Pentair SUDMO IntelliTop 2.0 Operating Instructions Manual
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Pentair SUDMO IntelliTop 2.0 Operating Instructions Manual

Pentair SUDMO IntelliTop 2.0 Operating Instructions Manual

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Summary of Contents for Pentair SUDMO IntelliTop 2.0

  • Page 1 IntelliTop® 2.0 Control Head Operating instructions...
  • Page 2 We reserve 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: Table Of Contents

    Control Head IntelliTop 2.0 ONTENTS OPERATING INSTRUCTIONS ................................8 AUTHORIZED USE .....................................9 2.1. Export restrictions .................................9 BASIC SAFETY INSTRUCTIONS ..............................10 GENERAL INFORMATION ................................12 4.1. Contact address ..................................12 4.2. Warranty ....................................12 4.3. Information on the Internet ............................12 SYSTEM DESCRIPTION ................................13 5.1. Intended application area ...............................13 5.2.
  • Page 4 6.8. Factory settings in the firmware ..........................26 6.8.1. Feedback fields (position measuring system) ...................26 6.8.2. Service/maintenance notification ......................27 6.8.3. Manual control function (magnetic) ......................27 6.8.4. Function „Cycle stroke color S3/S4 different“ ...................28 6.9. Resetting the device (Device Reset) ........................28 INSTALLATION ....................................30 7.1.
  • Page 5 10.5. Electrical installation / start-up ...........................42 10.5.1. Cable gland with screw terminals ......................42 10.5.2. Multi-pole connection ............................45 AS INTERFACE - DESIGN ................................46 11.1. Definition ....................................46 11.2. Electrical connection options for AS interface ....................47 11.3. Number of connectable control heads and maximum length of the bus line ........47 11.4.
  • Page 6 12.12. Configuration of the device ............................64 12.12.1. Configuration of the safety position of solenoid valves if bus error ........64 12.12.2. Configuration example ..........................65 12.13. Display of the status LEDs in the event of a bus error ..................66 12.13.1. State of device status LED "Modules" ....................66 12.13.2.
  • Page 7 SERVICE MODE / MANUAL CONTROL ..........................90 18.1. Magnetic manual control ..............................90 18.2. Mechanical manual control ............................91 MAINTENANCE, TROUBLESHOOTING ..........................92 19.1. Safety instructions ................................92 19.2. Safety positions ...................................93 19.3. Maintenance / service ..............................94 19.4. Cleaning ....................................94 19.5. Malfunctions ..................................94 REPLACEMENT OF COMPONENTS AND MODULES ....................96 20.1.

  • Page 8: Operating Instructions

    Operating Instructions OPERATING INSTRUCTIONS The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user, and make these instructions available to every new owner of the device. WARNING! The operating instructions contain important safety information! Failure to observe these instructions may result in hazardous situations.

  • Page 9: Authorized Use

    • In view of the large number of application options, check and, if required, 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.

  • Page 10: Basic Safety Instructions

    Basic Safety Instructions BASIC SAFETY INSTRUCTIONS These safety instructions do not make allowance for any • Contingencies and events which may arise during assembly, operation, and maintenance of the devices. • Local safety regulations – the operator is responsible for observing these regulations, also in relation to the instal- lation personnel.
  • Page 11 Basic Safety Instructions NOTE! Electrostatic sensitive components/modules! • The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact with electrostatically charged persons or objects may be hazardous to these components. In the worst case scenario, they will be destroyed immediately or will fail after start-up. •...

  • Page 12: General Information

    Check immediately upon receipt of the consignment that the contents are not damaged and that the type and scope agree with the delivery note and packing list. If there are any discrepancies, please contact us immediately. Contact address: Pentair Südmo GmbH Industriestraße 7 D-73469 Riesbürg T: +49 (0)9081 8030 F: +49 (0)9081 803 158 E: Email: info@suedmo.de...

