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35

Pneumatic Installation

9. 

PNEUMATIC INSTALLATION

9.1. 

Safety instructions

DANGER!

Risk of injury from high pressure in the system!

•  Before loosening lines and valves, turn off the pressure and vent the lines.

WARNING!

Risk of injury from improper installation!

•  Installation may be carried out by authorized technicians only and with the appropriate tools!

Risk of injury from unintentional activation of the system and uncontrolled restart!

•  Secure system against unintentional activation.

•  Following installation, ensure a controlled restart.

9.2. 

Pneumatic connection of the control head

DANGER!

Risk of injury from high pressure in the system!

•  Before loosening lines and valves, turn off the pressure and vent the lines.

Exhaust air  
connection 
(3/R) 
(Silencer 
not shown!)

Supply 
pressure  
connection 
(1/P)

Working connections (2/A1-3)

Solenoid valve 3 

(2/A3)

Solenoid valve 2 

(2/A2)

Solenoid valve 1 

(2/A1)

Fig. 12: 

Pneumatic connection

english

Summary of Contents for 2307193

Page 1: ...Operating instructions IntelliTop 2 0 Control Head ...

Page 2: ... the right to make technical changes without notice Technische Änderungen vorbehalten Sous resérve de modification techniques Südmo Components GmbH 2010 2020 Operating Instructions 2003 10_EN_00805843 Original DE ...

Page 3: ...ions designs 14 5 3 1 Structure of the control head 14 5 3 2 Structure of the control head feedback top 15 5 3 3 Fluid diagrams 16 5 3 4 Number of solenoid valves 17 5 3 5 Pneumatic interfaces 17 5 3 6 Manual control 18 5 3 7 Position measuring system 18 5 3 8 Other features 18 6 TECHNICAL DATA 19 6 1 Operating conditions 19 6 2 Conformity with the following standards 19 6 3 Rating plate specifica...

Page 4: ...l head 32 7 2 4 Assembly of the pneumatic and electrical connections 32 7 2 5 Recommended auxiliary materials 32 8 OPENING AND CLOSING THE HOUSING 33 8 1 Safety instructions 33 8 2 Opening and closing the housing 33 8 2 1 Opening the housing 33 8 2 2 Closing the housing 33 9 PNEUMATIC INSTALLATION 35 9 1 Safety instructions 35 9 2 Pneumatic connection of the control head 35 9 2 1 Pneumatic connect...

Page 5: ... 55 12 1 Definition 55 12 2 Electrical connection option 55 12 3 DeviceNet specification 55 12 3 1 Total line length and maximum line length according to DeviceNet specification 56 12 3 2 Drop line length 56 12 4 Electrical data 57 12 5 Safety position if the bus fails 57 12 6 Design aid 58 12 7 Safety instructions 59 12 8 Electrical installation DeviceNet 59 12 9 Network topology of a DeviceNet s...

Page 6: ...ESIGN FOR DOUBLE ACTING ACTUATORS 76 15 1 Anomalies 76 15 2 Fluid diagram 76 15 3 Electrical connection 24 V 120 V design 76 15 4 Programming data AS i design 76 16 POSITION MEASURING SYSTEM 77 16 1 Setting the position measuring system Teach In 77 16 2 Teach In functions 79 16 2 1 Teach In functions and Teach In reset 79 16 2 2 Autotune functions 79 16 2 3 Autotune sequence 80 16 3 Changing the f...

Page 7: ... 94 19 4 Cleaning 94 19 5 Malfunctions 94 20 REPLACEMENT OF COMPONENTS AND MODULES 96 20 1 Safety instructions 96 20 2 Changing the electronics module 97 20 3 Changing the valves 98 20 4 Changing the position measuring system 99 21 SPARE PARTS 102 22 SHUTDOWN 103 22 1 Safety instructions 103 22 2 Dismantling the control head IntelliTop 2 0 103 23 PACKAGING AND TRANSPORT 104 24 STORAGE 104 25 DISPO...

Page 8: ...stood Symbols DANGER Warns of an immediate danger Failure to observe the warning will result in a fatal or serious injury WARNING Warns of a potentially dangerous situation Failure to observe the warning may result in serious injuries or death CAUTION Warns of a possible danger Failure to observe this warning may result in a moderate or minor injury NOTE Warns of material damage Failure to observe...

Page 9: ...test prior to installation whether the control head is suitable for the specific application case If you are unsure please contact your Pentair Südmo contact The device may be used only in connection with third party devices and components which have been rec ommended or approved by Pentair Südmo Any unauthorized reconstructions and changes to the control head are prohibited for safety reasons Cor...

Page 10: ...damp or anti static cloth in the explosion risk area to prevent electrostatic charges Use only cables and cable glands which have been approved for the respective application area and which have been screwed into place according to the respective installation instructions Close all unnecessary openings with locking screws sealing plugs approved for explosions area WARNING Risk of electric shock Be...

