are used
for the device diagnostics.
The device contains a Local User Interface enabling
local configuration. A PC with FieldCare software can
be used for advanced configuration and diagnostics.
The powerful 32-bit microcontroller controls the valve
position during partial stroke and other special testing.
The measurements include:
❑
Safety 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 any measurement
does not cause the valve to go to fail-safe position if the
safety signal is operating correctly. After connections of
electric signals (FOUNDATION fieldbus and binary 24 V
DC) and pneumatic supply the micro controller (µC)
Fig. 1
1.3
The principle of operation
Markings
The valve controller is equipped with an identification
plate sticker (Fig. 2).
Fig. 2
Example of the identification plate
Identification plate markings from top to bottom include:
❑
Type designation of the safety controller
❑
Enclosure class
❑
Revision number
❑
Input signal (voltage range)
❑
Input resistance
❑
Maximum supply voltage
❑
Supply pressure range
❑
Operational temperature
❑
CE mark
❑
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: PH10011234 = controller, year 2010, week 1,
consecutive number 1234.
4
1.4
7 VG92F 70 en
Technical specifications
ATEX NOTE:
This manual contains technical specifications for
several types of the VG9200F 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.
VG9237
feed 380 Nm3/h / 223 scfm (Cv = 3.2)
exhaust 700 Nm3/h / 412 scfm (Cv = 6.4)
Consumption with 4 bar/60 psi supply:
actuator pressurized 0.22 Nm3/h / 1.13 scfm,
actuator vented 0.25 Nm3/h / 1.14 scfm
Spool valve identifiers:
Standard version SG9215_ SPCZ/2163/2
SG923_ SPCZ/2164/2
VG9200F SAFETY CONTROLLER
Electronics
General
Electrical connection: max. 2.5 mm2
FOUNDATION fieldbus powered diagnostics, 24 V DC
power from safety system for the safety part.
Suitable for rotary and sliding-stem valves.
Actuator connections in accordance with VDI/VDE 3845
and IEC 60534-6 standards.
Action:
Double or single acting
Travel range:
Linear: 10–120 mm
Rotary: 45–95°
Measurement range 110° with freely
rotating feedback shaft
Environmental influence
Standard temperature range:
-20° to +85 °C / -4° to +185 °F
Influence of vibration on valve position
under 2g 5–150 Hz,
1g 150–300 Hz, 0.5g 300–2000 Hz
Open and closed position: no effect
Deviation from profile (only with device usage type hybrid):
<10 %
Enclosure
Material:
Anodised aluminium alloy and
glass window
Protection class:
IP66, NEMA 4X
Pneumatic ports: VG9215
VG9235
VG9237
1/4 NPT
1/2 NPT
1 NPT (1/2 NPT supply)
(single acting only)
Conduit entry thread: M20 x 1.5
Weight:
VG9215
3.0 kg / 6.6 lb
VG9235
4.6 kg / 10.1 lb
VG9237
5.0 kg / 11 lb
limit switch options plus 1.0 kg / 2.2 lb
Mechanical and digital position indicator visible
through the main cover
Safety Signal (Binary input)
Connections:
24 V DC: '+' and '-'
Min voltage:
11 V DC
Max output resistance: Ro = 285 Ω
Ex ia IIC T4/T5/T6: Ui ≤ 28 V
Ii ≤ 150 mA
Pi ≤ 1.0 W
Ci < 15 nF
Li < 10 µH
Ex nA IIC T4/T5/T6: n/a
Ex d IIC T5/T6 Gb:
Ui ≤ 28 V
Pi ≤1.0 W
FOUNDATION fieldbus
Connections:
H1: '+' and '-'
Power supply:
taken from bus
Bus voltage:
9 to 32 V DC, reverse polarity protection
Max basic current: 14.2 mA
Operating current: 20.7 mA
Fault current (FDE): 6.3 mA
Ex d IIC T5/T6 Gb:
Ui ≤ 32 V
Ii ≤ 380 mA
Pi ≤ 5.32 W
Ex ia IIC T4/T5/T6: Ui ≤ 24 V
(pending)
Ii ≤ 380 mA
Pi ≤ 5.32 W
Ci < 5 nF
Li < 10 µH
Ex nL IIC T4/T5/T6: Ui ≤ 32 V
(pending)
Ii ≤ 380 mA
Pi ≤ 5.32 W
Ci < 5 nF
Li < 10 µH
FOUNDATION fieldbus function block execution times
Supply pressure: 3.0–7.5 bar / 44–109 psi
MDO
MDI
AI
Air quality:
Local user interface functions
Pneumatics
According to ISO 8573-1:2001
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:
VG9215
90 Nm3/h / 53 scfm (Cv = 0.7)
VG9235
380 Nm3/h / 223 scfm (Cv = 3.2)
15 ms
15 ms
20 ms
Depends on the usage option selected (see Chapter 4
for details).
❑
❑
❑
❑
Monitoring of valve position, temperature, supply,
actuator pressure difference, device usage
option and binary signal (on or off)
Guided start-up function
LUI may be locked remotely to prevent unauthorised access
Calibration: Automatic
7 VG92F 70 en
5
❑
❑
❑
❑
Positioner fail action, open/close
Actuator type: double/single acting
Valve type: rotary/linear IEC
Testing: Partial Stroke Test (automatic test enabled or disabled), Pneumatics test
❑
Language selection: English, German and French
APPROVALS
Safety
TÜV
IEC 61508 compliant up to
and including SIL 3
Intrinsically safe and non incendive
ATEX (pending)
CSA (pending)
FM (pending)
II 1 G Ex ia IIC T4...T6
II 2 G Ex ia IIC T4...T6
II 3 G Ex nA IIC T4...T6
II 3 G Ex nL IIC T4...T6
CAN/CSA-C22.2-0,-142, -157;
CAN/CSA-E60079-0,-11, -15
IS Class I, Div. 1, Groups A, B, C, D T4...T6
IS Class I, Zone 0, Ex ia IIC T4...T6
NI Class I, Div. 2, Groups A, B, C, D T4...T6
FM Class 3600, 3610, 3611, 3810:
IS Class I, Div. 1, Groups A, B, C, D T4...T6
IS Class I, Zone 0, AEx ia IIC T4...T6
NI Class I, Div. 2, Groups A, B, C, D T4...T6
NI Class I, Zone 2, Ex nA II T4...T6
Flameproof and explosion proof
ATEX / IECEx
II 2 G Ex d IIC T5/T6 Gb
(EN60079-0, EN60079-1)
CSA (pending)
Explosion proof Class I, II and III,
Division 1 and 2, Groups B, C, D, E, F
FM (pending)
Explosion proof Class I, II and III,
Division 1 and 2, Groups A, B, C, D, E, F
Electromagnetic protection
Safety precautions
CAUTION:
Opening the cover of VG9200F field device enclosure
is allowed for authorized and trained persons only!
Misuse of powered VG9200F field device may cause
a dangerous situation.
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 ValvGuard 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:
Make sure the enclosure exhaust port will not be
clogged!
It may prevent the device to do the safety action.
CAUTION:
Make sure that during the maintenance or commissioning when the device cover is open, water does
not go inside the enclosure.
Electromagnetic compatibility
Emission acc. to EN 61000-6-4 (2001)
and FCC 47 CFR PART 15,
SUBPART B, CLASS B (1994)
Immunity acc. to EN 61000-6-2 (2001)
WARNING:
During calibration and tuning the valve operates
between open and closed positions. Make sure
that the operation does not endanger people or
processes!
89/336/EEC
Electromagnetic compatibility
WARNING:
Do not operate the device with the cover removed!
Electromagnetic immunity is reduced, valve may
stroke.
CE marking
94/9/EC
ATEX
1.5
1.6
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.
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
7 VG92F 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
(part 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!
3
MOUNTING
3.1
General
NOTE:
The enclosure of ValvGuard safety valve controller meets
the IP66 protection class according to EN 60529 in any
position when the cable entry is plugged according to IP66.
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 ValvGuard is supplied with valve and actuator, the
tubes are mounted and the ValvGuard 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-VG9235FE6
The controller is equipped for connection according to
VDI/VDE 3845. 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. 4.
For mounting parts for Metso actuators, see 11.3 - 11.5.
Ex d and Ex n WARNING:
Use a cable gland with suitable Ex d and Ex n 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 VG9200F valve controller.
Damage to the equipment may result.
2
TRANSPORTATION, RECEPTION
AND STORAGE
The safety 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.
3.2
Mounting on Metso actuators
with VDI/VDE mounting face
See figures in Section 11.3.
❑
❑
❑
❑
❑
❑
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.
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 11.3. Secure the screw of the ear using e.g.
Loctite and tighten firmly.
Attach the bracket (1) to the ValvGuard.
Attach the bracket (1) to the actuator. The shaft coupling of the ValvGuard must fit into the ear (2) so that
the pointer is located in the position shown in Fig.3.
NOTE:
Special care must be taken that the shaft position has
been set according to marking in VG9000F housing
and the pointer in the shaft. Also make sure that the
positioner fail action parameter (PFA) is set correctly
(Section 4.4.3).