  • Page 13: System Description

    System Description SYSTEM DESCRIPTION 5.1. Intended application area The control head IntelliTop 2.0 has been designed for use as actuation of pneumatically operated process valves and / or for recording the switching states of these. 5.2. General description The control head IntelliTop 2.0 is used for actuating pneumatically operated process valves. For process valve actuation, the control head can be equipped with up to three solenoid valves.

  • Page 14: Functions / Options / Designs

    System Description 5.3. Functions / options / designs 5.3.1. Structure of the control head Electronics module Position measuring system with connection with LEDs in 3 colors terminals, service interface and Teach-In buttons (rear) Solenoid valve 1 Solenoid valve 2 Mechanical manual Solenoid valve 3 control (red lever) Flow restriction screw(s)

  • Page 15: Structure Of The Control Head (Feedback Top)

    System Description 5.3.2. Structure of the control head (feedback top) Position measuring system with LEDs in 3 colors Electronics module with connection terminals, service interface and Teach-in buttons (T1 to T3) Pressure relief valve (rear side) Sealing lug on the lower housing part;...

  • Page 16: Fluid Diagrams

    System Description 5.3.3. 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: Number Of Solenoid Valves

    System Description Control head IntelliTop 2.0 - design for double-acting actuators - fluid diagram (with restriction option of each solenoid valve): Model with 2 solenoid valves Type 6524 (solenoid valve 1: NC, solenoid valve 2: NO, e.g. for process valves actuated on both sides (rest position) - compare also Chapter "15. Design for Double- Acting Actuators"...

  • Page 18: Manual Control

    System Description • Actuation of Connection 2/A1 (Solenoid Valve 1; normally the main stroke of the process valve) using the mag- netic manual control that is externally accessible. (both solenoid valves are actuated simultaneously for the model for double-acting actuators) •...

  • Page 19: Technical Data

    The applied standards which are used to demonstrate compliance with the Directives are listed in the EU Decla- ration of Conformity. This may be requested from Pentair Südmo. The specifications on the respective rating plate or possibly existing additional plates apply to the respective control head.

  • Page 20: Rating Plate Specifications

    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 indicate special approvals or relevant approval information for this device Further possible symbols on the rating or additional plate: Device complies with European standards according to EU Declaration of Conformity Approval according to (potentially explosive atmospheres) “ATEX”...

  • Page 21: Information On The Additional Plates

    Technical Data Details of the Directives: ATEX Directive 2014/34/EU Ignition protection type: Gas ATEX category 3G Ex nA IIC T4 Gc X Dust ATEX category 3D Ex tc IIIC T135°C Dc X FM - Factory Mutual NI/I/2/ABCD/T5; +5°C < Ta < 55°C IP64 (cables and cable glands are not part of the FM approval of the device and are therefore not fitted at the factory.) c UL us - Underwriters Laboratories (Canada and USA)

  • Page 22: Mechanical Data

    Technical Data 6.5. Mechanical data M16x1.5 (2x) Securing the hood by lead seal (max Ø2) or optionally by plastic self- cutting screws *) 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.
  • Page 23 Technical Data M16x1.5 (2x) Securing the hood by lead seal (max Ø2) or optionally by plastic self-cutting screws *) Cover pressure-relief valve 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...

  • Page 24: Pneumatic Data

    Technical Data 6.6. Pneumatic data Control medium: Air, neutral gases Quality classes in accordance with DIN ISO 8573-1 (5 µm filter recommended) Dust content Quality class 7: max. particle size 40 µm, max. particle density 10 mg/m Water content Quality class 3: max. pressure dew point -20°C or min. 10°C below the lowest operating temperature Oil content Quality class X: max.

  • Page 25: Position Measuring System Data

    Technical Data 6.7. Position measuring system data Stroke range (measuring range): 0 ... 85 mm Total error: ±0.5 mm - when using a specification-compliant attachment kit (error refers to the reproducibility of a taught position) The diagram in "Fig. 8" shows the dimensional relationships between the control head and the piston with target. Target (in the upper end position) Piston rod...