Page 11: ...TE Risk of damage to property Do not connect any mechanically rigid connection parts in particular those with long lever arms as such con nections could generate torques that might damage the control head Do not supply the medium connections of the system with liquids or aggressive or flammable media Do not subject the housing to mechanical loads e g by placing objects on it or standing on it Do n...

Page 12: ... E Email info suedmo de Website www suedmo com 4 2 Warranty Please refer to our general terms of sales and business The warranty is only valid if the control head is used as intended in accordance with the specified application conditions The warranty extends only to defects in the control head IntelliTop 2 0 and its components We accept no liability for any kind of collateral damage which could o...

Page 13: ...ching positions to a higher level control the control head has been equipped with a contact free position measuring system which operates with 3 discrete adjustable feedback signals Teach In function The control head and the process valve are interconnected by an adapter This produces an integrated compact and decentralized system of feedback actuation and valve function The following advantages o...

Page 14: ...ons 2 A1 3 Flow restriction screw s for P and R 2 per solenoid valve Solenoid valve 3 2 A3 Solenoid valve 2 2 A2 Solenoid valve 1 2 A1 Position measuring system with LEDs in 3 colors Silencer in the exhaust air connection 3 R not shown Sealing lug on the lower housing part for securing the hood using a lead seal or plastic self cutting screws 2 locking screws shoulder screws M5 no sealing function...

Page 15: ...n measuring system with LEDs in 3 colors Sealing lug on the lower housing part for securing the hood using a lead seal or plastic self cutting screws 2 locking screws shoulder screws M5 no sealing function merely as protection against pulling off from the hub flange Locking groove 3x Pressure relief valve rear side Fig 2 Structure of a feedback top IntelliTop 2 0 without solenoid valves english ...

Page 16: ...3 Fluid diagrams Control head IntelliTop 2 0 fluid diagram with restriction capability for each solenoid valve Model with 3 solenoid valves Type 6524 e g for double seat valve Fig 3 Fluid diagram model 3 solenoid valves english ...

Page 17: ...on valves Type of use Number of solenoid valves Feedback top repeater 0 Control head for single acting actuators 1 NC Control head for actuators with 2 actuator chambers both not energized actuator chambers deaerated 2 2 x NC Control head for double seat valves with integrated lift function for both valve discs 3 3 x NC Control head for double acting actuators with rest position 2 1 x NC 1 x NO De...

Page 18: ...ntrol status service mode see chapters 17 LED Color Assignments and 18 Service Mode Manual Control For a detailed description of the manual control see Chapter 18 Service Mode Manual Control 5 3 7 Position measuring system The switching positions of the process valves are reported to the actuator by feedback signals from the solderless position measuring system Connection to the control head is do...

Page 19: ...on to the process valve was done correctly IP69K according to IEC 40050 9 Housing seal with connected exhaust air line instead of silencer and ideally closed cable glands confirmed through IP69K Standard testing Version for use in explosive atmosphere Zone 2 IP64 according to EN 60529 and requirements EN 60079 0 2009 only if cables plugs and sockets have been connected correctly the hood has been ...

Page 20: ...sure range Line 3 any specifications if applicable according to ATEX Directive 94 9 EC gas ambient tem perature Tamb Line 4 any specifications if applicable according to ATEX Directive 94 9 EC dust degree of pro tection specification IP Line 5 Additional ID number serial number S N Line 6 ID number Pentair Südmo manufacturer s specifications Further symbols and information on the rating plate indi...

Page 21: ... power supply with class 2 power supply unit 6 4 Information on the additional plates Additional plates indicate additional approvals and special operating conditions Warning sign for use of the device in potentially explosive atmosphere Line 1 Line 2 Line 3 Line 4 Line 1 Specifications according to ATEX directive gas ambient temperature Line 2 Specifications according to ATEX directive dust degre...

Page 22: ... cutting screws M16x1 5 2x G1 4 2x G1 8 3x Fig 5 Dimensional drawing for models with 1 to 3 solenoid valves Plastic self cutting screws Diameter 3 mm length approx 10 mm e g Ejot PT screw K 30 x 10 max tightening torque 0 4 Nm after completely screwing in the screw loosen it again by one half turn english ...

Page 23: ...c self cutting screws Cover pressure relief valve M16x1 5 2x Fig 6 Dimensional drawing for models without solenoid valves see note to Fig 5 Weight approx 0 8 kg Housing material exterior PA PC PPO VA inside ABS PA PMMA Sealing material exterior CR EPDM inside EPDM FKM NBR english ...

Page 24: ...ressure drops from 7 to 6 bar absolute at 20 C Connections Intake and exhaust air connection G1 4 Working connections G1 8 The intake and exhaust air can be set separately for each solenoid valve using flow restriction screws in order to be able to affect the expansion and retraction rates of the process valve see figure below Mechanical manual control Red lever left 0 right 1 Flow restriction scr...