7 VG92F 70 en
7
❑
❑
C2
11
S
C1
Fig. 3
3.3
The pointer on the coupling must
stay in this sector
Mounting on Metso actuator with VDI/VDE
mounting face
Mounting on linear actuator with IEC
60534 mounting face
See figure in Section 11.5
❑
❑
❑
❑
❑
Attach the feedback arm with spacer to the controller shaft. Note the position of the pointer on the
shaft as in 11.5. Apply thread locking compound
to the screws and tighten firmly. Attach the spring
to the feedback arm as shown in Section 11.5.
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.
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 11.5. 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.
NOTE:
Special care must be taken that the shaft position has
been set according to marking in VG9000F housing
and the pointer in the shaft. Also make sure that the
positioner fail action parameter (PFA) is set correctly
(Section 4.4.3).
VDI/VDE 3845 mounting
IEC 60534 mounting
45°
Fig. 4
45°
pointer
pointer
mark on
housing
mark on
housing
Shaft coupling alternatives
8
7 VG92F 70 en
3.4
Piping
NOTE:
An excess of sealant may result in faulty operation of
the controller.
Sealing tape is not recommended.
Do not exceed torque of 30 Nm/22 lbf ft when fitting
1/4" NPT connectors to C1, C2 and S (VG921_).
Ensure that the air piping is clean.
CAUTION:
Do not exceed the permitted supply pressure of
the ValvGuard!
Table 2 provides the recommended tube sizes in accordance with actuator sizes. Tube sizes are the minimum values allowed. For supply air choose a tube one size bigger.
NOTE:
A valve controller mounted on a spring actuator must
be connected only as single-acting. See Fig. 5.
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.
The air supply must be clean, dry and oil-free instrument
air, see Section 1.4.
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 ValvGuard must not fall
below 3 bar. Also note that if the air supply system
allows the pressure at the ValvGuard to fall below the
actuator minimum supply pressure during valve movement the stoke speed will be affected.
NOTE:
When extra instrumentation is used without bypass
valve, VG with small spool valve (VG_15_) is required.
Connect the air supply to S. Connect C1 and C2 to the
actuator, see Fig. 5. C1 must be plugged if single-acting actuator.
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.
Liquid sealants, such as Loctite 577 are recommended
for the pipe threads.
Table 2
Piping and stroke times
Actuator
B1C
Stroke vol.
dm3 / in3
NPT
6
0.3
18
1/4
9
0.6
37
1/4
11
1.1
67
3/8
13
2.3
140
3/8
17
4.3
262
1/2
20
5.4
330
1/2
25
10.5
610
1/2
32
21
1282
3/4
40
43
2624
3/4
50
84
5126
1
60
121
7380
1
75
189
11500
1
502
195
11900
1
602
282
17200
1
752
441
26900
1
B1J
B1JA
Stroke vol.
dm3 / in3
NPT
8
0.9
55
3/8
10
1.8
110
3/8
12
3.6
220
1/2
16
6.7
409
1/2
20
13
793
3/4
25
27
2048
3/4
32
53
3234
1
322
106
6468
1
VG_15_
Supply 1/4" NPT
Actuator 1/4" NPT
Piping
Open
Close
(s)
(s)
6 mm
0.6
0.6
or 1/4"
6 mm
1.0
1.1
or 1/4"
10 mm
0.7
0.7
or 3/8"
10 mm
1.3
1.4
or 3/8"
10 mm
2.0
2.3
or 3/8"
10 mm
2.4
2.6
or 3/8"
10 mm
4.5
4.9
or 3/8"
10 mm
9.4
9.4
or 3/8"
10 mm
19
19
or 3/8"
10 mm
38
38
or 3/8"
10 mm
54
54
or 3/8"
10 mm
85
85
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
Piping
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
10 mm
or 3/8"
87
87
126
126
197
197
Air
(s)
Spring
(s)
0.5
1.0
0.7
1.4
1.2
2.7
3.2
4.8
4.6
9.3
8.9
18
15
38
31
77
VG_35_
Supply 1/2" NPT
Actuator 1/2" NPT
Piping
Open
Close
(s)
(s)
VG_37_ (Single acting only)
Supply 1/2" NPT
Actuator 1" NPT
Piping
Open
Close
(s)
(s)
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1.3
1.5
-
-
-
2.4
2.7
-
-
-
4.9
5.6
-
-
-
9.6
11
-
-
-
14
16
-
-
-
22
25
-
-
-
22
25
-
-
-
32
37
-
-
-
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
50
57
-
-
-
Air
(s)
Spring
(s)
Piping
Air
(s)
Spring
(s)
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0.7
1.3
-
-
-
1.4
2.6
-
-
-
2.5
2.9
4.3
5.3
8.5
11
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"
2.9
5.4
4.9
11
9.8
21
25 mm
or 1"
25 mm
or 1"
25 mm
or 1"
7 VG92F 70 en
9
SINGLE-ACTING ACTUATOR, SPRING TO CLOSE
1. Self closing
C2
S
C1
Default setting:
ATYP = 1-A
PFA = CLO (must be in the spring direction)
VTYP according to valve type
SINGLE-ACTING ACTUATOR, SPRING TO OPEN
2. Self opening
C2
S
C1
Default setting:
ATYP = 1-A
PFA = OPE (must be in the spring direction)
VTYP according to valve type
DOUBLE-ACTING ACTUATOR
3. Self closing
C2
S
C1
Default setting:
ATYP = 2-A
PFA = CLO
VTYP according to valve type
DOUBLE-ACTING ACTUATOR, REVERSED PIPING
4. Self opening
C2
S
Default setting:
ATYP = 2-A
PFA = OPE
VTYP according to valve type
C1
Fig. 5
Operation directions, air connections and assembly related parameters
10
3.5
7 VG92F 70 en
Electrical connections
The VG9200F diagnostics part is powered by FOUNDATION fieldbus (IEC 61158-2). The same bus cable is
used also for the fieldbus communication. (Connections H1: '+' and '-', see Section 1.4 for electrical ratings).
Output from the safety system is used to power the
safety part. (Connections 24 V DC: '+' and '-').
See Section 11.6. for detailed connections.
The signal cables are led through M20 x 1.5 cable
glands.
Conductors to the terminal strip are prewired as shown
in Fig. 6. See Section 11.6 for detailed electric connections. The earthing of the cables shall be carried out at
HAZARDOUS LOCATION
Fig. 6
Prewired terminals in the circuit board
NONHAZARDOUS LOCATION
VG9200F
Associated
apparatus
24 V Safety signal
(Binary input)
Entity Parameters:
Ui ≤ 28.0 V
Ii ≤ 150 mA
Pi ≤ 1.0 W
Ci < 15 nF
Li < 10 µH
+
24 VDC
-
Entity Parameters:
Uo ≤ Ui
Io ≤ Ii
Po ≤ Pi
FOUNDATION Fieldbus
Entity Parameters:
Ui ≤ 24.0 V
Ii ≤ 380 mA
Pi ≤ 5.32 W
Ci < 5 nF
Li < 10 µH
+
H1
-
Entity Parameters:
Uo ≤ Ui
Io ≤ Ii
Po ≤ Pi
connect the cable
shield to earth ground
Fig. 7
VG9200F Connection diagram. Shown ratings are for intrinsically safe installations.
See Section 1.4. for other installations.
7 VG92F 70 en
4
11
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
4.1
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.
Local user interface (LUI)
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
Valve position
(POS)
Default unit
Percentage
(%) of full
scale
24 V DC input
signal (INP)
Actuator
pressure
difference
(PDIF)
Housing
pressure
(Pint)*
Supply
pressure
(SUPL)
Device
temperature
(TEMP)
Device usage
(USAG)
–
Optional unit Values
Angle (ANG), –
where 0 %
refers to 0
(angle)
–
On, OFF
bar (BAR)
psi (PSI)
— continuous push
–
— brief push
bar (BAR)
psi (PSI)
–
Fig. 9
bar (BAR)
psi (PSI)
–
Valve position (POS) shows the valve travel position in
percentage (%) of full scale. Optional unit is angle.
°Celsius (C)
°Fahrenheit (F) –
Input signal (INP) shows if the 24 V DC input signal is
connected (On) or not (OFF).
–
–
Safety (SAF),
On/Off (Ono),
Hybrid (HYb)
* Not in use in rev 1.1
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
Measurement monitoring and unit change
Actuator pressure difference (PDIF) shows the actuator pressure in single acting actuators or pressure difference in double acting actuators in bars (BAR).
Optional unit is psi (PSI).
Housing pressure (Pint) shows the pressure inside
the enclosure in bars (BAR). This is not in use in rev 1.1.
Supply pressure (SUPL) shows the air supply pressure
value in bars (BAR). Optional unit is psi (PSI).
12
7 VG92F 70 en
Device temperature (TEMP) shows the temperature
inside the device in degree Celsius (C). Optional unit is
degree Fahrenheit (F).
Device usage (USAG) shows if the device is set to operate as safety (SAF) device, On/Off (Ono) device or
Hybrid (HYb) device.
❑
Safety usage means that FOUNDATION fieldbus
powers up the diagnostic part of the device and
emergency action is implemented by the safety
system signal.
❑
On/Off usage means that FOUNDATION fieldbus
powers up the diagnostic part of the device, and
on/off action is implemented by the 24 V DC signal from the DCS. Device not used as an emergency valve controller. All closing actions are
then normal valve operations.