  • Page 26: Factory Settings In The Firmware

    Technical Data 6.8. Factory settings in the firmware The service interface may only be used in non-explosive atmosphere. The control head is supplied with the following factory settings of the firmware: 6.8.1. Feedback fields (position measuring system) A feedback field is the area within which a position (e.g. S1) is reported back. Signal Feedback field at top (positive) Feedback field at bottom (negative)

  • Page 27: Service/Maintenance Notification

    Technical Data 6.8.2. Service/maintenance notification Factory setting for the "Service/maintenance notification" function: not active. When Service/maintenance notification is activated, this is indicated by a special flashing pattern - see Chap. "17.2. Blinking pattern & fault signaling" on page 86. The Service/maintenance notification is used to observe predefined maintenance intervals which should occur either after an adjustable number of switching cycles or when a certain time has elapsed.

  • Page 28: Function „Cycle Stroke Color S3/S4 Different

    Technical Data 6.8.4. Function „Cycle stroke color S3/S4 different“ Factory setting of this function: not active To make the position feedback of S3 and S4 more clearly distinguishable than only in the flashing frequency, the "cycle stroke color S3/S4 different" function can be selected via the PC software. This function reports the position of S3 and S4 in different colors but with the same flashing frequency (250 ms ON / 250 ms OFF).
  • Page 29 Technical Data Device Reset does not reset the following values to factory settings: • Switching cycle 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") •...

  • Page 30: Installation

    Installation INSTALLATION 7.1. 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 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! •...

  • Page 31: Assembly Sequence In The Example Of A Double Seat Valve

    • 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.

  • Page 32: Realignment Of The Control Head

    Installation → Mount the control head on the hub flange (seamlessly 360° rotatable). → Secure control head with the two locking screws (shoulder screws M5) in the middle groove of the hub flange to prevent it from being pulled off the hub flange – tightening torque: max. 3.2 Nm (see "Fig. 11: Schematic diagram of the control head - process valve adaptation").

  • Page 33: Opening And Closing The Housing

    Opening and Closing the Housing OPENING AND CLOSING THE HOUSING 8.1. 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. Danger of explosion in explosive atmosphere (only in the event of a fault as zone 2)! •...
  • Page 34 Opening and Closing the Housing (O-rings and seals are wearing parts). → Turn the hood by approx. 1.5 cm clockwise (meaning 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.

  • Page 35: Pneumatic Installation

    Pneumatic Installation 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! •...

  • Page 36: Pneumatic Connection (Standard)

    Pneumatic Installation 9.2.1. Pneumatic connection (standard) Procedure: → If required, realign the control head (see Chapter "7.2.3. Realignment of the control head") → A silencer has already been mounted on the exhaust air connection (3/R) in the supplied state. As needed, the silencer can be replaced by an exhaust air hose (e.g.

  • Page 37: Flow Restriction Function Of The Solenoid Valves

    Pneumatic Installation Special cover plate with an inside connection from "A" to "R" for a free valve seat (featured in the color green) (order no. 2333187) Procedure: → Open the housing following the instructions in Chapter "8. Opening and Closing the Housing". →...
  • Page 38 Pneumatic Installation Settings of the flow rate or the control speed with the help of the flow restriction screws: → Open the housing following the instructions in Chapter "8. Opening and Closing the Housing". → For proper setting, it is advisable to turn the two flow restriction screws initially into the minimum flow-rate position.

  • Page 39: Dc - Design

    24 V DC - Design 24 V DC - DESIGN 10.1. Electrical connection options The following connection concepts are available for the electrical connection of the control head: Cable gland Cable gland with multi-pole connection (M12 plug according to IEC 61076-2-101, 12-pole) Connection left: Voltage, signals Connection left:...
  • Page 40 24 V DC - Design Solenoid valves: Max. switching capacity: max. 0.9 W (per solenoid valve) Type. Continuous output: 0.6 W (per solenoid valve) Power consumption per solenoid valve: 50 mA at 12 V DC 25 mA at 24 V DC 22mA at 28 V DC Operating mode: Long-term operation (100 % ED)

  • Page 41: Design Aid

    24 V DC - Design 10.3. Design aid Power consumption of the electronics: 0.7 W 30 mA at 24 V Power consumption of a valve during activation (200 ms): 0.9 W 38 mA at 24 V Valve-ON Valve-ON Power consumption of a valve after reduction: 0.6 W 25 mA at 24 V Valve...

