Mesto Neles ValvGuard VG9000H Manuals

Neles ValvGuard™ VG9000H Rev. 2.3 Installation, Maintenance and Operating Instructions 7 VG9H 70 en • 1/2019 2 7 VG9H 70 en READ THESE INSTRUCTIONS FIRST! These instructions provide information about the safe handling and operation of the ValvGuard. If you require additional assistance, please contact the manufacturer or manufacturer's representative. Addresses and phone numbers are printed on the back cover. See also www.metso.com/valves for the latest documentation. SAVE THESE INSTRUCTIONS! Subject to change without notice. All trademarks are property of their respective owners. Table of Contents 1 NELES VALVGUARD VG9000H INTELLIGENT SAFETY SOLENOID WITH HART COMMUNICATION ................................................ 3 1.1 General........................................................................3 1.2 Technical description of VG9000H....................3 1.3 System architecture ...............................................4 1.4 Markings.....................................................................4 1.5 Technical specifications........................................5 1.6 Recycling and disposal.........................................8 1.7 Safety precautions..................................................8 2 TRANSPORTATION, RECEPTION AND STORAGE ............................................................... 9 3 MOUNTING............................................................ 9 3.1 General........................................................................9 3.2 Mounting on Metso actuators with VDI/VDE mounting face........................................9 3.3 Mounting on linear actuator with IEC 60534 mounting face.....................................9 3.4 Mounting and installation of VG9300 ..........10 3.5 Piping .......................................................................11 3.6 Electrical connections.........................................15 4 LOCAL USER INTERFACE (LUI)............................16 4.1 Measurement monitoring.................................16 4.2 Guided start-up.....................................................17 4.3 Configuration menu...........................................17 4.4 Configuration parameters ................................17 4.5 Valve travel calibration.......................................19 4.6 Testing, TESt...........................................................19 4.7 Advance parameters...........................................20 4.8 Special displays.....................................................20 4.9 HART burst mode.................................................21 5 MAINTENANCE....................................................21 5.1 Opening and closing of the cover..................21 5.2 Prestage ..................................................................21 5.3 Spool valve ............................................................22 5.4 Communication circuit board ........................22 6 MESSAGES...........................................................23 7 TROUBLE SHOOTING.......................................... 24 8 VG9_H/D_, VG9_H/R_, VG9_H/I_, VG9_H/K_, VG9_H/T01 (WITH LIMIT SWITCHES OR SIL PT).................... 24 8.1 Introduction............................................................24 8.2 Installing limit switches on ValvGuard..........27 8.3 Electrical connections.........................................27 8.4 Adjustment of limit switches............................27 8.5 Position transmitter (T01) calibration instructions .............................................................27 8.6 Removal of the limit switches and position transmitter for accessing the ValvGuard.....28 8.7 Circuit diagrams....................................................28 8.8 Maintenance...........................................................28 9 TOOLS.................................................................. 28 10 ORDERING SPARE PARTS................................... 28 11 DRAWINGS AND PARTS LISTS ........................... 29 11.1 Exploded view and parts list, VG9000H .......29 11.2 Exploded view and parts list, VG9_/D_, VG9_/R_, VG9_/I_, VG9_/K_, VG9_/T01 .................................................................31 11.3 Mounting parts for Metso B_U-series actuators .................................................................33 11.4 Mounting parts for Quadra-Powr® actuators .................................................................33 11.5 Mounting parts for linear actuators...............34 11.6 Connection diagrams..........................................35 12 DIMENSIONS ................................................... 42 13 CONFIGURATION PARAMETERS........................ 49 14 EC DECLARATION OF CONFORMITY ................. 50 15 TYPE CODING...................................................... 51 7 VG9H 70 en 3 1 NELES VALVGUARD VG9000H INTELLIGENT SAFETY SOLENOID WITH HART COMMUNICATION 1.1 General This manual incorporates Installation, Maintenance and Oper- ation Instructions for the Metso’s Neles ValvGuard VG9000H. The VG9000H may be used with either cylinder or diaphragm type pneumatic actuators for rotary or linear valves. 