Mesto Neles ValvGuard VG9000H Operating Instructions Manual

Mesto Neles ValvGuard VG9000H Operating Instructions Manual

Rev. 2.3
Table of Contents

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Neles ValvGuard™
VG9000H
Rev. 2.3
Installation, Maintenance and
Operating Instructions

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Summary of Contents for Mesto Neles ValvGuard VG9000H

  • Page 1 Neles ValvGuard™ VG9000H Rev. 2.3 Installation, Maintenance and Operating Instructions...
  • Page 2: Table Of Contents

    7 VG9H 70 en Table of Contents TROUBLE SHOOTING.......... 24 VG9_H/D_, VG9_H/R_, VG9_H/I_, VG9_H/K_, NELES VALVGUARD VG9000H VG9_H/T01 INTELLIGENT SAFETY SOLENOID WITH HART (WITH LIMIT SWITCHES OR SIL PT) ....24 COMMUNICATION ..........3 Introduction............24 General................3 Installing limit switches on ValvGuard..27 Technical description of VG9000H....3...
  • Page 3: Neles Valvguard Vg9000H Intelligent Safety Solenoid With Hart Communication

    Valve position with contactless sensor This manual incorporates Installation, Maintenance and Oper-  Actuator pressures, 2 independent measurements ation Instructions for the Metso’s Neles ValvGuard VG9000H.  Supply pressure The VG9000H may be used with either cylinder or diaphragm ...
  • Page 4: System Architecture

    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.
  • Page 5: Technical Specifications

    7 VG9H 70 en Pneumatics NOTE: There may have two identification plates, if there is double Spool material: Hard anodized aluminium with approval (VG9_XE6_) asked. When the device is installed, special teflon coating remove the identification plate which is not valid. If device Supply pressure: 3.0–7.5 bar / 44–109 psi is installed to Ex d area, it can't be installed to Ex i area any-...
  • Page 6 7 VG9H 70 en Electronics (output) LCP9H interface Usage: Position transmitter (T) / Electrical connections: 0.25–2.5 mm device status output (S) Local user interface functions Electrical connections: 0.25–2.5 mm  Monitoring of valve position, temperature, supply Output signal: Defined by type code option T or S pressure, actuator pressure difference, housing pres- T: 4–20 mA = 0–100 % position sure, input signal and safety signal status...
  • Page 7 7 VG9H 70 en APPROVALS Table 1 Approvals and electrical values Certificate Approval Electrical values ATEX VG9_X II 1 G Ex ia IIC T6...T4 Ga Input: Ui ≤ 28 V, Ii ≤ 120 mA, Pi ≤ 1.0 W, Ci ≤ 9.6 nF, Li ≤ 53 μH VTT 14 ATEX 043X II 1 D Ex ia IIIC T95 °C...T125 °C Da PT: Ui ≤...
  • Page 8: Recycling And Disposal

    7 VG9H 70 en Recycling and disposal Ex WARNING: The locking screw (part 107) of the cover is essential Most ValvGuard parts can be recycled if sorted according to to explosion protection. material. The cover has to be locked in place for Ex d protection. Most parts have material marking.
  • Page 9: Transportation, Reception And Storage

    7 VG9H 70 en TRANSPORTATION, RECEPTION AND NOTE: STORAGE Special care must be taken that the shaft position has The safety controller is a sophisticated instrument, handle it been set according to marking in VG9000H housing and with care. the pointer in the shaft. Also make sure that the positioner fail action parameter (PFA) is set correctly (Section 4.4.3).
  • Page 10: Mounting And Installation Of Vg9300

    7 VG9H 70 en  Apply grease (Molykote or equivalent) to the contact Spool valve protective cover surfaces of the actuator pin and the feedback arm to  The spool valve protective cover (454) has 2 pcs. of 1/ reduce wear. 2”...
  • Page 11: Piping

    7 VG9H 70 en Piping CAUTION: The air supply system must be of sufficient size and CAUTION: capacity to ensure that at maximum flow during valve Do not exceed the permitted supply pressure of the movement the pressure at the ValvGuard must not fall ValvGuard! below 3 bar.
  • Page 12 7 VG9H 70 en Table 3 Piping and stroke times VG_12_ VG_15_ VG_35_ VG_37_ (Single acting only) Actuator Supply 1/4" NPT Supply 1/4" NPT Supply 1/2" NPT Supply 1/2" NPT Actuator 1/4" NPT Actuator 1/4" NPT Actuator 1/2" NPT Actuator 1" NPT Stroke vol.
  • Page 13 7 VG9H 70 en SINGLE-ACTING ACTUATOR, SPRING TO CLOSE 1. Self closing Default setting: ATYP = 1-A PFA = CLO (must be in the spring direction) VTYP according to valve type NOTE: Valve shown in trip position SINGLE-ACTING ACTUATOR, SPRING TO OPEN 2.
  • Page 14 7 VG9H 70 en SINGLE-ACTING ACTUATOR, SPRING TO CLOSE 1. Self closing Default setting: ATYP = 1-A PFA = OPE VTYP according to valve typ NOTE: SOV shown in energized condition, valve in normal position SINGLE-ACTING ACTUATOR, SPRING TO OPEN 2.
  • Page 15: Electrical Connections