  • Page 42: Safety Instructions

    24 V DC - Design 10.4. Safety 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! •...
  • Page 43 24 V DC - Design 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! •...
  • Page 44 24 V DC - Design Electronics Position measuring system with LEDs Power supply Service interface 24 V DC Output position 1 (0/24 V, PNP) Output position 2 DIP switches (0/24 V, PNP) for LEDs Output position 3 (0/24 V, PNP) Output ext.

  • Page 45: Multi-Pole Connection

    24 V DC - Design 10.5.2. Multi-pole connection Internal cabling work is not required for models with multi-pole connection, which makes installation and start-up on site considerably easier and quicker, reducing the risk of leaks. However, you will require the correspondingly assembled cable sets with the following pin assignment: Input and output signals to the higher-level control (PLC): 12-pole circular plug-in connector M12 x 1.0 - male (acc.

  • Page 46: As Interface - Design

    AS Interface - Design AS INTERFACE - DESIGN 11.1. Definition AS interface connection AS interface (Actuator Sensor Interface) is a field bus system which is used primarily for networking binary sensors and actuators (slaves) with a higher-level control (master). Connecting the control heads to higher bus systems is possible using commercially available gateways. Contact your distribution partner in this regard.

  • Page 47: Electrical Connection Options For As Interface

    AS Interface - Design 11.2. Electrical connection options for AS interface The following connection concepts are available for the electrical connection of the control head: • Cable gland with multi-pole connection on a cable (8 cm length) • Cable gland with multi-pole connection on a cable (80 cm length) with multi-pole connection (M12 plug with multi-pole connection (M12 plug according to according to IEC 61076-2-101, 4-pole)

  • Page 48: Electrical Data

    AS Interface - Design Table of calculated line length of the control head versions: When designing the system, consider the length of the round cable leading directly to the control head (see fol- lowing table and example calculation). Calculated line length Model (including internal cabling) Multi-pole (cable 8 cm)
  • Page 49 AS Interface - Design Connections: Multi-pole connection version 1 x M16 x 1.5 cable gland / SW19 with multi-pole connection (M12 plug according to IEC 61076-2-101, 4-pole on a cable of 8 or 80 cm length for power supply and signals) 1 x M16 x 1.5 –...

  • Page 50: Design Aid

    AS Interface - Design NOTE! If all 3 solenoid valves are simultaneously controlled via the AS interface, the electronics will activate the valves sequentially with a 200 ms time delay to protect the bus from overloads. Please follow the instructions on power requirement and maximum expansion stage of the AS interface network in Chapter "11.3.

  • Page 51: Safety Instructions

    AS Interface - Design Calculation examples: Example 1: 3 valves are activated simultaneously, one position is reported (state for 200 ms): + 1 x P + 2 x P + 1 x P Slave Valve-ON Valve 4.1 W 1.0 W + 1 x 0.9 W + 2 x 0.6 W + 1 x 1.0 W...

  • Page 52: Electrical Installation, As Interface

    AS Interface - Design 11.7. Electrical installation, AS interface Internal cabling work is not required for any of the AS Interface designs with multi-pole connection, which makes installation and start-up on site considerably easier and quicker, reducing the risk of leaks. However, you will require the correspondingly assembled cable sets with the following pin assignments.
  • Page 53 AS Interface - Design The optional ribbon cable terminal contacts the AS interface cable harness by means of penetration technology which allows installation by "clipping in" the AS interface cable harness without cutting and without removing insulation. Procedure: → Open the ribbon cable terminal (loosen screws and remove cover) →...

  • Page 54: Programming Data

    AS Interface - Design 11.8. Programming data The control heads have been configured as AS interface version with an extended address range (A/B slaves) for 62 slaves or optionally as an AS interface version for 31 slaves. A change between the two configurations in the control head is only possibly by exchanging the elec- tronic PCB! If one control head is replaced with another control head having a different configuration in the AS interface field bus system (e.g.