Page 25: ...am in Fig 8 shows the dimensional relationships between the control head and the piston with target Target in the upper end position Piston rod in the upper end position Note upper end position of the target H 157 5 mm to prevent putting control head at risk Target in the lower end position Piston rod in the lower end position Fig 8 Sectional view of control head and piston with target in upper an...

Page 26: ...50 12 00 S2 3 00 12 00 0 50 3 00 0 50 12 00 S3 1 00 12 00 0 50 1 00 0 50 12 00 Stroke mm Feedback field S1 mm Target Reference upper edge of the target Ensure that the teach points including their feedback fields are within the measuring range Fig 9 Schematic diagram of the feedback fields in the example of the position S1 not to scale Overlaps of S1 S2 S3 are possible see Chapter 17 3 Signal prio...

Page 27: ...tion occurs when a Service maintenance notification is activated after the following counter readings Counter readings service interval Factory setting Adjustment range Switching cycle counter V1 10 000 1 255 x 1000 Switching cycle counter V2 50 000 1 255 x 1000 Switching cycle counter V3 50 000 1 255 x 1000 Operating duration 365 days 1 65 535 days The resettable operating hour and switching cycl...

Page 28: ...2 5 s long this will reset the device The flashing pattern 250 ms ON 250 ms OFF in the fault color indicates that the device was reset Procedure Device Reset using PC software To do this select the General start up submenu in the SYSTEM main menu and press the DEV RESET button see also PC software manual Device Reset resets the following values to the factory setting Teach positions S1 S3 all posi...

Page 29: ...counter Total V1 V3 Operating duration Total Cycle stroke color S3 S4 different see chapter 17 1 2 on page 85 and PC software Averaging procedure position measuring system see PC software AS i address see chapter 11 8 on page 54 AS i profile DeviceNet Input Assembly see Chapter 12 11 1 on page 63 english ...

Page 30: ...ion position preferably with the hood face up The device should be installed such that layers of dust thicker than 5 mm cannot form meaning that such should be ensured through correspondingly regular cleaning When used in explosive atmosphere Zone 2 the devices must be installed in a protected installation location according to IEC EN 60079 0 7 2 1 Hub flange WARNING Risk of injury from improper a...

Page 31: ... material To ensure the proper function of the position measuring system the axial deviation of the adapter must be less than 0 1 mm to the spindle when mounted Use Pentair Südmo adaptations only Prior to assembling the control head onto the hub flange lightly grease the O rings with a silicone grease e g Paraliq GTE 703 The hood must be lead sealed in the explosion risk area to prevent the housin...

Page 32: ...ened sufficiently when the lower side of the screw head is flush with the auxiliary surface of the housing The locking screw is sufficiently tightened when the upper side of the screw head is flush with the auxiliary surface of the housing Tightening torque max 3 2 Nm Rotate the control head until the desired alignment has been achieved Secure the control head with locking screws again until the u...

Page 33: ...he appropriate tools Risk of injury from unintentional activation of the system and uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 8 2 Opening and closing the housing 8 2 1 Opening the housing NOTE Improper handling will damage the plastic hood seal Do not use excessive force e g by knocks for opening Make sure that the lubric...

Page 34: ...g until the sealing lugs are positioned over each other If required attach lead seal or plastic self cutting screws see note to Fig 5 on page 22 to prevent it from being opened without a tool The hood must be lead sealed secured in the explosion risk area to prevent the housing from being opened without a tool english ...

Page 35: ...f injury from unintentional activation of the system and uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 9 2 Pneumatic connection of the control head DANGER Risk of injury from high pressure in the system Before loosening lines and valves turn off the pressure and vent the lines Exhaust air connection 3 R Silencer not shown Sup...

Page 36: ...agonally pulling stresses curved outlet without eccentric stress Only use suitable hose qualities in particular for high ambient temperatures that bear up under common stresses caused by the quick connector Silencer or exhaust air hose When using an exhaust air hose accordingly dimension its length to ensure that a QNn value 620 l min is reached Tip Dimension the hose lengths so that the control h...

Page 37: ...cer into the exhaust air connection 3 R of the control head during external cleaning and thus could enter the control head via the non return valve it is recommended not to screw the silencer directly into the 3 R connection but to connect and fix it e g to an interposed angular quick fitting gland and a piece of hose with the opening downwards 9 3 Flow restriction function of the solenoid valves ...

Page 38: ...unterclockwise to set the required flow rate and therefore the opening time for the process valve Tool flat blade screwdriver width 3 mm Deactivate valve location Turn the flow restriction screw R counterclockwise to set the required flow rate and therefore the closing time for the process valve Flow restriction screw Exhaust air R Flow restriction screw Intake air P Hand lever of the mechanical m...