❑
Hybrid usage means that VG9000F can perform
normal on/off valve operation (i.e. closing or
opening) or Partial Stroke Test (PST) through
FOUNDATION fieldbus communication. In this
way the DCS can control the valve opening/closing and PST implementation and the safety system controls the safety action implementation.
NOTE: Default value is safety device.
NOTE: Device usage can only be changed via DD, i.e.
using fieldbus configurator.
4.2
Guided start-up
Guided startup offers a fast view of the most critical
parameters of the ValvGuard 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 4.4:
Actuator type
Valve type
Positioner fail action
Extra Pneumatics Instrumentation
Actuator size
Spool valve type
Automatic travel calibration
ATYP
VTYP
PFA
EXTI
ACTS
STYP
CAL
If you modify any of the parameters you will also need to
calibrate the device. See 4.5 for detailed description.
NOTE:
You may cancel any action by pressing the = button.
Cancelling of operation returns user interface view one
level up in menu hierarchy.
— brief push
Fig. 10
4.3
Guided start-up
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
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. Depending on the device usage option
selected (safety, on/off, hybrid) the menu has different
parameters, see Figures 11–13. NOTE: Device usage
option can not be selected from LUI, only from DD. 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. See also table in Chapter 13.
NOTE:
Default values can be restored by using DTM.
7 VG92F 70 en
13
— brief push
Fig. 12
— brief push
Fig. 11
Configuration. Device usage: safety
Configuration. Device usage: on/off
14
7 VG92F 70 en
4.4.1 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 1-A or 2-A using the +
and - keys. The value 1-A indicates a single acting actuator and 2-A a double acting actuator.
To conclude press the ? key when the desired
value is shown on the display.
4.4.2 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.
4.4.3 Positioner fail action, PFA
This section describes the function of the actuator.
Set value according to Fig. 5 for double acting actuators. Generally set value according to the valve fail safe
position. 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.
See 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.
4.4.4 Extra pneumatics instrumentation, EXTI
Only used when device usage type is Safety or Hybrid.
In order to optimise the control performance the device
needs to be informed about the extra pneumatics instrumentation, if any.
❑
❑
— brief push
Fig. 13
Configuration. Device usage: hybrid
After selecting EXTI on the display, press the ?
key to enter the edit state and EXTI starts to blink.
Select between the following values:
non = no external instrumentation
bo1 = booster type 1
bo2 = booster type 2
bo3 = booster type 3
qE1 = quick exhaust type 1
qE2 = quick exhaust type 2
qE3 = quick exhaust type 3
co1 = combination type 1
co2 = combination type 2
7 VG92F 70 en
15
❑
To conclude press the ? key when the desired
value is shown on the display.
co3 = combination type 3
Use the + and - keys to change the value.
❑
To conclude press the ? key when the desired
value is shown on the display.
NOTE: If nothing else is defined, please select type 1 in
any class.
4.4.7 Language selection, LANG
❑
❑
Select parameters as follows:
Table 4
Selecting extra pneumatics instrumentation
parameters
Instrumentation type
Volume booster (VB)
Quick exhaust (QEV)
Combination of VB and QEV
Parameter (EXTI)
Booster type 1 (bo1)
Quick exhaust 1 (qE1)
Combination type 1 (co1)
NOTE: Bypass valve is mandatory with volume boosters
and QEV. Contact Metso for separate instrumentation
diagrams and instructions.
NOTE: When QEV is used, VG with small spool valve
(VG_15_) is required.
4.4.5 Actuator size, ACTS
This parameter defines the actuator size.
❑
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.
4.5
Valve travel calibration
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.
NOTE:
Make sure to run the pneumatics test before the automatic travel calibration.
Select CAL from the menu by using + or - keys and
press the ? key.
CAUTION:
It is important to select the correct actuator size
because this parameter is used in device control.
Erroneous value may cause instability.
❑
❑
❑
❑
Look at e.g. the type code on the machine plate
in the Neles B1-series actuators to check the
size. If 3rd party actuator is used, please check
the actuator stroke volume.
After selecting ACTS on the display, press the ?
key to enter the edit state and ACTS starts to blink.
Select between the following values:
S 1
= Neles B1C6-9 or B1J8 actuator
(or stroke volume <1 dm3 / <61 in3)
S 3 = B1C11-13, B1J10 (1-3 dm3 / 61-183 in3)
S10 = B1C17-25, B1J16 (3-10 dm3 / 183-610 in3)
S30 = B1C32, B1J20-25 (10-30 dm3 / 610-1831 in3)
L30 = B1C40-, B1J32- (>30 dm3 / >1831 in3)
Use the + and - keys to change the value.
To conclude press the ? key when the desired
value is shown on the display.
4.4.6 Spool type, STYP
This parameter defines the spool type and size in
VG9000F.
CAUTION:
It is important to select the correct spool type
because this parameter is used in device control.
Erroneous value may cause instability.
❑
❑
❑
Look at the machine plate in the device to check
the typecode.
After selecting STYP on the display, press the ?
key to enter the edit state and STYP starts to blink.
Select between the following values:
15
= VG9215
35
= VG9235
37
= VG9237
Use the + and - keys to change the value.
Fig. 14
Calibration selection
NOTE: When device usage is hybrid the valve needs to
be in the normal position (not fail safe) for calibration to
be started.
4.5.1 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 TOO
SMALL", "CALIBRATION
TIMEOUT" or "CALIBRATION
FAILED". After calibration the device will return to the
main menu (measurement monitoring).
4.6
❑
❑
Testing, TESt
Select between two tests Partial Stroke Test
(PARt tst) or Pneumatics test (PNEU tst).
To conclude press the ? key when the desired
value is shown on the display.
4.6.1 Partial Stroke Test, PARt tst
WARNING:
Partial Stroke Test moves the valve according to
the stroke size. Make sure that this procedure can
be safely executed.
NOTE: Only used when device usage type is Safety or
Hybrid.
Partial stroke test can be run from here. Partial stroke test
will be run according to the stroke size (MStr) described
in Section 4.8. Advance parameters.
16
7 VG92F 70 en
NOTE: Max speed of the partial stroke test is always
restricted to 3 %/s.
❑
Select PARt tst from the menu by using + or
- keys and press the ? key.
Test can be cancelled by pressing =.
Slow Starting & Ending
Quick Starting
valve travel
❑
Linear
Equal Percentage
Slow Starting
100
90
80
70
NOTE:
Pneumatics test (Section 4.6.2.) will be run automatically before the partial stroke test in some cases, e.g.
when supply pressure has changed. Pneumatics test
timeout parameter is valid also in this case.
60
50
40
30
20
4.6.2 Pneumatics test, PNEU tst
10
0
Pneumatics test can be run from here.
❑
❑
Select PNEU tst from the menu by using + or
- keys and press the ? key.
This will check the pneumatics function of the
device by moving the spool valve only and not
moving the actuator or the valve.
Test can be cancelled by pressing =.
10
Fig. 15
20
30
40
50
60
70
80
90
100
% of stroke time
Stroke profile shapes, opening
Linear
Slow Starting & Ending
Quick Starting
valve travel
❑
0
Equal Percentage
Slow Starting
100
90
80
NOTE:
Pneumatics test timeout parameter is 600 s. The value
is hardcoded and cannot be changed.
70
60
50
4.7
Limit Switch LS status
40
LS shows the status of bus powered (VG9_/B_) mechanical limit switches:
30
--CLO
OPE
LSE
No limit switch active
Limit switch "Closed" active
Limit switch "Open" active
Limit switch error, both switches activated
at the same time
10
4.8
Advance parameters
Only used when device usage type is Safety or Hybrid.
4.8.1 Stroke time and profile,
STOP, STCL, SPOP, SPCL
20
0
0
Fig. 16
Opening and closing times can be set with STOP (open) and
STCL (close) parameters. Parameter is given in seconds.
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 stroke time to 0.
20
30
40
50
60
70
80
90
100
% of stroke time
Stroke profile shapes, closing
4.8.2 Manual Stroke Size, MSTr
Targeted manual partial stroke test size. Range is 3.0–
100 %.
❑
❑
NOTE: Only used when device usage type is Hybrid.
Valve open and close profiles can be configured with
Neles ValvGuard 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.
10
❑
Once MSTr is displayed, press the ? key to enter
the edit state and the MSTr will start blinking.
Select values by pressing the + or - key. Holding down + or - key will start scrolling the
value show on the display faster.
After the desired value is displayed, press the
key ? to conclude the operation.
4.8.3 Automatic Partial Stroke Test, APSt
Selection if automatic partial stroke test is disabled (diS),
enabled (EnA) or enabled with randomized range (rnd).
❑
Select between three options dis, EnA or rnd
using the + and - keys.
❑
To conclude press the ? key when the desired
value is shown on the display.
NOTE: Automatic partial stroke test stroke size and other
parameters can not be changed from the LUI. They can
only be changed via FOUNDATION fieldbus, e.g. in the
DTM.
7 VG92F 70 en
4.9
17
Special displays
For the list of events see Chapter 6.
4.9.1 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 only via
FOUNDATION fieldbus DD. When the Local User Interface is locked the lock symbol will be activated on the
display.
scrolling text
Fig. 19
Online alarm or warning state message
4.9.4 Write protection
The VG9200F is delivered from the factory with HW write
protection OFF as the default setting. Reading and
changing parameters is thus allowed. Write protection
can be enabled with the switch (DIP1) located on the circuit board. If you need to change the setting, please
contact Metso’s Automation business for instructions.