  • Page 55: Devicenet Design

    DeviceNet Design DEVICENET DESIGN 12.1. Definition • The DeviceNet is a field bus system which is based on the CAN protocol (Controller Area Network). It enables actuators and sensors (slaves) to be networked with higher-level controllers (master). • The control head in the DeviceNet is a slave device according to the Predefined Master/Slave Connection Set stipulated in the DeviceNet specification.

  • Page 56: Total Line Length And Maximum Line Length According To Devicenet Specification

    DeviceNet Design Inputs 3 discrete feedback signal of the position measuring system (positions S1 - S3) 1 discrete feedback signal of the external initiator (S4) 1 analog position signal in mm supply via DeviceNet string (11 ... 25 V DC) Switch level high signal ≥...

  • Page 57: Electrical Data

    DeviceNet Design 12.4. Electrical data Connections: "Multi-pole" 1 x M16 x 1.5 cable gland / SW22 with multi-pole connection (M12 plug according to IEC 61076-2-101, 5-pole on a cable of 80 cm length ) for DeviceNet bus and power supply 1 x M16 x 1.5 –...

  • Page 58: Design Aid

    DeviceNet Design 12.6. Design aid Power consumption of the electronics: 1.44 W 60 mA at 24 V Power consumption of a valve during activation (200 ms): 1.0 W 42 mA at 24 V Valve-ON Valve-ON Power consumption of a valve after reduction: 0.6 W 25 mA at 24 V Valve...

  • Page 59: Safety Instructions

    DeviceNet Design 12.7. Safety 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! •...
  • Page 60 DeviceNet Design DeviceNet electronics module: Teach-In buttons T1-3 Solenoid valve connection with status LED for Valve 1 Service interface DIP switches for setting the address and baud rate DIP switches for color coding the LEDs Status LED for device Status LED for network Solenoid valve connec- tions with status LED for Valves 2, 3...

  • Page 61: Network Topology Of A Devicenet System

    DeviceNet Design 12.9. Network topology of a DeviceNet system When installing a DeviceNet system, ensure that the terminating circuit of the data lines is correct. The circuit pre- vents the occurrence of interference caused by signals reflected onto the data lines. The trunk line must be terminated at both ends with resistors of 120 Ω...

  • Page 62: Settings Of The Devicenet Address

    DeviceNet Design 12.10.1. Settings of the DeviceNet address MAC ID address = Medium Access Control Identifier Address = [DIP 1 ⋅ 2 + DIP 2 ⋅ 2 + DIP 3 ⋅ 2 + DIP 4 ⋅ 2 + DIP 5 ⋅ 2 + DIP 6 ⋅...

  • Page 63: Setting The Baud Rate

    DeviceNet Design 12.10.2. Setting the baud rate Adjustment of the control head to the baud rate of the network. Baud rate DIP 7 DIP 8 125 kbaud 250 kbaud 500 kbaud not permitted: (on) (on) If the settings are changed by actuating the DIP switches, this change will not take effect until the device is restarted! For a restart •...

  • Page 64: Static Output Assembly

    DeviceNet Design The addresses listed in the table above ("Static input assemblies") can be used as path data for the Produced Connection Path attribute of an I/O connection. Nevertheless, by using this address data, the attributes combined in the assemblies can also be accessed acycli- cally via Explicit Messages.

  • Page 65: Configuration Example

    DeviceNet Design 12.12.2. Configuration example The example describes the principle procedure when configuring the device using the RSNetWorx software for DeviceNet (Rev. 4.21.00). Installation of the EDS file The EDS file is installed with the aid of the EDS Installation Wizard Tool associated with RSNetWorx. During the installation procedure the icon can be assigned (if this does not occur automatically).

  • Page 66: Display Of The Status Leds In The Event Of A Bus Error

    DeviceNet Design Online parameterization of the device Devices can also be parameterized online. In doing so, you can also select whether only individual parameters (single) or all parameters (all) of a group are read from the device (upload) or are loaded into the device (download). It is also possible to transfer individual parameters or all parameters of a group cyclically in monitor mode.