Page 39: ...sidual ripple 10 Connections Cable gland version 1 x M16 x 1 5 cable gland SW22 for power supply and signals only for transportation safety device sealed with dummy plugs remove these before use for cable diameter 5 10 mm for wire cross sections 0 14 1 5 mm2 1 x M16 x 1 5 connection option for external initiator sealed with dummy plug remove these before use Multi pole connection version 1 x M16 x...

Page 40: ...with self clocking short circuit protection Switchable output current max 100 mA per feedback signal Output voltage active operating voltage 2 V Output voltage inactive max 1 V in unloaded state Input proximity switches external initiator S4 in Power supply Voltage present at the control head 10 Current carrying capacity sensor supply max 90 mA Short circuit protection Design DC 2 and 3 wire Norma...

Page 41: ... stag gered to the valves Only one 0 9 W valve will ever be recorded Calculation examples Example 1 3 valves are activated simultaneously one position is reported state for 200 ms PTotal PEl 1 x PValve ON 2 x PValve 1 x PLED 3 8 W 0 7 W 1 x 0 9 W 2 x 0 6 W 1 x 1 0 W or ITotal IEl 1 x IValve ON 2 x IValve 1 x ILED 160 mA 30 mA 1 x 38 mA 2 x 25 mA 1 x 42 mA Example 2 3 valves have been activated sim...

Page 42: ...rt Secure system against unintentional activation Following installation ensure a controlled restart 10 5 Electrical installation start up 10 5 1 Cable gland with screw terminals Procedure Open the housing following the instructions in Chapter 8 Opening and Closing the Housing Assemble connection cables for signals and power supply as well as for the external initiator where necessary in observanc...

Page 43: ...olor coding the LEDs Connection for the external initiator Feedback signals S1 S4 OUT Control solenoid valves Y1 3 Teach In buttons T1 3 Solenoid valve connections with status LED for Valves 2 3 Terminal strip Fig 15 24 V DC electronics module Designation Terminal strip Configuration Designation Terminal strip Configuration for external initiator 24 V Power supply 24 V 24 V Power supply 24 V GND G...

Page 44: ... control monitor LEDs for valves Valve 1 Valve 2 Valve 3 Power supply 24 V DC GND Output position 1 0 24 V PNP Output position 2 0 24 V PNP Output position 3 0 24 V PNP Output ext initiator 0 24 V PNP Input solenoid valve 1 0 24 V Input solenoid valve 2 0 24 V Input solenoid valve 3 0 24 V Fig 16 Circuit diagram 24 V DC english ...

Page 45: ...e circular plug in connector M12 x 1 0 male acc to IEC 61076 2 101 10 Pin 9 Y3 Pin 8 Y2 12 Pin 6 S4 out Pin 7 Y1 Pin 1 24 V Pin 5 S3 out Pin 4 S2 out 11 Pin 3 S1 out Pin 2 GND The center pins 10 11 and 12 are not used Fig 17 12 pole multi pole connection view onto the plug pins Pin Designation Configuration 1 24 V Power supply 24 V 2 GND GND 3 S1 out Output position S1 4 S2 out Output position S2 ...

Page 46: ...elded two wire line AS interface line as AS interface cable harness along which both information data and energy power supply for the actuators and sensors are transmitted Network topology Freely selectable within wide limits i e star tree and line networks are possible Further details are described in the AS interface specification A B slave model complies with the version 3 0 specification The c...

Page 47: ...f connectable control heads and maximum length of the bus line The bus cable may be a maximum of 100 m long All AS interface lines of an AS interface string must be considered for the design i e even the drop lines to the individual slaves The level of expansion that is actually possible depends on the total number of all individual operating currents for each control head which are supplied via t...

Page 48: ... AS interface specification Observe the optional design AS Interface with External Power Supply to reduce the load on the AS interface bus segment see Chapters 11 4 and 11 7 Use cables according to the AS interface specification If other cables are used the maximum cable length will change 11 4 Electrical data Comments notes Outputs from master perspective 0 to 3 solenoid valves Inputs from master...

Page 49: ...rted back in binary format is described in Chapter 16 Position Measuring System Outputs from master perspective solenoid valves Max switching capacity max 0 9 W per solenoid valve Type Continuous output 0 6 W per solenoid valve Watchdog function integrated Power reduction integrated via AS interface electronics Pull in current 30 mA or 0 9 W 200 ms at 30 5V AS i voltage Holding current 20 mA or 0 ...

Page 50: ...mption from AS i for inputs and display 150 mA type Integrated short circuit protection Please follow the instructions on power requirement and maximum expansion stage of the AS interface network in Chapter 11 3 Number of connectable control heads and maximum length of the bus line and in the AS interface specifications where applicable 11 5 Design aid Design aid for supply of the valves via the A...

Page 51: ... instructions DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent re...