Fig. 17
LUI locked
4.9.2 Alarm or warning state
All failure conditions and statuses in VG9000F can be
individually configured to three different classes: Alarm,
Warning or Info, or they can be ignored. This configuration can be done with DTM (see separate DTM manual).
Alarm state causes a blinking & to be shown on the display. In Warning state, the & symbol is steady.
Device in Alarm state
Device in Warning state
Fig. 18
Alarm and Warning states
4.9.3 Viewing of latest event
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.
Write protection protects all write access to all writeable
parameters of the device. Changing the parameters
from the LUI, fieldbus configurator or FieldCare is thus
not allowed.
18
5
7 VG92F 70 en
MAINTENANCE
Ex d NOTE:
Maintenance of the parts of the flameproof enclosure is not allowed!
Device type VG9200F_E6_:
Housing (2), Cover (100), Shaft assembly (11), Limit
switch housing (300).
NOTE:
VG9000 maintenance can be done by Metso certified
service personnel only.
The maintenance requirements of the ValvGuard 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 ValvGuard 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 ValvGuard VG9200F includes the following modules: prestage unit (120), spool valve (420), communication circuit board 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 VG9200F, the device should be calibrated.
5.1
Prestage
5.1.2 Adapter plate removal
❑
5.1.3 Installation
❑
❑
❑
5.2
5.1.1 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).
Install the new adapter plate, if it has been
removed. Make sure the O-rings (411) are properly installed. Tighten the screw (412).
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.
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.
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.
5.2.1 Standard capacity
5.2.1.1 Removal
For spool valve removal it is usually necessary to
unmount the valve controller from the actuator.
❑
NOTE:
Prestage cannot be changed in the field.
NOTE:
The prestage and adapted plate 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. Make sure the prestage and
adapter plate are kept clean during the maintenance.
Remove the screw (412) and remove the adapter
plate. Adapter plate is only needed to be
removed when replaced with new one.
Working from the bottom side of the valve controller, unscrew the M5 screws (4 pcs.). Remove
the spool valve (420) with gasket (63). Do not
remove the spool valve adapter plate (421).
5.2.1.2 Installation
❑
Mount the spool valve (420) to the housing, and
tighten the four M5 screws evenly.
NOTE:
If adapter plate (421) is lifted away from its place, special attention must be paid to ensure that gasket (174)
and pipe (431) are properly attached to the housing.
O-rings of the pipe must be handled carefully in order
to avoid breakage.
5.2.2 High capacity
5.2.2.1 Removal
❑
Unscrew the M5 screws (4 pcs.). Remove the
spool valve (420) with gasket from the mounting
block (421).
7 VG92F 70 en
19
5.2.2.2 Installation
❑
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.
215
Fig. 21
Fig. 20
5.3
Spool valve assembly
Communication circuit board
NOTE:
Communication circuit board cannot be changed in
the field.
5.3.1 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.
5.3.2 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.
Communication board
20
6
7 VG92F 70 en
MESSAGES
These messages may appear in the local user interface.
Display message
Description
ACTUATOR FULL STROKES Actuator full stroke counter
COUNTER LIMIT EXCEEDED has exceeded the
configurable limit
CALIBRATION CANCELLED Calibration process has
been cancelled
CALIBRATION FAILED
Position calibration process
has failed
Calibration process has
failed
Calibration process has
failed
Coil calibration process has
failed
CALIBRATION START
Calibration process could
FAILED
not be started
CALIBRATION
Position calibration process
SUCCESSFUL
has ended successfully
Pressure calibration process
has ended successfully
Coil calibration process has
ended successfully
CALIBRATION TIMEOUT
Calibration process has
taken too long time
CONTINUED WATCHDOG
Too many consecutive
RESET
internal resets have been
generated
DEVICE USAGE CHANGED - Device usage (Safety/OnOff/
PLEASE REBOOT THE
Hybrid) was changed
DEVICE
EMERGENCY TRIP
Emergency trip was
ACTIVATED
activated
ETT CLOSING TIME TOO
Too high closing time
HIGH
detected in emergency trip
test
ETT OPENING TIME TOO
Too high opening time
HIGH
detected in emergency trip
test
FACTORY DEFAULTS
Device parameters were
ACTIVATED
changed to factory settings
FACTORY SETTINGS
Factory settings creation
CREATE FAILURE
failed
DETECTED
FACTORY SETTINGS
Factory settings restoration
RESTORE FAILURE
failed, i.e. current parameter
DETECTED
set could not be loaded with
factory settings
FIELDBUS
Communication with FBICOMMUNICATION FAILURE board was lost
RATE LIMIT EXCEEDED
PARAMETERS POOL
Parameter database
FAILURE DETECTED
initialization failed
PNEUMATICS FAILURE
Actuator pressure difference
DETECTED
has not changed even it
should have been. Spool
valve may be jammed
POSITION SENSOR FAILURE Position sensor defect has
DETECTED
been detected
POSITION SENSOR RANGE Too narrow position sensor
TOO SMALL
range was detected in
position calibration process
PRESSURE SENSOR 1
Pressure sensor #1 defect
FAILURE DETECTED
has been detected
PRESSURE SENSOR 2
Pressure sensor #2 defect
FAILURE DETECTED
has been detected
PRESSURE SENSOR 3
Pressure sensor #3 defect
FAILURE DETECTED
has been detected
PST BREAKAWAY
Too high breakaway pressure
PRESSURE TREND HIGH
detected in manual or
LIMIT EXCEEDED
automatic partial stroke test
PST BREAKAWAY
Too low breakaway pressure
PRESSURE TREND LOW
detected in manual or
LIMIT EXCEEDED
automatic partial stroke test
PST COUNTER LIMIT
EXCEEDED
Partial stroke test counter
has exceeded the
configurable limit
PST LOAD FACTOR TREND Too high load factor detected
HIGH LIMIT EXCEEDED
in manual or automatic
partial stroke test
PST LOAD FACTOR TREND Too low load factor detected
LOW LIMIT EXCEEDED
in manual or automatic
partial stroke test
STATISTICS DATABASE
Error occurred when writing
ERROR DETECTED
statistics to database
STROKE CLOSE TIME
Too high close stroke time
TREND LIMIT ECXCEEDED detected in OnOff device
STROKE OPEN TIME TREND Too high open stroke time
LIMIT ECXCEEDED
detected in OnOff device
SUPPLY PRESSURE LIMIT
Supply pressure is out of
EXCEEDED
warning limits
SUPPLY PRESSURE TREND Supply pressure trend value
LIMIT EXCEEDED
has exceeded the
configurable limits
TEMPERATURE LIMIT
Temperature is out of
EXCEEDED
warning limits
TEMPERATURE SENSOR
Temperature sensor defect
FAILURE DETECTED
has been detected
TEMPERATURE TREND
Temperature trend value has
LIMIT EXCEEDED
exceeded the configurable
limits
TEST CANCELLED
Automatic partial stroke test
was cancelled
Automatic or manual
pneumatic test was
cancelled
Emergency trip test was
cancelled
Manual partial stroke test
was cancelled
TEST DONE
Automatic Partial Stroke Test
has been completed
Automatic or manual
pneumatic test has been
completed
Emergency trip test has been
completed
Manual partial stroke test has
been completed
TEST FAILED
Automatic partial stroke test
failed
Automatic or manual
pneumatic test failed
Emergency trip test failed
Manual partial stroke test
failed
TEST OVERSHOOT
Overshoot was detected in
DETECTED
manual or automatic partial
stroke test
TEST PRESSURE DROP
Pressure drop was detected
DETECTED
in manual or automatic
partial stroke test. This
applies only for single acting
actuators.
TEST START FAILED
Couldn't start automatic
partial stroke test
Couldn't start automatic or
manual pneumatic test
Couldn't start emergency trip
test
Couldn't start manual partial
stroke test
TEST START FAILED Couldn't start test because
DEVICE IN ALARM STATE
device was in alarm state
TEST TIMEOUT DETECTED Test timeout was reached
TOTAL OPERATION TIME
Total operating time has
COUNTER LIMIT EXCEEDED exceeded the configurable
limit
7 VG92F 70 en
UNALLOWED VALVE
MOVEMENT DETECTED
Valve position has changed
but setpoint is still in open or
close position
VALVE CLOSE STUCK
Over 5 % difference between
DETECTED
setpoint and valve position.
Valve may be jammed at
close position. Difference is
a user configurable
parameter
VALVE FULL STROKES
Valve full stroke count has
COUNTER LIMIT EXCEEDED exceeded the configurable
limit
VALVE INTERMEDIATE
Over 5 % difference between
STUCK DETECTED
setpoint and valve position.
Valve may be stuck between
open and close positions.
Difference is a user
configurable parameter
VALVE OPEN STUCK
Over 5 % difference between
DETECTED
setpoint and valve position.