    7 VG9H 70 en Electrical connections Position transmitter/ Additional HART status output connection The VG9000H is powered by a 4–20 mA current loop from connection the safety system that also functions as a carrier to the HART communication. The input signal cable is led through a M20 x 1.5 or 1/2" NPT cable gland.
  • Page 16: Local User Interface (Lui)

    7 VG9H 70 en 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.
  • Page 17: Guided Start-Up

    7 VG9H 70 en Guided start-up Configuration menu Guided startup offers a fast view of the most critical param- The local user interface is organised in a menu structure. To enter the menus press + and - simultaneously in the eters of the ValvGuard controller, actuator and valve config- uration.
  • Page 18 7 VG9H 70 en qE2 = quick exhaust type 2 qE3 = quick exhaust type 3 co1 = combination type 1 co2 = combination type 2 co3 = combination type 3 Use the + and - keys to change the value. ...
  • Page 19: Valve Travel Calibration

    7 VG9H 70 en  Testing, TESt Select between the following values: = VG9_12 or VG9_15  Select between two tests Partial Stroke Test (PARt = VG9235 tst) or Pneumatics test (PNEU tst). = VG9237  To conclude press the ? key when the desired Use the + and - keys to change the value.
  • Page 20: Advance Parameters

    7 VG9H 70 en Advance parameters Manual Stroke Size, MSTr 4.7.1 Targeted manual partial stroke test size. Range is 3.0–100 %. In VG9000H_P version the range is 3.0-50%.  Once MSTr is displayed, press the ? key to enter the edit state and the MSTr will start blinking.
  • Page 21: Hart Burst Mode

    7 VG9H 70 en When the HART write protection is on, the lock symbol will When maintaining the ValvGuard ensure that the supply air be activated on the display, see Fig 21. 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 other- wise stated.
  • Page 22: Spool Valve

    7 VG9H 70 en 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 connec- tor can only be fitted in the correct position. Replace the inner cover (39) and tighten the M3 screws.
  • Page 23: Messages

    7 VG9H 70 en MESSAGES NOTE: These messages may appear in the local user interface. Parameter limits can only be changed via HART. See DTM manual for setting the parameter limits. Display message Description ACTUATOR FULL STROKES COUNTER LIMIT EXCEEDED Generated when actuator full stroke count exceeds the warning limit.
  • Page 24: Trouble Shooting

    7 VG9H 70 en TROUBLE SHOOTING Dual module terminals Mechanical/electrical defects 1. Any request to change the valve position has no affect to 2 cams the position  Spool valve sticks  Incorrect configuration parameters  Actuator and/or valve jammed ...
  • Page 25 7 VG9H 70 en 2 proximity Potentiometer unit transmitter card 2 cams switches terminal terminal conduit entry ground M20 x 1.5 Fig. 30 VG9_H/I45 layout Fig. 33 VG9_/T01 layout 2 or 4 2 micro switches 2 cams 2 or 4 cams switches conduit terminals...
  • Page 26 7 VG9H 70 en 8.1.3 Technical specifications SIL: Usable up to SIL3 acc. to IEC61508(02, 45) 8.1.3.1 VG92_H/D_ Usable up to SIL2 acc. to IEC 61508 (09, 57, 58) Proximity switch: Inductive, Dual Module 2 sensors, 8.1.3.4 VG9_H/K_ Normally Open (33) Microswitch type: OMRON D2VW-5...
  • Page 27: Installing Limit Switches On Valvguard

    7 VG9H 70 en Table 8 Ambient temperatures, Ex ia/ib Variant type II 1 G Ex ia IIC T6…T4 Ga / II 2 G Ex ib IIC T6…T4 Gb Ambient temperature ranges Close VG9_X_ -40…+50 °C -40…+65 °C -40…+80 °C VG9_X_/I02 -40…+64 °C Open...
  • Page 28: Removal Of The Limit Switches And Position Transmitter For Accessing The Valvguard