Page 52: ... via bus external power supply M12 x 1 circular plug 4 pole male according to IEC 61076 2 101 view onto the plug installed in the head from the front onto the pins Pin 2 NC Pin 3 ASI Pin 1 ASI Pin 4 NC Bus connection power supply via bus Pin 2 GND Pin 3 ASI Pin 1 ASI Pin 4 24 V Bus connection with external power supply Fig 19 AS interface bus connection power supply via bus external power supply P...

Page 53: ...y and position them on the existing threaded hole and screw in Fig 21 Optional ribbon cable terminal for AS interface cable harness AS interface electronics module LED status displays LED Status Displays Power and Fault LED 1 Power green LED 2 Fault red Signalized status off off Power OFF on on No data traffic expired Watchdog at slave address does not equal 0 on off OK flashing on Slave address 0...

Page 54: ...onal replacement the current configuration must be re projected in the AS interface master Please read the operating instructions of the used AS interface master Factory setting AS i address AS i address 0 Programming Data Table Programming data for 62 Slaves AS interface Device for A B slave addressing default device Programming data for 31 Slaves AS interface optional I O configuration 7 hex 4 i...

Page 55: ...l low priority management messages Explicit Messages The protocol process conforms to the DeviceNet specification Release April 2010 12 2 Electrical connection option Cable gland with multi pole connection M12 plug according to IEC 61076 2 101 5 pole Connection left Voltage signals Connection right external initiator Fig 22 Connection concept DeviceNet 12 3 DeviceNet specification EDS file INTELLI...

Page 56: ... which must conform to the DeviceNet specification The cable transmits both information data and energy power supply for low power actuators and sensors The maximum total line length sum of trunk lines and drop lines of a network depends on the baud rate Baud rate Maximum total line length 1 Thick Cable 2 Thin Cable 2 125 kbaud 500 m 100 m for all baud rates 250 kbaud 250 m 500 kbaud 100 m 1 Accor...

Page 57: ...s from master perspective binary or analog feedback signals The recovery of the 3 valve positions reported back in binary format or the analog position signal is described in Chapter 16 Position Measuring System Outputs from master perspective solenoid valves max switching capacity 1 0 W per solenoid valve typ continuous output 0 6 W per solenoid valve Power reduction integrated via DeviceNet elec...

Page 58: ... 24 V Calculation examples Example 1 3 valves are activated simultaneously one position is reported state for 200 ms PTotal PEl 3 x PValve ON 1 x PLED 5 44 W 1 44 W 3 x 1 0 W 1 x 1 0 W or ITotal IEl 3 x IValve ON 1 x ILED 228 mA 60 mA 3 x 42 mA 1 x 42 mA Example 2 3 valves have been activated simultaneously one position is reported persistent state PTotal PEl 3 x PValve 1 x PLED 4 24 W 1 44 W 3 x ...

Page 59: ...ury from unintentional activation of the system and uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 12 8 Electrical installation DeviceNet No internal cabling work is required for any of the DeviceNet designs cable with multi pole connection which makes installation and start up on site considerably easier and quicker reducing ...

Page 60: ...nals Teach In buttons T1 3 Solenoid valve connec tions with status LED for Valves 2 3 Status LED for device Status LED for network Fig 24 DeviceNet electronics module Terminal strip configuration Designation Terminal strip Configuration Designation Terminal strip Configuration V Power supply DeviceNet V Power supply for external initiator V Power supply DeviceNet S4 IN External initiator input CAN...

Page 61: ... 25 Fig 25 illustrates a line with one trunk line and several drop lines Trunk lines and drop lines consist of identical material Trunk line DeviceNet cable Terminating resistor 120 Ω W Terminating resistor 120 Ω W Drop lines DeviceNet cable max 6 m long T1 Tn Subscriber 1 node 1 Subscriber n node n V V CAN_H CAN_L Fig 25 Network topology 12 10 Configuring the DeviceNet address baud rate 8 DIP swi...

Page 62: ... on off on off off 42 off on off on off on 11 on on off on off off 43 on on off on off on 12 off off on on off off 44 off off on on off on 13 on off on on off off 45 on off on on off on 14 off on on on off off 46 off on on on off on 15 on on on on off off 47 on on on on off on 16 off off off off on off 48 off off off off on on 17 on off off off on off 49 on off off off on on 18 off on off off on o...

Page 63: ...lected attributes combined into one object so that process data can be transmitted collectively via an I O connection The process data is selected by setting the device parameters Active Input Assembly and Active Output Assembly or if supported by the DeviceNet Master Scanner by setting Produced Connection Path and Consumed Con nection Path when an I O connection is initialized according to the De...

Page 64: ...Configuration of the device 12 12 1 Configuration of the safety position of solenoid valves if bus error The valve safety position and safety module attributes can be used to configure the solenoid valves in the event of a bus error If a bus error occurs the configuration data of the solenoid valves can be accessed acyclically via Explicit Messages The Get_Attribute_Single service stands for a rea...