Valve may be jammed at
open position. Difference is a
user configurable parameter
SPOOL VALVE STUCK
No spool valve movemenent
DETECTED
detected during pneumatics
test
PRESTAGE CUT DETECTED Prestage coil cut has been
detected
TEST START FAILED User has disabled all tests
TEST DISABLED MODE
TEST START FAILED Invalid valve position in PST
INVALID START POSITION
CALIBRATION FAILED Too low supply pressure to
TOO LOW SUPPLY
perform position calibration
CALIBRATION FAILED Emergency trip has occurred
EMERGENCY TRIP ACTIVE during position calibration
CALIBRATION FAILED Calibration function is
CALIBRATION ALREADY
already active
ACTIVE
CALIBRATION FAILED Alarm state prevents
ALARM STATE ACTIVE
calibration
HOUSING PRESSURE LIMIT Housing pressure has
ECXCEEDED
exceeded the detection limit
NOTE:
Parameter limits can only be changed via FF.
21
7
TROUBLE SHOOTING
Mechanical/electrical defects
1. Any request to change the valve position has no affect
to the position
❑
❑
❑
❑
Supply pressure too low
Incorrect configuration parameters
Actuator and/or valve jammed
Signal wires incorrectly connected, no value on
display
❑
Circuit boards are defective
❑
Calibration has not been carried out
❑
Prestage is defective
❑
Spool valve sticks
2. Inaccurate positioning
❑
Too high actuator load
❑
Supply pressure too low
❑
Pressure sensors are defective
❑
Actuator leakage
❑
Spool valve dirty
3. Overshooting or positioning too slow
❑
❑
❑
Supply air tube too small or supply air filter dirty
Valve sticks
Check leakages in tubes between controller and
actuator
❑
Check leakages in mechanical stop screws
❑
Spool valve dirty
4. Error during valve travel calibration
❑
❑
❑
❑
❑
Check the coupling alignment with the pointer,
see Fig. 4.
The parameter setting PFA incorrectly selected
The actuator or valve did not move or was stuck
during calibration
Supply pressure too low
Spool valve dirty
22
7 VG92F 70 en
8
VG92_/K_, VG92_/I_, VG92_/D_
(WITH LIMIT SWITCHES)
8.1
Introduction
8.1.1
2 proximity
switches
2 cams
terminals
General description
VG9200F can be equipped with limit switches. VG92_/
K2_ has two microswitches, VG92_/K4_ has four microswitches, VG9200F/I__ has two inductive proximity
switches, VG92_/B_ has two bus powered mechanical
micro switches and VG92_/D_ has a Dual Module sensor
with two inductive proximity switches. Limit switches are
used for electrical position indication of the valves and
other devices.
M20 x 1.5
ground
M20 x 1.5
The switching points may be chosen freely.
2 micro switches
2 cams
Fig. 24
VG92_/I_ (I02, I09, I56) layout
2 proximity
switches
2 cams
terminals
terminal
M20 x 1.5
ground
M20 x 1.5
ground
M20 x 1.5
Fig. 22
M20 x 1.5
VG92_/K2_ layout
4 micro switches
4 cams
Fig. 25
VG92_/I45 layout
2 micro switches
2 cams
terminals
terminals
M20 x 1.5
ground
M20 x 1.5
ground
M20 x 1.5
M20 x 1.5
Fig. 23
VG92_/K4_ layout
Fig. 26
VG92_/B_ layout
7 VG92F 70 en
23
Protection class
Dual module
terminals
2 cams
M20 x 1.5
ground
M20 x 1.5
Fig. 27
VG92_/D_ layout
8.1.2
Markings
The limit switch is provided with an identification plate
sticker, see Fig. 28. Identification plate markings from
top to bottom are:
❑
Type designation
❑
Electrical values
❑
Temperature range
❑
Enclosure class
❑
Conduit entry
❑
Manufacturing serial number
The type designation is described in Chapter 15.
IP68 (02, 09, 45)
IP67 (56)
P+F NJ2-12GK-SN (02)
P+F NCB2-12GM35-N0 (09)
P+F NJ3-18GK-S1N (45)
ifm IFC2002-ARKG/UP (56)
Other switch types on special order
Electrical values: According to switch type
Switch accuracy: < 1°
Number of switches: 2
Protection class of housing:
IP66 (DIN 40050, IEC 60529)
SIL:
Usable up to SIL3 acc. to
IEC61508 (02, 45)
Usable up to SIL2 acc. to
IEC 61508 (09)
Conduit entry:
M20 x 1.5
Ambient temperature: -20° to +51 °C /-4° to +124 °F (02)
-20° to +85 °C / -4° to +185 °F (09, 45)
-20° to +80 °C / -4° to +176 °F (56)
Weight:
Approx. 1.0 kg / 2.2 lb
(limit switches only)
8.1.3.3 VG92_/B_
Microswitch type: OMRON D2VW-01
(gold-plated contacts)
Protection class IP67
(06)
Resistive load:
100 mA: 30 V DC/125 V AC (06)
Switch accuracy: < 2°
Number of switches: 2
Protection class of cover:
IP66 (DIN 40050, IEC 60529)
Conduit entry:
Fig. 28
Identification plate
8.1.3
Technical specifications
Ambient temperature: -20° to +80 °C / -4° to +176 °F
Weight:
8.1.3.1 VG92_/K_
Microswitch type: OMRON D2VW-5 (K25 or K45)
OMRON D2VW-01 (K26 or K46)
(gold-plated contacts)
Protection class IP67
Resistive load:
3A: 250 V AC (K25 or K45)
5A: 30 V DC
0.4A: 125 V DC
100 mA: 30 V DC / 125 V AC (K26 or K46)
Switch accuracy: < 2°
Number of switches: 2 (K25 or K26), 4 (K45 or K46)
Protection class of housing: IP66 (DIN 40050, IEC 60529)
Conduit entry:
M20 x 1.5
Ambient temperature: -20° to +80 °C / -4° to +176 °F
Weight:
Approx. 1.0 kg / 2.2 lb
(limit switches only)
8.1.3.2 VG92_/I_
Proximity switch:
Inductive, diameter 8–18 mm)
Sensing range
2 mm (02, 09, 56)
3 mm (45)
M20 x 1.5
Materials:
Body:
Internal parts:
Sealing:
Approx. 1.0 kg / 2.2 lb
(limit switches only)
Aluminium alloy, epoxy-coated
Stainless steel and polymer
Nitrile and neoprene rubber
8.1.3.4 VG92_/D_
Proximity switch:
Inductive, Dual Module
2 sensors,
Normally Open (D33),
Normally Closed (D44)
Electrical values:
SST Dual Module (D33)
Indications:
Target on sensor = LED on
Target off sensor = LED off
Operating voltage: 8–125 V DC; 24–125 V AC
Maximum voltage drop:
6.5 V / 10 mA
7.0 V / 100 mA
Current ratings:
Max inrush
2.0 A / 125 V DC / V AC
Max continuous 0.3 A / 125 V DC / V AC
Minimum on current 2.0 mA
24
7 VG92F 70 en
Leakage current
<0.15 mA with DC voltage
<0.25 mA with AC voltage
Namur Dual Module (D44)
Indications:
Target on sensor = LED off
Target off sensor = LED on
Operating voltage: 6–29 V DC
Current ratings:
the position of the cam discs (313) on the shaft. The
lower switch is activated at the closed limit and the
upper switch at the open limit.
❑
With the actuator in the open or closed position,
locate the switching point by turning the cam
disc so that the switch state changes approx. 5°–6°
before the limit.
Target on (LED off) <1.0 mA
Target off (LED on) >3.0 mA
16
15
14
13
12
11
Must use intrinsically safe repeater barrier.
Namur sensors conform to DIN 19234 standard.
Number of switches: 2
Protection class of housing: IP66 (DIN 40050, IEC 60529)
Conduit entry:
Close
Open
M20 x 1.5
Ambient temperature: -20° to +80 °C / -4° to +176 °F
Weight:
8.2
Approx. 1.0 kg / 2.2 lb
(limit switches only)
Installing VG92_F/K_, VG92_F/I_ or
VG92_F/D_ on a valve controller
Fig. 29
The limit switch may be installed on an existing valve
controller.
❑
❑
❑
❑
❑
❑
❑
❑
8.3
If the valve controller is already mounted on an
actuator/valve assembly, operate the actuator
into the closed or open position.
Remove the cover (100), the pointer (109), the
LUI (223) and electronics cover (39).
Turn the shaft (311) onto the shaft (11). Fasten
the screw (312) using a locking agent such as
Loctite.
Mount the electronics cover (39) and the limit
switch housing (300) on the valve controller. Lock
the housing in place with screw (326). Install the
base plate (324) with the limit switches and connector block into the limit switch housing. Fasten
the base plate with screws (325), 3 pcs.
Install the cam discs (313) and spacers (346) to
the shaft.
Mount the LUI (223) on the holder (306).
Replace the plastic plugs with metal ones in conduit entries which will not be used.
Mount the pointer (109) on the shaft (311). Adjust
the limit switch according to 8.4.
Electrical connections
Before connecting the power, make sure that the electrical specifications and the wiring meet the installation
conditions. See the diagrams in 11.6. Refer to the information on the identification plate.
VG9200/I or VG9200/D: Observe the functioning of the
proximity switch; activated when the active face is
either covered or free.
8.4
18
17
C
Close
16
15
14
13
12
11
Fig. 30
❑
❑
❑
8.5
❑
❑
❑
Adjustment
The pointer (109) need not be removed for adjustment.
When the limit switch is ordered together with the valve
and the actuator, the valve controller switches are factory-adjusted. The limits may be adjusted by altering
Limit switch adjustment, 2 switches
❑
C
O
Open
O
Limit switch adjustment, 4 switches
VG9200/I00 or VG9200/D: Use the LED indicator
or a separate measuring instrument as an aid.