  • Page 67: State Of Bus Status Led "Network

    DeviceNet Design 12.13.2. State of bus status LED "Network" Device state Explanation Troubleshooting No voltage / not • Device is not supplied with voltage • Connect other devices, if the online device is the only network • Device has still not ended Duplicate subscriber, MAC ID Test (test lasts approx.

  • Page 68: Ac Design

    120 V AC Design 120 V AC DESIGN 13.1. Electrical connection options Cable gland: Connection left: voltage, signals Connection right: external initiator Fig. 28: Connection concept 120 V AC 13.2. Electrical data Central power supply: 110 ... 130 V AC, 50/60 Hz Connections: Cable gland 1 x M16 x 1.5 cable gland / SW22 –...
  • Page 69 120 V AC Design Input / proximity switches (external initiator: S4 in): Power supply: voltage present at control head U = 120 V AC, 50/60 Hz Nominal Design: DC 2 and 3-wire, Normally open contact, L-switching input current 1-signal: < 2 mA Sensor Inputs valve actuation (Y1 - Y3): Signal level - active:...

  • Page 70: Design Aid

    120 V AC Design 13.3. Design aid Power consumption of the electronics: 1.2 VA 10 mA at 120 VA Power consumption of a valve during activation (200 ms): 1.7 VA 14 mA at 120 VA Valve-ON Valve-ON Power consumption of a valve after reduction: 1.4 VA 12 mA at 120 VA Valve...

  • Page 71: Safety Instructions

    120 V AC Design 13.4. Safety instructions 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 prevent restarting! •...
  • Page 72 120 V AC Design DANGER! Risk of electric shock if the PE connection is not connected! • the PE connection must be connected! → Clamp the protective conductor to the PE connection. → Check correct grounding. → Close the housing following the instructions in Chapter "8. Opening and Closing the Housing". NOTE! Ensure IP protection! •...
  • Page 73 120 V AC Design Designation Designation Configuration for external Configuration Terminal strip Terminal strip initiator Protection earth protective conductor Power supply - conductor Conductor Power S4 IN External initiator input Neutral supply 120 V AC Power supply - neutral conductor conductor S1 OUT Output position 1...

  • Page 74: Connection Of An External Initiator

    Connection of an External Initiator CONNECTION OF AN EXTERNAL INITIATOR 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! An external initiator can be connected via the small 3-fold screw terminal - at bottom right on the respective electronics module (in the example: AS-i).
  • Page 75 Connection of an External Initiator NOTE! Ensure IP protection! • To ensure IP protection, the union nuts of the cable glands must be tightened in accordance with the cable sizes or dummy plugs used (approx. 1.5 Nm). • If no external initiator is used, the right connection opening must be sealed with a dummy plug! Use of the control head in explosive atmosphere •...

  • Page 76: Design For Double-Acting Actuators

    Design for Double-Acting Actuators DESIGN FOR DOUBLE-ACTING ACTUATORS This control head has been configured for process valves actuated pneumatically (AA) on both sides. Of the two internal solenoid valves, one is designed for NC mode of operation and the other for NO mode of operation. 15.1.

  • Page 77: Position Measuring System

    Position Measuring System POSITION MEASURING SYSTEM Operating principle of the position measuring system The position measurement is based on recording the change in position of the ferromagnetic target inside the system. The geometry and the material of the target to be used are synchronized with the sensitivity of the system. The measurement precision is determined by the ferromagnetic properties of the target and all other parts in the system.
  • Page 78 Position Measuring System → Depress the lower Teach-In button (T1) for approx. 1.5 seconds: 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 remain continuously lit until the position of the piston is changed.

  • Page 79: Teach-In Functions

    Position Measuring System 16.2. Teach-In functions 16.2.1. Teach-In functions and Teach-In reset Teach-In Function Activation Optical feedback button duration Teach function S1 1.5 s S1 blinks quickly three times, then continuously in the encoded color Teach function S2 1.5 s S2 blinks quickly three times, then continuously in the encoded color Teach function S3...