Page 65: ...rization of the device When a device has been inserted into the DeviceNet configuration of RSNetWorx the device can be parameterized offline Fig 27 indicates how for example an input assembly which deviates from the factory setting input process data can be transferred via I O connection can be selected However ensure that the length of the process data during a subsequent configuration of the Dev...

Page 66: ...colored status display see Chapter 17 2 Blinking pattern fault signaling The device status LED modules and the bus status LED network are located on the electronics module Function tests for both status LEDs after power has been switched on connection of the network cable Status LED Colors of the LED Function test Modules green 250 ms ON green Network green red 250 ms ON green 250 ms ON red Then a...

Page 67: ...nection to master exists Normal operating state with estab lished connection to the master Flashes green Online without connection to master Normal operating state without estab lished connection to the master Flashes red Connection time out One or more I O connections are in Time Out state New connection establishment by master to ensure that the I O data is transmitted cyclically Red Critical fa...

Page 68: ... sealed with dummy plug remove these before use Power consumption standby current 10 mA at 120 V AC Solenoid valves Max switching capacity 1 7 VA per solenoid valve Type Continuous output 1 4 VA per solenoid valve Power consumption per solenoid valve 12 mA at 120 V AC Operating mode Long term operation 100 ED Central display of the switching states 13 mA with a power supply of 120 V AC per illumin...

Page 69: ... supply voltage present at control head UNominal 120 V AC 50 60 Hz Design DC 2 and 3 wire Normally open contact L switching input current 1 signal ISensor 2 mA Inputs valve actuation Y1 Y3 Signal level active U 60 V AC Signal level inactive U 20 V AC Impedance 40 kOhm english ...

Page 70: ...ent stag gered to the valves Only one valve 1 7 VA will ever be recorded Calculation examples Example 1 3 valves are activated simultaneously one position is reported state for 200 ms PTotal PEl 1 x PValve ON 2 x PValve 1 x PLED 7 3 VA 1 2 VA 1 x 1 7 VA 2 x 1 4 VA 1 x 1 6 VA or ITotal IEl 1 x IValve ON 2 x IValve 1 x ILED 61 mA 10 mA 1 x 14 mA 2 x 12 mA 1 x 13 mA Example 2 3 valves have been activ...

Page 71: ...ntentional activation of the system and uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 13 5 Electrical installation start up DANGER Risk of injury due to electric shock 110 130 V AC Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to preve...

Page 72: ... NOTE Use of the control head in explosive atmosphere Only use cables and cable glands which are approved for the respective application area and fit the cable glands according to the respective operating instructions Close all unnecessary openings with lock screws plugs approved for explosions area 120 V AC Electronics module terminal strip configuration Solenoid valve connec tion with status LED...

Page 73: ...lenoid valve 1 input Y2 Solenoid valve 2 input Y3 Solenoid valve 3 input Circuit diagram 120 V AC Electronics Position measuring system with LEDs Service interface DIP switches for LEDs Teach In button Valve control monitor LEDs for valves Valve 1 Valve 2 Valve 3 Central power supply 120 V AC Protective conductor Output position 1 0 120 V AC L switching Output ext initiator 0 120 V AC L switching ...

Page 74: ...e different electronics modules Designation according to design Configuration 24 V DC AS i DevNet 120 V AC 24 V V L Power supply according to design S4 IN S4 IN S4 IN External initiator input GND GND N GND external initiator 24 V DC AS i DevNet or power supply 120 V AC design Electrical requirements of the external initiator for the different designs The electrical requirements of the external ini...

Page 75: ...opening must be sealed with a dummy plug Use of the control head in explosive atmosphere Only use cables and cable glands which are approved for the respective application area and fit the cable glands according to the respective operating instructions Close all unnecessary openings with lock screws plugs approved for explosions area Connection of a 2 wire initiator 24 V DC AS i DevNet 120 V AC Co...

Page 76: ...as no function 15 2 Fluid diagram See Fig 4 Fluid diagram model for double acting actuators 2 solenoid valves NC NO on page 17 15 3 Electrical connection 24 V 120 V design To open or close the process valve both solenoid valves V1 and V2 are switched simultaneously by the software When a signal is applied to Y1 valves V1 and V2 are actuated simultaneously by software for the designs 24 V and 120 V...

Page 77: ...s have been provided for comparison with the actual stroke range see Chapter 16 1 Setting the position measuring system Teach In The switching positions for the position measuring system can be determined with these Teach In buttons or by means of the PC software connection via the Service interface on the electronics module A discrete external feedback signal standard proximity switch can also be...

Page 78: ...nds The LED corresponding to this position will flash quickly 3 times during the teaching phase When this position has been saved the corresponding LED will flash continuously until the position of the piston is changed If required return control head and system to normal state switching position power supply Close the housing following the instructions in Chapter 8 Opening and Closing the Housing...