After re-installation of the actuator, first adjust its
mechanical limits according to the valve, then
the valve controller, and finally the limit switch.
When adjustment is completed, turn the pointer
(109) so that the yellow line is parallel with the
valve closure member.
Removal of the limit switches
VG92_F/K_, VG92_F/I_ or VG92_F/D
for accessing the valve controller
Remove the cover (100) and the pointer (109).
Loosen the screws (314) in the cam disks (313)
and remove the cam disks and spacers (346)
from the shaft.
Remove the LUI cabling from the circuit board.
Disconnect and remove all cabling which enters
the limit switch housing (300).
Remove screws (325), 3 pcs and lift out the limit
switch base plate (324) complete with switches,
LUI and connector block.
7 VG92F 70 en
❑
❑
❑
❑
Open screw (326) and turn the limit switch housing (300) from the positioner housing.
Remove the electronics cover (39).
Proceed with the valve controller as applicable.
Re-install the limit switch according to 8.2 and
check the adjustment according to 8.4.
ATEX WARNING:
The locking screw of the limit switch housing (Part
326) is essential to explosion protection.
The limit switch housing has to be locked in place for
Ex d protection. The screw grounds the limit switch
housing to the housing of the valve controller.
8.6
Circuit diagrams
The internal circuitry of the limit switch is shown in the
connection diagrams in 11.6 and inside the cover.
8.7
Maintenance
Regular maintenance of the limit switch is not necessary.
9
TOOLS
Following tools are needed for the product installation
and service:
❑
❑
❑
Flat screwdriver
❑ 2.0 x 060 mm
Torx screwdriver
❑ T20
Hexagon screwdrivers
❑ 3 mm
6 mm
10
ORDERING SPARE PARTS
Spare parts are delivered as modules. The modules
available are indicated in 11.1.
When ordering spare parts, always include the following information:
❑
❑
type code, sales order number, serial number
number of the parts list, part number, name of
the part and quantity required
This information can be found from the identification
plate or documents.
25
26
11
7 VG92F 70 en
DRAWINGS AND PARTS LISTS
11.1 Exploded view and parts list, VG92_J
100
107
110
109
228
223
42
39
217
218
215
219
220
210
183
203
182
139
120
412
140
400
411
19
18
104
222
221
73
420
417
428
72
63
11
2
424
426
427
421
63
428
433
434
435
429
62
61
437 353
417
426
427
421
432
431
432
174
15
16
12*
14*
416
62
61
422
432
431
VG923_
36
423
62
61
421
63
420
VG921_
57
111
436
7 VG92F 70 en
Item
2
11
15
16
18
19
36
39
42
57
61
62
63
72
73
100
104
107
109
110
111
120
139
140
174
182
183
210
215
217
218
219
220
221
222
223
228
353
400
411
412
416
417
420
421
422
423
424
426
427
428
429
431
432
433
434
435
436
437
Qty
1
1
1
1
1
1
1
1
3
1
1
2
4
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
4
1
2
2
3
1
1
2
2
1
2
1
2
1
1
1
1
4
2
1
1
6
4
2
4
4
1
1
1
1
27
Description
Housing
Shaft assembly
O-ring
Washer
Wave spring
Bushing
Grounding screw
Protection cover
Screw
Conduit entry adapter
Exhaust cover
Screw (ISO 1)
Screw (ISO 3)
Gasket
Cooling plate
Screw
Cover
O-ring
Screw
Pointer
Stop screw
Spring
Prestage unit
Screw
O-ring
Gasket
Prestage board
Screw
Controller circuit board
Communication circuit board
Screw
Support
Screw
Threaded spacer
O-ring
Insulation part
Local User Interface (LUI)
Screw
Nut
Adapter plate
O-ring
Screw
O-ring
O-ring
Spool valve
Adapter plate
Adapter plate
Screw
Screw
Plate
O-ring
Screw
Screw
Connection pipe
O-ring
Screw
Flange
O-ring
Connection box
Nipple
AVAILABLE SPARE PART SETS:
- LUI (Local User Interface)
- Pointer
- Cover
- Limit switches
28
7 VG92F 70 en
11.2 Exploded view and parts list,
VG92_/_, VG92_J/__
100
D00
323
I45
322
I02, 09, 56
351
K200
K400
358
360
348
110
109
349
350
358
357
107
308
223
347
349
355
347
348
359
313
307
346
306
314
355
315
366
305
304
365
367
325
324
367
305
366
301
302
365
315
304
300
326
309
111
104
311
312
437 353
309
111
436
7 VG92F 70 en
Item
100
107
109
110
111
223
300
301
302
304
305
306
307
308
309
311
312
313
314
315
322
323
324
325
326
346
347
348
349
350
351
353
355
357
358
359
360
365
366
367
436
437
Qty
1
1
1
1
2
1
1
1
1
2
4
1
3
2
2
1
2
2 or 4
2 or 4
1 or 2
1
2
1
2
1
1
2
1
2
1
1
2
2 or 4
2
2
1
2
1 or 2
2 or 4
2 or 4
1
1
29
Description
Cover
Screw
Pointer
Stop screw
Spring
Local user interface (LUI)
Housing
O-ring
Screw
Bracket
Screw
Bracket
Screw
Screw
Plug
Extension shaft
Screw
Cam disc
Screw
Terminal block
Proximity switch
Screw
Base plate
Screw
Screw
Bearing bushing
Proximity switch
Fixing plate
Screw
Washer
Screw
Nut
Microswitch
Spring washer
Screw
Support band
Screw
Bracket
Screw
Hex nut
Connection box
Nipple
30
7 VG92F 70 en
11.3 Mounting parts for Metso actuators with VDI/VDE mounting face
Item
1
2
3
4
13
14
28
29
36
47
48
53
11.4
Qty
1
1
2
2
4
4
4
1
1
1
2
1
Description
Mounting bracket
Ear
Washer
Screw
Screw
Hexagon nut
Screw
Screw
Couplings jacket
Coupler socket
Screw
Plug (BJ actuators only)
Mounting parts for Quadra-Powr® actuators
VG9200
VG9200
Item
1
2
4
28
29
30
35
Qty
1
1
4
4
1
4
1
35
1
36
47
48
53
1
1
2
1
Description
Mounting bracket
Ear
Screw
Screw
Screw
Screw
Adapter plug
(QP II 1/S- 6/S only)
Adapter plate
(QP II 2B/K thr. 6_/K)
Couplings jacket
Coupler socket
Screw
Plug
Item
1
2
3
4
5
6
7
8
9
10
47
48
53
Qty
1
2
1
4
4
1
4
4
4
4
1
2
1
Description
Mounting bracket
Coupling half
Adapter
Screw
Hex nut
Screw
Screw
Washer
Screw
Washer
Coupler socket
Screw
Plug
7 VG92F 70 en
31
11.5 Mounting parts for linear actuators
Feedback lever in horizontal position
at mid travel of stroke.
45°
Stroke 10 - 80 mm
9
11
Stroke 60 - 120 mm
Plane in the shaft in this position
with feedback lever
45°
45°
12
11
14
3
6
5
19
18
15
17
16
Maximum stroke 80 mm
1
4
45°
2
7
45°
Maximum stroke 120 mm
Scale on this side
8
Allowed travel range 45–90°
Item
1
2
3
4
5
6
7
8
9
11
12
14
15
16
17
18
19
54
Qty
1
1
1
1
4
4
4
4
4
4
2
2
1
1
1
2
2
2
Description
Bracket
Feedback lever
Filling piece
Clearance remove spring
Cross rec head screw
Washer
Hexagon screw
Washer
Hexagon screw
Spring washer
Hexagon nut
Clamp
Fixing plate
Special screw
Hexagon nut
Washer
Hexagon screw
Plug
32
7 VG92F 70 en
11.6 Connection diagrams
See Section 8.1.3 for additional limit switch data.
FOUNDATION fieldbus and Safety Signal (Binary Input) connections
6
blue
H1
brown
5
black
red
4
24 V DC
3
Note: Cable colors are valid only when separate junction box (type code option J)is used.
VG92_F/I02, I09
VG92_F/I45
BLUE
OPEN
A
11
BROWN
BLUE
CLOSED
K
S1N
OPEN
13
A
14
BROWN
S1N
CLOSED
16
K
BLACK 11
12
BLUE
BROWN 13
BLACK 14
15
BLUE
BROWN 16
L-
L+
L-
L+
Factory adjustment:
Active faces of proximity switches are covered when actuator is in intermediate position.
Active face A (upper switch) becomes free at open limit of travel and face K (lower switch) at closed limit.
Function can be inverted on site by re-adjusting the cam discs.
Sensing distance 2...4 mm, depending on type of switch
Current consumption
active face free, > 3 mA
active f ace covered, < 1 mA
PROXIMITY SWITCH
Intrinsically safe II 1 G Ex ia IIC T6.
According to EN 60079-0:2006, EN 60079-11:2007.
Voltage (Ui), current (Ii), power (Pi), inductance (Li) and
capacitance (Ci) according to certificate of switch, see table below.