    7 VG9H 70 en  Once you have the potentiometer inner section Removal of the limit switches and position aligned to correct resistance value, tighten the transmitter for accessing the ValvGuard potentiometer set screw to connect the potentiome-  Remove the cover (100) and the pointer (109). ter firmly to the valve controller axis.
  • Page 29: Drawings And Parts Lists

    7 VG9H 70 en DRAWINGS AND PARTS LISTS 11.1 Exploded view and parts list, VG9000H VG9300H 437 439 VG9200H VG9300H 437 439 VG923_ VG921_ VG931_...
  • Page 30 7 VG9H 70 en Item Description Housing Exhaust adapter Screw Shaft assembly O-ring Washer Wave spring Bushing Grounding screw Protection cover Screw Conduit entry adapter Exhaust cover Screw (VG921_) Screw (VG923_) Gasket O-ring Cooling plate Screw Cover (VG9000H red, VG9000H_P green) O-ring Screw Pointer...
  • Page 31: 11.2 Exploded View And Parts List

    7 VG9H 70 en 11.2 Exploded view and parts list, VG9_/D_, VG9_/R_, VG9_/I_, VG9_/K_, VG9_/T01 VG9300H I02, 09, 56 K2_, I57, R_ K4_, I58 VG9300H VG9200H...
  • Page 32 7 VG9H 70 en Item Description Cover Screw Pointer Stop screw Spring Local user interface (LUI) Housing O-ring Screw Bracket Screw Bracket Screw Screw Plug Extension shaft 2 or 4 Screw 2 or 4 Cam disc 2 or 4 Screw Terminal block Proximity switch Screw...
  • Page 33: 11.3 Mounting Parts For Metso B_U-Series

    7 VG9H 70 en 11.3 Mounting parts for Metso B_U-series actuators Item Description Mounting bracket Washer Screw Screw Hexagon nut Screw Screw Couplings jacket Coupler socket Screw Plug (BJ actuators only) 11.4 Mounting parts for Quadra-Powr® actuators Item Description Mounting bracket Screw Screw Screw...
  • Page 34: 11.5 Mounting Parts For Linear Actuators

    7 VG9H 70 en 11.5 Mounting parts for linear actuators Feedback lever in horizontal position at mid travel of stroke. Stroke 10 - 80 mm Stroke 60 - 120 mm Plane in the shaft in this position 45° with feedback lever 45°...
  • Page 35: 11.6 Connection Diagrams

    7 VG9H 70 en 11.6 Connection diagrams See Section 8.1.3 for additional limit switch data. mA input and output (position transmitter / device status output) signal connections Note: Terminal numbers are valid only when extension housing or junction box are used. VG9_H/D33 SOL 1 SOL 2...
  • Page 36 7 VG9H 70 en VG9_H/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 +: Positive connection for top switch TOP SW -: Negative connection for top switch...
  • Page 37 7 VG9H 70 en VG9_H/R35 Green Black Blue CLOSED C Black Blue OPEN Connection diagram shows limit switch when actuator is in intermediate position. Switch C (upper) is activated at the closed limit of the travel and switch O (lower) at the open limit. VG9_H/I02, I09, I57 VG9_H/I45 VG9_H/I58...
  • Page 38 7 VG9H 70 en VG9_H/I56 black OPEN black black CLOSED black Factory adjustment: Active faces of proximity switches are free when actuator is in intermediate position. Active face A (upper switch) becomes covered 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.
  • Page 39 7 VG9H 70 en AO, HART multiplexer Hazardous area Safe area VG9000H Safety system mA input + HART (4 - 20 mA) output HART Multiplexer (SIL) (4-20 mA, source DO, RCI, HART AI VG9000H RCI9H2* SAFETY OUTPUT SIGNAL Safety system mA input + HART (0/24 VDC)
  • Page 40 7 VG9H 70 en VG9_H_J VG9000H blue brown black VG9_H_L2_ + LCP9H_ Hazardous area Safe area VG9_H_L2_ Safety system (4 - 20 mA, HA R T) LCP9H_ Loop B - 24 V DC Loop B + PWR_IN + supply PWR_IN - Loop A - Loop A +...
  • Page 41 7 VG9H 70 en VG9_H_L3_ + LCP9H_L Hazardous area Safe area LCP9H_L VG9_H_L3_ Loop_B - Loop_B + Loop_A - Loop_A + PWR_IN - 8-20mA 8…20 mA PWR_IN + + HART 4-20mA VG9_T01 Hazardous area Safe area Safety system VG9_/T01 mA input 4-20mA + HART + HART...
  • Page 42: Dimensions