Page 79: ...ck Teach In button Function Activation duration Opt feed back T2 T3 Autotune mode 2 5s green yellow red continu ously ON T1 Autotune 1 0 5s green yellow red chaser mode T2 Autotune 2 T3 Autotune 3 T1 T2 Autotune 4 T1 T3 Autotune 5 T2 T3 Autotune 6 The Autotune function can be selected after changing to Autotune mode If an Autotune function has not been started 10 seconds after the change to Autotu...

Page 80: ...rror T2 T3 Autotune mode starts T2 Autotune 2 starts Open position Teach T2 Valve closing Activate V1 Wait period 10s Closed position Teach T1 Valve opening Deactivate V1 Valve opens Wait on position S2 S2 Timeout 15s Autotune mode completed Autotune 3 Double seat valves with liftable lower valve disc Control Effect on the process valve Internal program Error T2 T3 Autotune mode starts T3 Autotune...

Page 81: ...eutral position Deactivate V2 Autotune mode completed Autotune 5 Single seat valves NC with 3 position actuator Butterfly valves NC with 3 position actuator Control Effect on the process valve Internal program Error T2 T3 Autotune mode starts T1 T3 Autotune 5 starts Closed position Teach T1 Valve opening Activate V1 Wait period 10s Open position Teach T2 Valve closing Deactivate V1 Valve closes Wa...

Page 82: ... or by Feedback Field Mode see Chapter 16 3 on page 83 A Device Reset will also reset all settings made by the Autotune function 6 comp Chapter 6 9 Resetting the device Device Reset on page 28 Control Effect on the process valve Internal program Error T2 T3 Autotune mode starts T2 T3 Autotune 6 starts Closed position Teach T1 Valve opening Activate V1 Wait period 10s Open position Teach T2 Valve c...

Page 83: ...he feedback fields press one of the Teach buttons for 3 s according to the table below the successful change of the feedback field for the three sensor positions is displayed by the following flashing pattern 3 s ON 3 s OFF of one of the LEDs according to the table below FFM no Teach In button Optical feedback by LED Feedback field S1 mm Feedback field S2 mm Feedback field S3 mm FFM 1 T1 red 3 s O...

Page 84: ...he different process valve designs and signaling philosophies of the customers the assignment of functions to the available colors can be configured individually by means of the 4 DIP switches on site Delivered state DIP 1 4 each set to position 0 When using the control head in explosive atmosphere the housing may be opened in a not energized state only 4 DIP switches Position 1 On up Position 0 B...

Page 85: ... green green red 1 0 1 1 green red red red yellow 0 1 1 1 red green green green yellow 1 1 1 1 Color of S4 as S3 if function cycle stroke color S3 S4 different is not active S4IN is always an open contact Delivered state DIP 1 4 each set to position 0 17 1 2 Color combinations with active function cycle stroke color S3 S4 different The function cycle stroke color S3 S4 different can be only de act...

Page 86: ...t flashing in the fault color Teaching does not occur or Teach Reset implemented or bus error or Device Reset implemented permanent flashing in the color for that position Signal from position 3 also signal of the external initiator S4 if the function cycle stroke color S3 S4 different is active 450 ms 50 ms Internal Fault fault color 50 ms 450 ms Service mode manual operating mode active fault co...

Page 87: ...ult signaling If position feedback signals overlap the following priorities apply Only the fields colors highlighted in gray in the 3 examples below are reported back by LED display regardless of whether a signal is present 1 or no signal is present 0 This means only the optical display LEDs for the positions S1 4 is subject to the priority control whereas the electrical signals are applied to the...

Page 88: ...ed the valve is only considered safely closed if S1 and S4 1 the function cycle stroke color S3 S4 different is not active S1 S2 S3 S4 Fault green yellow flashing green 250 ms 250 ms flashing green 125 ms 125 ms red S1 S2 S3 S4 Fault 0 0 0 1 1 0 0 1 0 1 0 1 0 0 1 1 0 0 0 0 1 0 0 0 1 0 1 1 0 1 0 0 0 1 1 0 0 1 1 1 1 1 0 1 1 1 0 0 1 0 1 0 0 0 1 0 1 1 1 1 1 1 1 0 english ...

Page 89: ...ator monitors whether the upper valve disc has been opened the function cycle stroke color S3 S4 different is not active S1 S2 S3 S4 Fault green yellow flashing green 250 ms 250 ms flashing green 125 ms 125 ms red S1 S2 S3 S4 Fault 0 0 0 0 1 0 0 0 0 1 0 0 0 0 1 0 0 0 0 1 1 0 0 1 1 0 1 0 0 1 0 1 0 1 1 1 0 1 1 0 1 1 0 0 1 1 0 1 1 0 1 1 0 0 1 1 1 1 1 0 1 1 1 1 english ...