Type of proximity switch
Ui
Electrical values
Ii
Pi
Li
Ex classification
Certificate
Ci
(V) (mA) (mW) (µH) (nF)
02
09
45
P+F NJ2-12GK-SN
P+F NCB2-12GM35-N0
P+F NJ3-18GK-S1N
16
16
16
52
52
52
169
169
169
150
100
200
50
90
70
II 1 G Ex ia IIC T6
II 1 G Ex ia IIC T6
II 1 G Ex ia IIC T6
PTB 00 ATEX 2049 X
PTB 00 ATEX 2048 X
PTB 00 ATEX 2049 X
7 VG92F 70 en
33
VG92_F/I56
OPEN
A
CLOSED K
BLACK
11
BLACK
13
BLACK
14
BLACK
16
DC
DC
Factory adjustment:
Active faces of proximity switches are free when actuator is in intermediate position. Active face A (upper
switch) becomes covered at the open limit of the travel and face K (lower switch) at the closed limit.
Function can be inverted on site by re-adjusting the cam discs.
Connections: Load can be connected to + or -.
PROXIMITY SWITCH
ifm electronic IFC2002-ARKG/UP
2-wire type
Sensing distance 2 mm
Rated voltage U = 10 - 36 V DC
Output current < 150 mA
active face covered, LED on
Quiescent current < 0,6 mA
active face free
Ambient temperature -20 ... +80 °C / -4 ... +176 °F
34
7 VG92F 70 en
VG92_F/D33
SOL 1
SOL 2
SOL PWR 1
SOL PWR 2
TOP SW NO
TOP SW C
BTM SW NO
BTM SW C
Connections SOL1, SOL2, SOL PWR1 and SOLPWR2 are not used.
TOP SW NO: Positive connection for top switch
TOP SW C: Negative connection for top switch
BTM SW NO: Positive connection for bottom switch
BTM SW C: Negative connection for bottom switch
See Section 8.1.3.4 for electrical ratings.
VG92_F/D44
SOL 1
SOL 2
SOL PWR 1
SOL PWR 2
TOP SW +
TOP SW BTM SW +
BTM SW -
Connections SOL1, SOL2, SOL PWR1 and SOLPWR2 are not used.
TOP SW +:
TOP SW -:
BTM SW +:
BTM SW -:
Positive connection for top switch
Negative connection for top switch
Positive connection for bottom switch
Negative connection for bottom switch
See Section 8.1.3.4 for electrical ratings.
7 VG92F 70 en
35
VG92_F/B06
LS1
O
12
13
LS2
C
15
16
1: LS1 (open)
2: LS2 (closed)
3: GND
1 2 3
Bus powered switches, no external connections.
36
7 VG92F 70 en
VG92_F/K25, K26, K45, K46
RED
A
OPEN
OPEN
A
CLOSED K
11
BLUE
12
BLACK
13
RED
14
BLUE
15
BLACK
16
BLACK
12
BLUE
13
BLACK
14
RED
K
2 pcs.
11
RED
A
RED
BLUE
CLOSED
BLUE
15
BLACK
16
RED
K
BLUE
17
BLACK
18
4 pcs.
Connection diagram shows limit switch when actuator is in intermediate position.
Switch A (upper) is activated at the open limit of the travel and switch K (lower) at the closed limit.
Electrical characteristics:
OMRON D2VW-5 (K_5):
3 A - 250 V AC, 0.4 A - 125 V DC,
5 A - 30 V DC
OMRON D2VW-01, gold plated contacts (K_6):
100 mA - 30 V DC / 125 V AC
Ambient temperature -20 ... +80 °C / -4 ... +176 °F
7 VG92F 70 en
DIMENSIONS
47
95
190
min. 60
VG921_ or VG921_/_
VG921_E6: M20x1.5
25
VDI/VDE 3845
174
103
5/16UNCx13
63
31
30
39
1/4NPT
26
33
161
26.8
33
ø6
M6x10
14.5
(35.4)
62
F05-
47
190
min. 60
VG923_ or VG923_/_
VG923_E6: M20x1.5
25
VDI/VDE 3845
243
5/16UNCx13
31
72
63
30
172
32
26.8
26
ø6
151
161
12
37
M6x10
14.5
42.4
62
28
(35.4)
F05-
38
7 VG92F 70 en
VG921_J
151
31
35.4
162
min. 60
103
63
M20x1.5
35.4
(VDI/VDE 3845)
F05-ø50
M6
67
30
133
5/16UNC
33
15
33
47
100
39
M6x12
4
25
ø6
14
52
1/4 NPT
3
9
25
14
26.8
VG923_J
151
35.4
231
min. 60
172
63
133
67
31
M20x1.5
5/16UNC
35.4
(VDI/VDE 3845)
F05-ø50
47
M6
30
14
72
M6x12
4
3
32
25
ø6
14
42
28
1/2 NPT
26.8
25
9
15
100
7 VG92F 70 en
39
min. 60
VG921_J/_
47
95
190
M20x1.5
25
174
(35.4)
5/16UNCx13
31
30
39
1/4NPT
63
F05- 50
VDI/VDE 3845
62
103
33
161
26.8
33
26
ø6
M6x10
107
14.5
50
67
min. 60
VG923_J/_
47
190
M20x1.5
25
VDI/VDE 3845
F05- 50
62
243
42.4
(35.4)
28
172
31
72
63
30
5/16UNCx13
32
151
M6x10
14.5
107
161
26.8
26
ø6
50
67
40
13
7 VG92F 70 en
CONFIGURATION PARAMETERS
Parameter Name
Actuator Type (Atyp)
Valve Type (Vtyp)
Positioner Fail Action (PFA)
Extra Pneumatics Instrumentation (EXTI)
Actuator size (ACTS)
Spool type (STYP)
Stroke Profile Open (SPOP)
Stroke Profile Close (SPCL)
Stroke Time Open (STOP)
Stroke Time Close (STCL)
Automatic Partial Stroke Test (APSt)
Manual Partial Stroke Test Size (MSTr)
Language (LANG)
Values
Single acting actuator (1-A)
Double acting actuator (2-A)
Rotary (rot)
Linear (Lin)
Close (CLO)
Open (OPE)
non = none
bo1 = Volume Booster type 1
bo2 = Volume Booster type 2
bo3 = Volume Booster type 3
qE1 = Quick Exhaust type 1
qE2 = Quick Exhaust type 2
qE3 = Quick Exhaust type 3
co1 = Combination type 1
co2 = Combination type 2
co3 = Combination type 3
S 1 = B1C6-9, B1J8 (<1 dm3 / <61 in3)
S 3 = B1C11-13, B1J10 (1-3 dm3 / 61-183 in3)
S10 = B1C17-25, B1J16 (3-10 dm3 / 183-610 in3)
S30 = B1C32, B1J20-25 (10-30 dm3 / 610-1831 in3)
L30 = B1C40-, B1J32- (>30 dm3 / >1831 in3)
15 = VG9215
35 = VG9235
37 = VG9237
1 = linear
2 = slow starting
3 = slow starting and ending
4 = equal percentage
5 = quick starting
0 = undefined profile (cannot be selected from LUI)
1 = linear
2 = slow starting
3 = slow starting and ending
4 = equal percentage
5 = quick starting
0 = undefined profile (cannot be selected from LUI)
dis = auto PST disabled
EnA = auto PST enabled
rnd = auto PST enabled with randomized range
English (EnG)
German (GEr)
French (FrE)
Visibility by Device Usage
Safety
Hybrid
On/Off
x
x
x
Default value
1-A
x
x
x
rot
x
x
x
CLO
x
x
x
x
x
S1
x
x
x
15
Unit
non
x
1 (linear)
x
1 (linear)
x
x
10
10
dIS
0–999
0–999
s
s
10.0
EnG
3.0–100.0
%
x
x
x
Valid range
x
x
x
7 VG92F 70 en
14
41
EC DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
Manufacturer:
Metso Automation Oy
00811 Helsinki
Finland
Product:
Intelligent Safety Valve Controller Neles ValvGuard VG9000-series
Approvals:
Type
VG92_F_E6_/_
VG92_H_E6_/_
VG92_H_X1_/_
VG92_H_X2_/_
VG92_H_X3_/_
Approval
ATEX II 2 G
ATEX II 2 G
ATEX II 1 G
ATEX II 2 G
ATEX II 3 G
Applicable directives:
EMC 89/336/EC and 93/68/EC
ATEX 94/9/EC
Ex d IIC T5/T6 Gb
Ex d IIC T5/T6 Gb
Ex ia IIC T4/T5/T6 Ga
Ex ia IIC T4/T5/T6 Gb
Ex nA nL IIC T4/T5/T6 Gc
EC Type examination Certificate
ZELM 07 ATEX 0342 X
ZELM 07 ATEX 0342 X
KEMA 10 ATEX0125 X
KEMA 10 ATEX0125 X
KEMA 10 ATEX0126
Electrical components
Electrical and non-electrical components
As the products within our sole responsibility of design and manufacture may be used as parts or components in machinery and are not
alone performing functions as described in Article 6(2) in the Machinery Directive (2006/42/EC), we declare that our product(s) to which
this Declaration of Conformity relates must NOT be put into service until the relevant machinery into which it is to be incorporated has
been declared in conformity with the provisions of the Machinery Directive.
The product above is manufactured in compliance with the applicable European directives and technical specifications/standards.
Protection from e.g. static electricity caused by the process or connected equipment must be considered by the user (EN 60079-14 §6).