  • Page 80: Autotune Sequence

    Position Measuring System 16.2.3. Autotune sequence Autotune 1: Single seat valves NC, Butterfly valves NC, Double seat valves without liftable lower valve disc Control Effect on the process valve Internal program Error T2 + T3 Autotune mode starts Autotune 1 starts Closed position Teach Valve opening...
  • Page 81 Position Measuring System Autotune 4: Single seat valves AA, Butterfly valves AA Control Effect on the process valve Internal program Error T2 + T3 Autotune mode starts T1 + T2 Autotune 4 starts Valve closing Activate Wait period Closed position Teach Valve opening Deactivate...
  • Page 82 Position Measuring System Autotune 6: PMO double seat valves with liftable lower valve disc Autotune 6 is identical to Autotune 3, but with feedback fields for S1 changed in comparison to the factory set- tings (see Chapter "6.8" on page 26): S1 ± 1.0 mm. The feedback fields are already switched during the Autotune process.

  • Page 83: Changing The Feedback Field - Feedback Field Mode (Ffm)

    Position Measuring System 16.3. Changing the feedback field - Feedback Field Mode (FFM) The size of the feedback fields for sensor positions S1 to S3 can be changed – either using the PC software or using the "Feedback Field Mode". Procedure: →...

  • Page 84: Led - Color Assignments

    LED - Color Assignments LED - COLOR ASSIGNMENTS The switching states of the feedback positions are signaled centrally to the outside by super-bright LEDs so that quick visual control is possible also for large systems. The color assignments for all signals to the process valve states corresponds to the subsequently listed tables. To be able to respond in the systems to the 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.

  • Page 85: Setting The Color Combinations

    LED - Color Assignments 17.1. Setting the color combinations 17.1.1. Setting of possible color combinations (classic) The color combinations will be set via the 4 color DIP switches (see "Fig. 32") after following scheme: S4 *) Fault DIP1 DIP2 DIP3 DIP4 green yellow...

  • Page 86: Blinking Pattern & Fault Signaling

    LED - Color Assignments 17.2. Blinking pattern & fault signaling The LEDs flash in different "flashing patterns" in the event of a fault or in various states: Blinking patterns Note Flashes three times in the corresponding color for that position: 100 ms 100 ms Teach-In confirmation (after successful teaching:...

  • Page 87: Signal Priorities

    LED - Color Assignments 17.3. Signal priorities If a valve has several overlapping states, the following priority list applies: 1. Internal Fault (fault color: 450 ms ON, 50 ms OFF) 2. Manual operating mode is active, e.g. by magnetic manual control - see Chapter "18. Service Mode / Manual Control"...
  • Page 88 LED - Color Assignments Example 2: Position of the DIP switches (color combination): 0 0 0 1 (The external S4 initiator monitors whether the upper valve disc has been closed, the valve is only considered safely closed if S1 and S4 = 1; the function „cycle stroke color S3/S4 different“...
  • Page 89 LED - Color Assignments Example 3: Position of the DIP switches (color combination): 0 0 0 1 (Logic S4 -> Changeover via the Service interface required) (The external S4 initiator monitors whether the upper valve disc has been opened, the function „cycle stroke color S3/S4 different“ is not active) Fault green yellow...

  • Page 90: Service Mode / Manual Control

    Service Mode / Manual Control SERVICE MODE / MANUAL CONTROL By default, the control head provides the following (e.g. for service purposes): • a magnetic manual control which is easily accessible from the outside for Solenoid Valve 1 (2/A1) as well as •...

  • Page 91: Mechanical Manual Control

    Service Mode / Manual Control The activation of the manual control is signaled by an illuminated LED display in the fault color: "Flashing patterns": 50 ms ON, 450 ms OFF. The "flashing pattern" 100 ms ON, 100 ms OFF (3x) in the fault color signals that the manual control function was disabled by PC software - the magnetic manual control does not function in this case! (see Chapter "17.2.