Page 90: ...e signal of the higher level control the magnetic manual control sets the output of Solenoid Valve 1 electrically to an ON signal and if control pressure is present switches the 2 A1 output However if the output of solenoid valve 1 is activated by the control ON signal this switching state cannot be set to an OFF signal with the manual control Caution When the magnetic manual control Solenoid Valv...

Page 91: ...ompleted deactivate the magnetic manual control Hold the manual control tool on the identification points between the cable glands for another three seconds see Fig 33 After a power failure the magnetic manual control is reset and the control head restarts in standard oper ating mode i e the signal of the higher level control is accepted 18 2 Mechanical manual control If additional manual controls...

Page 92: ...G Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment Risk of injury from improper maintenance Maintenance may be carried out by authorized technicians only and with th...

Page 93: ... NC Solenoid valve 2 NO not defined By default the control head is equipped with solenoid valves which operate in NC mode the model for double acting actuators is equipped with 1 solenoid valve NC and 1 solenoid valve NO If process valves with several switching positions e g double seat valves are connected the safety positions of the individual actuators can be viewed according to the same logic ...

Page 94: ... the formation of deposits in grooves and recesses If cleaning agent is not rinsed off properly its concentration may considerably exceed the concentration for use when the water has evaporated The chemical effect will thus be several times stronger Observe the specifications of the manufacturer and the recommendations for use of the cleaning agent manufacturer 19 5 Malfunctions In the event of an...

Page 95: ...onding descrip tions of the respective communication variant in these operating instructions compare Chap 17 2 Blinking pattern fault signaling on page 86 No or faulty function of the process valves No electrical power supply or com munication for the control head Check the power supply and the com munication settings also refer to detailed descriptions of the respective versions in these operatin...

Page 96: ...stem except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment Risk of injury due to improper maintenance work Maintenance work may be carried out by authorized technicians only and with the appropriate tools Risk of injury from unintentional ...

Page 97: ...ired note the position of the DIP switches for the set color code and the DIP switches 8 switch block on the DeviceNet electronics module for baud rate and address On the AS i electronics module note the AS interface address and the jumper positions power supply to AS interface If required read out and note special settings by PC software Loosen all electrical connections on the electronics module...

Page 98: ...ing PC software Perform Teach In procedure see Chapter 16 1 Setting the position measuring system Teach In Be sure to work carefully and cautiously so that the electronics are not damaged Close the housing following the instructions in Chapter 8 Opening and Closing the Housing 20 3 Changing the valves According to the design 0 to 3 valve modules have been installed in the control head The valves h...

Page 99: ...n them to a torque of 1 2 Nm Reattach the electrical connections If other connections apart from the solenoid valve connections have been removed read the corresponding chapters on the electrical installation of the respective voltage bus connection version Close the housing following the instructions in Chapter 8 Opening and Closing the Housing 20 4 Changing the position measuring system The posi...

Page 100: ...ponents In the worst case scenario they will be destroyed immediately or will fail after start up Observe the requirements in accordance with DIN EN 61340 5 1 to minimize or avoid the possibility of damage caused by sudden electrostatic discharge Also ensure that you do not touch electronic components when the supply voltage is on Deinstallation procedure Switch the electrical power to the control...

Page 101: ...t the new position measuring system from above so that the contact pins are located on the side of the electronics module Carefully push the housing of the position measuring system downwards until the snap fit hooks snap into place Slide the electronics module carefully onto the contacts pins and fasten the electronics module using the Torx screw Remount the control head on the process valve as d...

Page 102: ...ox 10 cm 24 V DC 2307261 6 Cable with 4 pole plug M12 IEC 61076 2 101 approx 10 cm AS interface 2307263 6 Cable with 4 pole plug M12 IEC 61076 2 101 approx 80 cm AS interface 2307262 6 Cable with 5 pole plug M12 IEC 61076 2 101 approx 80 cm DeviceNet 2307264 7 Cable gland M16 Ø 2 6 mm possibly instead of dummy plug 2307259 8 Cable gland M16 Ø 5 10 mm 2307260 9 Silencer 2307267 10 Hood coated with ...

Page 103: ... out by authorized technicians only and with the appropriate tools 22 2 Dismantling the control head IntelliTop 2 0 Prior to starting with the work check the system status Procedure Cable gland versions Open the housing following the instructions in Chapter 8 Opening and Closing the Housing Uninstall the electrical connections at the terminal strip Close the housing following the instructions in C...

Page 104: ...tly that the electrical and pneumatic lines cannot be accidentally damaged and or cannot indirectly damage the control head that the control head is not used as support during packaging and transport that the control head is not exposed to any mechanical stress 24 STORAGE NOTE Incorrect storage may damage the device Store the device in a dry and dust free location Storage temperature 20 65 C Kindl...

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