The product do not possess any residual risk according to hazard analyses made under the applicable directives providing that the
procedures stated by the Installation, Operation and Maintenance manual are followed and the product is used under conditions
mentioned in the technical specifications.
Manufacturer’s certificates:
Standard / Directive
Notified Body
Certificate No.
ISO 9001:2000
ATEX 94/9/EC Annex IV
DNV
DNV 0575
24888-2008-AQ-FIN-FINAS
DNV-2006-OSL-ATEX-0260Q
Helsinki 15 June 2010
Ralf Liljestrand, Quality Manager
Authorized person of the manufacturer within the European Community
42
7 VG92F 70 en
15
TYPE CODING
VALVGUARD VG9200F
1.
VG
2.
9
3.
2
4.
12
15
35
37
1.
2.
3.
4.
5.
6.
VG
9
2
15
F
E6
PRODUCT GROUP
Neles ValvGuard, Intelligent Safety Controller.
TÜV SIL 3 certified according to IEC 61508.
7.
SERIES CODE
Series 9000 Intelligent safety valve controller with universal shaft and
attachment face according to standard VDI/VDE 3845.
Relevant shaft adapter included in mounting kits. When valve
controllers are separate deliveries, shaft adapter kit is supplied.
Y
ENCLOSURE
Standard IP66/NEMA 4X enclosure.
Temperature range -20° to +85 °C / -4° to +185 °F.
2 pcs. M20x1.5 conduit entry when limit switches (8. sign) are not included.
4 pcs. M20x1.5 conduit entry when limit switches (8. sign) are included.
SPOOL VALVE
Restricted capacity.
Standard capacity.
Stroke volume of actuator < 13 dm3
High capacity.
Stroke volume of actuator > 13 dm3
Extended capacity.
Single acting actuators.
S, C1, C2 = 1/2 NPT
I45
S = 1/2 NPT, C2= 1 NPT
6.
N
APPROVALS FOR HAZARDOUS AREAS
No approvals for hazardous areas.
ATEX certifications (pending):
II 1 G Ex ia IIC T4...T6
VG9_FX1:
Ui < 28 V, Ii < 120 mA, Pi < 1 W, Li = 53 µH, Ci = 22 nF.
Temperature range: T4; -20° to +80 °C / -4° to +176 °F,
T5; < +65 °C / < +149 °F, T6; < +50 °C / < +122 °F.
Not available with limit switches.
ATEX certifications (pending):
II 2 G Ex ia IIC T4...T6
VG9_FX2:
Ui = 28 V, Ii = 120 mA, Pi = 1 W, Li = 53 µH, Ci = 22 nF.
Temperature range: T4; -20° to +80 °C / -4° to +176 °F,
T5; < +65 °C / +149 °F, T6; < +50 °C / +122 °F.
Only available with ATEX certified inductive limit switches (e.g. I02, I09).
ATEX certifications (pending):
II 3 G Ex nA IIC T4...T6
No Zener Barrier needed.
VG9_FX3:
Ui = 30 V, Pmax = device limits itself.
Temperature range: T4; -20° to +85 °C / -4° to +185 °F,
T5; < +75 °C / +167 °F, T6; < +60 °C / +140 °F.
Available without limit switches or with ATEX certified inductive limit
switches (e.g. I02, I09)
ATEX and IECEx certifications:
II 2 G Ex d IIC T5/T6 Gb
VG9_FE6:
Safety signal: Ui ≤ 28 V, Pi ≤ 1.0 W
FF signal: Ui ≤ 32 V, Ii ≤ 380 mA, Pi ≤ 5.32 W
Temperature range:
T5; -20° to +80 °C / -4° to +176 °F
T6; -20° to +70 °C / -4° to +158 °F
Available with or without limit switches.
X3
E6
I02
I09
COMMUNICATION / INPUT SIGNAL RANGE
FOUNDATION fieldbus, physical layer according to IEC 61158-2
X2
8.
CONNECTIONS
S, C1, C2 = 1/4 NPT
S, C1, C2 = 1/4 NPT
5.
F
X1
J
I56
D33
D44
K25
K26
K45
K46
B06
7.
8.
/
9.
I02
OPTIONS OF VALVE CONTROLLER
External junction box for FF and 24 V DC wiring, 2 pcs. M20x1.5
conduit entry.
Units without limit switches (8. sign) are without extension housing.
Special construction.
LIMIT SWITCH TYPE
Inductive proximity switches, 2 pcs.
IP66/NEMA 4X enclosure.
P+F; NJ2-12GK-SN, 2-wire type, DC; > 3 mA; < 1 mA.
Intrinsically safe according to ATEX II 1 G Ex ia IIC T6.
Temperature range -20° to +85 °C / -4° to +185 °F.
Usable up to SIL3 acc. to IEC61508.
Not applicable to 6. sign "N" or "X1".
P+F; NCB2-12GM35-N0, 2-wire type, DC; > 3 mA; < 1 mA.
Intrinsically safe according to ATEX II 2 G Ex ia IIC T6.
Temperature range -20° to +85 °C / -4° to +185 °F.
Usable up to SIL2 acc. to IEC61508.
Not applicable to 6. sign "N" or "X1".
P+F; NJ3-13GK-S1N, 2-wire type, DC; > 3 mA; < 1 mA, NAMUR NO.
Intrinsically safe according to ATEX II 1 G Ex ia IIC T6.
Temperature range -20° to +85 °C / -4° to +185 °F.
Usable up to SIL3 acc. to IEC61508.
Not applicable to 6. sign "N" or "X1".
ifm IFC2002-ARKG/UP, 2-wire type, DC; 150 mA, 10–36 V DC,
leakage current < 0.6 mA.
Temperature range -20° to +80 °C / -4° to +176 °F.
Not applicable to 6. sign X1, X2 and X3.
SST Sensor Dual Module, NO, 8–125 V DC / 24–125 V AC
Temperature range -20° to +82 °C / -4° to +179 °F.
Not applicable to 6. sign X1, X2, and X3.
Namur Sensor Dual Module, 6–29 V DC, > 3 mA; < 1 mA.
Temperature range -20° to +82 °C / -4° to +179 °F.
Not applicable to 6. sign X1, X2 and X3.
Mechanical micro switches
IP66/NEMA 4X enclosure.
Temperature range -20° to +85 °C / -4° to +185 °F.
2 pcs. OMRON D2VW-5; 3 A – 250 V AC, 0.4 A – 125 V DC, 5 A – 30 V DC.
Not applicable to 6. sign X1, X2 and X3.
2 pcs. OMRON D2VW-01; gold plated contacts, 100 mA - 30 V DC /
125 V AC.
Not applicable to 6. sign X1, X2 and X3.
4 pcs. OMRON D2VW-5; 3 A – 250 V AC, 0.4 A – 125 V DC, 5 A – 30 V DC.
Not applicable to 6. sign X1, X2 and X3.
4 pcs. OMRON D2VW-01; gold plated contacts, 100 mA - 30 V DC /
125 V AC.
Not applicable to 6. sign X1, X2 and X3.
Bus powered mechanical micro switches, 2 pcs.
IP66/NEMA 4X enclosure.
Temperature range -20° to +85 °C / -4° to +185 °F.
OMRON D2VW-01, gold plated contacts;
Bus Powered, no external power needed.
Not applicable to 6. sign X1, X2 and X3
9.
Y
Special construction.
K
ADDITIONAL ACCESSORIES
FILTER REGULATOR
Filter regulator for supply air. Filter size 5 µm.
Pressure gauge, scale bar/psi/kPa, basic material brass, nickel
plated, housing stainless steel, glycerine filled.
Temperature range -40 °C to +82 °C / -40 °F to +180 °F.
A3
K option includes a thread nipple 1/4"NPT to 1/4"NPT which is
suitable with VG9215 and with option A3. 1/4"NPT air connection.
For filter regulator option for VG923_ please contact Metso.
PRESSURE GAUGES
Pressure gauges, scale bar/psi/kPa, basic material brass, housing
nickel plated stainless steel, glycerine filled.
Connections 1/4 NPT (S, C1, C2).
Temperature range -40 °C to +85 °C / -40 °C to+185 °F.
CE09
OPTIONS
A3 option is suitable with VG9215.
For pressure gauge option for VG923_ please contact Metso.
CONDUIT ENTRY NIPPLES
1/2 NPT conduit entry nipples M20x1,5 / 1/2 NPT, Exd approved
7 VG92F 70 en
43
44
7 VG92F 70 en
Metso Automation Inc.
Europe, Levytie 6, P.O. Box 310, 00811 Helsinki, Finland. Tel. +358 20 483 150. Fax +358 20 483 151
North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA. Tel. +1 508 852 0200. Fax +1 508 852 8172
South America, Av. Independéncia, 2500-Iporanga, 18087-101, Sorocaba-São Paulo, Brazil. Tel. +55 15 3235 9700. Fax +55 15 3235 9748/49
Asia Pacific, 20 Kallang Avenue, Lobby B, #06-00, PICO Creative Centre, Singapore 339411, Singapore. Tel. +65 6511 1011. Fax +65 6250 0830
China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaoyang Dist, 100022 Beijing, China. Tel. +86-10-6566-6600. Fax +86-10-6566-2575
Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates. Tel. +971 4 883 6974. Fax +971 4 883 6836
www.metso.com/automation
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