  • Page 92: Maintenance, Troubleshooting

    Maintenance, troubleshooting MAINTENANCE, TROUBLESHOOTING 19.1. 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. Danger of explosion in explosive atmosphere (only in the event of a fault as zone 2)! •...

  • Page 93: Safety Positions

    Maintenance, troubleshooting 19.2. Safety positions Safety positions after failure of the electrical or pneumatic auxiliary power: Safety positions after failure of the auxiliary power Operating mode Process valve design electrical pneumatic single-acting Control function A (NC) down down • air opening •...

  • Page 94: Maintenance / Service

    Maintenance, troubleshooting 19.3. Maintenance / service When used properly, the control head IntelliTop 2.0 operates maintenance- and trouble-free. For service work, we offer spare part sets for certain components or modules (see chapter entitled "21. Spare Parts" on page 102). However, only the manufacturer may repair the control head for use in explosive atmosphere. For active Service/maintenance notification function (see Chapter"6.8.
  • Page 95 Check the correct electrical connection electronics module of the solenoid valves - comp. "Fig. 15: 24 V DC electronics module" In the event of any undefined faults, be sure to contact the service department of Pentair Südmo GmbH! Contact: Email: info@suedmo.de Telephone: +49(0)9081/803-0...

  • Page 96: Replacement Of Components And Modules

    Replacement of Components and Modules REPLACEMENT OF COMPONENTS AND MODULES If components or modules need to be replaced for maintenance or service reasons, please observe the following notes and descriptions. Devices that are used in the explosion-risk area may be repaired by the manufacturer only! 20.1.

  • Page 97: Changing The Electronics Module

    Replacement of Components and Modules 20.2. Changing the electronics module NOTE! Electrostatic sensitive components/modules! • The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact with electrostatically charged persons or objects may be hazardous to these components. In the worst case scenario, they will be destroyed immediately or will fail after start-up.

  • Page 98: Changing The Valves

    Replacement of Components and Modules Installation procedure: → Carefully insert the entire electronics module into the recess in the lower housing part. → Plug the electronics module carefully onto the contact pins for the position measuring system. → Refasten the electronics module with the Torx T10 screw (torque 0.4 Nm). →...

  • Page 99: Changing The Position Measuring System

    Replacement of Components and Modules → If necessary, mark the electrical connections to ensure correct assignment during reinstallation. → Loosen the electrical connections. → Loosen the connecting screws (Torx T10) for the corresponding valve module. → Take out the valve module and replace it with the spare part set. →...
  • Page 100 Replacement of Components and Modules DANGER! Risk of injury from high pressure! • Before loosening lines and valves, turn off the pressure and vent the lines. NOTE! Electrostatic sensitive components/modules! • Before changing the position measuring system, switch the electrical power for the control head off so that destruction of the PCB and electronics module is avoided.
  • Page 101 Replacement of Components and Modules → Loosen the fastening screw (Torx 10) of the electronics module (see Chapter "20.2. Changing the electronics module") → Tilt the electronics forwards to loosen the position measuring system's contact pins from the electronics module. →...

  • Page 102: Spare Parts

    Risk of injury and/or damage by the use of incorrect parts! Incorrect accessories and unsuitable spare parts may cause injuries and damage the device and the sur- rounding area. • Use only original accessories and original spare parts from Pentair Südmo. Item No. Spare parts ID No.

  • Page 103: Shutdown

    Shutdown SHUTDOWN 22.1. Safety instructions DANGER! Risk of injury from high pressure! • Before loosening lines and valves, turn off the pressure and vent the lines. Danger of explosion in explosive atmosphere (only in the event of a fault as zone 2)! •...

  • Page 104: Packaging And Transport

    Packaging and Transport PACKAGING AND TRANSPORT NOTE! Transport damage! Inadequately protected devices may be damaged during transportation. • During transportation protect the device against moisture and dirt in shock-resistant packaging. • Avoid the effects of heat and cold which could result in temperatures above or below the permitted storage temperature.
  • Page 105 english...

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