1.2 Technical description of VG9000H Neles ValvGuard VG9000H is a 4–20 mA loop-powered microcontroller-based intelligent safety solenoid and par- tial stroke test device with HART communication. Device is suitable to be used in safety related application up to and including SIL 3 acc. to IEC 61508. See Safety Manual for functional safety figures and other safety related details. The device safety position is 6.0 mA or below. When VG9_L3 version is used, the safety position is 10.0 mA or below. The device stays alive even at 3.7 mA input signal (at 7.7 mA when VG9_L3 is used) and communicates via HART. Optional Remote Communication Interface RCI9H2 is required if the safety system output is binary (DO) 24 V DC. See separate RCI9H2 technical bulletin (9RCI21EN) for detailed instructions. Main components of ValvGuard are spool valve (SV), pre- stage 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- (S), actuator- (C1, C2) and exhaust (EXH) connections. The spool is operated by spring force to fail safe position and by pneumatic force generated by the pre- stage valve to the normal position. The prestage valve is coil operated flapper valve (normally open). Coil of the pre- stage is energized with the safety control part and it is con- trolled 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 con- trolling the PST and other tests. Measurements from the sensors are used for the device diagnostics. The VG9000H contains a Local User Interface enabling local configuration. A PC with Metso Valve ManagerTM software together with Metso's FieldCare or any other FDT frame soft- ware can be used for advanced configuration and diagnostics. The powerful 32-bit microcontroller controls the valve posi- tion during partial stroke and other special testing. The measurements include:  Input signal  Valve position with contactless sensor  Actuator pressures, 2 independent measurements  Supply pressure  Device temperature  Housing pressure Advanced self-diagnostics guarantees that all measure- ments operate correctly. Failure of any measurement does not cause the valve to go to fail-safe position. After connec- tions of electric signal and pneumatic supply the micro con- troller (μC) 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. 1.2.1 Technical description of VG9000H_P Neles ValvGuard VG9000H with P-option (VG9000H_P) is a 4–20 mA loop-powered microcontroller-based partial stroke test device with HART communication. This device is for partial stroke test (PST) only and must be used together with an additional solenoid valve for the safety action. The prestage valve of the device is coil operated flapper valve (normally open). Coil of the prestage is normally de- energized and it is controlled by the micro controller for testing and calibration. Signal failure does not affect to the valve position. NOTE: The selection and use of the ValvGuard in a specific appli- cation 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 install- ing, using or servicing the ValvGuard. If you are uncertain about the use of the controller or its suitability for your intended use, please contact local Metso office for more information. NOTE: HART communication can be used for informational pur- poses, but is not safety certified for diagnostic annunciation. NOTE: RCI9H2 includes the Ex-isolator, so there is no need for separate Ex-isolator in intrinsically safe installations. NOTE: Micro controller is only able to control the prestage if safety control part is energized. Micro controller can never prevent the safety action to happen since safety action is the same as there’s no voltage in the safety control part. Fig. 1 The principle of operation NOTE: VG9000H_P version has fundamentally different function- ality to other VG9000H versions. This version can be iden- tified by the green cover. 4 7 VG9H 70 en The device stays alive even at 3.7 mA input signal and com- municates via HART. 4 mA is a normal state of the device. When input signal is 6 mA and above, PST is possible. When input signal is 8 mA and above, PST and travel calibration are possible. The valve cannot be driven from the normal position by any input signal. Thus the safety action needs to be done with an additional solenoid valve. 1.3 System architecture VG9000H can be connected directly to safety system analog output module (AO, 4-20 mA). See Fig. 2 for the gen- eral wiring principle. VG9000H can also be connected to safety system digital output module (DO, 0/24 V DC) via RCI unit. See Fig. 3 for the wiring principle with RCI unit. There is also a Local Control Panel option (LCP9H_). It can be used together with VG9000H or VG9000H with RCI unit. See Fig. 4. for the wiring principles with Local Control Panel. See Section 3.5 for wiring details. See LCP manual (7LCP9H70en) for further LCP details. See RCI bulletin (9RCI21en) for further RCI details. VG9000H_P must be used together with an additional sole- noid valve (SOV). See Fig. 5 for the general wiring principle. 1.4 Markings The ValvGuard is equipped with an identification plate (Fig. 6). Identification plate markings include:  Type designation of the ValvGuard  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: PH13011234 = controller, year 2013, week 1, consecutive number 1234. Fig. 2 General wiring principle of VG9000H Fig. 3 VG9000H wiring principle with RCI unit Fig. 4 VG9000H wiring with Local Control Panel Air supply 1. ValvGuard VG9000H 2. Pneumatic actuator AO (mA) from safety system Air supply 1. ValvGuard VG9000H 2. Pneumatic actuator 3. RCI9H2 DO (0/24 V DC) from safety system 24 V DC supply Air supply 1. ValvGuard VG9000H 2. Pneumatic actuator 3. Local Control Panel LCP9H_ AO (mA) from safety system or from RCI unit 24 V DC or 4 mA supply depending on the LCP type Serial communication Fig. 5 VG9000H_P wiring with additional solenoid valve Fig. 6 Examples of identification plates 1. ValvGuard VG9000H_P 2. Pneumatic actuator 3. Solenoid Valve 3 2 1 TYPE VG9215HE6 REV 2.0 METSO AUTOMATION OY VANHA PORVOONTIE 229, 01380 VANTAA, FINLAND NO: PH11020005 ID: SO519559001POS II 2 G Ex d IIC T6...T4 Gb II 2 D Ex tb IIIC T80 °C...T105 °C Db IP66 SIRA 11 ATEX 1006X / IECEx SIR 11.0001X 4 - 20 mA INPUT: (9.7 V DC / 20 mA / 485 Ohm) Ui: 30 V DC Tamb. T6: -20 ... +60 °C, T5: -20 ... +75 °C, T4: -20 ... +85 °C SUPPLY PRESSURE: 3 - 7.5 bar / 44 - 109 psi CONDUIT ENTRY M20X1.5 WARNING: DO NOT OPEN WHILE ENERGIZED! 0575