    7 VG9H 70 en DIMENSIONS VG921_ M20x1.5 5/16UNC 35.4 (VDI/VDE 3845) F05-ø50 M6x12 1/4 NPT 26.8 VG9235_ M20x1.5 5/16UNC 35.4 (VDI/VDE 3845) F05-ø50 M6x12 1/2 NPT 26.8...
  • Page 43 7 VG9H 70 en Pressure gauges optional (block without gauges as standard) VG9237_ SG/VG9237: M20x1.5 SG/VG9237/E2: M20x1.5-1/2 NPT (CABLE ADAPTER) Grounding Removable VDI/VDE 3845 (for rotary actuators) finger guard 5/16 UNCx13 1" NPT (C2) M6x10 35,4 F05- 70,5 1/2" NPT (S) VG921_J_ M20x1.5 5/16UNC...
  • Page 44 7 VG9H 70 en VG923_J M20x1.5 5/16UNC 35.4 (VDI/VDE 3845) F05-ø50 M6x12 1/2 NPT 26.8 VG921_/_ or VG921_L_ VG921_E6: M20x1.5 VDI/VDE 3845 5/16UNCx13 1/4NPT ø6 14.5 M6x10 (35.4) F05-...
  • Page 45 7 VG9H 70 en VG923_/_ or VG923_L_ VG923_E6: M20x1.5 VDI/VDE 3845 5/16UNCx13 1/2NPT ø6 M6x10 14.5 (35.4) 42.4 F05- VG921_J_/_ or VG921_JL_ M20x1.5 F05- 50 VDI/VDE 3845 (35.4) 5/16UNCx13 1/4NPT ø6 14.5 M6x10...
  • Page 46 7 VG9H 70 en VG923_J_/_, or VG923_JL_ M20x1.5 VDI/VDE 3845 F05- 50 (35.4) 42.4 5/16UNCx13 1/2NPT ø6 14.5 M6x10 VG931_ ø6.5 M20x1.5 35.4 VDI/VDE 3845 1/4 NPT F05- 50 44.5 1/2 NPT 1/2 NPT 26.8...
  • Page 47 7 VG9H 70 en VG931_J_ M20x1.5 M20x1.5 1/2 NPT ø6.5 1/2 NPT 35.4 VDI/VDE 3845 F05- 44.5 1/4 NPT M20x1.5 26.8 M20x1.5 VG931_/_ or VG931_L_ M20x1.5 1/4 NPT ø6.5 1/2 NPT 35.4 1/2 NPT VDI/VDE 3845 26.8 F05- 50 44.5...
  • Page 48 7 VG9H 70 en VG931_J_/_ or VG921_JL_ 1/4 NPT 35.4 ø6 ø6.5 M20x1.5 M20x1.5 M20x1.5 1/2 NPT...
  • Page 49: Configuration Parameters

    7 VG9H 70 en CONFIGURATION PARAMETERS Parameter Name Values Default value Actuator Type (Atyp) Single acting actuator (1-A) Double acting actuator (2-A) NOTE: See 4.6.1. Partial Stroke Test Valve Type (Vtyp) Rotary (rot) Linear (Lin) Positioner Fail Action (PFA) Close (CLO) Open (OPE) Extra Pneumatics Instrumentation (EXTI) non = none...
  • Page 50: Ec Declaration Of Conformity

    7 VG9H 70 en EC DECLARATION OF CONFORMITY EC DECLARATION OF CONFORMITY Manufacturer: Metso Automation Oy 01301 Vantaa Finland Product: Intelligent Safety Solenoid Neles ValvGuard VG9000-series Approvals: Type Approval EC Type examination Certificate VG9_HX_/_ ATEX II 1 G Ex ia IIC T6...T4 Ga VTT 14 ATEX 043X ATEX II 1 D Ex ia IIIC T95 °C...T125 °C Da EN 60079-0: 2012, EN 60079-11:2012,...
  • Page 51: Type Coding

    7 VG9H 70 en TYPE CODING NELES VALVGUARD VG9000 *) Slash shall always be marked in places shown above. 1. sign PRODUCT GROUP 6. sign APPROVALS FOR HAZARDOUS AREAS Neles ValvGuard VG9000, intelligent safety solenoid. cCSAus certification: TÜV SIL 3 certified according to IEC 61508. Class I, Div 1, Groups B, C, D;...
  • Page 52 7 VG9H 70 en 8. sign LIMIT SWITCHES & POSITION TRANSMITTERS 8. sign LIMIT SWITCHES & POSITION TRANSMITTERS Extension housing with additional conduit entries, Mechanical micro switches 4 pcs M20x1.5. Temperature range -40 to +85 °C / -40 to +185 °F Position transmitters 2 pcs, OMRON D2VW-5L2A-1MS, SPDT, 3 A –...

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